HD465 7 Shop Manual SN 7001 Up

SEBM027612

MACHINE MODEL

SERIAL NUMBER

HD465-7 HD605-7

7001 and up 7001 and up

• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • HD465-7, HD605-7 mount the SAA6D170E-3 engine. For details of the engine, see the 170-3 Series Engine Shop Manual.

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

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CONTENTS No. of page

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GENERAL

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ................................................................. 10-1

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

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DISASSEMBLY AND ASSEMBLY ................................................................. 30-1

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OTHERS

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........................................................................................................................... 01-1

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

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30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-113-1 30-113-2 30-113-3 30-114 30-115 30-116 30-117 30-117-1 30-117-2 30-117-3 30-118 30-119 30-120

(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (4) (10) (10) (3) (10) (3) (3) (10) (3) (3) (10) (10) (10) (3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (10) (3) (10) (10) (8) (10) (3) (10) (3) (10) (10) (8) (10) (10) (10) (10)

00-2-5 (12)

Mark

Page

30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152

q 90-1 q q

Q Q q Q

90-2 90-3 90-5 90-7 90-9 90-11 90-13 90-15 90-17 90-19 90-21 90-23 90-25 90-26-1 90-26-3 90-27 90-29

00-2-6 (12)


Page


Page


Page


Page

Revision number

(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (3) (3) (3) (3) (4) (3) (3) (3) (3) (3) (10) (3) (3) (7) (4) (4) (10) (4) (10) (4) (4) (10) (12) (12) (12)

(7) (7) (10) (10) (12) (12) (12) (12) HD465-7, HD605-7

SAFETY

SAFETY NOTICE

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

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

k

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

5

Oil, water

Places where oil, water or fuel must be added, and the capacity.

6

Drain

Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.

a

4

3 2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

Allowable load

mm

kN

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

! The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ! The adapter can be pushed in about 3.5 mm. ! Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ! Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ! Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ! When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ! For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

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

LT-4

790-129-9040

Holtz MH 705

790-126-9120

Three bond 1735

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond 1211

790-129-9090

Three bond 1207B

419-15-18131

Adhesives

Gasket sealant

00-10

Q’ty

Container

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. • Features: Resistance to heat and chemicals Polyethylene 50 g • Used for anti-loosening and sealant container purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g

Tube

FOREWORD

Molybdenum disulphide lubricant

Komatsu code

Part No.

Q’ty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

Various

G2-LI

G2-CA

Grease

Primer

Adhesive

Caulking material

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

Various

Various

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

400 g 16 kg

400 g 16 kg

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass container

22M-54-27210

320 ml

Ecocart (Special container)

• Used as primer for cab side (Using limit: 4 months)

417-926-3910

417-926-3910

320 ml

Polyethylene container

20Y-54-39850

310 ml


417-926-3920

320 ml


20Y-54-55130

333 ml


22M-54-27220

333 ml

Cartridge

• Used as primer for glass side (Using limit: 4 months)

Adhesive for cab glass

Category

COATING MATERIALS

• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

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

Width across flats

mm

mm

Nm

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ! In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

FOREWORD


TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

mm

mm

14 20 24 33 42

Varies depending on type of connector.

Tightening torque (Nm {kgm})

Norminal No.

02 03, 04 05, 06 10, 12 14

Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010

{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}

Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

mm

mm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm})

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5

{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}

Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD


TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12

10 0 2 24 0 4 43 0 6 77 0 12

1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12 14

802 10 0 2 12 0 2 24 0 4 36 0 5

0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

kgm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9

0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.20 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ! Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series

Range

Target

34 – 54 {3.5 – 5.5}

44 {4.5}

–

9 — – 18UN 16

14.3

34 – 63 {3.5 – 6.5}

44 {4.5}

14

–

–

22

54 – 93 {5.5 – 9.5}

74 {7.5}

–

11 — – 16UN 16

17.5

24

59 – 98 {6.0 – 10.0}

78 {8.0}

18

–

–

04

27

84 – 132 {8.5 – 13.5}

103 {10.5}

22

13 — – 16UN 16

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

3 1 — – 12UN 16

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

–

–

02

03

00-14

19

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

11

0.32

2

26

5

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

1

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

—

BW

RW

YR

GW

LW

2 Color White & Red

—

Code

—

WB

White & Black Red & White Rellow & Red Green & White Blue & White BY

RB

YB

GR

LR

3

4

Auxiliary

Color White & Black

—

Code

—

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

—

Color White & Green

—

—

Code

—

—

—

Color

—

—

—

WG

RY

Black & Red Red & Yellow RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

YW

GL

6 Red & Blue Yellow & White Green & Blue

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches 1 mm = 0.03937 in

(A)

00-16

0

1

2

3

4

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6

7

8

9

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0

1

2

3

4

5

6

7

8

9

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

0

Kilogram to Pound 1 kg = 2.2046 lb

0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

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

0

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0

1

2

3

4

5

6

7

8

9

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {

}.

Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

04-05

01 GENERAL Specification drawings....................................... 01- 2 Specifications .................................................... 01- 3 Weight table ...................................................... 01- 9 Fuel, coolant and lubricants .............................. 01-10

HD465-7, HD605-7

01-1

GENERAL

SPECIFICATION DRAWINGS

SPECIFICATION DRAWINGS HD465-7

HD605-7

01-2

HD465-7, HD605-7

SPECIFICATIONS

GENERAL

Machine model

HD465-7

Serial No.

7001 and up

Empty

kg

42,800

Max. load

kg

55,000

Gross

kg

97,875

(front)

kg

20,120 (47%)

(rear)

kg

22,680 (53%)

(front)

kg

31,320 (32%)

(rear)

kg

66,555 (68%)

Struck

m3

25

Heaped (2 :1)

m3

34.2

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

Wheel base

mm

4,300

Front wheel

mm

3,515

Rear wheel

mm

3,080

mm

645

Weight distribution

Weight

SPECIFICATIONS

Empty

Gross

Dimensions

Performance

Dump body capacity

Tread

Ground clearance Model

KOMATSU SAA6D170E-3

Type

4-cycle, water-cooled, in-line 6-cylinder, direct injection, with turbocharger and after-cooler

No. of cylinders – Bore x stroke Engine

Piston displacement

mm {cc}

6 – 170 x 170 23.15 {23,150}

Rated output

kW/rpm{HP/rpm}

533/2,000 {715/2,000}

Max. torque

Nm/rpm{kgm/rpm}

3,256/1,400 {332/1,400}

Fuel consumption (Min.)

g/kWh {g/HPh}

207 {154}

Stating motor Alternator Battery

HD465-7, HD605-7

24V, 7.5 kW x 2 units 24V, 50A 12V, 200Ah x 2 units

01-3 (10)

GENERAL

SPECIFICATIONS

Machine model

HD465-7

Serial No.

7001 and up

Structure

3-element, 1-stage, 2-phase

Torque converter Lock- up clutch

Hydraulically actuated, wet-type, multiple-disk clutch

TORQFLOW planetary gear Fully automatic, electrically-hydraulically actuated, force-feed type pump

Type Power train

Transmission No. of speeds

F7, R1

Type Reduction gear

Spiral bevel gear, splash lubrication

Reduction ratio

3.538

Differential type

Straight bevel gear, splash lubrication

Type

Planetary gear, splash lubrication

Final drive

Tires

Suspension

Steering system

Reduction ratio

4.737

Type

Axle type

Fully hydraulic steering system

Front axle

Independent suspension (Mac Pherson type)

Rear axle

Full floating

Front axle

Hydropneumatic (Automatic damping force selection type)

Rear axle

Hydropneumatic

Front tire

24.00 – 35 – 36PR x 2

Rear tire

24.00 – 35 – 36PR x 4

Suspension method

Size and No. Tire pressure

Front and rear tire

Front wheel

kPa {kg/cm2}

470 {4.75}

Single dry disc type, Hydraulically controlled

Breke system

Service brake Rear axle

Parking brake

Retarder

01-4 (10)

Oil cooled multiple disc brake, Hydraulically controlled

Multiple disc wet type disc brake, Hydraulically released spring type

Oil cooled multiple disc type, Hydraulically controlled

HD465-7, HD605-7

SPECIFICATIONS

GENERAL

Machine model

HD465-7

Serial No.

7001 and up

For both steering and work equipment Type

Hydraulic pump

Hydraulic system

Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

348

For charging torque converter Type Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

228

For brake cooling Type Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

456

Hoist cylinder

Cylinder

Type No. – bore (1st – 2nd) x stroke

2-stage piston type (only 2nd stage: double-acting) 2 – (170 mm – 150 mm) x 1,774 mm

Steering cylinder Type No. – bore x stroke

HD465-7, HD605-7

Piston type, double acting 2 – 85 mm x 410 mm

01-5

SPECIFICATIONS

Machine model

HD605-7

Serial No.

7001 and up

Empty

kg

45,900

Max. load

kg

63,000

Gross

kg

108,975

(front)

kg

21,575 (47%)

(rear)

kg

24,325 (53%)

(front)

kg

34,870 (32%)

(rear)

kg

74,105 (68%)

Struck

m3

29

Heaped (2 :1)

m3

40

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

Wheel base

mm

4,300

Front wheel

mm

3,515

Rear wheel

mm

3,080

mm

645

Weight distribution

Weight

GENERAL

Empty

Gross

Dimensions

Performance

Dump body capacity

Tread

Ground clearance Model

KOMATSU SAA6D170E-3

Type

4-cycle, water-cooled, in-line 6-cylinder, direct injection, with turbocharger and after-cooler

No. of cylinders – Bore x stroke Engine

Piston displacement

{cc}

6 – 170 x 170 23.15 {23,150}

Rated output

kW/rpm{HP/rpm}

533/2,000 {715/2,000}

Max. torque

Nm/rpm{kgm/rpm}

3,256/1,400 {332/1,400}

Fuel consumption (Min.)

g/kWh {g/HPh}

207 {154}

Stating motor Alternator Battery

01-6 (10)

mm

24V, 7.5 kW x 2 units 24V, 50A 12V, 200Ah x 2 units

HD465-7, HD605-7

SPECIFICATIONS

GENERAL

Machine model

HD605-7

Serial No.

7001 and up

Structure

3-element, 1-stage, 2-phase

Torque converter Lock- up clutch

Hydraulically actuated, wet-type, multiple-disk clutch

TORQFLOW planetary gear Fully automatic, electrically-hydraulically actuated, force-feed type pump

Type Power train

Transmission No. of speeds

F7, R1

Type Reduction gear

Spiral bevel gear, splash lubrication

Reduction ratio

3.538

Differential type

Straight bevel gear, splash lubrication

Type

Planetary gear, splash lubrication

Final drive

Tires

Suspension

Steering system

Reduction ratio

4.737

Type

Axle type

Fully hydraulic steering system

Front axle

Independent suspension (Mac Pherson type)

Rear axle

Full floating

Front axle

Hydropneumatic (Automatic damping force selection type)

Rear axle

Hydropneumatic

Front tire

24.00 R35 aa x 2

Rear tire

24.00 R35 aa x 4

Suspension method

Size and No. Tire pressure

Front and rear tire

Front wheel

kPa {kg/cm2}

686 {7.0}

Single dry disc type, Hydraulically controlled

Breke system

Service brake Rear axle

Parking brake

Retarder

HD465-7, HD605-7

Oil cooled multiple disc brake, Hydraulically controlled

Multiple disc wet type disc brake, Hydraulically released spring type

Oil cooled multiple disc type, Hydraulically controlled

01-7 (10)

GENERAL

SPECIFICATIONS

Machine model

HD605-7

Serial No.

7001 and up

For both steering and work equipment Type

Hydraulic pump

Hydraulic system

Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

348

For charging torque converter Type Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

228

For brake cooling Type Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

456

Hoist cylinder

Cylinder

Type No. – bore (1st – 2nd) x stroke

2 – (170 mm – 150 mm) x 1,774 mm

Steering cylinder Type No. – bore x stroke

01-8

2-stage piston type (only 2nd stage: double-acting)

Piston type, double acting 2 – 85 mm x 410 mm

HD465-7, HD605-7

WEIGHT TABLE

GENERAL

WEIGHT TABLE This weight table is a guide for use when transporting or handling component. Unit: kg Machine model

HD465-7

HD605-7

Serial Number

7001 and up

7001 and up

2,740

2,740

Output shaft assembly

123

123

Radiator assembly

304

304

Fuel tank

276

276

Torque converter assembly

403

403

1,184

1,184

Drive shaft assembly (front)

28

28

Drive shaft assembly (rear)

62

62

6,355

6,355

822

822

• Final drive (one-side)

1,502

1,502

• Rear brake (one-side)

646

646

Front axle (one-side)

330

330

Front brake (one-side)

142

142

Front suspension cylinder

460

460

Rear suspension cylinder

172

172

4,698

4,698

Cab (Platform)

920

920

Operator's seat

63

63

Steering cylinder

44

44

Hoist cylinder

206

206

Demand valve

26

26

Steering valve

20

20

Hoist valve

34

34

Hydraulic pump (SAR(3)–100+100)

28

28

Hydraulic pump (SAR(3)–80+80)

33

33

Hydraulic pump (SAR(3)100+(1)25)

23

23

10,730

13,418

Engine assembly

Transmission assembly

Rear axle assembly

• Differential

Frame

Dump body

HD465-7, HD605-7

01-9 (10)

GENERAL

FUEL, COOLANT AND LUBRICANTS


01-10 (10)

HD465-7, HD605-7

GENERAL


Engine Oil Pan

Transmission Case

Steering, Hoist Oil Tank

Front Suspension

Rear Suspension

Differential Case

Specified capacity ( )

67

285

180

17 each for right and left

11.3 each for right and left

95

Refill capacity ( )

57

190

122

—

—

95

Final drive case

Fuel tank

Cooling system

Specified oil level ( )


780

154

Refill capacity ( )


—

—

Fuel and oil Select fuel and oil according to the above table. Coolant Since Komatsu genuine Supercoolant (AF-ACL) is added to the cooling water, the latter does not need to be replaced while the atmospheric temperature is above – 10°C. If the atmospheric temperature drops below – 10°C, adjust the concentration of AF-ACL according to the operation and meintenance manual. a The specified capacity means the total amount of oil including oil for components and oil in piping. The refill capacity means the amount of oil needed to refill the system during normal inspection and maintenance. a When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use e n g i n e o i l o f S A E 1 0 W, S A E 1 0 W - 3 0 o r SAE15W-40, even through the atmospheric temperature goes up to 10°C or above during the day.

HD465-7, HD605-7

01-11 (10)

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler ....... 10- 3 Brake oil cooler............................................ 10- 4 Power train skeleton.................................... 10- 5 Output shaft................................................. 10- 6 Drive shaft .................................................. 10-7-1 Torque converter and transmission hydraulic piping......................................................... 10- 8 Torque converter ......................................... 10-10 Transmission ............................................... 10-18 Transmission valve...................................... 10-27 ECMV ......................................................... 10-28 Axle ............................................................. 10-38 Differential ................................................... 10-42 Final drive.................................................... 10-44 Wheels ........................................................ 10-46 Suspension.................................................. 10-48 Suspension cylinder .................................... 10-50 Rear axle support ........................................ 10-56 Steering column........................................... 10-58 Steering linkage........................................... 10-59 Brake piping ................................................ 10-62 Brake valve.................................................. 10-64 Emergency brake valve............................... 10-67 Relay valve.................................................. 10-68 Front brake off valve.................................... 10-69 Accumulator charge valve ........................... 10-71 Accumulator ................................................ 10-75 Slack adjuster.............................................. 10-76 Brake ........................................................... 10-78 Proportional reducing valve......................... 10-83 Parking brake solenoid valve ...................... 10-84 Steering and hoist hydraulic piping.............. 10-86

Steering and hoist hydraulic system diagram...................................................... 10-88 Dump body control ...................................... 10-90 HYdraulic tank ............................................. 10-91 Steering control valve .................................. 10-92 Crossover relief valve .................................. 10-96 Steering cylinder .......................................... 10-97 Demand valve.............................................. 10-98 Hoist valve ................................................. 10-102 EPC valve.................................................. 10-108 Hoist cylinder ............................................. 10-109 Hydraulic pump.......................................... 10-110 Air conditioner............................................ 10-114 Machine monitor system............................ 10-119 Engine control system ............................... 10-134 Automatic shift control system ................... 10-136 Payload meter (card type)...................... 10-151 Automatic emergency steering system...... 10-184 Automatic suspension system ................... 10-188 Retarder control system ............................ 10-192 Sensors, switches...................................... 10-204 Dump lever ................................................ 10-212 [Related to VHMS controller] VHMS controller ........................................ 10-216 BLOW-BY pressure sensor ....................... 10-216 Engine oil temperature sensor................... 10-217 Exhaust temperature sensor/amp ............. 10-218 Ambient temperature sensor...................... 10-218 Communications (orb•••orbcomm) controller/antenna.................................... 10-219 Payload meter (Having VHMS) ................. 10-220

For details of VHMS, see TESTING AND ADJUSTING.

HD465-7, HD605-7

10-1 (10)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER

RADIATOR, TORQUE CONVERTER OIL COOLER, AFTER COOLER, WORK EQUIPMENT OIL COOLER, FUEL COOLER

1. Pick-up for radiator coolant level sensor 2. Upper tank 3. Lower tank 4. Core 5. Work equipment oil cooler 6. After cooler 7. Fuel cooler A : Coolant inlet port B : Coolant outlet port

HD465-7, HD605-7

Specifications Radiator Core type: CF4-5 Total radiation surface: 130.6 m2 Work equipment oil cooler Core type: CF40-1 Radiation surface: 2.90 m2 Fuel cooler Core type: FC1-3 Heat radiation area: 6.75 m2

10-3 (10)


BRAKE OIL COOLER

BRAKE OIL COOLER

1. Cooler element A : Oil inlet B : Oil outlet C : Coolant inlet D : Coolant outlet

10-4 (10)

Oil cooler specifications Element type : Multiple plate Radiation surface: 8.13 m2 Pressure resistance (oil side): 2.9 MPa {30 kg/cm2}

HD465-7, HD605-7


POWER TRAIN SKELETON

POWER TRAIN SKELETON 1. 2. 3. 4. 5.

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

HD465-7, HD605-7

Engine Output shaft Front drive shaft Brake cooling pump (SAR(3)100+100) Torque converter transmission charge pump and brake cooling brake control pump (SAR(3)100+25) PTO Torque converter Transmission Rear drive shaft Differential gear Drive shaft Brake Tire Final drive Parking brake Steering, hoist and hoist control pump (SAR(3)80+80+(1)6)

10-5


OUTPUT SHAFT

OUTPUT SHAFT

1. Rubber cushion 2. Outer body 3. Flange 4. Shaft 5. Coupling 6. Inner body 7. Cover

10-6

Function The output shaft is installed to the engine flywheel, and absorbs the twisting vibration caused by changes in the engine torque.

HD465-7, HD605-7

OUTPUT SHAFT


Unit: mm

No.

Check item

Criteria Tolerance Hole

Standard clearance

Clearance limit

Shaft 100

0 –0.015

–0.010 –0.045

–0.045 – 0.005

0.02

Standard size 1

Remedy

Clearance between flywheel and bearing

2

Clearance between shaft and bearing

55

–0.010 –0.040

0 –0.015

–0.005 – 0.040

0.10

3

Clearance between bearing and cover

150

+0.006 –0.024

–0.008 –0.033

–0.039 – 0.016

0.06

4

Clearance between bearing and shaft

85

+0.025 +0.003

+0.005 –0.025

–0.050 – 0.002

0.013

5

Wear of oil seal contact surface of coupling

6

Standard size

Repair limit

110

0 –0.1

Standard backlash

Backlash limit

0.080 – 0.231

0.4

Original dimension: Lo

Standard backlash (Dimension at smallest width: L)

90

81

75

67

Replace

Repair or replace

Backlash at spline

Defomation of rubber cushion 7

External

HD465-7, HD605-7

Replace

No cracks

10-7 (10)


DRIVE SHAFT

DRIVE SHAFT

1. Front drive shaft 2. Rear drive shaft

10-7-1 (6)

Outline • The power from the engine is transmitted through the output shaft, the front drive shaft (1) and the transmission, to the rear drive shaft (2).

HD465-7, HD605-7


TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING


10-8

HD465-7, HD605-7



1. Torque converter 2. Transmission 3. Oil filler tube 4. Hydraulic pump (SAR(3)100+(1)25) 5. Torque converter valve 6. Transmission oil filter

HD465-7, HD605-7

10-9


TORQUE CONVERTER

TORQUE CONVERTER

1. PTO Gear (Number of teeth : 91) A : Main oil pressure detection port B : Torque converter oil inlet C : Torque converter oil inlet pressure detection port D : Torque converter oil outlet E : To transmission control valve F : To lock-up clutch G: Torque converter oil outlet pressure detection port H : To transmission lubrication

10-10 (10)

Specification Type : 3-element, 1-stage, 2-phase With modulation With lock-up clutch Lock-up clutch : Wet type double plate clutch Hydraulic control (with modulation mechanism) Stall torque ratio: 2.32

HD465-7, HD605-7


1. 2. 3. 4. 5. 6. 7. 8. 9.

Coupling Input shaft (Number of teeth : 108) Front housing Drive case Turbine Race Torque converter valve Pump Rear housing

HD465-7, HD605-7

10. 11. 12. 13. 14. 15. 16.

TORQUE CONVERTER

Stator shaft One-way clutch Stator Disc Piston Clutch housing Retainer

10-11


10-12

TORQUE CONVERTER

HD465-7, HD605-7

TORQUE CONVERTER


Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

φ 110

0 –0.087

φ 109.8

Input shaft seal ring sliding portion inside diameter

φ 35

+0.025 0

φ 35.1

3

Pump housing seal ring sliding portion inside diameter

φ 135

+0.040 0

φ 135.5

4

Input shaft seal ring sliding portion inside diameter

φ 75

+0.030 0

φ 75.1

Stator shaft seal ring wear

Width

3.95

0 –0.1

3.55

5

Thickness

5.1

±0.1

4.59

1

Coupling oil seal sliding portion outside diameter

2

6

Outer race one-way clutch transmission face inside diameter

φ 127.844

±0.013

φ 127.874

7

Inner race one-way clutch transmission face outside diameter

φ 108.883

±0.013

φ 108.853

8

Bushing sliding portion inside diameter

φ 108.96

+0.040 +0.018

φ 109.04

9

Bushing sliding portion thickness

5

0 –0.1

4.5

10

Clutch disc thickness

5.4

±0.1

4.8

Tolerance

Standard clearance

Clearance limit

+0.097 0

0.5 – 0.797

0.88

+0.081 0

0.11 – 0.272

0.30

Standard size 11

12

Clearance between clutch housing and piston (outside)

Clearance between clutch housing and piston (inside)

HD465-7, HD605-7

Shaft

Hole

φ 420

–0.5 –0.7

φ 295

–0.110 –0.191

Correction by chrome plating or replacement

Replace

10-13


TORQUE CONVERTER

POWER TRAIN When the lock-up clutch is [RELEASED]

When the lock-up clutch is [IN]

•

•

•

•

When the lock-up clutch is [RELEASED], the drive case (1) is separated from the turbine (2) and the torque converter functions as a normal torque converter. The power generated with the engine is transmitted to the coupling (3), the input shaft (4) and the clutch housing (5) through the drive shaft and the damper and rotates the drive case (1) and the pump (6) as one part. Power of the pump (6) rotates the turbine (2) using oil as the medium and is transmitted from the turbine (2) to the transmission input shaft (7).

10-14 (9)

•

•

When the lock-up clutch is [IN], the drive case (1) and the turbine (2) are connected and integrated, and the stator (8) rotates with the pump (6) and the turbine (2). The power generated with the engine is transmitted to the coupling (3), the input shaft (4) and the clutch housing (5) through the propeller shaft from the damper and rotates the drive case (5) and the pump (6) as one part. Since the drive case (1) and the turbine (2) were connected, the power is transmitted directly to the transmission input shaft (7) from the turbine (2) not using oil as the medium.

HD465-7, HD605-7


TORQUE CONVERTER

OIL FLOW

•

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

HD465-7, HD605-7

10-15 (9)

TORQUE CONVERTER


TORQUE CONVERTER VALVE

Unit: mm

No.

Check item

Criteria Tolerance Shaft

Hole

Standard clearance

32

–0.035 –0.045

+0.016 0

0.035 – 0.061

0.081

32

–0.035 –0.045

+0.016 0

0.035 – 0.061

0.081

Standard size 1

2

Clearance between torque converter spool and body

Clearance between main relief spoon and body

Remedy

Standard size 3

Main relief valve spring

Clearance limit

Repair limit

Replace

Free length

Installed length

Installed load

Free length

Installed load

118

94.5

1213.2 N {123.8 kg}

114.5

1153.8 N {117.6 kg}

4

Torque converter relief valve spring

137

93.5

331.2 N {33.8 kg}

132.9

315.0 N {32.1 kg}

5

Poppet spring (touque converter relief, main relief)

26

17

32.0 N {3.3 kg}

25.2

30.8 N {3.1 kg}

10-16 (10)

HD465-7, HD605-7


TRANSMISSION

TRANSMISSION

10-18

HD465-7, HD605-7


1. Input shaft 2. Transmission valve 3. Coupling 4. Strainer 5. Drain valve

HD465-7, HD605-7

TRANSMISSION

A : Speed sensor (for input shaft) B : Speed sensor (for intermediate shaft) C : Speed sensor (for output shaft) D : Lubricating oil pressure detection port E : To pump (suction) F : To lock up G: From torque converter (main circuit) J : From oil cooler H : From torque converter (lubrication circuit) K : From torque converter (drain circuit) L : Brake cooling relief valve M: Lubrication relief valve N : To breather

10-19


10-20

TRANSMISSION

HD465-7, HD605-7


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

TRANSMISSION

Input shaft No. 1 sun gear (Number of teeth : 34) No. 1 clutch hub No. 1 clutch (High) No. 1 planetary pinion (Number of teeth : 32) No. 1 planetary carrier No. 2 clutch hub No. 2 clutch (Low) No. 1 ring gear (Number of teeth : 98) No. 2 clutch housing No. 3 clutch housing No. 3 clutch drum No. 3 clutch (4th) No. 3 clutch hub No. 4 planetary pinion (Number of teeth : 21) No. 4 clutch (3rd) No. 4 ring gear (Number of teeth : 93) No. 4 sun gear (Number of teeth : 51) No. 5 clutch (R) No. 5 planetary pinion (Number of teeth : 21) No. 5 sun gear (Number of teeth : 41) No. 5 ring gear (Number of teeth : 93) No. 6 clutch (2nd) No. 6 ring gear (Number of teeth : 105) No. 6 planetary pinion (Number of teeth : 30) No. 6 sun gear (Number of teeth : 45) No. 6, 7 planetary carrier No. 7 clutch (1st) No. 7 ring gear (Number of teeth : 104) Output shaft No. 7 planetary pinion (Number of teeth : 38) No. 7 clutch piston No. 6 clutch piston Intermediate shaft (No. 7 sun gear : Number of teeth 28) No. 5 clutch piston No. 5 planetary pinion (Number of teeth : 21) No. 4, 5 planetary carrier No. 3 clutch piston No. 2 clutch piston No. 1 clutch piston No. 4 clutch piston

HD465-7, HD605-7

10-21


10-22

TRANSMISSION

HD465-7, HD605-7

TRANSMISSION


Unit: mm

No.

Check item

Criteria

Remedy

Standard size 1

No. 1 clutch spring

Repair limit

Free length

Installed length

Installed load

Free length

Installed load

42.0

32.0

74.5 N {7.6 kg}

39.5

63.7 N {6.5 kg}

2

No. 4 clutch spring

52.0

49.1

49.1 N {5.0 kg}

48.9

42.2 N {4.3 kg}

3

No. 5 clutch spring

91.0

75.0

141.2 N {14.4 kg}

85.5

119.6 N {12.2 kg}

4

No. 6 clutch spring

68.0

57.85

113.8 N {11.6 kg}

63.9

97.1 N {9.9 kg}

5

No. 7 clutch spring

68.0

52.0

179.5 N {18.3 kg}

63.9

153.0 N {15.6 kg}

6

Total thickness of 3 discs and 2 plates for No. 1 clutch

Standard size

Tolerance

Repair limit

27.8

±0.22

25.8

7


45.0

±0.30

42

8


35.0

±0.26

32.3

9


36.6

±0.26

33.9

10


47

±0.30

43.7

11


44.8

±0.28

42.1

12


39.0

±0.26

36.3

No. 1,4,5,6,7

5.4

±0.10

4.8

13

Thickness of 1 disc

No. 2,3

5.0

±0.10

4.4

No. 1,6,7

5.8

±0.10

5.6

No. 2,3,4,5

5.0

±0.10

4.8

Width

2.56

–0.01 –0.03

2.30

Thickness

1.7

±0.10

1.55

Width

3.0

–0.01 –0.03

2.70

Thickness

3.1

±0.10

2.95

Wear of No. 1 car- Width rier, No. 3 clutch hub and No. 4 sun Thickness gear seal rings

4.0

–0.01 –0.03

3.6

4.6

±0.12

4.45

14

15

16

17

Thickness of 1 plate

Wear of transmission input shaft seal ring (small)

Wear of transmission input shaft seal ring (large)

HD465-7, HD605-7

Replace

10-23

TRANSMISSION


Unit: mm

No.

18

19

20

21

22

Check item

Wear of No. 2 and 3 clutch collar seal rings

Wear of No. 4 and 5 carrier seal rings




Criteria Standard size

Tolerance

Repair limit

4.0

–0.01 –0.03

3.6

Thickness

5.1

±0.12

4.85

Width

4.0

–0.01 –0.04

3.6

Thickness

6.3

±0.15

6.15

Width

4.0

–0.01 –0.04

3.6

Thickness

4.0

±0.15

3.85

Width

3.95

0 –0.1

3.56

Thickness

5.25

±0.1

4.73

Width

4.0

–0.01 –0.04

3.6

Thickness

4.0

±0.15

3.85

Width

23

Backlash between No. 1 sun gear and planetary gear

0.13 – 0.36

24

Backlash between No. 1 planetary gear and ring gear

0.16 – 0.41

25


0.14 – 0.36

26


0.15 – 0.39

27


0.14 – 0.36

28

Backlash between No. 5 planetary gear and planetary gear

0.13 – 0.34

29


0.15 – 0.39

30


0.16 – 0.41

31


0.16 – 0.41

32


0.13 – 0.36

33


0.17 – 0.44

34

Disc inner teeth deformation

35

Thrust washer thickness (No. 1, 4 and 5 planetary gears)

36

Thrust washer thickness (No. 6 and 7 planetary gears)

10-24

Remedy

Replace

Repair limit : 0.3 Standard size

Tolerance

Repair limit

2

±0.1

1.6

3

±0.1

2.4

HD465-7, HD605-7

TRANSMISSION


Unit: mm

No.

37

38

Check item

Criteria

Remedy

Location

Standard clearance

Clearance limit

No. 1 gear train

0.30 – 0.80

1.5

No. 4 gear train

0.30 – 0.80

1.5

No. 5 gear train

0.30 – 0.80

1.5

No. 6 gear train

0.30 – 0.80

1.5

No. 7 gear train

0.30 – 0.80

1.5

Replace the thrust washer or the carrier

Planetary gear side clearance

Stepped-type wear of seal ring counter face

Standard size

Wear

—

0.05 max.

Standard size

Repair limit

120

119.8

Replace 39

Output shaft oil seal contact surface

Hole

Standard clearance

Clearance limit

430

–0.5 –0.7

+0.097 0

0.5 – 0.797

0.88

Inside

405

–0.135 –0.232

+0.097 0

0.135 – 0.329

0.36

No. 2,3 Outside

275

–0.5 –0.7

+0.081 0

0.5 – 0.781

0.86

Middle

255

–0.110 –0.191

+0.081 0

0.110 – 0.272

0.30

Inside

175

–0.5 –0.7

+0.063 0

0.5 – 0.763

0.84

No. 4,5,6,7 Outside

430

–0.5 –0.7

+0.089 0

0.5 – 0.789

0.87

No. 4 Inside

395

–0.125 –0.214

+0.089 0

0.125 – 0.303

0.33

No. 5,7 Inside

380

–0.125 –0.214

+0.089 0

0.125 – 0.303

0.33

No. 6 Inside

375

–0.125 –0.214

+0.089 0

0.125 – 0.303

0.33

No. 1 Outside

40

Clearance between cylinder and piston

HD465-7, HD605-7

Standard size

Tolerance Shaft

Clutch No.

When any damage like seized streak is found on any surface, if corrected and the allowable clearance is maintained, it can be used. Replace it if damaged remarkably

10-25

TRANSMISSION


Outline • The transmission consists of an F7 R1 planetary gear type transmission with a control valve. • The transmission and torque converter are connected at the transmission input shaft. • Gear shifting is carried out automatically by the automatic transmission according to changes in engine speed. Gear Shifting Function • The inside of the transmission consists of 7 clutch packs and 5 sets of planetary gears. These are divided into the front group and rear group. •

One clutch pack in the front group and one clutch pack in the rear group are actuated simultaneously by oil pressure sent from the transmission valve to give the speed range and reduction ratio.

10-26 (10)

Group

Clutch pack

Front group

No. 1 clutch (High) No. 2 clutch (Low)

Planetary gear

No. 1 planetary gear

No. 3 clutch (4th)

Rear group

No. 4 clutch (3rd)


No. 5 clutch (R)


No. 6 clutch (2nd)


No. 7 clutch (1st)


Speed range

Clutches engaged

Reduction ration

F1 F2 F3 F4 F5 F6 F7 R

No. 2 – No. 7 (Low – 1st) No. 2 – No. 6 (Low – 2nd) No. 1 – No. 6 (High – 2nd) No. 2 – No. 4 (Low – 3rd) No. 1 – No. 4 (High – 3rd) No. 2 – No. 3 (Low – 4th) No. 1 – No. 3 (High – 4th) No. 2 – No. 5 (Low – R)

4.714 3.333 2.475 1.825 1.355 1.000 0.742 3.969

HD465-7, HD605-7

TRANSMISSION VALVE


TRANSMISSION VALVE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

ECMV (for high clutch) ECMV (for lockup clutch) ECMV (for low clutch) ECMV (for 4th clutch) ECMV (for 3rd clutch) ECMV (for R clutch) ECMV (for 2nd clutch) ECMV (for 1st clutch) Valve oil filter Seat

HD465-7, HD605-7

A : High clutch pressure detection port B : Lockup clutch pressure detection port C : Low clutch pressure detection port D : 4th clutch pressure detection port E : 3rd clutch pressure detection port F : R clutch pressure detection port G: 2nd clutch pressure detection port H : 1st clutch pressure detection port

ECMV Clutch Operation Table ECMV Gear range

R

F1

1st 2nd 3rd 4th Low High ¡

¡

F2

¡

F3

¡

¡ ¡

F4

¡

F5

¡

¡ ¡

F6

¡

F7

¡

¡ ¡

N R1

¡

¡

10-27 (9)

ECMV


ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve (FOR HIGH, LOCKUP, REV AND 1ST CLUTCHES)

1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve (*1) 7. Nameplate (*2) A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port

10-28 (9)

*1: The spool of pressure control valve is difference between the clutch for High, Rev and 1st clutches, and the clutch for lockup. *2: The character on nameplate is different between nameplates for high, Rev and 1st clutches and that for lockup clutch. Applicable clutch

Character on nameplate

High, Rev, 1st

A*******

Lockup

E*******

HD465-7, HD605-7


ECMV

ECMV FOR LOCKUP CLUTCH Outline • This valve is used for setting oil pressure of the lockup clutch to the set pressure, and for switching lockup clutch. Since the modulation actuates as shown below, the valve enables to engage the lockup clutch smoothly and to reduce shocks at the time of gearshift. Also, the valve prevents the power train from causing peak torque. This improves operator comfort and makes the power train more durable.

Operation When the torque converter is operating without lockup.

WHEN SWITCHING LOCKUP CLUTCH (Lockup clutch OFF to ON)

WHEN SHIFTING GEAR (At direct driving)

•

HD465-7, HD605-7

When the torque converter is operating without lockup, no current is flowing to the proportional solenoid (1). The pressure control valve (3) drains oil from the clutch port A through the drain port T, and the lockup clutch is [RELEASED]. Since oil pressure force does not work to the pressure detection valve (4), the fill switch (5) is turned "OFF".

10-29 (10)


WHEN THE TORQUE CONVERTER IS OPERATING WITH LOCKUP (Torque converter operation with lockup : Lockup operation) At filling time

At pressure adjusting time

•

•

Electric signal commands to flow the current to the proportional solenoid (1) in case of lockup operation. Then oil pressure force balancing with solenoid force works in Chamber B and pushes the pressure control valve (3) to the left. Then the pump port P and the clutch port A open, the valve starts filling the clutch with oil, and when the clutch is filled with oil, the fill switch (5) is turned "ON".

10-30 (9)

ECMV

When the current is supplied to the proportional solenoid (1), the solenoid generates thrusting force in proportion to the current. The solenoid thrust force balances with the sum of the clutch port thrust force by oil pressure, and bounce force of the pressure control valve spring (2). Then the pressure is adjusted. To reduce gear shift shock, the oil pressure of the lockup clutch is lowered once at the time of gear shift. At the time, the oil pressure becomes to such pressure as that the lockup piston push force balances with the torque converter internal pressure.

HD465-7, HD605-7


ECMV

ECMV FOR SPEED RANGE CLUTCH Outline of ECMV • The ECMV consists of a pressure regulator valve and a fill switch. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil pressure. • Fill switch Detects that the clutch is filled with oil. It has the functions below. 1. When the clutch is filled with oil, a signal (the fill signal) is sent to the controller to notify that filling is finished. 2. While oil pressure is being applied to the clutch, a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied.

ECMV and proportional solenoid • One proportional solenoid is installed for one ECMV. After receiving the command current from the controller, it produces thrust shown in the graph below. By making the proportional solenoid-produced thrust act on the pressure control valve spool, it produces an oil pressure shown in the graph below. By controlling the amount of command current, the thrust is changed to operate the pressure control valve, controlling the oil flow and oil pressure. Current-Propulsion force characteristics of propotional solenoid

Propulsion force-Hydraulic pressure characteristics of proportional solenoid

A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

HD465-7, HD605-7

ECMV and fill switch • One fill switch is installed for one ECMV. If the clutch finishes filling, the fill switch is turned "ON" by the pressure of the clutch. By this signal, the oil pressure starts build-up.

10-31 (9)

ECMV


ECMV operation • The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. The relationship between the proportional command current for the ECMV, clutch input pressure and output signal of the fill switch is shown in the graph below.

Before shifting gear (when drained) (A range in chart)

•

When no current is supplied to the proportional solenoid (1), the pressure control valve (3) is draining oil from the clutch port A through the drain port T. Since no oil pressure works to the pressure detection valve (4), the fill switch (5) is "OFF".

A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

10-32 (9)

HD465-7, HD605-7


Filling (B range in chart)

Pressure regulation (C range in chart)

•

•

When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil, an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. Then, the pump port P and the clutch port A open, the valve starts filling the clutch with oil, and when the clutch fills with oil, the fill switch (5) is turned "ON".

HD465-7, HD605-7

ECMV

When a current is supplied to the proportional solenoid (1), the solenoid generates a thrust in proportion to the current. The solenoid thrust, and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure.

10-33 (9)

ECMV


(FOR LOW, 4TH, 3RD AND 2ND CLUTCHES WITH FLOW DETECTION VALVE)

1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve 7. Nameplate (*1) *1:

Applicable clutch

Character on nameplate

Low, 4th, 3rd, 2nd

D*******

10-34 (9)

A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port

HD465-7, HD605-7


ECMV

ECMV FOR SPEED RANGE CLUTCH Outline of ECMV • The ECMV consists of a pressure regulator valve and a fill switch. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil pressure. • Fill switch Detects that the clutch is filled with oil. It has the functions below. 1. When the clutch is filled with oil, a signal (the fill signal) is sent to the controller to notify that filling is finished. 2. While oil pressure is being applied to the clutch, a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied.

ECMV and proportional solenoid • One proportional solenoid is installed for one ECMV. After receiving the command current from the controller, it produces thrust shown in the graph below. By making the proportional solenoid-produced thrust act on the pressure control valve spool, it produces an oil pressure shown in the graph below. By controlling the amount of command current, the thrust is changed to operate the pressure control valve, controlling the oil flow and oil pressure. Current-Propulsion force characteristics of propotional solenoid

Propulsion force-Hydraulic pressure characteristics of proportional solenoid

A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

HD465-7, HD605-7

ECMV and fill switch • One fill switch is installed for one ECMV. If the clutch finishes filling, the fill switch is turned "ON" by the pressure of the clutch. By this signal, the oil pressure starts build-up.

10-35 (9)

ECMV


ECMV operation • The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. The relationship between the proportional command current for the ECMV, clutch input pressure and output signal of the fill switch is shown in the graph below.

Before shifting gear (when drained) (A range in chart)

•

A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

10-36 (9)

When no current is supplied to the proportional solenoid (1), the pressure control valve (3) is draining oil from the clutch port A through the drain port T. Since no oil pressure works to the flow detection valve (4), the fill switch (5) is "OFF".

HD465-7, HD605-7


Filling (B range in chart)

Pressure regulation (C range in chart)

• •

When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil, an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. Then, the valve starts filling the clutch chamber with oil from the pump port P through the orifice a of the flow detection valve spool (4). At the time, a differential pressure occurs between the upper stream and the lower stream of the orifice a of the flow detection valve spool. The differential pressure pushes the flow detection valve spool (4) to the left. When the clutch chamber is filled with oil and oil no longer comes to flow from the pump port P to the clutch port A, the differential pressure disappears on both sides of the orifice a of the flow detection valve spool (4) and the flow detection valve spool (4) is pushed to the right by oil pressure force, and the fill switch (5) is turned "ON".

HD465-7, HD605-7

ECMV

When a current is supplied to the proportional solenoid (1), the solenoid generates a thrust in proportion to the current. The solenoid thrust, and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure.

10-37 (9)

AXLE


AXLE FRONT

1. Wheel hub Unit: mm

No.

Check item

2

Wear of oil seal sliding surface

10-38 (10)

Criteria

Remedy

Standard size

Tolerance

Repair limit

280

0 –0.130

—

Repair or replace

HD465-7, HD605-7

AXLE


REAR

1. Differential 2. Axle housing 3. Brake 4. Final drive

HD465-7, HD605-7

Specifications Reduction ratio Differential: 3.538 Final drive : 4.737 Oil Differential: EO30-CD (95 liters) Final drive : EO30-CD (32 liters each side) Tire size : 24.00-35 (HD465-7) 24.00R35 (HD605-7) Rim size: 17.00-35

10-41


DIFFERENTIAL

DIFFERENTIAL

1. Coupling 2. Cross shaft 3. Bevel gear (No. of teeth: 46) 4. Side gear (No. of teeth: 24) 5. Pinion gear (No. of teeth: 17) 6. Bevel pinion (No. of teeth: 13)

10-42

Specifications Type: Spiral bevel gear, splash-type lubrication Reduction ratio: 3.538 Differential: Straight bevel gear, splash-type lubrication Oil: EO30-CD (95 liters)

HD465-7, HD605-7

DIFFERENTIAL


Unit: mm

No. 7

Check item Wear of oil seal contact surface of coupling

8

Thickness of side gear thrust washer

9

Backlash between bevel gear and pinion

HD465-7, HD605-7

Criteria

Remedy

Standard size

Tolerance

Repair limit

150

0 –0.100

—

Repair or replace

6

0 –0.050

5.5

Replace

0.41 – 0.56

Adjust

10-43


FINAL DRIVE

FINAL DRIVE

1. Sun gear (No. of teeth: 19) 2. Planet gear (No. of teeth: 31) 3. Planet gear shaft 4. Ring gear (No. of teeth: 87) 5. Inner hub 6. Wheel hub 7. Drive shaft

10-44

Specification Type: Planetary gear, splash-type lubrication Reduction ratio: 4.737 Oil: EO30-CD (32 liters each side)

HD465-7, HD605-7

FINAL DRIVE


Unit: mm

No.

Check item

8

Backlash between planet gear and sun gear

9

Backlash between planet gear and ring gear

10

Curvature of drive shaft

11

Criteria

Remedy

Standard backlash

Repair limit

0.22 – 0.67

0.8

0.28 – 0.77

1.0

Replace

Repair or replace

Repair limit: 1.5 TIR Standard size

Tolerance

Repair limit

51.5

±0.1

50

Thickness of spacer

HD465-7, HD605-7

Replace

10-45


WHEELS

WHEELS FRONT WHEEL 1. Tire 2. Rim assembly 3. Valve Specifications Rim size: 17.00 × 35 Tire size : 24.00-35 (HD465-7) 24.00R35 (HD605-7)

REAR WHEEL

1. Rim assembly 2. Valve 3. Extension Specifications Rim size: 17.00 × 35 Tire size : 24.00-35 (HD465-7) 24.00R35 (HD605-7)

10-46

HD465-7, HD605-7


SUSPENSION

SUSPENSION

1. Front suspension cylinder 2. Radius rod (Upper rod) 3. Rear suspension cylinder 4. Radius rod (Lower rod) 5. Arm (A-frame)

Outline • The suspension system supports the weight of the chassis, and absorbs the shock from uneven road surfaces to provide a comfortable ride for the operator. At the same time, it maintains the stability of the machine by ensuring that all four wheels are always in contact with the ground surface. In this way, it allows the machine to demonstrate its full performance in items such as acceleration, braking, and turning, even when traveling at high speed. • Hydropneumatic cylinders are used for the suspension cylinders to reduce the shock. With

10-48 (10)

•

hydropneumatic cylinders, the suspension cylinder is charged (sealed) with oil and nitrogen gas. This acts as a shock absorber (spring and damper) by contracting and expanding the nitrogen gas and oil to absorb the load from the road surface. In addition to these functions, the front suspension employs an automatic suspension system. In this system, the force of the suspension is automatically changed by selecting the dumping force to match the travel conditions and load conditions. This further increases the stability and riding comfort of the machine. HD465-7, HD605-7


SUSPENSION

Function 1. Front suspension The front suspension cylinder functions as a shock absorber and spring, and is connected by spherical bearings to the lower arm (A-frame) and main frame. The wheels move up and down in accordance with the retraction and extension of the suspension cylinder to maintain the proper alignment for the wheels and to improve the stability of the machine.

2. Rear suspension The differential housing is supported by the frame and two radius rods at the bottom, and at the top by two inverted-V-shaped rods and two suspension cylinders. It is connected to these at both ends by spherical bearings. It transmits the load and motive force through the top and bottom rods. The inverted-V-shaped rods at the top also function to maintain the center of the machine (axle). Employment of the inverted-V-shaped link improves the rolling steering characteristics.

HD465-7, HD605-7

10-49 (6)


SUSPENSION CYLINDER

SUSPENSION CYLINDER FRONT

1. 2. 3. 4.

Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) 5. Air bleeding valve 6. Tube

10-50 (10)

7. 8. 9. 10.

Air cylinder Valve assembly Damping force selector valve Damping force selector valve lever

A : Port B : Port

HD465-7, HD605-7

SUSPENSION CYLINDER


Unit: mm

No.

Check item


Hole

Standard clearance

160

–0.043 –0.106

+0.240 0

0.043 – 0.346

0.4

Standard size 11

Remedy

Clearance between piston rod and bushing

Clearance limit Replace bushing

12


160

–0.043 –0.106

+0.540 +0.360

0.403 – 0.646

0.7

Replace bushing

13

Clearance between cylinder and wear ring

200

–0.05 –0.26

+0.115 0

0.05 – 0.375

0.8

Replace 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.

15

Deformation of stopper

HD465-7, HD605-7

Elongation : Max. 5 mm Protrusion: Max. 2 mm No cracks

10-51 (10)


SUSPENSION CYLINDER

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

10-52 (10)

HD465-7, HD605-7


SUSPENSION CYLINDER

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

HD465-7, HD605-7

10-53 (6)


SUSPENSION CYLINDER

REAR

1. 2. 3. 4. 5.

Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) Ball

10-54 (10)

HD465-7, HD605-7

SUSPENSION CYLINDER


Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Hole

Standard clearance

Clearance limit

Shaft 180

–0.043 –0.106

+0.246 0

0.043 – 0.352

0.4

7


180

–0.043 –0.106

+0.246 0

0.043 – 0.352

0.4

8

Clearance between cylinder and wear ring

220

–0.050 –0.260

+0.115 –0.008

0.05 – 0.375

0.8

Standard size 6


Replace

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

HD465-7, HD605-7

1. Valve (for bleeding and mounting pressure sensor) 2. Cavity 3. Check ball 4. Orifice 5. Orifice 6. Oil chamber

7. 8. 9. 10.

Nitrogen gas chamber Cylinder rod Cylinder Feed valve

a : When extending b : When retracting

10-55 (10)


REAR AXLE SUPPORT

REAR AXLE SUPPORT

1. Rod 2. Rod 3. Axle 4. Suspension cylinder

10-56 (6)

HD465-7, HD605-7

REAR AXLE SUPPORT


Unit: mm

No.

Check item


Hole

Standard clearance

–0.030 –0.076

+0.046 0

0.030 – 0.122

0.3

0.110 – 0.180

0.5

0.030 – 0.122

0.3

0.110 – 0.180

0.5

Standard size 5

Clearance between rod mounting pin and bushing 70

6

Clearance between inner and outer bushing

100

7

Clearance between suspension cylinder mounting pin and frame or axle

70

8


100

HD465-7, HD605-7

Remedy

–0.030 –0.076

+0.046 0

Clearance limit

Replace

10-57 (10)


STEERING COLUMN

STEERING COLUMN

1. Steering shaft 2. Steering column 3. Lock lever 4. Yoke 5. Joint shaft 6. Steering valve

10-58 (6)

HD465-7, HD605-7


STEERING LINKAGE

STEERING LINKAGE

1. Center lever 2. Tie rod 3. Arm (A-frame) 4. Knuckle arm

HD465-7, HD605-7

10-59 (6)


10-60 (6)

STEERING LINKAGE

HD465-7, HD605-7

STEERING LINKAGE


Unit: mm

No.

Check item

Criteria Tolerance Standard size

5

Clearance between inner and outer for knuckle arm bushing

Shaft

Hole

165

Remedy Standard clearance

Clearance limit

0.150 – 0.300

0.7

6

Clearance between bushing and pin

85

0 –0.035

+0.054 0

0–

7

Clearance between steering cylinder mounting pin and bushing

45

–0.025 –0.064

+0.069 +0.030

0.055 – 0.133

0.3

8


80

0.120 – 0.250

0.4

9

Clearance between tie rod mounting pin and bushing

40

0.055 – 0.133

0.3

10


110

0.120 – 0.250

0.4

11

Clearance between arm mounting pin and bushing

55

0.060 – 0.152

0.3

12


100

0.110 – 0.180

0.5

13

Clearance between arm mounting pin and bushing

70

–0.030 –0.076

+0.091 +0.045

0.075 – 0.167

0.3

14

Clearance between center lever mounting pin and bushing

55

–0.030 –0.076

+0.197 +0.137

0.167 – 0.273

1.0

15


80

0.120 – 0.250

0.4

16

Clearance between tie rod mounting pin and bushing

40

–0.025 –0.064

+0.069 +0.030

0.055 – 0.133

0.3

17

Clearance between suspension cylinder mounting pin and bushing

60

–0.030 –0.076

+0.046 0

0.030 – 0.122

0.3

HD465-7, HD605-7

–0.025 –0.064

–0.030 –0.076

+0.069 +0.030

+0.076 +0.030

0.089

0.3

Replace

10-61 (10)


BRAKE PIPING

BRAKE PIPING HD465-7 Serial No.: 7001 – 7265 HD605-7 Serial No.: 7001 – 7112

10-62 (12)

HD465-7, HD605-7


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

BRAKE PIPING

Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder)

HD465-7, HD605-7

10-63 (10)


BRAKE PIPING

HD465-7 Serial No.: 7266 and up HD605-7 Serial No.: 7113 and up

10-63-1 (12)

HD465-7, HD605-7


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

BRAKE PIPING

Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder) Reducing valve

HD465-7, HD605-7

10-63-2 (12)


BRAKE VALVE

BRAKE VALVE

1. Pilot piston 2. Rod 3. Lower cylinder 4. Spool 5. Upper cylinder 6. Spool

10-64 (6)

A : To rear brake B : To front brake C : To transmission oil pan D : From front accumulator E : From rear accumulator

HD465-7, HD605-7


Operation Upper portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. Lower portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed down by plunger (6). When this happens, drain port b is closed, and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders.

BRAKE VALVE

Applying brake when upper valve fails • Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails • Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.

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

HD465-7, HD605-7

10-65 (6)


Lower portion • When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D. Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. • The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.

10-66 (6)

BRAKE VALVE

Brake released Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the rear brakes. Lower portion • When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the front brake.

HD465-7, HD605-7


EMERGENCY BRAKE VALVE

EMERGENCY BRAKE VALVE

1. Rod 2. Spool 3. Cylinder

Function • This valve operates the brake depending on the parking brake release pressure controlled by the emergency brake pedal.

A. To parking brake valve P. From accumulator T. To transmission oil pan

HD465-7, HD605-7

10-67 (10)


RELAY VALVE

RELAY VALVE

1. Spool 2. Upper cylinder 3. Lower cylinder 4. Spool

Function • This valve operates the front brake depending on the parking brake release pressure controlled by the emergency brake pedal.

A : To front brake P : From accumulator Pp: From emergency brake valve T : To transmission oil pan

10-68 (10)

HD465-7, HD605-7


FRONT BRAKE OFF VALVE

FRONT BRAKE OFF VALVE

WHITE

1. Connector 2. Solenoid A : To front brake P : From brake valve T : To transmission oil pan

HD465-7, HD605-7

Function • This valve is installed on the brake oil circuit between the brake valve and the front brake. When the front brake off switch of the operator's seat is pressed, the solenoid is energized, and the valve cuts off the circuit between the brake valve and the front brake.

10-69 (6)


ACCUMULATOR CHARGE VALVE


ACC : To accumulator P : From hydraulic pump PP : From accumulator T : To transmission oil pan H1 : Relief valve R1 : Relief valve R3 : Main relief valve

HD465-7, HD605-7

Specification • Cut in pressure : 14.2 MPa {145 kg/cm2} • Cut out pressure: 20.6 MPa {210 kg/cm2} Function • The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. • When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load of the pump.

10-71 (10)


1. Main relief valve (R3) 2. Valve body 3. Relief valve (R1)

10-72 (6)


4. Relief valve (H1) 5. Filter 6. Filter

HD465-7, HD605-7


Operation 1. When no oil is being supplied to accumulator (cut-out condition) • The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). It also passes through orifices (17), (18) and (16), and flows to the brake oil tank.

HD465-7, HD605-7


2. When oil supplied to accumulator 1) Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port C and port T are shut off. • The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way. • When the pressure at port P goes above the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed.

10-73 (6)


2) When cut-out pressure is reached • When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. • When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the brake oil tank pressure. • The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port B is stopped.

10-74 (6)


3. Main relief valve (R3) • If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this set the maximum pressure in the brake circuit and protects the circuit.

HD465-7, HD605-7


ACCUMULATOR

ACCUMULATOR

1. Valve 2. Top cover 3. Cylinder 4. Piston Function • The accumulator is installed between the accumulator charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop. Specifications Front brake Gas used : Nitrogen gas Charge amount : 3,500 cc Charging pressure: 11.8 MPa {120 kg/cm2} Rear brake, Parking brake Gas used : Nitrogen gas Charge amount : 4,000 cc Charging pressure: 6.9 MPa {70 kg/cm2}

HD465-7, HD605-7

10-75 (6)

SLACK ADJUSTER


SLACK ADJUSTER

Specifications Piston operation pressure: 9.8 – 19.6 kPa {0.1 – 0.2 kg/cm2} Check valve cracking pressure (When cooling pressure is 0): 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2} Check valve closing pressure: 1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}

1. Cylinder 2. Check valve 3. Piston A : Inlet port B : Outlet port

Unit: mm

No.

Check item


Standard clearance

Clearance limit

Shaft –0.030 –0.076

+0.074 0

0.030 – 0.150

0.25

Standard size 4

Clearance between body and piston 55

Remedy

Standard size 5

Slack adjuster spring

10-76 (10)

Replace

Repair limit

Spring coefficient

Installed length

Installed load

Free length

Installed load

0.45 N/mm {0.046 kg/mm}

97

45.6 N {4.7 kg}

–

–

HD465-7, HD605-7


Function • The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. in this way it acts to keep a constant time lag when the brake is operated.

•

SLACK ADJUSTER

If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above to set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.

Operation 1. When brake pedal is depressed • Before the brake is depressed, piston (4) is returned by the distance of stoke S (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke S to the left and right. 2. When brake pedal is released • When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for the stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc. •

When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston and dics is to 0, the greater the braking force becomes.

HD465-7, HD605-7

10-77 (6)


BRAKE

BRAKE FRONT

1. Piston 2. Pad 3. Disc

10-78 (6)

HD465-7, HD605-7

BRAKE


Unit: mm

No.

Check item

4

Wear of pad (remaining thickness of wear material)

5

Missing portion of pad

6

Face runout of disc (Note 1)

7

Wear of disc (thickness of disc)

Criteria

Remedy

Standard size

Repair limit

19.5

3.0

–

Ratio of surface: 10%

0.15

0.50

30

Less than 27

Replace

Co r re c t o r replace

Replace Open crack in radial direction 8

Damage to disc surface

– Electric wear, marked damage (Note 2)

Correct

Note 1: • If there is excessive face runout of the disc, check the front wheel bearing also. Note 2: • If the depth of the scratch exceeds 1.5 mm. • If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or there is protrusion. • If there are vertical scratches other than concentric scratches.

HD465-7, HD605-7

10-79 (9)


BRAKE

REAR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Inner gear Retainer Outer gear Plate Disc Damper Piston Spring (for parking brake) Cylinder Cylinder (for parking brake)

10-80 (6)

HD465-7, HD605-7

BRAKE


Unit: mm

No.

Check item

11

Backlash between outer gear and plate

12

Backlash between inner gear and disc

13

Thickness of plate

Criteria

Remedy

Standard size

Repair limit

0.21 – 0.64

2.2

0.21 – 0.64

2.2

Standard size

Repair limit

2.4

2.15

14

Thickness of disc

5.1

4.6

15

Thickness of damper

6.9

5.1

16

Thickness of damper

3.4

3.0

Distortion of disc friction surface

Standard distortion

Repair limit

17

Max. 0.45

0.7

Max. 0.50

0.7

Standard size

Repair limit

93.9

86.2

18

Distortion of plate and damper friction surface

19

Assemble thickness of plate and disc

HD465-7, HD605-7

Replace

10-81 (10)


BRAKE

Operation of brake • When the brake pedal is depressed, pressure oil from the brake valve moves brake piston (7) to the right in the direction of the arrow. This presses disc (5) and plate (4) together and generates friction between the disc and plate. The wheel is rotating together with the disc, so this friction reduces the travel speed and stops the machine.

Operation of parking brake • The parking brake contained in the rear brake is structurally designed to operate mechanically by spring (8) force and to be released by hydraulic pressure. • The parking releasing hydraulic pressure acts on the parking brake piston (10) from the accumulator through the brake valve and parking brake solenoid. • With the parking brake switch at the driver's seat in the travel position, the parking releasing hydraulic pressure releases the parking brake by pressing the parking brake piston (10) and retracting the spring (8).

•

•

Function • The rear brake is of an oil cooled multiple disc type, and it operates as a parking brake by use of spring.

10-82 (6)

When the brake pedal is released, the pressure at the back face of brake piston (7) is released, so the piston is moved to the left in the direction of the arrow by the internal pressure, and this releases the brake.

With the parking brake switch in the parking position, the parking brake solenoid is demagnetized and the parking releasing hydraulic pressure is released. Then, the parking brake is engaged through the parking brake piston (10), brake piston (7), plate (4), and disk (5) pressed by spring force.

HD465-7, HD605-7


PROPORTIONAL REDUCING VALVE

PROPORTIONAL REDUCING VALVE

1. Filter 2. Connector 3. Solenoid assembly A : To slack adjuster P : From accumulator T : To transmission oil pan

HD465-7, HD605-7

Function • The proportional reducing valve is a valve used for retarder control. It is installed between the accumulator and the slack adjuster in the brake circuit. It varies the discharge pressure of the pressure oil in accordance with the turning angle of the retarder control lever, so the retarder control can be carried out as desired.

10-83 (10)


PARKING BRAKE SOLENOID VALVE

PARKING BRAKE SOLENOID VALVE

1. Connector 2. Solenoid B : To parking brake P : From emergency brake valve T : To transmission oil pan

10-84 (10)

Function • The parking brake solenoid is installed in the brake oil circuit between the emergency brake valve and the rear brake. When the parking brake switch is set to PARK, the solenoid valve is demagnetized and cut off the parking brake release oil pressure. Then, the spring force of brake will operate the parking brake.

HD465-7, HD605-7


STEERING AND HOIST HYDRAULIC PIPING


10-86 (6)

HD465-7, HD605-7



1. Cross-over relief valve 2. Steering cylinder 3. Hydraulic pump (SAR(3)80+80+(1)6) 4. Demand valve 5. Hoist valve 6. Hoist cylinder 7. Hydraulic tank 8. Steering hoist filter 9. Steering control valve

HD465-7, HD605-7

10-87


STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM


10-88 (6)

HD465-7, HD605-7


HD465-7, HD605-7


10-89 (6)


DUMP BODY CONTROL

DUMP BODY CONTROL

1. 2. 3. 4. 5. 6.

Dump lever Hydraulic pump (SAR(3)80+80+(1)6) Hoist valve EPC valve Body positioner sensor Hoist cylinder

10-90 (10)

Function • The positioner sensor senses the body operation, and from this data the retarder controller controls output to the EPC valve. • The signal from the dump lever is controlled by the retarder controller, and actuates the EPC valve. The pilot pressure generated by the EPC valve moves the spool of the hoist valve and controls the hoist cylinder.

HD465-7, HD605-7


HYDRAULIC TANK

HYDRAULIC TANK

1. Breather 2. Drain 3. Oil level gauge

HD465-7, HD605-7

10-91 (6)


STEERING CONTROL VALVE


1. 2. 3. 4. 5. 6. 7.

Input shaft Upper cover Valve spool Housing Ball Stator Lower cover

10-92

8. 9. 10. 11. 12. 13. 14.

Ball Torsion bar Link Sleeve Rotor Manifold Commutator

a : From demand valve (P port) b : To tank (R port) c : To steering cylinder (RT port) d : To hoist valve (AUX port) e : To steering cylinder (LT port)

HD465-7, HD605-7



Operation 1. when steering is at neutral

•

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

HD465-7, HD605-7

10-93



2. Steering to right (When steering wheel is turned to the right)

•

When the machine is steered to the right (when the steering wheel is turned to the right), valve spool (3) moves down. When this happens, the oil from the pump flows from port A through port B and enters the metering positions (6, 12). Here the flow of oil to the steering cylinders is measured, and it then passes through the steering valve. From here it flows from hole a of valve spool (3) through port

10-94

•

•

G and goes to the steering cylinders. As a result, the two steering cylinders are actuated, and the wheels turn to the right. The return oil from the steering cylinder flows from port C through port D and port E, and return to the tank. The oil remaining in the steering circuit enters port I from port J and flows to the hoist control valve.

HD465-7, HD605-7



3. Steering to left (When the steering wheel is turned to the left.)

•

When the machine is steered to the left (when the steering wheel is turned to the left), valve spool (3) moves up. When this happens, the oil from the pump flows from port H through hole a, passes through the steering valve and enters the metering portions. Here the flow of oil to the steering cylinder is measured, and it then flows from port B to port C and flows to the steering cylinder.

HD465-7, HD605-7

•

•

As a result, the two steering cylinders are actuated, and the wheels turned to the left. The return oil from the steering cylinder flows from port G through port F and port E, and return to the tank. The oil remaining in the steering circuit enters port I from port H and flows to the hoist control valve.

10-95


CROSSOVER RELIEF VALVE

CROSSOVER RELIEF VALVE

SC1 : To steering cylinder SC2 : To steering cylinder SC3 : To steering cylinder SC4 : To steering cylinder SV1 : To steering valve SV2 : To steering valve

10-96

1. Valve body 2. Valve seat 3. Relief valve 4. Valve spring 5. Sleeve 6. Adjustment screw 7. Lock nut

HD465-7, HD605-7

STEERING CYLINDER


STEERING CYLINDER

Unit: mm

No.

Check item


Standard clearance

Clearance limit

Shaft 55

–0.030 –0.104

+0.163 +0.006

0.036 – 0.267

0.567

Standard size 1

Remedy


Replace bushing

2

Clearance between piston rod supports shaft and bushing

45

–

+0.039 0

–

1.0

3

Clearance between cylinder bottom support shaft and bushing

45

–

+0.039 0

–

1.0

HD465-7, HD605-7

Replace

10-97 (9)


DEMAND VALVE

DEMAND VALVE

10-98

HD465-7, HD605-7

DEMAND VALVE


P1 : From hydraulic pump P2 : From hydraulic pump PH : To hoist control valve PE : From emergency steering pump PT : To tank PST: To steering control valve 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Spool return spring Demand spool Check valve Check valve spring Valve body Main relief valve Main relief valve spring Pilot poppet Pilot poppet spring Lock nut Adjustment screw

Unit: mm

No.

Check item

Criteria

Remedy

Standard size 12

13

Spool return spring

Check valve spring

HD465-7, HD605-7

Repair limit

Free length x O.D

Installed length

Installed load

Free length

Installed load

172.2 x 29.7

140

130.4 N {13.3 kg}

–

120.6 N {12.3 kg}

42.2 x 17

33.5

3.4 N {0.345 kg}

–

3.1 N {0.315 kg}

Replace

10-99 (10)


Function • This valve distributes oil which comes from the steering pump and from the work equipment pump , to the steering circuit and to the work equipment circuit depending on the engine speed (pump delivery).

DEMAND VALVE

circuit directly through the port D. The whole oil of the steering pump and part of oil from the work equipment pump flow into the steering circuit.

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

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

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

10-100

HD465-7, HD605-7


DEMAND VALVE

STEERING RELIEF VALVE

1. 2. 3. 4. 5.

•

When the pressures in port A and port B balance with the poppet spring force (set pressure), the pilot poppet (3) will open. Oil in port B will escape through port D to port C, and the pressure in port B will lower.

•

When the pressure in port B lowers, the orifice of the main valve (1) generates a differential pressure between ports A and B, and the pressure in port A pushes to opens the main valve (1) to release oil from port A.

Main valve Valve seat Pilot poppet Spring Adjustment screw

Function • This valve is located in the demand valve and release oil from the pump to prevent the pump from being damaged when the steering cylinder comes to the stroke end, or when an abnormal pressure occurs. (This valve sets the maximum pressure of the circuit.) Operation • Port A is connected to the pump circuit, and port C is connected to the tank drain circuit. • Oil flows through the orifice of the main valve (1), and port B is filled with oil. • Also, the pilot poppet (3) is seated to the valve seat (2).

HD465-7, HD605-7

10-101


HOIST VALVE

HOIST VALVE

10-102

HD465-7, HD605-7

HOIST VALVE


T P A1 B1 PA PB

: To tank : From flow amplifier : To hoist cylinder bottom : To hoist cylinder head : From EPC valve (pressurized side in lowering or floating operation) : From EPC valve (pressurized side in lifting operation)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Body Spool Retainer Spring (lifting) Relief valve Spring (floating) Spring (lowering) Retainer Retainer Retainer Check valve

Unit: mm

No.

Check item

Criteria

Remedy

Standard size 12

Relief valve poppet spring

Free length × O.D.

Repair limit

Installed length

Installed load

Free length

Installed load

49.3

× 12.8

41.9

259 N {26.4 kg}

–

233 N {23.8 kg}

13

Check valve spring

32.6

× 10.9

24.5

44 N {4.5 kg}

–

40 N {4.1 kg}

14

Spool return spring (lifting)

51.3

× 34.5

50

156 N {15.9 kg}

–

140 N {14.3 kg}

15

Spool return spring (lowering)

34.2

× 28.7

32

124 N {12.7 kg}

–

112 N {11.4 kg}

16

Spool return spring (floating)

74.0

× 36.0

55.5

927 N {94.5 kg}

–

849 N {85.1 kg}\

HD465-7, HD605-7

If damaged or deformated, replace the spring

10-103


HOIST VALVE

Operation 1. Hoist valve HOLD Position

•

Oil from the demand valve flows into chamber C. Since the hoist spool (2) blocks the path to the hoist cylinder, oil flows through chamber D to the tank.

10-104

•

Since both the bottom side port and the head side port of the hoist cylinder are blocked, the hoist cylinder is locked where it is.

HD465-7, HD605-7


HOIST VALVE

2. Hoist valve at LIFT Position

•

•

When the hoist lever in the cab is set to the RAISE position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the left. Therefore, oil from chamber C opens the check valve (11) and flows into chamber A.

HD465-7, HD605-7

•

•

Oil flows out of chamber A, flows in the bottom side of the hoist cylinder, extends the hoist cylinder and raise the body. On the other hand, the return oil from the head side flows out of chamber B, flows into chamber D and to the tank circuit.

10-105 (10)


HOIST VALVE

3. Hoist valve at FLOAT Position

•

When the hoist lever in the cab is set to the FLOAT position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the right. Then, chambers C, D, B, H and D are all connected.

10-106 (10)

•

•

Oil from the demand valve flows from chamber C through chamber B to the host cylinder and from chamber C through chamber D to the oil cooler circuit. Since the bottom side and the head side of the hoist cylinder are connected through the hoist valve, the hoist cylinder is in a free state. HD465-7, HD605-7


HOIST VALVE

4. Hoist valve at LOWER Position

•

•

When the hoist lever in the cab is set from the FLOAT position to the LOWER position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the right further from the FLOAT position. Therefore, oil from chamber C pushes to open the check valve (11) and flows into chamber B. Then, oil flows into the head side of the hoist cylinder through chamber B, retracts the hoist cylinder and lowers the body.

HD465-7, HD605-7

•

•

On the other hand, the return oil from the head side of the hoist cylinder flows out of chamber A and flows into chamber H. At the time of lowering, the output pressure of the solenoid valve rises over the cracking pressure of the pilot check valve, and therefore, the return oil from chamber H returns through chamber D to the tank.

10-107 (10)


EPC VALVE

EPC VALVE

1. Manual operation button 2. Solenoid assembly 3. Solenoid assembly A : To hoist valve B : From hoist valve P1 : From hydraulic tank T1 : To hydraulic tank T2 : To hydraulic tank

10-108

Function • The EPC valve controlled by the retarder controller switches the pilot pressure of the hoist valve, and controls pressure, and controls the hoist valve.

HD465-7, HD605-7

HOIST CYLINDER


HOIST CYLINDER

Unit: mm

No.

Check item


Standard clearance

Clearance limit

Shaft 170

–0.043 –0.143

+0.264 +0.046

0.089 – 0.407

0.707

Standard size 1

Remedy

Clearance between cylinder and bushing

2


100

–0.036 –0.123

+0.207 +0.067

0.103 – 0.393

0.693

3

Clearance between piston rod support pin and bushing

70

–

+0.004 –0.019

–

1.0

4

Clearance between cylinder support pin and bushing

70

–

+0.004 –0.019

–

1.0

HD465-7, HD605-7

Replace

10-109 (9)

HYDRAULIC PUMP


HYDRAULIC PUMP STEERING, HOIST AND HOIST CONTROL PUMP SAR(3)80+80+(1)6

Unit: mm

No.

Check item

Criteria Model

1

Side clearance

2

Clearance between inside diameter of plain bearing and outside of diameter of gear shaft

SAR(3)-80 SAR(3)-80 SAR(1)-6 SAR(3)-80 SAR(3)-80

Depth to knock in pin

Discharge amount Oil: EO10-CD Oil temperature: 45–55°C

SAR(1)-6

(10)

0.19

0.060 – 0.149

0.20

0.06 – 0.144

0.20

13 10

0 –0.5

Rotating speed (rpm)

Delivery pressure MPa {kg/cm2}

2,500

20.6 {210}

SAR(3)-80 SAR(3)-80

10-110

0.10 – 0.15

Repair limit

–

15.8 – 28.5 Nm {1.6 – 2.9 kgm} Model

–

0.19

0 –0.5

SAR(3)-80

Rotating torque of spline shaft

0.10 – 0.15

Tolerance

SAR(1)-6 4

Clearance limit

Standard size

SAR(3)-80 3

Standard clearance

Replace

SAR(1)-6 Model

Remedy

Standard delivery amount ( /min)

Delivery amount limit ( /min)

184

170

13.2

12.6

–

HD465-7, HD605-7

HYDRAULIC PUMP


RETARDER COOLING PUMP SAR(3)100+100

Unit: mm

No.

Check item

1

Clearance between gear case and side plate, gear

2

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

Criteria

Remedy

Model

Standard clearance

Clearance limit

SAR(3)-100

0.13 – 0.18

0.22

SAR(3)-100

0.06 – 0.149

0.20 Replace

3

4

–

Model

Standard size

Tolerance

Repair limit

SAR(3)-100

14

0 –0.5

–


Rotating torque of splined shaft

Delivery amount Oil: EO10-CD Oil temperature: 45 – 55°C

13.7 – 23.5 Nm {1.4 – 2.4 kgm}

Model

SAR(3)-100

HD465-7, HD605-7


Delivery pressure

2,500

3.9 MPa {40 kg/cm2}

Standard delivery amount ( /min.)

Delivery amount limit ( /min.)

236

216

–

10-111


HYDRAULIC PUMP

TORQUE CONVERTER, TRANSMISSION, RETERDER COOLING AND BRAKE PUMP SAR(3)100+(1)25

Unit: mm

No. 1

2

3

Check item Side clearance Clearance between inside diameter of plain bearing and outside of diameter of gear shaft Depth to knock in pin

–

Model

Standard clearance

Clearance limit

0.13 – 0.18

0.21

SAR(1)-25

0.10 – 0.15

0.19

SAR(3)-100

0.06 – 0.149

SAR(1)-25

0.06 – 0.144 Tolerance

SAR(3)-100

14

SAR(1)-25

10

0 –0.5

(10)

–

8.9 – 16.7 Nm {0.9 – 1.7 kgm} Model SAR(3)-100 SAR(1)-25

10-112

Replace

0.20

Standard size

Rotating torque of spline shaft

Discharge amount Oil: EO10-CD Oil temperature: 45–55°C

Remedy

SAR(3)-100

Model

4 5

Criteria

Rotating speed (rpm) 2,500

Delivery pressure MPa {kg/cm2}

Standard delivery amount ( /min)

Delivery amount limit ( /min)

20.6 {210}

231.5

213.5

20.6 {210}

57.0

50.7

–

HD465-7, HD605-7

HYDRAULIC PUMP


EMERGENCY STEERING PUMP SBL(1)-014

Unit: mm

No.

Check item Model

Standard clearance

Clearance limit

1

Clearance between gear case and side plate, gear

SBL(1)-014

0.10 – 0.15

0.19

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

SBL(1)-014

0.06 – 0.119

0.20

2

3

4

–

Criteria

Replace Model

Standard size

Tolerance

Repair limit

SBL(1)-014

10

0 –0.5

–


Rotating torque of splined shaft

Delivery amount Oil: EO10-CD Temperature: 45 – 55°C

2.0 – 4.9 Nm {0.2 – 0.5 kgm}

Model

SBL(1)-014

HD465-7, HD605-7

Remedy


Delivery pressure

3,500

20.6 MPa {210 kg/cm2}

Standard delivery amount ( /min.)

Delivery amount limit ( /min.)

45.7

42.4

–

10-113


AIR CONDITIONER

AIR CONDITIONER

1. Receiver dryer 2. Air conditioner unit 3. Compressor 4. Condenser

Heating • Heating is carried out using the coolant from the engine. High-temperature coolant from the hot water takeoff port flows to the air conditioner unit, and hot air is blown out by a fan. When the temperature of the coolant drops, it is returned to the hot water return port and flows as coolant for the engine.

Function • The air conditioner makes a pleasant operating environment for the operator and acts to reduce fatigue.

Cooling • The refrigerant gas compressed and pressurized by the air conditioner compressor enters the air conditioner condenser where it is cooled by dissipating the heat It then enters the air conditioner unit and cold air is blown out by the fan. When the temperature of the refrigerant gas rises, it is returned to the compressor.

10-114 (10)

HD465-7, HD605-7


AIR CONDITIONER

AIR CONDITIONER UNIT

1. FRESH/RECIRC selector damper 2. Evaporator 3. Heater core 4. Blower motor A : Hot water inlet port B : Hot water outlet port C : Refrigerant gas inlet port D : Refrigerant gas outlet port E : Dehumidified water drain port

HD465-7, HD605-7

10-115 (10)


AIR CONDITIONER

RECEIVER DRYER

1. Body 2. Dryer

10-116

HD465-7, HD605-7


AIR CONDITIONER

CONDENSER

1. Fin 2. Tube A : Refrigerant gas inlet port B : Refrigerant gas outlet port

HD465-7, HD605-7

10-117


AIR CONDITIONER

COMPRESSOR

1. Case 2. Clutch A : Suction service valve B : Discharge service valve

10-118

HD465-7, HD605-7


MACHINE MONITOR SYSTEM


Network data 1. From machine monitor to each controller • Switch input data • Option setting data 2. From each controller to machine monitor • Display data related to each controller • Service mode data • Troubleshooting data 3. From transmission controller to machine monitor • Model selection data

HD465-7, HD605-7

10-119 (6)


Outline • With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to observe and control the condition of the machine and transmit that data as network data to the machine monitor. • The machine monitor is a system to display these data and inform the operator of the condition of the machine. • There are two types of display on the machine monitor: the normal mode and the service mode. • The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items • Meters (speedometer, tachometer) • Gauges (engine water temperature, torque converter oil temperature, retarder oil temperature, fuel level) • Pilot display • Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (if an action code is being displayed, press machine monitor mode selector switch (2), then release it. A failure code (6-digit) is then displayed.) 3. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Other functions using the character display and the machine monitor mode selector switch to operate include the following: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and language selection. •


4. ECMV compensation This is used for the initial adjustment of the transmission. 5. Changing replacement time for filter, oil. This changes the original setting for the replacement interval. 6. Snapshot For details, see "TESTING AND ADJUSTING, Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7. Controller initialize This function is used to set the machine monitor when the machine is shipped from the factory. •

The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and the sensors inputting data to the monitor panel.

•

If the payload meter (having VHMS) is set optionally, execute display of load mass and setting of items related to the payload meter, too. For details, see "OPERATION AND MAINTENANCE MANUAL" and "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)".

To make it easier to carry out troubleshooting of the controllers (including the monitor panel itself), a service mode function is provided. Its main content is as follows. 1. Displaying failure history for electrical system, deleting from memory • Displays failure history for electrical system from each controller that is saved in machine monitor • Deletes data from memory 2. Failure history for machine system • Displays failure history for machine system from each controller that is saved in machine monitor 3. Real-time monitor • Takes input and output signal values recognized by each controller on network and displays in real time.

10-120 (10)

HD465-7, HD605-7



MACHINE MONITOR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Speedometer Engine tachometer Retarder oil temperature gauge Torque converter oil temperature gauge Coolant temperature gauge Fuel gauge Character display Centralized warning lamp Retarder oil temperature caution lamp Torque converter oil temperature caution lamp Coolant temperature caution lamp Fuel level caution lamp Maintenance caution lamp Battery charging circuit caution lamp Steering oil temperature caution lamp (if equipped) Engine oil pressure caution lamp Retarder oil pressure caution lamp Parking brake caution lamp Machine monitor option system caution lamp Engine system caution lamp Transmission system caution lamp Retarder system caution lamp Inclination caution lamp

HD465-7, HD605-7

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42 43. 44. 45.

Seat belt caution lamp Body caution lamp Emergency steering pilot lamp Turn signal pilot lamp (right) Turn signal pilot lamp (left) Headlamp highbeem pilot lamp Shift lever position pilot lamp Shift indicator Retarder pilot lamp Lockup pilot lamp Output mode pilot lamp (power mode) Output mode pilot lamp (economy mode) Suspension mode pilot lamp (hard) (if equipped) Suspension mode pilot lamp (medium) (if equipped) Suspension mode pilot lamp (soft) (if equipped) ABS pilot lamp (if equipped) ASR pilot lamp (if equipped) Preheater pilot lamp Automatic retarder READY pilot lamp Automatic retarder set speed indicator Automatic retarder set speed unit indicator (km/h) Automatic retarder set speed unit indicator (MPH)

10-121 (10)


41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.


Travel speed compensation switch [SW1] Rotary switch [SW2] Rotary switch [SW3] Dipswitch [SW5-4] Dipswitch [SW5-3] Dipswitch [SW5-2] Dipswitch [SW5-1] Dipswitch [SW6-4] Dipswitch [SW6-3] Dipswitch [SW6-2] Dipswitch (SW6-1]

10-122

HD465-7, HD605-7



OPTION SETTING CONNECTOR DIAGRAM

52. 53. 54. 55. 56. 57. 58.

Option setting connector [OP1] Option setting connector [OP2] Option setting connector [OP3] Option setting connector [OP4] Option setting connector [OP5] Option setting connector [OP6] Setting connector [OP7]

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

HD465-7, HD605-7

10-123



MACHINE MONITOR NORMAL DISPLAY FUNCTIONS : Lighted up : Discontinuous sounds ✩1: The mark shows that the light is lit up while the machine monitor check switch is ON. ✩2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second. ✩1 When ✩2 machine Immediately Central Warn- monitor check after warning switch is turning ing buzzer oper- key ON. lamp ated. Related operation

No.

1

Display item

Display category

Meter

Analog display

—

—

Backlight

LED

Amber

When the small lamp is lit up.

Lit up during operation

—

—

0 – 3,400 rpm

Analog display * When the overrun prevention brake is operated, the buzzer and central warning lamp is lit up.



Engine speed

Gauge Oil temperature of retarder

Scale: white, red MoveBackment ground color: black

LED

Amber

Scale: white, red 50 – 150°C MoveBack(120°C or higher ment ground in the red zone) color: black

Analog display

Warning

LED

Red

At 120°C or higher

Lit up during warning

Backlight

LED

Amber


Lit up during operation.

Gauge Oil tem4 perature 10 of torque converter

(9)

Display method

0 – 80 km/h or 0 – 50 MPH (MPH is displayed when nonSI is used.)

Machine speed

10-124

Display range/ conditions

Movement

Backlight

3 9

Color

Scale: white Background color: black

Meter 2

Device

Scale: white, red Back50 – 135°C Moveground (120°C or higher ment color: in the red zone) black

Analog display

Warning

LED

Red

At 120°C or higher


Backlight

LED

Amber



(Note)

(Note)

—

Remarks

—

Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

—


—


—


—

—

—

—

—

—

—





(Note)

(Note)

HD465-7, HD605-7



When machine Immedimonitor ately check after Central switch is turning warn- Warn- opering key ON. ing ated. lamp buzzer Related operation

No.

Display item

Display category

Gauge Engine 5 coolant tempera11 ture


Scale: white, red 50 – 135°C MoveBack(102°C or higher ment ground in the red zone) color: black

Display method

Analog display

LED

Red

At 102°C or higher


Backlight

LED

Amber



Scale: white, red MoveBackment ground color: black

—

—

—

—

EMPTY – FULL

Analog display

—

—


—

—

(Note)

(Note)

Fuel level

Service meter (Regular display item)

Action code

Failure code

Remarks

—


—


Warning

LED

Red

Specified level or less (remaining quantity in the tank at 120 or less)

Backlight

LED

Amber



—

—

0 – 65535.0h

Operates when the engine is running. 1:1 against clock time

—

—

When 65535.0h is exceeded, fixed at 65535.

—

—

When 999999.9 km is exceeded, fixed at 999999.9 km.

* Displayed in the

Service meter

"upper column" on the character display

Odometer (Regular Odometer display item)

7

Color

Warning

Gauge

6 12

Device

Action code

Failure code

HD465-7, HD605-7

* Displayed in the "lower col- Operates durumn" on the char- ing traveling. acter display

LCD

When any problem or When any prob- failure occurs, lem or failure the action Display occurs on the code is discharacter: machine, * Dis- played in the black upper column played in the Backupper and lower and remedies ground columns on the or description color: character display. of problem in green the lower column. Press machine monitor mode selector switch > during the occurrence of the problem or failure on the machine. * Appears in the upper and lower columns on the character display.

The failure code (6 digits) and detection controller are displayed in the upper column and the faulty system or description of problem in the lower column.

—

—

—

—

Note 1

Note 1:"HD-465" is displayed in the upper column. Note 2: "KOMATSU" is Note 2 displayed in the upper column and "SYSTEM CHECK" in the lower column.

For information on how to operate display, see the Operation & Maintenance Manual.

10-125 (10)



When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation

No.

Display item

Display category

Reverse travel integrating meter Reset of time to Other displays change filter and oil. Telephone number setting Language selection

7

Night lighting

Backlight

Central warning lamp

8

Device

Color

LCD

Display character: black Background color: green

LED

Green

LED

Red

During system is abnormal

Display method

Switch screen by operating machine monitor mode selector switch ">" or "<".

Dimmed down by a step when the small lamp is lit up. Lit up during warning.

Red

When maintenance-related alarm is given or the time to change filter and oil has elapsed.

Lit up or turn ON and OFF

LED

Red

During battery charging circuit being abnormal

Lit up during warning.

LED

Red

When the steering oil temperature rises.


13

LED

14

Battery charging circuit warning

Warning

Press machine monitor mode selector switch " "


Maintenance warning

Steering oil tempera15 ture warning (option)


16

Engine oil pressure warning

LED

Red

When the engine oil pressure drops.


17

Retarder oil pressure warning

LED

Red

When the retarder oil pressure drops.

Lit up during being abnormal.

18

Parking brake warning

Red

When the parking brake is operated.




LED

Machine monitor or 19 optional system warning

LED

Red

During being abnormal in machine monitor or optional controller system

Engine system warning

LED

Red

During being abnormal in engine control system.

20

10-126 (10)

Remarks

For details, see the Operation & Maintenance Manual.

—

—

—

—

(Note) (Note)

(Note) (Note)

Note 1:The moment when the lamp lights up, the action code: E01 and the location where an alarm has been given appear on the character display. Note 2:For details on the target items, etc., see the Operation & Maintenance Manual.

Operates when the alternator R terminal is ON. Operates when the parking brake is operated and the shift lever is in other than the "N" position. Under present conditions, used in the event of failure of the machine monitor.

HD465-7, HD605-7



When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation

No.

Display item

21

Device

Color


Display method

Transmission system warning

LED

Red

Being abnormal in transmission control system


22

Retarder system warning

LED

Red

During being abnormal in retarder control system


23

Inclination warning

LED

Red

When the body is lifted and inclined excessively from side to side.


Red

When the seatbelt is not worn.

During operation: lit up During nonoperation: turned OFF.

Red

See the instruction manual


Red

When the emergency steering is operated.






During operation


—

—

During operation


—

—

—

—

24

Display category

Warning

Seatbelt warning

25

Body warning

26

Emergency steering

27

Turn signal, right

28

Turn signal, left

29

Headlight, high beam

LED

LED

LED

LED

LED

Green

Green

—

Remarks

—

(Note) (Note)

Note: Operates when the shift lever is in other than the "N" position.

LED

Blue

During operation


Shift 30 lever (R) position R

LED

Green

When the shift lever is in the "R" position

Lit up (*)

—

—

Shift 30 lever (N) position N

LED

Orange

When the shift lever is in the "N" position

Lit up

—

—

Shift 30 lever (D) position D

LED

Green

When the shift lever is in the "D" position

Lit up (*)

—

—

* Blinks when the neu-

30 (6)

Shift lever position 6

LED

Green

When the shift lever is in the "6" position

Lit up (*)

—

—


30 (5)

Shift lever position 5

LED

Green


Lit up (*)

—

—


Pilot

HD465-7, HD605-7

* Blinks when the neutral safety is operated.

tral safety is operated.



10-127 (9)


Display category

Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp

Device

Color


Display method

Shift 30 lever (4) position 4

LED

Green


Lit up (*)

—

—


LED

Green


Lit up (*)

—

—


LED

Green


Lit up (*)

—

—

Shift 30 lever (L) position L

LED

Green

When the shift lever is in the "L" position

Lit up (*)

—

—

LCD

Background color: gray

F1, F2, F3, F4, F5, F6, F7, N, R * According to the gear shift signal received from the transmission controller. * When an alarm is raised in the event of emergency escape, "E-" and the "gear speed range" are alternatively displayed.

When the gear shift range signal is received from the transmission controller.





LED

Amber

When the small lamp is lighted up.

During operation: lit up

—

—

Orange

When the retarder brake is operated.

During operation: lit up During nonoperation: turned OFF

—

—

Green

When lockup of the torque converter is activated and direct drive is effective


—

—

At high-power mode

High-power mode in operation: lit up During nonoperation: turned OFF

—

—

—

—

—

—

No.

Display item


Pilot

Shift indicator 31

Night lighting

Backlight

32 Retarder

LED

33

Lockup

34

Output mode (power mode)

35

Output mode (economy mode)

LED

Green

At economy mode

Economy mode in operation: lit up During nonoperation: turned OFF

36

Suspension mode (hard) (option)

LED

Green

At suspension "hard" mode

Lit up in "hard" mode

10-128 (9)

LED

Pilot

LED

Green

Remarks





All lit up.

All lit up.

HD465-7, HD605-7


Color


Display method

Suspension mode 37 (medium) (if equipped)

LED

Green

In suspension "medium" mode

Lit up in "medium" mode

—

—

Suspension 38 mode (soft) (if equipped)

LED

Green

In suspension "soft" mode

Lit up in "soft" mode

—

—


—

—

39

40

Display category

Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp

Device

No.

Display item


ABS (if equipped)

LED

ASR (if equipped)

LED

Orange

When ABS is operated.

Orange

When ASR is operated.

During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF

—

—

LED

Red

When electric intake air heater for preheating engine is operated.

42

Automatic retarder being ready

LED

Green

When automatic retarder is ready to be operated.

When ready to be operated: lit up

—

—

43

Automatic retarder set speed

LCD

Background color: gray

When automatic Display of set retarder switch is speed (*) turned ON.

—

—

44

Automatic retarder unit display (km/h)

Green

When automatic retarder switch is turned ON and the unit km/h is selected.


—

—

45

automatic retarder display unit (MPH)

Green

When automatic retarder switch is turned on and the unit km/h is selected.


—

—

41

Preheating

Pilot

HD465-7, HD605-7

LED

LED

Remarks

* Zero is displayed when the set speed is cancelled.

10-129 (10)



Self-diagnostic function when operating starting switch 1. When the starting switch is turned to the ON position before starting the engine, the system check is carried out for 3 seconds. 2. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch at the ON position, everything will go to the normal operating condition. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have passed after the starting switch was turned to the ON position. Check function of central warning lamp, alarm buzzer, monitor lamps, and meters To check the normal display function of the machine monitor, press the machine monitor check switch to check the actuation. For details of the actuation, see "When operating machine monitor normal display functions with machine monitor check switch".

10-130

HD465-7, HD605-7



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

HD465-7, HD605-7

10-131 (10)



@@@@@ : Displays time that has elapsed since failure last occurred The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory. 3) Real-time monitor This function is used when checking the input and output signals recognized by the controllers on the network. The real-time monitor display on the character display is as shown right. *** : Displays name of item ##### : Displays ID No. given to each item %%% : Displays data. If units are used, the unit is displayed on the right side of the data By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same time. The character display when a second item is displayed at the same time is as shown right ##### : Displays specified ID No. %%% : Displays data. If units are used, theunit is displayed on the right side of the data 4) ECMV compensation For details of this function, see TESTING AND ADJUSTING, SPECIAL FUNCTIONS OF MACHINE MONITOR. 5) Changing filter, oil replacement time For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter, oil replacement time display. This is used when changing the replacement interval. 6) Snapshot function When the VHMS controller is installed, this menu is displayed. For details, see "TESTING AND ADJUSTING, [Items related to PM Clinic], Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7) PLM setting function When payload meter (having VHMS) is set optionally, this menu is displayed. For details, see "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)". 8) Controller initialize This function is used only at the factory, so do not touch it.

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HD465-7, HD605-7


2. Method of operation For details of the method of operating each ser vice mode function, see TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR.

HD465-7, HD605-7


REMARK : When the starting switch is turned OFF, it returns to the normal mode.

10-133 (10)


ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM SYSTEM DRAWING

10-134

HD465-7, HD605-7


•

With the control system using engine controller, the signals detected by the sensers are input and the engine controller calculates these. It then outputs the signal for the results to the actuators to control the fuel injection amount and the fuel injection timing.

•

The machine monitor stores data transmitted from engine controller, as common data.

ENGINE CONTROL SYSTEM

AISS (Automatic Idle Setting system) Outline • The AISS is a system which sets the engine low idle speed at manual or automatic to two levels according to the operating conditions of the machine. In this way it is possible to imoprove the fuel consumption and the starting and acceleration ability. Set idle speeds Low idle speed : 750 rpm High idle speed : 945 rpm High, low speed set conditions Conditions Set to low position

Operating methods Manual

Engine coolant temperature above 50°C and parking brake applied

Automatic

Engine coolant temperature above 50°C and retarder lever actuated

Automatic

Engine coolant temperature less than 50°C

Automatic

Parking brake released and retarder lever not actuated

Automatic

HD465-7, HD605-7

High/low category

Low speed

High speed

10-135 (10)


AUTOMATIC SHIFT CONTROL SYSTEM

AUTOMATIC SHIFT CONTROL SYSTEM (Transmission control system with all-range electronic modulation)

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HD465-7, HD605-7



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

HD465-7, HD605-7

10-137



TRANSMISSION CONTROLLER

1. Self-diagnostic display window 2. Connector 3. Case 4. Motherboard 5. Model selector switch (rotary switch 1) 6. Model selector switch (rotary switch 2) Outline • The transmission controller controls the transmission system. It has the following features and functions. 1. It has a high power mode and economy mode, and the gearshifting pattern can be selected. 2. The braking mode is the mode when the brake is used. By raising the gearshifting point and increasing the speed of the brake cooling pump, it is possible to raise the cooling effect of the retarder and make effective use of the engine brake. 3. It controls the torque converter lock-up solenoid valve and overrun prevention brake. 4. To reduce the shock when shifting gear, it outputs the throttle correction command to the engine controller when shifting gear and limits the engine speed.

10-138 (10)

5. Speed sensors are installed at three places (transmission input shaft, intermediate shaft, and output shaft). This makes it possible to detect slippage of the transmission clutches and to protect the transmission when there is any abnormality in the hydraulic system. 6. It connects to the network and shares various data with other controllers. 7. It receives input of the model selection data (what model it is mounted on), and uses the network to contact other controllers. (For details of the method of setting, see TESTING AND ADJUSTING, AND TROUBLESHOOTING.) 8. It has a self-diagnostic function which divides the input and output systems further into small parts. 9. The self-diagnostic function is displayed in two digits. 10. When an abnormality is detected, it transmits the details to the network and displays it on the other displays. 11. It uses the machine monitor to display if the failure is still existing. 12. It provides an escape function for use when there is a failure in the electrical system.

HD465-7, HD605-7



CN1 (MIC 17-POLE) Machine Connector Number : ATC1_MIC Pin No.

Specification

Signal name

Remarks

1

ON/OFF OUT (POWER) 0

N.C

2


N.C

3


Power output (+24V) for torque converter oil pressure sensor

POWER SUPPLY (+24V) FOR T/C

4

ON/OFF OUT (POWER) 6H

Power input (+24V) for overrun prevention brake output

POWER INPUT (+24V) FOR OVERRUN

5

ON/OFF OUT (POWER) 7H

Power input (+24V) for transmission cut relay output

POWER INPUT (+24V) T/M CUT RELAY

6

ON/OFF OUT (SIG) 8

Droop mode output 3 (Idling controll)

DROOP MODE OUT 3 FOR ENG

7

Battery direct power supply (+24V)

Battery direct power supply (+24V)

BATTERY DIRECT (+24V)

8

Controller power supply (GND)

GND

INPUT GND

9

Controller power supply (+24V)

Power supply voltage (+24V)

POWER INPUT (+24V)

10


N.C

11


N.C

12


N.C

13

ON/OFF OUT (POWER) 6L

Overrun prevention brake output command

OVERRUN OUT

14

ON/OFF OUT (POWER) 7L

Transmission cut relay output

T/M CUT RELAY

15

ON/OFF OUT (SIG) 9

Droop mode output 2 (Power/Economy selection)

DROOP MODE OUT 2 FOR ENG

16

Controller power supply (GND)

GND

INPUT GND

17

Controller power supply (+24V)

Power supply voltage (+24V)

POWER INPUT (+24V)

HD465-7, HD605-7

10-139



CN2 (MIC 21-POLE) Machine Connector Number : ATC2_MIC Pin No.

Specification

Signal name

Remarks

1

SOL power supply (+24V)

SOL power input (+24V)

POWER INPUT (+24V) FOR SOLENOID

2

SOL_OUT 4A+

ECMV current output (+) "1st clutch"

ECMV SOLENOID "1ST" (+)

3

SOL_OUT 4B+

ECMV current output (+) "4th clutch"

ECMV SOLENOID "4TH" (+)

4

SOL_OUT 5A+

ECMV current output (+) "2nd clutch"

ECMV SOLENOID "2ND" (+)

5

SOL_OUT 5B+

ECMV current output (+) "Rev clutch"

ECMV SOLENOID "REV" (+)

6

A_OUT 0

N.C

7

SOL_OUT 0+

ECMV current output (+) "Low clutch"

ECMV SOLENOID "LOW" (+)

8

SOL_OUT 1+

ECMV current output (+) "3rd clutch"

ECMV SOLENOID "3RD" (+)

9

SOL_OUT 2+

ECMV current output (+) "High clutch"

ECMV SOLENOID "HIGH" (+)

10

SOL_OUT 3+

ECMV current output (+) "lockup clutch"

ECMV SOLENOID "L/U" (+)

11

A_OUT 1

N.C

12

SOL power supply (+24V)

SOL power input (+24V)

POWER INPUT (+24V) FOR SOLENOID

13

SOL_OUT 4A–, 4B–

ECMV current output (–) "1st, 4th clutch"

ECMV SOLENOID "1ST, 4TH" (–)

14

VDD_OUT (24V)

N.C

15

SOL_OUT 5A–, 5B–

ECMV current output (–) "2nd, Rev clutch"

16

VDD_OUT (+5V)

N.C

17

SOL_OUT 0–

ECMV current output (–) "Low clutch"

ECMV SOLENOID "LOW" (–)

18

SOL_OUT 1–

ECMV current output (–) "3rd clutch"

ECMV SOLENOID "3RD" (–)

19

SOL_OUT 2–

ECMV current output (–) "High clutch"

ECMV SOLENOID "HIGH" (–)

20

SOL_OUT 3–

ECMV current output (–) "lockup clutch"

ECMV SOLENOID "L/U" (–)

21

Power GND

GND

INPUT GND

10-140

ECMV SOLENOID "2ND, REV" (–)

HD465-7, HD605-7



CN3 (040 20+16-POLE) Machine Connector Number : ATCA_040, ATC3B_040 Pin No.

Specification

Signal name

Remarks

1

CN_CHKO

N.C

2

PULS INPUT 0

Transmission input shaft speed sensor

TRANSMISSION INPUT SPEED

3

PULS INPUT 1

Transmission output shaft speed sensor

TRANSMISSION OUTPUT SPEED

4

PWM_IN

N.C

5

PULS OUTPUT

Throttle modification signal output

THROTTLE MODIFICATION

6

Sensor power supply (+5V)

Potentio power supply

SENSOR POWER SUPPLY (+5V)

7

Analog_INPUT

0(+)

Torque converter oil pressure sensor

TORQUE CONVERTER PRESS SENSOR

8

Analog_INPUT

1(+)

N.C

9

Analog_INPUT

2

Transmission oil level switch (if equipped)

TRANSMISSION OIL LEVEL SW (if equipped)

10

Analog_INPUT

3

Emergency escape signal

LIMP HOME SW

11

ON/OFF INPUT 35

Steering oil temperature switch (if equipped)

STEERING OIL TEMP SW (if equipped)

12

PULS INPUT 2

Transmission intermediate shaft speed sensor

TRANSMISSION MIDDLE SPEED

13

PULS INPUT 3

Engine speed sensor

ENGINE SPEED

14

PULS GND

GND

SPEED GND

15

PWM_OUT

N.C

16

Analog GND

GND for sensor

ANALOG SENSOR GND

17

Analog_INPUT

GND (Analog GND is connected)

INPUT ANALOG SENSOR GND

18

Analog_INPUT

1(–)

N.C

19

Analog_INPUT

4

Air cleaner clogging switch

20

Analog_INPUT

5

N.C

21

Analog_INPUT

6

Alternator Terminal R voltage

22

Analog_INPUT

7

N.C

23

Analog_INPUT

8

Electrolyte level switch (if equipped)

BATTERY LEVEL SW (if equipped)

24

Analog_INPUT

9

Fuel level sensor

FUEL LEVEL

25

Analog_INPUT 10

N.C

26

Analog_INPUT 11

N.C

27

Analog_INPUT 12

Torque converter oil temperature sensor

0(–)

28

Analog_INPUT 13

N.C

29

Analog_INPUT 14

Transmission valve oil temperature sensor

30

Analog_INPUT 15

N.C

31

Analog_INPUT 16

Accelerator pedal signal

32

Analog_INPUT 17

N.C

33

Analog_INPUT 18

N.C

34

Analog_INPUT 19

N.C

35

Analog_INPUT 20

N.C

36

Analog_INPUT 21

N.C

HD465-7, HD605-7

AIR CLEANER SW

ALTERNATOR R

TORQUE CONVERTER OIL TEMP

ECMV OIL TEMP

ACCEL SIGNAL

10-141 (10)



CN4 (040 12-POLE) Machine Connector Number : ATC4_040 Pin No.

Specification

1

RS422 TX (+)

2

RS422 RX (+)

3

RS232C TXD

4

RS232C RXD

5

RS485 (+)

6

S-NET (+)

7

RS422 TX (–)

8

Flash write switch

9

RS422 RX (–)

10

RS232 C/S-NET GND

11

RS485 (–)

12

S-NET (+)

10-142

Signal name

Remarks

—

S-NET (+)

S-NET GND

S-NET (+)

HD465-7, HD605-7



CN5 (040 20+16-POLE) Machine Connector Number : ATC5A_040 Pin No.

Specification

Signal name

Remarks

1

CN_CHKI

GND

INPUT GND

2

ON/OFF INPUT 0

Hydraulic tank level switch (option)

STEERING HOIST OIL TANK LEVEL SWITCH (OPTION)

3

ON/OFF INPUT 1

Coolant level

COOLANT LEVEL SWITCH

4

ON/OFF INPUT 2

N.C

5

ON/OFF INPUT 3

N.C

6

ON/OFF INPUT 4

Transmission filter clogging switch

TRANSMISSION FILTER SWITCH

7

ON/OFF INPUT 5

Engine oil level switch (option)

ENG OIL LEVEL SWITCH (OPTION)

8

ON/OFF INPUT 6

Engine oil filter clogging switch (option)

ENG OIL FILTER SWITCH (OPTION)

9

ON/OFF INPUT 7

Hydraulic oil filter clogging switch (option)

STEERING HOIST FILTER SWITCH (OPTION)

10

ON/OFF INPUT 8

Fill switch signal "Low clutch"

FILL SIGNAL "LOW"

11

ON/OFF INPUT 9

Fill switch signal "4th clutch"

FILL SIGNAL "4TH"

12

ON/OFF INPUT 10

Fill switch signal "High clutch"

FILL SIGNAL "HIGH"

13

ON/OFF INPUT 11

Fill switch signal "1st clutch"

FILL SIGNAL "1ST"

14

ON/OFF INPUT 12

Fill switch signal "2nd clutch"

FILL SIGNAL "2ND"

15

ON/OFF INPUT 13

Fill switch signal "3rd clutch"

FILL SIGNAL "3RD"

16

ON/OFF INPUT 14

Fill switch signal "Rev clutch"

FILL SIGNAL "REV"

17

ON/OFF INPUT 15

Fill switch signal "lockup clutch"

FILL SIGNAL "L/U"

18

ON/OFF INPUT 16

Key C signal

KEY SWITCH C

19

ON/OFF INPUT 17

Emergency steering operation signal 1

EMERGENCY STEERING RELAY 1

20

ON/OFF INPUT 18

Heater signal

HEATER SIGNAL

21

ON/OFF INPUT 19

N.C

22

ON/OFF INPUT 20

Shift lever signal "R"

SHIFT LEVER "R"

23

ON/OFF INPUT 21

Shift lever signal "N"

SHIFT LEVER "N"

24

ON/OFF INPUT 22

Shift lever signal "D"

SHIFT LEVER "D"

25

ON/OFF INPUT 23

Shift lever signal "6"

SHIFT LEVER "6"

26

ON/OFF INPUT 24


SHIFT LEVER "5"

27

ON/OFF INPUT 25


SHIFT LEVER "4"

28

ON/OFF INPUT 26


SHIFT LEVER "3"

29

ON/OFF INPUT 27


SHIFT LEVER "2"

30

ON/OFF INPUT 28


SHIFT LEVER "L"

31

ON/OFF INPUT 29

N.C

32

ON/OFF INPUT 30

N.C

33

ON/OFF INPUT 31

N.C

34

ON/OFF INPUT 32

Machine select 1

MACHINE SELECT 1

35

ON/OFF INPUT 33

Machine select 2

MACHINE SELECT 2

36

ON/OFF INPUT 34

Machine select 3

MACHINE SELECT 3

HD465-7, HD605-7

10-143 (10)



GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE • The relationship between each gearshift position and the automatic gearshifting range is as shown in the table below.

Gearshifting characteristics • Shifting the transmission up and down is carried out according to the shift map saved in the controller memory. There are three types of shift map, depending on the condition of the input signals. The settings for each mode are as shown in the table below. HD465-7 Serial No.: 7001 – 7483 HD605-7 Serial No.: 7001 – 7181 Mode

Set conditions

Braking mode

When either of the following conditions is fulfilled 1. Brake signal ON (footbrake, retarder brake operated) 2. Accelerator pedal released

High power mode

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

Economy mode

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

HD465-7 Serial No.: 7484 and up HD605-7 Serial No.: 7182 and up Mode

Set conditions

Braking mode

1. Brake signal ON (footbrake, retarder brake operated)

High power mode

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

Economy mode

When the following two conditions are fulfilled 1. Brake signal OFF (footbrake, retarder brake not operated) 2. Power mode selector switch is at economy

Braking mode: The shift-down point and the shift-up point are both raised, the engine speed is maintained at a higher level, and the amount of cooling oil for the retarder is ensured to provide greater effect when the engine is used as a brake. High power mode: The high power mode uses the power of the machine to the maximum to provide the maximum payload. Economy mode: When the machine is being used under light load, such as when traveling unloaded or on flat ground, the shift-up point and shift-down point are both lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and transmission shock are improved.

10-144 (12)

HD465-7, HD605-7



AUTOMATIC GEARSHIFTING GRAPH HD465-7 Serial No.: 7001 – 7483 HD605-7 Serial No.: 7001 – 7181 • The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below.

Lock-up • For the lock-up ON point, the optimum point between 1,300 and 1,500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). • When the machine moves off downhill F1, F2 with the accelerator pedal released, the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.

HD465-7, HD605-7

10-145 (12)



HD465-7 Serial No.: 7484 and up HD605-7 Serial No.: 7182 and up • The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below.

Lock-up • For the lock-up ON point, the optimum point between 1,300 and 1,500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). • When the machine moves off downhill F1, F2 with the accelerator pedal released, the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.

10-145-1 (12)

HD465-7, HD605-7


Gearshift lever positions and method of shifting 1) Gearshift lever position D When shifting up (in high power mode) i) When the gearshift lever is set at position D, the transmission is set to F2 torque converter range. ii) When the accelerator pedal is depressed, the engine speed rises and accelerates. When the transmission input shaft speed reaches 1,300 – 1,500 rpm, the lock-up clutch is engaged, so the torque converter is directly engaged and the transmission is set to direct travel. iii) As the engine speed rises further and reaches 2,100 rpm, the transmission shifts up to F3. While the transmission is shifting up, the engine speed is also lowered (a command is output to the engine controller) in order to reduce the shock when shifting gear. iv) Immediately after shifting up, the engine speed momentarily goes down, but as the machine accelerates, it rises again and the transmission shifts up in turn to F4 to F7 in the same way as in iii) above.


4) Gearshift lever position N At the neutral position, none of the transmission clutches are actuated. Gearshifting load time • In the automatic shift range, to prevent mistaken operation caused by excessive variation in the speed when shifting gear, a time delay is used to prevent the gears from being shifted within the set time. The gearshifting time delay is controlled precisely by each gearshifting pattern through the use of the all-range electronic modulation system. The approximate values for the gearshifting pattern and gearshifting time delay are shown in the diagram below.

When shifting down (in high power mode) i) When the load increases and the engine speed drops to 1,400 rpm, the transmission shifts down one speed. (For example, when traveling in F6, the transmission shifts down to F5.) While the transmission is shifting down, the engine speed is also raised (a command is output to the engine controller) in order to reduce the shock when shifting gear. ii) As the engine speed goes down further and the transmission shifts down in turn to F2, the torque converter lock-up clutch is disengaged and the transmission enters the torque converter drive. •

In the above explanation, the set speed or actuation may differ according to the travel conditions. For details, see the automatic gearshifting graph.

2) Gearshift lever positions 6, 5, 4, 3, 2, L The method of shifting automatically from F1 to F6 (F5, F4, F3, F2) is the same as for gearshift lever position D above. 3) Gearshift lever positions R This is the shift lever position for REVERSE travel. So, the lockup does not work. The safety functions related to travel in reverse are the directional inhibitor and reverse safety. If the operation is not correct, gearshifting is restricted, and the engine speed is reduced at a time.

10-146 (12)

HD465-7, HD605-7


Safety functions 1) Down-shift inhibition function If gearshift lever is operated D → 6-L, 6 → 5-L, 5 → 4-L, 4 → 3-L, 3 → 2-L, 2 → L For example, when traveling in D (F6), even if the gearshift lever is operated to 4, the transmission does not shift directly F6 → F4. It shifts down F6 → F5 → F4 in turn according to the travel speed. (The transmission does not jump two speed ranges if the operator makes a mistake when operating the gearshift lever. This is to prevent the engine from overrunning.) 2) Neutral safety function This circuit prevents the engine from starting if the gearshift lever is not at the N position, even if the starting switch is turned to the START position. (This is a safety circuit to prevent the machine from moving unexpectedly when the engine is started.) 3) Directional inhibition function When traveling forward at a speed of more than 4 km/h, even if the gearshift lever is operated to positions R, the transmission will not be shifted immediately to travel in reverse. The speed range is shifted to N and the engine speed is lowered to reduce the travel speed. When the travel speed goes below 4 km/h, the transmission is shifted to REVERSE. (To prevent overload on power train, to improve durability and reliability) 4) Power train overrun prevention rear brake function When the engine speed exceeds 2,500 rpm in high-speed mode or 2,400 rpm in low-speed mode, the central warning lamp flashes and the warning buzzer sounds. When the engine speed exceeds 2,600 rpm in high-speed mode or 2,450 rpm in low-speed mode, the rear brake is activated automatically. (To prevent overrun of engine, torque converter, and transmission, to improve durability and reliability) Condition in which high speed mode can be selected: Any of coditions below is sattisfied (1) Shifting up is possible (2) Gear shift is placed in any of F7, N, and R positions Condition in which low speed mode can be seleced: In the condition other than high speed mode 5) REVERSE safety The machine will not travel in reverse if the dump control lever is not at FLOAT and the dump body is not completely lowered. (Turnover prevention function)

HD465-7, HD605-7


6) Speed range limit function when dump body is raised. After dumping the load, if the body is not completely lowered, shifting up is limited. If the gearshift lever is at D, the machine starts in F2, and if it is at positions 6 to L, the machine starts in F1. The transmission does not shift up until the body is completely lowered. Self-diagnostic function The controller carries out self-diagnosis of the system and displays any abnormalities. If any abnormality is detected by the self-diagnosis function, the abnormality data is transmitted to the network and is displayed as an action code on the machine monitor. The transmission system caution, warning lamp, or alarm buzzer may also be actuated.

10-147


PAYLOAD METER

PAYLOAD METER

(CARD TYPE)

(CARD TYPE)

STRUCTURE OF SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Shift lever neutral detection switch (relay) Body FLOAT signal (reterder controller) Clinometer Pressure sensor (for front left) Pressure sensor (for front right) Pressure sensor (for rear left) Pressure sensor (for rear right) Suspension cylinder Payload meter Lamp drive relay External display lamp Battery Fuse (for external display lamp) Fuse (for controller) Memory card Travel signal sensor RS232C output (PC cable communication) socket Battery charge signal (alternator terminal R)

HD465-7, HD605-7

Outline • A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the external display lamps. The load mass, distance, time, time when engine was turned ON/OFF, time of occurrence/cancellation of abnormalities or warnings, and other data of each transportation cycle are automatically saved in memory. These data can be later transmitted to a PC or written in a memory card. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading.

10-151 (6)


PAYLOAD METER

(CARD TYPE)

BLOCK DIAGRAM OF PAYLOAD METER

•

•

If a dump truck having the VHMS controller is equipped with the payload meter (having VHMS) optionally, the payload meter (card type) cannot be mounted. When the payload meter (card type) is installed for the first time, replaced, or removed on a dump truck having the VHMS controller, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)". For setting procedure, see STRUCTURE, FUNCTION, and MAINTENANCE STANDARD, "Initial Setting of Payload Meter" and TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and [Items related to VHMS controller] "VHMS Initial Setting Manual (Tool)".

10-151-1 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

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

10-152 (6)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

2. Measurement of mass when empty (Calibration) Drive the empty dump truck at a speed of about 10 km/h for about 30 seconds, and then measure the average load and use it as the mass when empty. The reason why the mass is measured while the dump truck is traveling is that the sliding resistance of the suspension cylinders must be averaged by extracting and retracting the cylinders by changing the condition of the dump truck. The measured mass when empty is saved as a calibration data in the memory in the controller. 3. Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose, set the gearshift lever in the "N" position and set the dump control lever in the "FLOAT" position on a ground where the longitudinal inclination of the dump truck is ± 5°. 4. Correction on slope If the dump truck is loaded on a slope, the measured mass is different from the mass measured on a level ground. To solve this problem, the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. (Correction range of inclination angle: ± 5°) 5. Detecting distance, travel speed The travel speed and distance are detected from the travel signal sensor on the truck. a Travel signal sensor: Transmission output speed sensor

HD465-7, HD605-7

10-153 (10)


PAYLOAD METER

(CARD TYPE)

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

10-154 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

LEFT FACE

•

Details of switches on left face No.

Name

Type

Remarks

1.

Load mass compensation trimmer

Rotary volume

–20% – (Counterclockwise)

2.

Speed compensation trimmer

0 – F rotary selector switch

0 : 107% –7 : 107% – F : 92%

3.

Distance compensation trimmer


0 : 107% –7 : 107% – F : 92%

4.

Model 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


Up : Not used Down : Used

7.

Mass unit setting switch


Up: t (Metric ton), Down: US ton (Short ton)

8.

Switch forcible prohibition setting switch


Up : Permitted Down : Prohibited According to Permitted/prohibited setting table for switches

B.

Buzzer volume adjustment

Rotatory volume

Turn CLOCKWISE to DECREASE volume Turn COUNTERCLOCKWISE to INCREASE volume

+20% (Clockwise)

a The switches are adjusted before the machine is shipped. Only No. 7 and No. B can be adjusted. For this reason, do not touch any other switch.

HD465-7, HD605-7

10-155 (10)


•

PAYLOAD METER

(CARD TYPE)

Table of model selector code No. of model selector switches

Model

0 (*1)

HD1200-1 STD Large-tire Cummins engine

1

HD785-3 STD Large-tire Komatsu engine

2

HD465-5 STD Small-tire Komatsu engine

3


4 5 6

HD785-3 STD Small-tire Komatsu engine

7

HD465-5,7 STD Large-tire Komatsu engine

8


9

HD985-3 STD 30:00-51 Komatsu engine

A

HD605-5,7 STD Large-tire Komatsu engine

B


C D E

*1. The PLM on HD1200-1 has a different part No.

•

Permitted/prohibited setting table for switches Left side switch No. 8

Left side switch No. 5

Top (permitted)

Bottom (prohibited)

Top (memory card not used)

(1)

(2)

Bottom (memory card used)

(3)

(4)

(1) Left side switch No. 5 (top), No. 8 (top) All switches can be operated. (2) Left side switch No. 5 (top), No. 8 (bottom) Calibration, data all clear, time, date setting operations only are possible. (3) Left side switch No. 5 (bottom), No. 8 (top) All switches can be operated. (4) Left side switch No. 5 (bottom), No. 8 (bottom) Calibration, data all clear, card dump, time, date setting operations only are possible.

10-156 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

Payload meter has the following basic functions. i) Power ON (reset) When the power is turned ON, all functions are checked and displayed. a If the engine is started during the flow for this display, even there are items left to display, the display will switch after several seconds to iii) Normal operation display.

HD465-7, HD605-7

10-157 (10)


PAYLOAD METER

(CARD TYPE)

Normal operation display Shift lever position

Dump lever position

Stopped

N

FLOAT

Mass display (*1)

Mass display

Traveling

Except N

FLOAT

Time display

OFF

Stopped

N

FLOAT

Mass display

Mass display and estimated display

Traveling

Except N

FLOAT

Mass display

OFF

Stopped

N

FLOAT

Mass display

Mass display and estimated display

Traveling

Except N

FLOAT

Travel distance displayed in units of m from 0 – 160 m (each 5 m)

OFF

Traveling

Except N

FLOAT

after completion, changes to time display

OFF

Stopped

N

FLOAT

Mass display

Mass display

When dumping (*2)

N

FLOATo RAISE o LOWER o FLOAT

Aggregate mass display (*3)

OFF

Abnormality, warning generated

—

—

(Error code displayed in order of priority)

See Operation and Maintenance Manual

Condition of the machine

Payload meter display

External display lamps

Empty

During loading, before reaching 50% of correct mass During loading, after reaching 50% of correct mass

Loaded

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

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

10-158 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

V) Content of memory (for details, see Operation and Maintenance Manual) a) Cycle data a The period between one dumping operation and the next dumping operation is taken as one cycle and the data are recorded. a The cycle data are recorded when the dumping conditions are fulfilled (see right). a The maximum limit for cycle data in memory is 2900 cycles.

Item

Unit

Range

Engine operation number Month Day Time Hour Time Minute Machine ID Open ID Load mass

Integer Month Day Hour Minute Integer Integer t (Metric ton) or US ton (Short ton)

1-65535 1-12 1-31 Displayed as 0-23 Displays value and set value at time of 0-59 dumping 0-200 0-200 0-6553.5

Empty travel time Empty travel distance Empty max. travel speed Empty average travel speed Empty stopped time Loading stopped time Loaded travel time Loaded travel distance Loaded max. travel speed Loaded average travel speed Loaded stopped time Dumping time Limit speed Warning items/cycle

min km km/h km/h min min min km km/h km/h

0-6553.5 0-25.5 0-99 0-99 0-6553.5 0-6553.5 0-6553.5 0-25.5 0-99 0-99

min min km/h

0-6553.5 0-25.5 0-99

V V V

0-4.0 0-4.0 0-4.0

V V V

0-4.0 0-4.0 0-4.0

Times

0-255

Times

0-255

Analog spare 1 MAX electric potential MIN electric potential Average electric potential Analog spare 2 MAX electric potential MIN electric potential Average electric potential Digital spare 1 Lo frequency Digital spare 2 Lo frequency

HD465-7, HD605-7

Displays set value at time of dumping

Data processing on PC Data inside cycle are handled separately as spare signal input data.

10-159 (10)


PAYLOAD METER

(CARD TYPE)

b) Engine ON/OFF data a Each time the engine was stopped and started is recorded. a The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets. Item

Unit

Range

Engine operation number

Integer

1-65535

Year (last 2 digits) Month Day Time Hour Time Minute

Year Month Day Hour Minute

0-99 1-12 1-31 Shows when engine was switched ON Displayed as 0-23 0-59



0-99 1-12 1-31 Shows when engine was switched OFF Displayed as 0-23 0-59

Aggregate load mass

t (Metric ton) or US ton (Short ton) Times

0-9999000

Total number of cycles

0-9999

Consecutive number for operation of engine

Total value between engine ON and engine OFF

c) Abnormality, warning data a Each time a payload meter abnormality or warning is generated or cancelled is recorded. a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets Item

Unit

Range

Engine operation number when According to 5 error code was generated Integer Frequency of generation Times after engine is switched ON

0-65535 1-255


Year Month Day Hour (0 – 23) Minute

0-99 1-12 Shows when error code was generated 1-31 Displayed as 0-23 0-59

Engine operation number when cancelled

Integer

0-65535


Year Month Day Hour (0 – 23) Minute

0-99 1-12 Shows when error code was cancelled 1-31 Displayed as 0-23 0-59

10-160 (10)

HD465-7, HD605-7

PAYLOAD METER


(CARD TYPE)

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

Unit

Range 0-999900.0

Total number of cycles

t (Metric ton) or US ton (Short ton) Times



0-99 1-12 1-31 Shows date and time when data were cleared Displayed as 0-23 0-59

Aggregate load mass

0-9999

Shows aggregate from time when data were cleared

e) Other data Content

Item

Unit

Range

Operator check mode set data

Machine ID Open ID Limit speed Option code

Integer Integer km/h Integer

0-200 0-200 0-99 0-11

Operator check mode set in input operation

Calibration performance data



0-99 1-12 1-31 Displayed as 0-23 0-59

Date and time when calibration was performed

User write data

Data 1 Data 2 Data 3 Data 4

HD465-7, HD605-7

20 Characters 20 Characters 20 Characters 20 Characters

Comments that can be written freely into payload meter. Note: Input and settings are possible only from PC through cable communications. (For details, see software manual.)

10-161 (10)


PAYLOAD METER

(CARD TYPE)

f) Calibration data a These are saved in RAM each time calibration is performed. a The maximum limit in memory for calibration data is 15 sets. Item

Unit

Range

Year Month Day Time Hour Time Minute Model selection code

Year (last 2 digits) Month Day Hour Minute Integer

00-99 1-12 1-31 0-23 0-59 0-F

Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear)

x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton)

0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 –9.99 – +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5

Tilt angle

x 180 rad Front wheel tilt compensation factor Integer Rear wheel tilt compensation factor Integer Integer Front wheel link factor Integer Rear wheel link factor t (Metric ton) Mass on spring (empty)

Shows values and settings when calibration was performed

Shows values before compensation factor was calculated

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

Year Month Day Time Hour Time Minute Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear)

Year (last 2 digits) Month Day Hour Minute x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton)

Tilt angle

x 180 rad Integer Integer Integer Integer t (Metric ton)

Front wheel tilt compensation factor Rear wheel tilt compensation factor Front wheel link factor Rear wheel link factor Mass on spring (empty) (Calibration value) Trimmer gain value Load mass Backup battery voltage

Integer t (Metric ton) V

Range 00-99 1-12 1-31 0-23 0-59 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 0-6553.5 –9.99 – +9.99 0-9.99999 0-9.99999 0-9.99999 0-9.99999 0-6553.5 0.7500 –1.2500 0-6553.5 0-25.5

The above data items a) – g) are retained even when the power is switched OFF.

10-162 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

vi) Forced display of aggregate load mass, total number of cycles Forced display of existing abnormalities and warnings By operating the TOTAL/SFT switch of payload meter II, it is possible to carry out forcible display of these items. For details, see the Operation and Maintenance Manual.

x) Service check mode By operating the switches of payload meter , it is possible to forcibly carry out display, setting, and correction of the following items.

vii) Operator check mode By operating the switch of payload meter , it is possible to carry out the following items. For details, see the Operation and Maintenance Manual. a) Memory card dump b) Data all clear c) Abnormality, warning exists/cancelled, input signal condition display d) Machine ID setting e) Open ID setting f) Limit speed setting g) Option code setting h) Time, date correction

b) Detailed load mass calculation data display (analog data) The display shows the suspension pressure and machine angle used when calculating the present load mass.

viii) Dimming of display portion It is possible to adjust the brightness of the payload meter II display portion to 10 levels with the LIGHT/INC switch.

d) Data all clear (service area) This forcibly deletes all the calibration data and analog data, except for the latest calibration data.

ix) Downloading saved data It is possible to download any data recorded in payload meter to a PC through a cable (ANSI/ E1A RS-232C). For details, see the PC software manual provided by Komatsu.

a Before clearing the data, always download the data to a PC or carry out a) Card dump.

a) Detailed calibration data display The display shows the date, suspension pressure, etc. when the latest calibration was carried out.

c) Memory card dump (service area) This writes all the data displayed for Items 66 and 6-7 to the memory card inserted in the machine. a This function is available only when the No. 5 switch on the left side of the controller (memory card use switches) is set for "Use"

e) Input signal condition display This displays some of the signal conditions for the sensors input to payload meter and the present recognition condition of the payload meter. f)

Forced initialization This forcibly deletes all the data in payload meter .

a Before carrying out this operation, check the time and date. Always carry out the operation with the machine unloaded. Do not carry out the operation unless necessary. g) Extra load mass setting when loading The extra load can be forcibly input or corrected to set the load mass when loading. Available range for setting: –9 – +9 (%)

HD465-7, HD605-7

10-163 (10)

PAYLOAD METER


(CARD TYPE)

h) Load mass fixed display and cycle data recording, load mass value setting (1) Load mass fixed display When displaying the load mass in the range shown in the table below, it is possible to input and correct to set the display for the load mass when loading is completed (when loading at least 50% of set load mass and traveling 160 m and starting to dump), not the real-time load mass. Setting

Range

TALKS not set (option codes 0 – 3, 10, 11 set) When there is permission to start TALKS set option codes 4 – 9 set

When disconnection of line from payload meter is requested

Payload fixed display

The time that machine is stopped when loading at least 50% of set load mass and traveling 160 m and starting to dump

Load mass when stopped in previous cycle

The time that machine is stopped from permission to move off to starting to dump

Load mass last displayed in previous cycle (Final radio transmission value)

The time that machine is stopped from disconnection of line to starting to dump

Load mass last displayed in previous cycle

(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 completion 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: HD325-6 1 480 – 1,480 [ x 100 t] HD405-6 HD465-7 HD605-7 HD785-5 HD985-3

10-164 (10)

690 – 1,690 [ x

1 100

t]

1,000 – 2,000 [ x

1 100

t]

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

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

External display lamp display range setting This is used to input and correct the values to set the lamp display load mass range when displaying the load mass. Possible set range: Lamp 1 (green)

A : 510 – 255

Lamp 2 (yellow)

B : A – 255

Lamp 3 (red)

C : B – 255

The set value is displayed as a proportion (%) of the correct load mass. t Of the service check mode functions, the following functions can be downloaded to a PC using the PC downloading software provided by Komatsu. • Calibration data • Load mass calculation data (analog data) For details, see the software manual. (1) Method of operation ALways actuate the service check mode Note, c) and d) are actuated on the HD1200-1 when the parking brake is ON or when the brake lock is ON, and on machines other than the HD1200-1 when the shift lever is at the N position and when the dump lever is at FLOAT. f) is actuated only when the power is ON. a When the service mode is working, on the HD1200-1, set the parking brake to ON or the brake lock to ON, and on machines other than the HD1200-1, set the shift lever to the N position and the dump lever to FLOAT. If they are operated to other positions, the payload meter will return to the normal operation display, but in this case, the data set and input in the service check mode may not be processed correctly.

HD465-7, HD605-7

10-165 (10)


10-166 (6)

PAYLOAD METER

(CARD TYPE)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

(a) Operation for calibration data display

1. Set to CHEC display, then press CAL/CLE switch (1) for at least 2 seconds. Display: CALO

2. Every time the CAL/CLE switch (1) is pressed, the display changes in the order shown on the right. 3. If MODE switch (2) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)

From CALO flashing 1

Last 2 digits of year for date when CAL was carried out

2

Month and day for date when CAL was carried out

3

Hour and minute for date when CAL was carried out

4

Model selection switch (decimal value) when CAL was carried out

5

x 98kPa P'FL (Front left)

6

x 98kPa P'FR (Front right)

7

x 98kPa P'RL (Rear left)

8

x 98kPa P'RR (Rear right)

9 10

t

Mass on front axle x 2 (P'FL+P'RL)) (= – D F– 4

t

Mass on rear axle x 2 (= –4 D R – (P'RL+P'RR))

Angle of tilt when CAL was 11 x 180 rad carried out 12

Front axle tilt coefficient

13

Rear axle tilt coefficient

14

Front axle link coefficient

15

Rear axle link coefficient

Spring-up mass calculated All are rounded to 16displayed values according to calibration the value given. CALO flashes 17

Remarks

Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X Less than 100 t: XX.X More than 100 t: XXX.X Appears when value is negative O (–) X.XX

X.XXX

Same number of digits as 9. and 10.

Returns to 1. and repeats sequence

HD465-7, HD605-7

10-167 (10)

PAYLOAD METER


(CARD TYPE)

(b) Operation for payload calculation data (analog data) display

1. Set to CHEC display, then press LIGHT/INC switch (1) for at least 2 seconds. Display: ALLO (when data in memory is less than 170 cycles) A.FUL (when data in memory is more than 170 cycles) A.FUL (when data in memory is more than 180 cycles) 2. Every time the LIGHT/INC switch (1) is pressed, the display changes in the order shown on the right. 3. If MODE switch (2) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)

From ALLO flashing or A.FUL flashing Hour, minute

1 2

x 98kPa P'FL (Front left)

3

x 98kPa P'FR (Front right)

4

x 98kPa P'RL (Rear left)

5

x 98kPa P'RR (Rear right)

6 7

8

Remarks

t

Mass on front axle x 2 (= – D– (P'FL+P'RL)) 4 F

t

Mass on rear axle x 2 (= – D– (P'RL+P'RR)) 4 R

x 180

Angle of tilt when CAL was rad carried out

9

Front axle tilt coefficient

10

Rear axle tilt coefficient

11

Front axle link coefficient

12

Rear axle link coefficient

13

t

Spring-up mass calculated according to calibration

Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X Suspension pressure less than 100 x 98 kPa: XX.X More than 100 x 98 kPa: XXX.X Appears when value is negative

O

(–) X.XX

X.XXX

Same as 7. and 8.

14

—

GT

o Gain trimmer

15

t

Present load mass

Same as 7. and 8.

16

V

Backup battery Voltage

17

X.X

ALLO flashing Returns to (1) and repeats sequence

All displayed values are rounded to the value given.

10-168 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

(c) Operation for memory card dump (service area)

(d) Operation for data all clear (service area)

1. Set to CHEC display, then press TOTAL/SFT switch (1) Display: Cd : dP

1. Set to CHEC display, then press LIGHT/INC switch (1) and CAL/CLEswitch (2) at the same time for at least 2 seconds. Display: A : CLE

2. Press TOTAL/SFT switch (1) again. The main display will go out and memory card access lamp (3) will light up. When the memory card dump operation is completed, it will return automatically to the CHEC display. (End) If it is desired to stop the memory card dump operation when the display is Cd : dP, press MODE switch (2), and the display will return to CHEC without performing the memory card dump operation. The memory card dump function can be used only when the No. 5 switch (memory card use switch) on the left side of the controller is set to "Use".

HD465-7, HD605-7

2. Press CAL/CLE switch (2). The display will become A.CLE (lighted up), and when the data all clear operation is completed, it will return automatically to the CHEC display. (End) If it is desired to stop the data all clear operation when the display is A : CLE, presss MODE witch (3), and the display will return to CHEC without performing the data all clear operation. a Before clearing the data, download the necessary data to a PC or carry out the card dump operation in Item (c).

10-169 (10)


PAYLOAD METER

(CARD TYPE)

(e) Operation for input signal condition display

1. Set to CHEC display, then press TOTAL/SFT switch (1) and CAL/CLR switch (2) at the same time for at least 2 seconds. Display: S : CHE 2. Every time CAL/CLR switch (1) is pressed, the display changes in the order shown below. (2-a) Parking brake, brake lock switch signal condition [HD1200-1] Display: C1:XX (lights up for 3 seconds) Either one ON:CL : oo Both OFF:CL : — — O (2-a’) Shift lever position signal condition [except HD1200-1] Display: C1: XX (lights up for 3 seconds) "N":CL : oo Except "N":CL : — — O (2-b) Dump lever position signal condition Display: C2:XX (lights up for 3 seconds)

(2-d) Battery charge signal condition Display: C4:XX (lights up for 3 seconds) Engine running: C4 : oo Engine stopped: C4 : — — O (2-e) Analog spare input 1 signal condition Display: C5:XX (lights up for 3 seconds) X.X .... Input signal (V) O (2-f) Analog spare input 2 signal condition Display: C6:XX (lights up for 3 seconds) X.X .... Same as C5 O (2-g) Digital spare input 1 signal condition Display: C7:XX (lights up for 3 seconds) Hi:C7 : oo Lo: C7 : — —

O (2-h) Digital spare input 2 signal condition Display: C8 : XX (lights up for 3 seconds) X.X .... Same as C7 O (2-i) Travel speed display Display: C9 : XX X.X .... Travel speed (km/h) O (2-j) Travel distance display Travel distance with machine in present condition (empty or loaded) for that cycle XXXX .... (m) * If the value goes above 9999m, the display starts again from 0. O Go to next page

F. FLOAT:C2 : oo Except FLOAT:C2 : — — O (2-c) Engine oil pressure signal condition Display: C3:XX (lights up for 3 seconds) Engine running:C3 : oo Engine stopped:C3 : — — O

10-170 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

( f ) Operation for performing forced initialization From previous page O (2-k) Payload meter present recognition display Counter display

Empty stopped ............. 03.01 Empty traveling............. 01.02 Loading......................... 06.03 Loaded traveling ........... 02.04 Loaded stopped............ 04.05 Dumping ....................... 05.06 Invariable

May change according to N signal when dumping

O (2-l) Machine condition time display shown below

Every time CAL/CLR switch (1) is pressed, the display advances one place in order from a) to f). a b c d e f

Empty traveling Empty stopped Loaded traveling Loaded stopped Dumping Loading

S1 : S2 : S3 : S4 : S5 : S6 :

*

1. Set to CHEC display, then press CAL/CLR switche (11), TOTAL/SFT switch (2) and LIGHT/ INC switch (3) at the same time for at least 2 seconds. Display: :

2. Press CAL/CLR switch (1) for at least 2 seconds. The display becomes : (lighted up) (2 seconds), and when all the data is completely cleared, it automatically displays F.CAL. (End) After that, it carries out the process from 10.3. If it is desired to stop the forced initialization operation when the display is : , press MODE switch (4), and the display will return to CHEC without performing the forced initialization operation.

The value for the present machine recognition condition increases in minutes in real time.

3. If MODE switch (3) is pressed at any time during the display in Steps 1. or 2., the display will return to CHEC. (End)

HD465-7, HD605-7

10-171 (10)


(g) Operation for setting extra load mass when loading

1. Set to CHEC display, then press TOTAL/SFT switch (1) and LIGHT/INC switch (2) at the same time for at least 2 seconds. Display: S.5EL 2. Press CAL/CLR switch (3). Display UP : XX present set value:for + : X for – : – X If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct.

PAYLOAD METER

(CARD TYPE)

(h) Operation for setting load mass fixed display and cycle data record value

1. Set to UP : XX display, then press CAL/CLR switch (4) Display: PL : XX (present set value) If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct. When the correction operation is completed, press MODE switch (1) at any time to return to the CHEC display. (End)

3. When the correction operation from Step 1. is completed, press MODE switch (4) at any time to return to the CHEC display. (End)

10-172 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

( i) Operation for setting loading completion recognition travel distance

( j ) Operation for setting loading start recognition load mass

1. Set to PL : XX display, then press CAL/CLR switch (4)

1. Set to O.SEL display, then press CAL/CLRswitch (4)

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

Display: P.SEL 2. Press TOTAL/SFT switch (2).

Display: XXX

Display: XXXX

If it is necessary to correct the setting for the units, press LIGHT/INC switch (2) and correct.

If it is necessary to correct the setting for the tens, press LIGHT/INC switch (2) and correct.

3. Press CAL/CLR switch (4).

3. Press CAL/CLR switch (4).

Display: XXX

Display: XXXX

If it is necessary to correct the setting

If it is necessary to correct the setting for the hundreds, press LIGHT/INC switch (2) and correct.

for the tens, press LIGHT/INC switch (2) and correct.

4. Press CAL/CLR switch (4) again. 4. Press CAL/CLR switch (4) again. Display: XXX If it is necessary to correct the setting for the hundreds, press LIGHT/INC switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the display will return to XXX, so it is possible to correct the units again. 6. When the correction operation from Step 1. is completed, pressMODE switch (1) at any time to return to the CHEC display after displaying O.XXX (input value). (End) If it is impossible to set the input values even when MODE switch (1) is pressed, it displays O.XXX (input value) and returns to Step 2..

HD465-7, HD605-7

Display: XXXX If it is necessary to correct the setting for the thousands, press LIGHT/INC switch (2) and correct. 5. If CAL/CLR switch (4) is pressed again, the display will return to Step 3, so it is possible to correct again. 6. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End) If it is impossible to set the input values even when MODE switch (1) is pressed, it returns to Step 1.

10-173 (10)


PAYLOAD METER

(CARD TYPE)

(k) Operation for setting 0 ton display range

1. Set to P.SEL display, then press CAL/CLR switch (4) Display: H.SEL 2. Press TOTAL/SFT switch (3). Display: – – XX (present value) If it is necessary to correct the setting, press LIGHT/INC switch (2) and correct. 3. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End)

10-174 (10)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

( l) Operation for setting display range of external display lamps 6. Press CAL/CLR switch (4) again. Display: E.XXX (present value of lamp 5) If it is necessary to correct the display range for lamp 5, press LIGHT/INC switch (2) and correct. 7. When the correction operation from Step 1. is completed, press MODE switch (1) at any time to return to the CHEC display. (End)

1. Set to H.SEL display, then press CAL/CLR switch (4) Display: E.SEL

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.

2. Press TOTAL/SFT switch (3). Display: A.XXX (present value of lamp 1) If it is necessary to correct the display range for lamp 1, press LIGHT/INC switch (2) and correct. 3. Press CAL/CLR switch (4). Display: b.XXX (present value of lamp 2) If it is necessary to correct the display range for lamp 2, press LIGHT/INC switch (2) and correct. 4. Press CAL/CLR switch (4) again. Display: C.XXX (present value of lamp 3) If it is necessary to correct the display range for lamp 3, press LIGHT/INC switch (2) and correct. 5. Press CAL/CLR switch (4) again. Display: d.XXX (present value of lamp 4) If it is necessary to correct the display range for lamp 4, press LIGHT/INC switch (2) and correct.

HD465-7, HD605-7

10-175 (10)


PAYLOAD METER

(CARD TYPE)

2. Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom.

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

The output characteristics of the sensor are as shown in the diagram on the right. Voltage between pin (1) (GND) and pin (3) (output) of each pressure sensor connector or voltage of output (pins (4), (5), (6), (7)) of each sensor when pin (3) of payload meter controller connector (PM6) is grounded

Pressure sensor

1. Sensor 2. Tube 3. Connector

10-178 (6)

HD465-7, HD605-7


PAYLOAD METER

(CARD TYPE)

3. Clinometer To carry out compensation on slopes, the clinometer measures the tilt angle of the chassis in the front-to-rear direction.

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

4. Lamp drive relay The external display lamps are driven by a signal from the payload meter.

HD465-7, HD605-7

10-179

PAYLOAD METER


(CARD TYPE)

5. Self-diagnostic function The controller always observes the condition of the sensors and outputs, and if any abnormality occurs, it displays an error message. Error message display Order of display priority 1

Content Dump lever at position other than FLOAT (except when dumping)

Judgement standard —

—

Error code display Controller display

External lamp display

Cancellation of display

Timing for display

b-FL ON

All flash

When removed

[for HD1200-1] When parking brake or brake lock is ON

b-FL ON

—

When removed

[for HD1200-1] When parking brake or brake lock is OFF

Cd flashes

—

When removed

Removal detection only for card dump

2

Memory card removed

3

Drop in backup battery voltage

Defective contact or voltage below 2.7 V

F-09 flashes

—

When removed

Except during loading

4

Cycle data memory FULL

See (*1)

See (*1)

—

See (*1)

Except during loading

Engine ON/OFF data memory FULL Abnormality, warning data memory FULL Aggregate payload, number of cycles data memory FULL 5

Disconnection in terminal R

Output below 2 V when engine is running

F-18 flashes

All flash

When removed

When engine is running

6

Abnormality in sensor power source (18 V)

Output is less than 15 V and power source voltage is more than 20 V

F-20 flashes

All flash

When removed

Any time

7

Short circuit with ground, disconnection in front left suspension pressure sensor system

Suspension pressure sensor input signal is 0 kg/cm2 or below

F-21 flashes

All flash

When removed

Any time

8

Short circuit with ground, disconnection in front right suspension pressure sensor system

F-22 flashes

9

Short circuit with ground, disconnection in rear left suspension pressure sensor system

F-23 flashes

10

Short circuit with ground, disconnection in rear right suspension pressure sensor system

F-24 flashes

10-180

HD465-7, HD605-7


Saving abnormality, warning data (PC software display code)

(CARD TYPE)

Remarks

—

Display timing for other than HD1200-1: Shift lever position N

—

Display timing for other than HD1200-1: Shift lever position other than N

—

Detected only when performing card dump

Records (000-009)

PAYLOAD METER

Rated voltage: 3.6 V

Records (000-011) (000-012) (000-013) (000-014)

Records (000-018)

—

Records (000-020)

Calibration cannot be performed when there is abnormality

Records (000-021)

Calibration cannot be performed when there is abnormality

(000-022)

(000-023)

(000-024)

HD465-7, HD605-7

10-181

PAYLOAD METER


Order of display priority

Content

11

Short circuit with power source in front left suspension pressure sensor system

12

Short circuit with power source in front right suspension pressure sensor system

Judgement standard Suspension pressure sensor input signal is 19.6 MPa {200 kg/cm2} or more

(CARD TYPE)

Error code display Controller display F-25 flashes

External lamp display

Cancellation of display

Timing for display

All flash

When removed

Any time

All flash

When removed

Any time

F-26 flashes

13

Short circuit with power source in rear left suspension pressure sensor system

F-27 flashes

14

Short circuit with power source in rear right suspension pressure sensor system

F-28 flashes

15

Short circuit with ground, disconnection in clinometer system

Clinometer input signal above +100

F-31 flashes

16

Short circuit with power source in clinometer system

Clinometer input signal above – 100 EG

F-32 flashes

17

Calibration not performed or abnormality in RAM

Calibration data in memory damaged

F • CAL flashes

All flash

When removed

Any time

18

Short circuit in external display lamp No. 1 relay

F-41 flashes


See Remarks column

When removed

19

When coil is conducting electricity, relay coil short circuits with power source

Except when loading (for external display lamps, see Remarks column)

20


F-43 flashes

21


F-44 flashes

22


F-45 flashes

23

Defective cycle data payload (*2)

See (*2)

L.bad flashes

—

Start of empty travel

Start of dumping start of empty travel

24

Over speed limit

Travel speed is over set speed limit

SP:SP flashes

—

Set value – 2km/h

When problem occurs

25

Defective communications or defective setting of option code

F-71 F-73 F-80 F-81 F-91 F-92 F-93 F-94 F-95 F-96 F-97 F-98 F-99

—

When removed

10-182

F-42 flashes

—

HD465-7, HD605-7


Saving abnormality, warning data (PC software display code) Records (000-025)

PAYLOAD METER

(CARD TYPE)

Remarks Calibration cannot be performed when there is abnormality

(000-026)

(000-027)

(000-028)

Records (000-031) (000-032)

Applicable only when clinometer "use" switch is at "use" Calibration cannot be performed when there is abnormality

Records (000-019)

Payload calculation stopped while problem occurs

Records (000-041)

External display lamps actuated as follows Applicable lamp Machine stopped: Always ON Machine traveling: OFF Other lamps during loading: Specified actuation Other than loading Machine stopped: Flashes Machine traveling: OFF

(000-042) (000-043) (000-044) (000-045) —

—

Records (000-071) (000-073) (000-080) (000-081) (000-091) (000-092) (000-093) (000-094) (000-095) (000-096) (000-097) (000-098) (000-099)

HD465-7, HD605-7

—

10-183


AUTOMATIC EMERGENCY STEERING SYSTEM

AUTOMATIC EMERGENCY STEERING SYSTEM HD465-7 Serial No.: 7001 – 7151 HD605-7 Serial No.: 7001 – 7059

1. Timer 2. Batter 3. Flow switch 4. Emergency steering motor 5. Emergency steering pump 6. Demand valve

10-184 (12)

Outline If the engine should stop when the machie is traveling, or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit, the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering, thereby making it possible to use the steering. This system can also be operated manually.

HD465-7, HD605-7



FLOW SWITCH

1. Wire cable 2. Housing 3. Magnet 4. Pivot pin 5. Disc 6. Spring 7. Lead switch

HD465-7, HD605-7

Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. If the flow of oil inside the hydraulic piping drops below the specified level or stops, the flow switch detects this and actuates the lead switch.

10-185



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

•

When oil flow is below specified level or stops. The force of the oil in the piping pushing plate (5) is weaker than spring (6), so magnet (3) returns to the left. When this happens, the contact with the lead switch is closed and the circuit is switched ON.

10-186

HD465-7, HD605-7



RELAY TIMER

1. Dial 2. Lock 3. Pin

Set time: 1 seconds

HD465-7, HD605-7

Outline The relay timer is a delay timer to prevent the emergency steering system from being actuated when the flow switch is acuated mistakenly by the pulse of the oil or fluttering of the flow switch. With this relay timer, the relay points are switched after electric current is passed through the coil for the time set by the timer.

10-187 (9)




1. Timer 2. Batter 3. Steering oil pressure switch 4. Emergency steering motor 5. Emergency steering pump 6. Demand valve

10-187-1 (12)

Outline If the engine should stop when the machie is traveling, or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit, the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering, thereby making it possible to use the steering. This system can also be operated manually.

HD465-7, HD605-7



FLOW SWITCH

1. Wire cable 2. Housing 3. Magnet 4. Pivot pin 5. Disc 6. Spring 7. Lead switch

HD465-7, HD605-7

Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. If the flow of oil inside the hydraulic piping drops below the specified level or stops, the flow switch detects this and actuates the lead switch.

10-187-2 (12)



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

•

When oil flow is below specified level or stops. The force of the oil in the piping pushing plate (5) is weaker than spring (6), so magnet (3) returns to the left. When this happens, the contact with the lead switch is closed and the circuit is switched ON.

10-187-3 (12)

HD465-7, HD605-7



RELAY TIMER

1. Dial 2. Lock 3. Pin

Outline The relay timer is a delay timer to prevent emergency steering system from malfunctioning. After the current flows in the coil for the time set by the timer, the relay contacts are switched.

Set time: 1 seconds

HD465-7, HD605-7

10-187-4 (12)


AUTOMATIC SUSPENSION SYSTEM


1. Dump control lever 2. Retarder controller 3. Suspension cylinder 4. Solenoid valve 5. Hydraulic cylinder

10-188 (6)

Outline The front suspension mode (damper force) is automatically switched according to the travel condition and load condition to give a more comfortable ride to the operator and to improve the travel stability. For details of the internal mechanism of the suspension, see SUSPENSION

HD465-7, HD605-7



AUTOMATIC SUSPENSION MODE SELECTION CONTROL With the front suspension, the mode (damping force) is automatically changed according to the travel conditions and load conditions to ensure a comfortable ride and to improve the travel stability of the machine. The control patterns and functions of the modes (damping force) are as shown in the table below.

When a liner has been installed to the body for HD465 to make it equivalent to the rock body, the increased load on the springs will affect the loaded/unloaded judgement in the table below. In this case, select the machine model HD605 by the switch for the transmission control system.

S:Soft M:Medium H:Heard Set mode Control pattern

Function

Content of control

Empty S

Distinguishing empty/loaded

To set damping force according to load on machine

Internal pressure of front suspension cylinder is measured and compared with standard valve

Anti-roll

To prevent the chassis from rolling when turning at high speed

This detects the travel speed and steering angle, and switches the mode according to certain conditions. (Not controlled when traveling empty)

To prevent nose-diving when braking

The damping force is made stronger when the brakes are applied.

To prevent the front from lifting up when dumping

The damping force is made stronger when the dump body control lever is at any position except FLOAT.

To improve stability when traveling at high speed

Detects travel speed and selects damping force. (No control when traveling empty)

Anti-dive

Anti-lift

High speed stability

HD465-7, HD605-7

M

Loaded H

S

M

H

(When turning)

(Brake (Brake ON) OFF)

(Float)

(Brake (Brake ON) OFF)

(Other than Float)

(Float) (Other than Flot)

10-189 (10)



AUTO SUSPENSION SOLENOID VALVE

1. Connector 2. Solenoid A : To hydraulic cylinder head B : To hydraulic cylinder bottom P : From pump T : To transmission oil pan

10-190 (6)

Function • The automatic suspension solenoid valve is installed in the circuit between the hydraulic pump and the suspension cylinder. The valve switches oil pressure of the hydraulic cylinder which is installed to the front suspension, according to signal from the retarder controller. Two solenoid valves are combined to select three modes of Soft, Medium and Hard.

HD465-7, HD605-7



STEERING ANGLE SENSOR (If equipped)

1. Body 2. Tube 3. Connector Principle of operation: Magnetic contactless proximity switch Form of output: Turning ON when object of sensing approaches.

Function • A round disc with teeth like a comb is installed to the steering column. As this disc passes through the slit in the sensor, the sensor outputs a pulse signal. The suspension controller can obtain the steering speed from the number of pulses per time.

PRESSURE SENSOR


HD465-7, HD605-7

Function • The pressure sensor is installed to the suspension cylinder. If pressure is applied through the pressure receiving part to the diaphragm of the pressure sensing unit, the diaphragm is deformed. A bridge of strain gauges is formed in front of the diaphragm so that the resistance of the strain gauges will change when the diaphragm is deformed. A constant voltage is applied to the strain gauges. The change of the resistance of the strain gauges is sent as a change of the voltage to the amplifier. The amplifier amplifies the change of the voltage and outputs it to the controller.

10-191 (10)


RETARDER CONTROL SYSTEM


10-192 (6)

HD465-7, HD605-7



RETARDER CONTROLLER

1. 2. 3. 4. 5.

Self-diagnostic display window Rotary switch Motherboard Case Connector

Outline The retarder controller has the following functions. 1. Retarder control The electromagnetic proportional valve is controlled according to the operating angle of the retarder control lever and actuates the retarder. 2. Overrun prevention, retarder control when there is transmission abuse The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount. 3. Hoist control This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) according to the position of the dump control lever and actuates the dump body.

HD465-7, HD605-7

4. Automatic retarder speed control (ARSC) This device controls retarder braking force by movement of electromagnetic proportional control valve to maintain the machine speed set by the automatic retarder machine speed setting switch when driving down hills. 5. Automatic Suspension Control The controller switches output to the automatic suspension solenoid valve according to the travel conditions and loading conditions such as unloading or loading, turning. braking, etc. according to the signal sent from various sensors, and the controller switches damping force of front suspension in three stages of Soft, Medium and Hard. 6. ASR Control (if equipped) The controller detects slips of the drive wheels according to machine speed and steering angle of the right and left drive wheels, and the controller controls the ASR proportional valve so that the speed difference between the both wheels become constant. The brake torque is transmitted to the lower speed wheel by braking the higher speed slipping wheel, so the traveling ability is improved.

10-193 (10)



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

10-194 (6)

HD465-7, HD605-7



CN1 Pin No.

Specification

Signal name

Function

Remarks

1

D_OUT_0

Automatic suspension solenoid 1

H side (1A)

AUTO SUS SOL A

2

D_OUT_2

Automatic suspension solenoid 2

H side (1A)

AUTO SUS SOL B

3

D_OUT_4

H side (1A)

4

D_OUT_6H

24V/L side

5

D_OUT_7H

24V/L side

6

D_OUT_8

7

Push button retarder switch

L side (150mA)

Battery direct

Battery direct IN

8

Power GND

GND

9

Power supply +24V

Power supply +24V

P/B RETARD SW (FOR E/G Controller)

10

D_OUT_1

Front brake cut solenoid

H side (1A)

FRONT BRAKE CUT SOLENOID

11

D_OUT_3

Kick out solenoid

H side (1A)

KICK OUT SOLENOID

12

D_OUT_5

Hoist changeover valve

H side (1A)

DUMP CHANGE CONTROL VALVE

13

D_OUT_6L

Brake cut relay output

H side/GND

BRAKE CUT RELAY

14

D_OUT_7L

Sensor power supply

H side/GND

SENSOR POWER

15

D_OUT_9

Body float signal

L side (150mA)

BODY FLOAT SIG (FOR PLM)

16

Power GND

GND

17

Power supply +24V

Power supply +24V

CN2 Pin No.

Specification

1

Signal name

Function

Solenoid power supply +24V

Solenoid power supply

Remarks

2

A_OUT_4A+

Shut off valve

0 – 1A

SHUT OFF VALVE (+) (FOR ASR)

3

A_OUT_4B+

—

0 – 1A

—

4

A_OUT_5A+

—

0 – 1A

—

5

A_OUT_5B+

—

0 – 1A

—

6

V_OUT

7

A_OUT_0+

Rear wheel retarder EPC output

0 – 1A

RETARD BRAKE VALVE (L) (+) (MANU AND AUTO)

8

A_OUT_1+

EPC output for ASR (left rear wheel)

0 – 1A

RL BRAKE VALVE (+) (FOR ASR)

Interlocked with A_OUT0 (0 – 5V)

9

A_OUT_2+

EPC output for ASR (right rear wheel)

0 – 1A

RR BRAKE VALVE (+) (FOR ASR)

10

A_OUT_3+

Hoist EPC valve

0 – 1A

DUMP CONTROL PCV (+)

11

V_OUT

12 13

Power supply +24V A_OUT_4A, 4B–

14 15

Interlocked with A_OUT1 (0 – 5V)

A_OUT4AB (COM) Suspress, steering speed sensor power +12V

Sensor power supply

Shut off valve (–) (option)

A_OUT5AB (COM)

(option)

Retarder lever, steering angle potentio power +5V

Sensor power supply +5V (400mA)

A_OUT_5A, 5B–

16

Solenoid power supply

17

A_OUT_0–

A_OUT0 (COM)

RETARD BRAKE VALVE (–)

18

A_OUT_1–

A_OUT1 (COM)

RL BRAKE VALVE (–) (OPTION)

19

A_OUT_2–

A_OUT2 (COM)

RR BRAKE VALVE (–) (OPTION)

20

A_OUT_3–

A_OUT3 (COM)

DUMP CONTROL VALVE (–)

21

HD465-7, HD605-7

Power GND

10-195 (6)



CN3 Pin No.

Specification

Signal name

Function

Remarks

1

D_IN

Connector check 0 (pull up)

CONNECTOR CHECK 1

2

PLS_AC_IN_0

Wheel speed sensor (left rear wheel)

—

WHEEL SPEED (RL) (FOR ASR)

3

PLS_AC_IN_1

Wheel speed sensor (right rear wheel) —

WHEEL SPEED (RR) (FOR ASR)

4

PWM_IN

5 6

Hoist lever, body potentio ARSC set switch power +5V

Potentio power +5V (20mA)

7

A_IN_0

Steering angle potentiometer

A_IN0 (+)

S/T ANGLE POTENTIO (+) (FOR ASR)

8

A_IN_1

—

A_IN1 (+)

—

9

A_IN_2

Accumulator oil pressure sensor (front)

Pull down/(up)

ACC OLL PRESS (FRONT)

10

A_IN_3

Accumulator oil pressure sensor (rear) Pull down/(up)

ACC OLL PRESS (REAR)

11

A_IN_35

—

Pull up/down4

—

12

PLS_AC_IN_2

Steering angle speed

—

S/T SPEED SENSOR (FOR AUTO SUS)

13

PLS_AC_IN_3


—

T/M OUTPUT SPEED (+)

Speed GND

GND

14 15

PWM_OUT

16

Analog sensor GND

17

A_IN_0(–)

18

A_IN_1(–)

GND(Analog) A_IN0 (–)

S/T ANGLE POTENTIO (–)

A_IN1 (–)

19

A_IN_4

Suspension pressure sensor (left front wheel)

20

A_IN_5

Suspension pressure sensor (right front wheel)

Pull down/(up)

SUS PRESS (FR)

21

A_IN_6

—

Pull down

—

22

A_IN_7

—

Pull up (1K)

—

23

A_IN_8

Retarder oil temperature sensor

Pull up (4.7K)

RETARD OIL TEMP

24

A_IN_9

—

Pull up (150)

—

Pull down/(up)

SUS PRESS (FL)

25

A_IN_10

Pull up (4.7K)

26

A_IN_11

Pull up (4.7K)

27

A_IN_12

28

A_IN_13

29

A_IN_14

Pull up (4.7K)

30

A_IN_15

Pull up (4.7K)

31

A_IN_16

Accelerator signal

Pull down

ACCEL SIGNAL (T/M) (FOR ARSC/ASR)

32

A_IN_17

Hoist lever potentiometer 1

Pull down

DUMP LEVER POTENTIO1

Pull up (4.7K) —

Pull up (4.7K)

—

33

A_IN_18

Body potentio

Pull down

BODY POSITION SENSOR

34

A_IN_19

Hoist lever potentiometer 2

Pull down

DUMP LEVER POTENTIO2

35

A_IN_20

ARSC set switch

Pull down

ASRC SET SW (FOR ARSC)

36

A_IN_21

Manual retarder lever signal

Pull down

MANUAL RETARD LEVER

10-196 (6)

HD465-7, HD605-7



CN4 Pin No.

Specification

Signal name

Function

1

RS422 TX (+)

RS422 TX (+)

2

RS422 RX (+)

RS422 RX (+)

3

RS232C TXD

RS232C TXD

4

RS232C RXD

RS232C RXD

5

RS485 (+)

RS485 (+)

6

S-NET (+)

S-NET (+)

7

RS422 TX (–)

RS422 TX (–)

8

Flash switch (ON/OFF)

Flash switch (ON/OFF)

9

RS422 RX (–)

RS422 RX (–)

10

GND (serial)

GND (serial)

11

RS485 (–)

RS485 (–)

12

S-NET (+)

S-NET (+)

HD465-7, HD605-7

Remarks

10-197 (6)



CN5 Pin No.

Specification

Signal name

1

Function Connector check 1 (to GND)

2

D_IN_0

3

D_IN_1

Remarks CONNECTOR CHECK 2

Pull up (5mA) Service brake switch

Pull up (5mA)

SERVICE BRAKE PRESS SW

4

D_IN_2

Retarder switch

Pull up (5mA)

RETARD BRAKE PRESS SW

5

D_IN_3

Parking brake switch

Pull up (5mA)

P/B, EMERG BRAKE PRESS SW

6

D_IN_4

Lever validation 1 switch

Pull up (5mA)

LEVER VALIDATION SW 1

7

D_IN_5

Lever validation 2 switch

Pull up (5mA)

LEVER VALIDATION SW 2

8

D_IN_6

—

Pull up (5mA)

SYSTEM FILTER

9

D_IN_7

Retarder cooling filter switch

Pull up (5mA)

RETARD COOLING FILTER

10

D_IN_8

—

Pull up (8mA)

—

11

D_IN_9

—

Pull up (8mA)

—

12

D_IN_10

Inclination switch

Pull up (8mA)

INCLINATION SW

13

D_IN_11

—

Pull up (8mA)

—

14

D_IN_12

—

Pull up (8mA)

—

15

D_IN_13

—

Pull up (8mA)

—

16

D_IN_14

—

Pull up (8mA)

—

17

D_IN_15

Memory clear switch

Pull up (8mA)

MEMORY CLEAR SW

18

D_IN_16

Engine starting signal

Pull down

KEY SW (E/G START SIGNAL)

19

D_IN_17

ABS signal

Pull down

COMMAND FROM ABS

20

D_IN_18

—

Pull down

—

21

D_IN_19

—

Pull down/potentio power +5V

—

22

D_IN_20

Brake wear sensor (left rear wheel)

Pull up/down 1

BRAKE WEAR RL

23

D_IN_21

Brake wear sensor (right rear wheel)

Pull up/down 1

BRAKE WEAR RR

24

D_IN_22

Exhaust brake command (from transmission controller)

Pull up/down 1

EXHAUST BRAKE COMMAND (FROM T/M)

25

D_IN_23

Overrun prevention command (from transmission controller)

Pull up/down 1

OVERRUN COMMAND (FROM T/M)

26

D_IN_24

ASR actuating pressure switch (left rear wheel)

Pull up/down 2

RL BRAKE PRESS SW (FOR ASR)

27

D_IN_25

ASR actuating pressure switch (right rear wheel)

Pull up/down 2

RR BRAKE PRESS SW (FOR ASR)

28

D_IN_26

—

Pull up/down 2

—

29

D_IN_27

—

Pull up/down 2

—

30

D_IN_28

—

Pull up/down 3

—

31

D_IN_29

—

Pull up/down 3

—

32

D_IN_30

—

Pull up/down 3

—

33

D_IN_31

—

Pull up/down 3

—

34

D_IN_32

—

Pull up/down 4

—

35

D_IN_33

—

Pull up/down 4

—

36

D_IN_34

—

Pull up/down 4

—

10-198 (9)

HD465-7, HD605-7



RETARDER CONTROL FUNCTION RETARDER CONTROL SYSTEM DIAGRAM

Retarder lever control • The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this is output to the electromagnetic proportional valve to actuate the retarder. Overrun prevention, retarder control when there is transmission abuse • The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount.

HD465-7, HD605-7

10-199 (6)



Relationship between retarder lever potentiometer and output to electromagnetic proportional valve

A: To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger output) is set to a high value. B: To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a high value. C: In the range where the retarder is normally used, the output is proportional to the angle of the lever. D: To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low value.

10-200 (10)

HD465-7, HD605-7



HOIST CONTROL FUNCTION HOIST CONTROL SYSTEM DIAGRAM

1. Hoist control function When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve are controlled according to the operation of the dump control lever and operate the dump body. 2. Lever positioner function The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER. If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD position. If the lever is kept at the RAISE position, the RAISE output continues to be given.

4. Control when starting switch is turned to ON, OFF, or START Starting switch at ON: The output is set to HOLD, regardless of the position of the lever. If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD. Starting switch at OFF: The dump body is held in position regardless of the position of the lever. Engine started: Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever. After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.

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

10-201 (6)



5. Reverse inhibit function The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the judgment through the network to the transmission controller. "FLOAT OUTPUT" and "SEATED" o Reverse travel permitted "NO FLOAT OUTPUT" or "NOT SEATED" o Reverse travel not permitted 6. Calibration function To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the dump body seating and the body cylinder stopper condition. After adjusting the installation of the body potentiometer or after replacing the retarder controller, carry out calibration in the following order. Order of dump control calibration (hydraulic oil temperature: 80 – 90°C) 1) Lower the dump body completely, run the engine, and keep the lever at FLOAT for at least 5 seconds. (Check that the float caution has gone out.) 2) Operate the lever to the RAISE position until and raise the dump body until it contacts the stopper. Keep the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds. 3) Lower the body to the seat, and then keep the lever at the FLOAT position for at least 5 seconds. 4) Run the engine at low idling and operate RAISE o FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times. 5) Run the engine at high idling and operate RAISE o FLOAT with the dump body raised to the maximum height, then lower the dump body completely. Repeat this operation 10 times.

10-202 (10)

HD465-7, HD605-7


SENSORS, SWITCHES

SENSORS, SWITCHES ENGINE SPEED SENSOR

1. Magnet 2. Locknut 3. Wiring harness 4. Connector

10-204 (6)

Function • The engine speed sensor is installed to the ring gear of the flywheel housing. It uses the rotation of the gear teeth to generate a pulse voltage and transmits a signal to the transmission controller.

HD465-7, HD605-7


SENSORS, SWITCHES

ACCELERATOR SENSOR

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

HD465-7, HD605-7

10-205 (6)


SENSORS, SWITCHES

RETARDER OIL TEMPERATURE SENSOR

1. 2. 3. 4.

Thermistor Plug Wiring harness Connector

Function • The sensor is installed to the retarder piping. It take the change in resistance of the thermistor as the change in the temperature and transmit a signal to the retarder controller. The signal is sent from the retarder controller through the network to the machine monitor panel to display the temperature level. When the display on the monitor panel reaches the specified position, the lamp lights up and the buzzer sounds to warn of an abnormality.

COOLANT LEVEL SENSOR

1. Float 2. Sensor 3. Connector

10-206 (10)

Function • This sensor is installed to the top of the radiator, and when the coolant level goes below the specified level, the float goes down and the switch goes OFF. The maintenance caution lamp lights up and the character display shows message to warn of abnormality.

HD465-7, HD605-7


SENSORS, SWITCHES

TRANSMISSION OIL FILTER CLOGGING SENSOR

1. Body 2. Tube 3. Connector A : Low pressure pickup port B : High pressure pickup port

Function • This sensor are installed to each filter, and when the filter becomes clogged, and the difference in pressure between the low-pressure side and high-pressure side reaches the specified pressure, the switch goes OFF. The maintenance caution lamp lights up and the character display shown message to warn of abnormality. Actuating pressure: 275 kPa {2.8 kg/cm2} Principle of switch: Pressure difference sliding piston type

STEERING OIL PRESSURE SWITCH (FOR AUTOMATIC EMERGENCY STEERING SYSTEM)

1. Piston 2. Body 3. Switch 4. Connector

HD465-7, HD605-7

Function • The steering pressure switch is installed to the steering and hoist piping. If the oil pressure in the steering circuit lowers below the set level while the engine is running, the steering pressure switch starts the electric pump to secure the oil pressure for steering.

10-207 (12)


SENSORS, SWITCHES

FUEL LEVEL SENSOR

1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer

10-208 (6)

Function • The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display of the monitor panel reaches a certain level, a warning lamp flashes.

HD465-7, HD605-7


SENSORS, SWITCHES

AIR CLEANER CLOGGING SENSOR

1. Indicator 2. Spring 3. Adapter

HD465-7, HD605-7

Function • The air cleaner clogging sensor is installed to the outward port of the air cleaner. If the air cleaner becomes clogged and reaches the set pressure (negative pressure), the maintenance caution lamp lights up and character display shows message to warn of the abnormality.

10-209 (6)


SENSORS, SWITCHES

BODY POSITIONER SENSOR

1. Bearing 2. Rotor 3. Connector

10-210 (6)

Function • The body position sensor is installed to the rear of the chassis. When the angle of the dump body changes, the shaft receives sliding resistance through the link installed to the dump body, and the dump body angle is detected.

HD465-7, HD605-7


SENSORS, SWITCHES

TILT SWITCH

1. Magnet 2. Plate 3. Gasket 4. Print card 5. Bracket 6. Plate 7. Plate 8. Plate 9. Connector

HD465-7, HD605-7

Function • If the chassis tilts to the left or right, the disc magnet moves to the left or right. If the chassis tilts into the roll-over danger range, either the left or right switch is turned OFF. If the dump lever is operated to the RAISE position in this condition, the lamp lights up and the buzzer sounds to warn of the danger.

10-211 (6)


DUMP LEVER

DUMP LEVER

10-212 (10)

HD465-7, HD605-7


DUMP LEVER

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

HD465-7, HD605-7

10-213 (10)


DUMP LEVER

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

10-214 (10)

HD465-7, HD605-7


2. Dump lever FLOAT canceled • When lever (1) is returned from the FLOAT position, it is pushed down by a force greater than the holding force of rod (19), detent spring (20), retainer (13), and ball (14). 3. Dump lever operated to LOWER • When lever (1) is operated further from the FLOAT position, it moves to the LOWER position. • Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated. • Lever (17) and rod (19), which are installed to the rotating shaft of potentiometer (16), are interconnected, so a voltage matching the up or down movement of the rod is output from potentiometer (16).

DUMP LEVER

4. Dump lever operated to RAISE • When RAISE rod (18) is pushed by lever (1) and moves down, ball (14) contacts protrusion a of rod (19) during the stroke. (Before start of actuation of mechanical detent) • When rods (18) and (19) are pushed in further, ball (14) is being held by detent spring (20). While pushing retainer (13) up, it escapes to the outside, and rod (19) passes over protrusion a. • When this happens, rod (2) on the opposite side is pushed up by spring (4). • When an electric current is flowing to solenoid (19), if rod (2) is pushed up, nut (10) is held in contact with bushing (8). • As a result, rod (2) is held at the pushed up position, so even if the lever is released, it is held at the RAISE position.

5. Dump lever RAISE canceled • When lever (1) is returned from the RAISE position, it is pushed down by a force greater than the attraction force of the solenoid. Or, when the solenoid power source is turned OFF, the RAISE position is canceled and the lever returns to the N position.

HD465-7, HD605-7

10-215 (10)


VHMS CONTROLLER BLOW-BY PRESSURE SENSOR

VHMS CONTROLLER For details of the basic precautions, outlines, method of sending and receiving data, and the procedure for the initial setup, see TESTING AND ADJUSTING. Specifications 1. Voltage of power supply : DC20V - DC30V 2. Size (mm) : W272 x D169 x H72 Function The VHMS controller collects and stores signals from each sensor and signals from the machine controller. It also gives commands for transmitting the accumulated data through the communications satellite.

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

10-216 (10)

HD465-7, HD605-7


ENGINE OIL TEMPERATURE SENSOR

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

35.27

80

6.571

110

2.887

40

24.28

85

5.682

115

2.544

50

17.05

90

4.931

120

2.248

60

12.20

95

4.293

125

1.992

70

8.884

100

3.750

130

1.769

a : Heat sensing portion of sensor, outside diameter of mount R 1/4 Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change in temperature to the VHMS controller as a change in the resistance of the thermistor.

HD465-7, HD605-7

10-217 (10)


EXHAUST TEMPERATURE SENSOR/AMP AMBIENT TEMPERATURE SENSOR

EXHAUST TEMPERATURE SENSOR/AMP Specifications 1. Rated voltage : DC24V 2. Detection temperature range : 100 – 1,000 °C : 300 – 800 °C (guaranteed accuracy ± 10 °C) 3. Output voltage characteristics: See table below 4. Actuation temperature range : --40 to 110 °C 5. Consumption current : Max. 30 mA a : Heat sensing portion of sensor, outside diameter of mount R 1/8 b : Amp c : Connector (power source end) d : Connector (sensor end) Output voltage characteristics (ambient temperature: 20 °C) ••• Reference value Detection temperature (°C)

50

100

400

700

800

Output voltage (V)

1.191

1.397

2.626

3.899

4.316

Function The exhaust temperature sensor is a thermoelectric type temperature sensor. It is installed to the turbocharger inlet port and outputs the exhaust temperature data to the VHMS controller.

AMBIENT TEMPERATURE SENSOR Specifications 1. Electricity consumption 2. Pressure resistance

: Max. 0.5 mW : 0.98 MPa {10 kg/cm2} 3. Detected temperature range (surrounding) : --30 to 120°C 4. Retention temperature range: --30 to 140°C 5. Performance table below Detection temperature (°C) Resistance (kz)

--20

--10

0

10

20

50

30.32 18.58 11.74 7.623 5.077 1.712

a : Heat sensing portion of sensor, diameter of mount 16 x 1.5 Function The ambient temperature sensor inputs the ambient temperature to the VHMS controller as a change in the resistance of the thermistor.

10-218 (10)

HD465-7, HD605-7


COMMUNIVSTIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA

COMMUNICATIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA CONTROLLER Specifications 1. Power supply voltage : DC12V – DC30V 2. Size : W306 x D152 x H52 (mm) Installation location Install under assistant's seat. Connector portion CN1A (ORB-A) : AMP070-14 CN1B (ORB-B) : AMP070-10 CN2 : Communications antenna cable connector

ANTENNA Specifications 1. Type : Helical whip antenna (1) 2. Impedance : 50 Ω 3. Input terminal : M-P type 4. Length : 165 ± 20 mm a : Communications antenna mount Installation location Install pole at right front of machine and set antenna on top of it. Function The antenna transmits the data collected and accumulated by the VHMS controller through the communications satellite to the computer center.

HD465-7, HD605-7

10-219 (6)


PAYLOAD METER

PAYLOAD METER (HAVING VHMS) SYSTEM CONFIGURATION

10-220 (6)

HD465-7, HD605-7


Outline • A dump truck is supported by 4 suspension cylinders. By measuring the total of the loads on each cylinder, it is possible to know the mass on the springs of the dump truck. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the outside indicator lamps. It also has an estimation display function: when loading the next load, the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading. •

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

•

The VHMS controller executes the functions of the payload meter and saves the data of each transportation cycle. It displays, sets, and operates various items through the machine monitor and network. When the payload meter is installed for the first time or the VHMS controller is replaced, the necessary items of the VHMS controller must be set again. Payload meter (card type) set for HD465/6055 can be installed for a user who needs a memory card. If it is installed, however, have the machine monitor and VHMS controller recognize that it will execute the functions of the payload meter, by using rotary switch 2 of the transmission controller and VHMS initial setting tool. For setting procedure, see TESTING AND ADJUSTING, "Initial Setting of Payload Meter", and "Replacing Parts".

HD465-7, HD605-7

•

PAYLOAD METER

The payload meter (having VHMS) cannot be installed to a dump truck which is not equipped with the VHMS controller or which is equipped with the VHMS controller and payload meter (card type).

10-221 (10)


PAYLOAD METER

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

10-222 (10)

HD465-7, HD605-7

PAYLOAD METER


INITIAL SETTING OF PAYLOAD METER In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to the following table. 1. When the payload meter (having VHMS) or payload meter II (card type) is installed for the first time 2. When the payload meter (having VHMS) or payload meter II (card type) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller is changed

Setting of payload meter

Payload meter function is not installed

Payload meter function is installed

VHMS controller

Not installed Installed

PLM-II (card type)

Not installed

Set position of rotary switch 2 (SW2) of transmission controller (*1) F

Setting with VHMS initial setting tool (*2)

Model

Serial No.

Variation code

Date Time Time difference Summer time

–

–

–

–

B

Payload meter function is installed VHMS

Installed

Not installed

9

PLM

Installed

Installed

B

PLM (Without VHMS)

Not installed

Installed

F

ST HD465 or HD605

–7

PV

Set properly

P2 –

–

–

–

(*1) See "TESTING AND ADJUSTING, Adjusting transmission controller". (*2) See "TESTING AND ADJUSTING, Setting up VHMS controller. When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. Wrong setting of rotary switch 2 (SW2) of transmission controller 2. While the payload meter (having VHMS) is not set, there are the menus related to the payload meter on the machine monitor. Wrong setting of rotary switch 2 (SW2) of transmission controller

4. The storage place of the data file made by the download software is not found. Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. Wrong setting of the date and time with the VHMS initial setting tool.

3. While the payload meter (having VHMS) is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. Wrong setting of the model and serial No. with the VHMS initial setting tool. HD465-7, HD605-7

10-223 (10)


BASIC FUNCTIONS OF PAYLOAD METER

PAYLOAD METER

7. Setting of OFFSET range This function is used to adjust the calculated load mass by a set amount.

For details, see Operation and Maintenance Manual.

VARIOUS SETTING FUNCTIONS (SERVICE FUNCTIONS) 1. Setting of travel distance to recognize completion of loading When the dump truck travels 160 m from the loading area, the payload meter judges that the loading operation is finished. If the dump truck is unloaded before it travels 160 m, the payload meter does not judge that the dump truck is unloaded and the cycle data is not completed at this time. This function is used to change the travel distance to recognize completion of loading when the distance between the loading area and dump area is very short.

8. Selection of method of entering saved load mass This function is used to select either of the following methods of entering the hauled load mass. 1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). 2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area.

2. Correction of calculation of load mass If the load mass indicated by the payload meter is different from that indicated by the user's load meter, measure the operating mass (when the truck is empty) and gross truck mass (when the truck is loaded with the rated load mass) with the user's load meter, then correct the relation table of the suspension pressure and load mass forcibly with the measured masses and this function. 3. Correction of level of inclination sensor This function is used to correct the level of the inclination sensor. 4. Setting of criterion of maximum travel speed This function is used to set a criterion of the maximum travel speed for the machine control system. 5. Setting of load mass to recognize start of loading The payload meter recognizes that loading is completed when the load mass changes by certain amount. This function is used to change that amount. Since an easy change can cause wrong recognition of loading, verify the machine condition thoroughly when changing. 6. Setting of indication range of outside indicator lamp This function is used to change the indication range of the outside indicator lamp. The condition for turning on the red lamp cannot be changed. If it is changed, the red lamp cannot warn of overloading.

10-224 (10)

HD465-7, HD605-7


PAYLOAD METER

OPERATING METHOD Select "PLM" in Service Mode 1 on the machine monitor. For method of selection, see TESTING AND ADJUSTING, "Special functions of machine monitor (EMMS)".

HD465-7, HD605-7

10-225 (10)


1. Setting of travel distance to recognize completion of loading

Input a travel distance to recognize completion of loading by pressing the following buttons. The setting range is 0 – 255 m (0.0 – 0.158 miles). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. If the set value is too small, the system may recognize that loading is completed while the dump truck is still being loaded.

PAYLOAD METER

2. Correction of calculation of payload Since this function affects the accuracy directly, execute the following procedure securely. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. Accordingly, secure a road for this purpose. The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment. Accordingly, perform the following procedure very carefully. This function is used to match the calculation result to the indication of the load meter to be used. It does not always heighten the absolute accuracy. 1) Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper, etc.) 2) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. i) Select "EMPTY WEIGHT".

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

10-226 (6)

HD465-7, HD605-7

PAYLOAD METER


ii) Check that measurement of the weight of the empty dump truck has been completed.

• [

] button: Check that measurement has been completed and go to the next step. • [ ] button: Return to the previous screen. iii) Input the measured weight of the empty dump truck.

iv) Check the input value.

• [>] button: Select "YES". • [<] button: Select "NO". • [ ] button: Enter. v) Move the dump truck to a place where you can drive it for about 3 minutes.

• [

• [>] •

• •

•

button: Number at cursor moves forward. [<] button: Number at cursor moves backward. [ ] button: Enter number at cursor. [ ] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. Inputtable range HD465-7: 43.6 [t] (Operating weight ± 13%) (metric ton) HD605-7: 46.8 [t] (Operating weight ± 13%) (metric ton)

HD465-7, HD605-7

] button: After getting ready for drive, press this button and start driving the dump truck. • [ ] button: Return to the screen for inputting values. Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight.

10-227 (6)

PAYLOAD METER


vi) Display the progress of measurement.

] button: Stop measurement and return to the previous screen. As measurement is executed, the number of [ ] increases. When measurement is finished, the next screen appears automatically. 3) Load the dump truck to measure the weight of the fully loaded dump truck.

i)

Select "LOADED WEIGHT". For the method of displaying the following screen, see the steps up to the above step.

• [

] button: Return to the menu screen. When loading is started, the menu screen appears automatically. When indicating the current load for reference while the dump truck is being loaded, go out of "Service mode 1" temporarily and return to "Display of load/integrated odometer". On this screen, you can check the current load. 4) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper, etc.) 5) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes.

• [>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". • [ ] button: Enter the selection. • [ ] button: Return to the previous screen. If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected. Check the unit of the input value. The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC): metric ton (SHORT): short ton ii) Check that measurement of the weight of the fully loaded dump truck has been completed.

• [

• [

• [

10-228 (6)

] button: Check that measurement has been completed and go to the next step. ] button: Return to the previous screen.

HD465-7, HD605-7

PAYLOAD METER


iii) Input the measured weight of the fully loaded dump truck.

• [>]

button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. Inputtable range HD465-7: A1 ± (A1 x 0.25) (metric ton) However, A1 = {43.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 ± (A2 x 0.25) (metric ton) However, A2 = {46.8 [t] (Operating weight) + 63 [t] (Load capacity)} iv) Check the input value.

v) Move the dump truck to a place where you can drive it for about 3 minutes.

• [

] button: After getting ready for drive, press this button and start driving the dump truck. • [ ] button: Return to the screen for inputting values. Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. vi) Display the progress of measurement (Fig. 9).

• [

] button: Stop measurement and return to the previous screen. As measurement is executed, the number of [ ] increases. When measurement is finished, the next screen appears automatically.

• [<] button: Select "YES". • [>] button: Select "NO". • [ ] button: Enter.

HD465-7, HD605-7

10-229 (6)

PAYLOAD METER


6) Dump the load in the dump area.

3. Correction of level of inclination sensor 1) Move the dump truck to a level place. 2) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. i) Enter value of (F).

• [

] button: Return to the menu screen. If the load is dumped with the dump lever, the menu screen appears automatically. If the load is dumped normally, correction is finished. • [ • [

] button: Enter the flashing value. ] button: Return to the menu screen. The current standard level value is displayed on the upper line. The clinometer value (F) at the current position flashes. Enter it when it is stabilized. ii) Turn the dump truck 180 degrees (Stop it in the opposite direction). iii) Enter value of (R).

• [ • [

] button: Enter the flashing value. ] button: Return to the menu screen. The current standard level value is displayed on the upper line. The clinometer value at the current position flashes. Enter it when it is stabilized.

10-230 (10)

HD465-7, HD605-7


iv) Enter the standard level value.


HD465-7, HD605-7

PAYLOAD METER

4. Setting of criterion of maximum travel speed

Input a criterion of the maximum travel speed by pressing the following buttons. • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. The setting range is 0 – 99 km/h (0 – 62 MPH). (Default: 99 km/h)

10-231 (6)


PAYLOAD METER

5. Setting of payload to recognize start of loading

6. Setting of indication range of outside indicator lamps

Input a payload to recognize start of loading by pressing the following buttons. • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. The setting range is 0 – 25.5%. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below. • If the value is reduced, start of loading may be recognized wrongly. • If the value is increased and a loader having a small-capacity bucket is used, the forecast function of the outside indicator lamps and the MMS communication may not operate normally.

Input an indication range of the outside indicator lamps by pressing the following buttons. • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. The setting range is 0 – 130% of the load capacity. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp), however.

10-232 (6)

HD465-7, HD605-7


7. Setting of OFFSET range

Input an offset range by pressing the following buttons. • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. The setting range is - 5.0 – +5.0 [t]. Check the unit of the input value on the previous menu screen. The unit is indicated in the ( ) on the right side of the input value [t]. (METRIC): metric ton (SHORT): short ton

PAYLOAD METEROR

8. Selection of method of entering saved payload i) Select the method of entering the saved payload.

• [>], [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped. • [ ] button: Enter the selected method. • [ ] button: Return to the menu screen. ii) Enter the selected method.


HD465-7, HD605-7

10-233 (6)


PAYLOAD METER

Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom.

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

The output characteristics of the sensor are as shown in the diagram on the right.


10-234 (10)

HD465-7, HD605-7


PAYLOAD METER

Clinometer To carry out compensation on slopes, the clinometer measures the tilt angle of the chassis in the front-torear direction.

The output characteristics of the clinometer are as shown in the diagram on the right.

HD465-7, HD605-7

10-235 (6)


PAYLOAD METER

FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING The following 2 functions of communicating with external devices are installed. They use the RS232C communication port which is installed to download the data of the payload meter. 1. Automatic transmission When dumping is finished, the data of the concerned cycle are transmitted automatically. The data saved in the payload meter can be made by accumulating the above cycle data with the system on the user side. 2. MMS communication If the mass of a bucketful is recognized, the load mass at that time is transmitted automatically. If the final load mass (hauled load mass of the concerned cycle) is entered, its value is transmitted automatically. Upon receiving a request command, the load mass is transmitted in real time. RS232C is used for only the selected one of data downloading, automatic transmission, and MMS communication. • Specifications of RS232C connection Baud rate: 9600 bps Data length: 8 bits Stop bit: 2 bits Parity: Not applied Flow control: Not executed

•

Connection of RS232C (communication line) (3-wire method)

•

Selecting wiring harness for downloading/automatic transmission/MMS communication

10-236 (6)

HD465-7, HD605-7


•

PAYLOAD METER

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

•••

STX (02h)

•••

ETX (03h) BCC

DLE (10h)

STX (02h)

Transmitted frame STX (02h)

HD465-7, HD605-7

•••

•••

ETX (03h) BCC

10-237 (6)

PAYLOAD METER


•

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

Header "L"

ASCI1

Unused

Integer

Month Day Time, hour

1 – 65535

Number of byte

Remarks

1

L (Fixed)

2

0 (Fixed)

Month (BCD)

1

Day (BCD)

1

Hour (BCD)

Time, minute

Range

0 – 23 expression

Minute (BCD)

1 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

km/h

0 – 255

1

Empty max. travel speed Empty ave. travel speed

0 – 255

1

Empty stoppage time

MIN (10-time value)

km/h

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

0 – 6553.5

2

Loaded stoppage time

MIN (10-time value)

Dumping time

MIN (10-time value)

Limited speed

km/h

Cycle warning code

0 – 25.5

1

0 – 99

1

0 – FFFF (HEX)

2

Unused

MIN (10-time value)

0 – 4.0

1

0 (Fixed)

Unused

MIN (10-time value)

0 – 4.0

1

0 (Fixed)

Unused

MIN (10-time value)

0 – 4.0

1

0 (Fixed)

Unused

MIN (10-time value)

0 – 4.0

1

0 (Fixed)

Unused

MIN (10-time value)

0 – 4.0

1

0 (Fixed)

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 STX (02h)

NAK (15h)

VHMS controller)

31H (ASCII 1)

ETX (03h) BCC

Action that VHMS controller takes when answer is abnormal If "NAK" is returned, the VHMS controller transmits up to 2 more times. If "NAK" is still returned, the VHMS controller stops transmission.

10-238 (6)

HD465-7, HD605-7


•

PAYLOAD METER

MMS communication Transmission of unit distinction setting (a) Timing of transmission After the VHMS controller is started by turning the key to the ON position, it transmits the unit distinction setting information automatically. (b) Contents of communication Format (VHMS controller ) STX (02h)

[1]

[2]

ETX (03h) BCC

[1]: K (ASCII) fixed [2]: 02 (h) fixed (Unit classification [HEX]) The unit classification is the same as one used for PLM2. It is fixed to 02 (h) in the VHMS controller. [BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller) STX (02h)

ACK (06h)

31H (ASCII 1)

ETX (03h) BCC

NAK (15h)

31H (ASCII 1)

ETX (03h) BCC

or STX (02h)

Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of load mass, estimated load mass, and suspension pressure (a) Timing of transmission When mass of 1 bucketful is recognized.

HD465-7, HD605-7

10-239 (6)

PAYLOAD METER


(b) Contents of communication Format (VHMS controller) STX (02h)

[1]

[2]

[3]

[4]

[5]

[6]

ETX (03h) BCC

[1]: M (ASCII) fixed [2]: 4 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) [5]: Estimated load mass (C) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) [6]: (B) Calculated suspension pressure [HEX] [8 BYTES] From head Signal name P FL P FR P RL P RR

Position (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position)

Name

HEX

Front left suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

Front right suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

Rear left suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

Rear right suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

[BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller) STX (02h)

ACK (06h)

31H (ASCII 1)

ETX (03h) BCC

NAK (15h)

31H (ASCII 1)

ETX (03h) BCC

or STX (02h)

Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of final load mass (a) Timing of transmission When the concerned cycle data are entered (When dumping is finished), the final load mass (= the load mass to be saved as the hauled load mass of the concerned cycle in the memory) is transmitted automatically. (b) Contents of communication Format (VHMS controller) STX (02h)

[1]

[2]

ETX (03h) BCC

[1]: P (ASCII) fixed [2]: Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place) Order: Lower position upper position from the head byte of [2] [BCC]: EX-OR of each bit from STX to ETX Answer ( STX (02h)

VHMS controller) ACK (06h)

31H (ASCII 1)

ETX (03h) BCC

NAK (15h)

31H (ASCII 1)

ETX (03h) BCC

or STX (02h)

10-240 (6)

HD465-7, HD605-7


PAYLOAD METER

Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission. Transmission of real-time data (a) Outline of communication procedure 1) The VHMS controller receives a request for the real-time data from MMS. 2) After receiving the request for the real-time data, the VHMS controller transmits the real-time data at intervals of 0.2 seconds. 3) When the VHMS controller receives a request for finishing transmission of the real-time data, it finishes transmission of the real-time data. When the key is turned to the OFF position, transmission of the real-time data is finished, too. (b) Contents of communication 1) Request for real-time data ( VHMS controller) Format STX (02h)

[1]

[2]

ETX (03h) BCC

[1]: M (ASCII) fixed [2]: A (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller ) Transmission of the real-time data from the VHMS controller is used as a substitute for the answer.

HD465-7, HD605-7

10-241 (6)

PAYLOAD METER


2) Transmission of real-time data (VHMS controller Format (VHMS controller ) STX (02h)

[1]

[2]

[3]

[4]

)

ETX (03h) BCC

[1]: M (ASCII) fixed [2]: 2 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Real-time data (17 BYTES) From head Signal name

Position

Name

HEX

P FL

(Lower position) (Upper position)

Front left suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

P FR

(Lower position) (Upper position)

Front right suspension pressure (kg/ cm2)

[10-time value] 0 – 6553.5

Rear left suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

Rear right suspension pressure (kg/cm2)

[10-time value] 0 – 6553.5

P RL P RR INC PAYLD SP DIG STST

(Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position)

Inclination angle (degree)

[Complement of 2 of 100-time value]

Real-time load mass (Metric ton)

[10-time value, to 1 decimal place)

(Current) Travel speed (km/h) Status of digital signals

0 – 99 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 [BCC]: EX-OR of each bit from STX to ETX

10-242 (6)

HD465-7, HD605-7

PAYLOAD METER


Answer ( STX (02h)

VHMS controller) ACK (06h)

ETX (03h) BCC

NAK (15h)

ETX (03h) BCC

or STX (02h)

Action that VHMS controller takes when answer is abnormal Even if "NAK" is returned or any of "ACK", "NAK", and a request for finishing RTM is not returned in RTM transmission timing, the VHMS controller transmits the real-time data normally after 0.2 seconds. If this condition is repeated 10 times, the VHMS controller stops transmission. 3) Request for finishing transmission of real-time data ( Format STX (02h)

[1]

[2]

VHMS controller)

ETX (03h) BCC

[1]: Q (ASCII) fixed [2]: 2 (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller STX (02h)

)

ACK (06h)

ETX (03h) BCC

NAK (15h)

ETX (03h) BCC

or STX (02h)

HD465-7, HD605-7

10-243 (6)

20 TESTING AND ADJUSTING STANDARD VALUE TABLE Standard value table for engine related parts . 20- 2 Standard value table for chassis ..................... 20- 3 TESTING AND ADJUSTING........................... 20-101 TROUBLESHOOTING .................................... 20-301

a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims.

When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.

HD465-7, HD605-7

20-1 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS


Item

Model

HD465-7 Serial No.: 7001 – 7483 HD605-7 Serial No.: 7001 – 7181

Engine

SAA6D170E-3 Standard value

Permissible value

Power mode

2,270 ± 50

2,270 ± 50

Economy mode

2,200 ± 50

2,200 ± 50

Stationary mode (*1)

2,100

Measurement conditions

High idle

Engine Speed

Unit

rpm

Hi

+0 – 100

2,100

+0 – 100

945 ± 50

945 ± 50

750 ± 50

750 ± 50

Power mode

2,000 ± 50

2,000 ± 50

Economy mode

1,900 ± 50

1,900 ± 50

Min. 106.6 {Min. 800}

Min. 93.3 {Min. 700}

Max. 670

Max. 700

Max. 670

Max. 700

Max. 3.5

Max. 6.0

Max. 1.0

Max. 2.5

0.32

—

0.62

—

Min. 2.9 {30}

Min. 1.96 {20}

Max. 5.4 {550}

Max. 8.8 {900}

0.392 – 0.539 {4.0 – 5.5} 0.343 – 0.539 {3.5 – 5.5}

Min. 0.206 {2.1}

At low idle (SAE30)

Min. 0.118 {1.2}

Min. 0.080 {0.8}

At low idle (SAE10W)

Min. 0.098 {1.0}

Min. 0.069 {0.7}

Low idle Lo

Rated speed

Boost pressure

• Hi power mode • Torque convertor stall

Exhaust temperature


kPa {mmHg} # 1, 2, 3 °C # 4, 5, 6

At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature)

Bosch index

Intake valve mm Exhaust valve

Compression pressure (SAE30 oil)

Oil temperature: 40 – 60°C (Engine speed: 210 – 250 rpm)

Blow-by pressure

(Coolant temperature: Operating range) kPa • Power mode {mmH2O} • Torque convertor stall

MPa {kg/cm2}

(Coolant temperature: Operating range) At high idle (SAE30) Oil pressure

At high idle (SAE10W)

MPa {kg/cm2}

Min. 0.177 {1.8}

Oil temperature

Whole speed range (Inside oil pan)

°C

90 – 110

120

Belt tension (Alternator)

Deflection when pressed with finger force of approx. 58.8 N {6 kg}

mm

15

15

*1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position. When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" position.

20-2 (12)

HD465-7, HD605-7


STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS HD465-7 Serial No.: 7001 – 7483 HD605-7 Serial No.: 7001 – 7181 Component

Standard value

Permissible value

Standard tires

Standard tires

11.5 ± 5 %

11.5 ± 5 %

16.0 ± 5 %

16.0 ± 5 %

21.5 ± 5 %

21.5 ± 5 %

29.5 ± 5 %

29.5 ± 5 %

F5

39.0 ± 5 %

39.0 ± 5 %

F6

52.5 ± 5 %

52.5 ± 5 %

F7

70.0 ± 5 %

70.0 ± 5 %

R

12.0 ± 5 %

12.0 ± 5 %

2,100 ± 50

2,100 ± 50

1,400 ± 50

1,400 ± 50

Item


F1

F3 Travel speed

F4

Shift up Economy mode

Auto lock-up Overrun prevention

• Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C • “Braking mode” refers to when the accelerator is OFF or the rear brake is ON.

1,325 ± 35 1,325 ± 35 (F2 o F1 only) (F2 o F1 only)

Shift down

2,000 ± 50

1,300 ± 50

1,300 ± 50

1,250 ± 50 1,250 ± 50 (F2 o F1 only) (F2 o F1 only) 2,450 ± 50

2,450 ± 50

Shift down

1,550 ± 50

1,550 ± 50

*1

*1

*2

*2

Set

2,600 ± 10

2,600 ± 10

Reset

2,350 ± 10

2,350 ± 10

Set Reset

rpm

1,325 ± 35 1,325 ± 35 (F2 o F1 only) (F2 o F1 only)

Down-shift inhibitor

Torque converter

2,000 ± 50

Shift up

Braking mode

Engine speed

Shift down

km/h

Engine speed at torque converter stall

• Transmission oil temperature: 85 – 110°C • Hydraulic oil temperature: 45 – 55°C • Engine coolant temperature: Within operating range

Power mode

Automatic shift control

Shift up High power mode

• Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Machine unloaded • Travel resistance: 3.3 %

1,910±100

1,910 ± 100

Economy mode

Performance

F2

Unit

1,910±100

1,910 ± 100

*1. Torque converter speed ratio is min. 0.85 at min. 1,500 rpm or min. 1,300 rpm *2. F3 – F7: 1,050 ± 50 F1, F2 : 1,100 ± 50

HD465-7, HD605-7

20-3 (12)


Accelerator pedal

Component

Item


Starting to depress Operating force

Travel

• Operating effort at a point 150 mm from pedal fulcrum

Fully Starting to depress i o fully

Unit

N {kg}

Standard value

Permissible value

22.5 ± 4.9 {2.3 ± 0.5}

22.5 ± 4.9 {2.3 ± 0.5}

2.0 42.1 +– 7.8

2.0 42.1 –+ 7.8

{4.3

+ 0.3 – 0.8

}

{4.3

+ 0.3 – 0.8

}

• Travel at a point 150 mm from pedal fulcrum

mm

45 ± 5

45 ± 5

• At center of lever knob

N {kg}

21.6 ± 3.9 {2.2 ± 0.4}

Max. 29.4{3}

mm

24.5 ± 1

24.5 ± 2

At engine speed 2,000 rpm

0.74 ± 0.05 {7.5 ± 0.5}

0.74 ± 0.05 {7.5 ± 0.5}

At high idle (2,270 rpm) (Reference value)

0.88 ± 0.05 {8.9 ± 0.5}

0.88 ± 0.05 {8.9 ± 0.5}

At low idle (750 rpm) (Reference value)

0.17 ± 0.05 {1.7 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}


0.59 ± 0.05 {6.0 ± 0.5}

0.59 ± 0.05 {6.0 ± 0.5}


0.71 ± 0.05 {7.2 ± 0.5}

0.71 ± 0.05 {7.2 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


3.68 ± 0.15 {37.5 ± 1.5}

3.68 ± 0.15 {37.5 ± 1.5}


3.77 ± 0.15 {38.5 ± 1.5}

3.77 ± 0.15 {38.5 ± 1.5}


3.33 ± 0.15 {34 ± 1.5}

3.33 ± 0.15 {34 ± 1.5}

1.67 ± 0.2 {17 ± 2}

1.67 ± 0.2 {17 ± 2}

1.82 ± 0.2 {18.5 ± 2}

1.82 ± 0.2 {18.5 ± 2}

1.77 ± 0.2 {18 ± 2}

1.77 ± 0.2 {18 ± 2}

2nd clutch

3.33 ± 0.2 {34 ± 2}

3.33 ± 0.2 {34 ± 2}

1st clutch

3.58 ± 0.2 {36.5 ± 2}

3.58 ± 0.2 {36.5 ± 2}

Operating force Transmission shift lever


R–N N–D D–5 Travel 5–4 4–3 3–L

Torque converter

Inlet oil pressure

Outlet oil pressure • Oil temperature: 75 – 85°C Lock-up oil pressure

Main relief oil pressure

Transmission

H, 4th clutch

20-4 (10)

At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm

MPa {kg/cm2}

• Oil temperature: 60 – 80°C • Engine: at rated speed

L clutch Control valve set pressure

3rd clutch

MPa {kg/cm2}

HD465-7, HD605-7


Parking brake

Tires (Inflation pressure)

Transmission

Component

Item

Lubricating oil pressure

Standard tires


• Oil temperature: 60 – 80°C (When using EO10-CD) or Oil temperature: 80 – 100°C (When using EO30-CD) 24.00-35-36PR (Front and rear tires)

Standard value

Permissible value

0.15 ± 0.05 {1.5 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}

0.09 ± 0.05 {0.9 ± 0.5}

0.09 ± 0.05 {0.9 ± 0.5}

0.46 {4.75}

0.46 {4.75}

0.69 {7.0}

0.69 {7.0}

%

Min. 25

Min. 25

rpm

Min. 1,540

Min. 1,540

Unit

At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value)

MPa {kg/cm2}


• Machine unloaded

MPa {kg/cm2} Tire (If equipped)

24.00-R35 (Front and rear tires)

Braking capacity

• With 46ton payload

Starting test

• F2 • Torque converter stall

Releasing pressure

See Brake

Front Suspension cylinder


A

MPa {kg/cm2}

• On flat road surface • When empty

Installed length

Steering wheel

249 ± 10

249 ± 20

249 ± 10 (*1)

249 ± 20 (*1)

220 ± 10

220 ± 20

204 ± 10 (*1)

204 ± 20 (*1)

3.82 ± 0.39 {39 ± 4}

3.82 ± 0.39 {39 ± 4}

2.26 ± 0.29 {23 ± 3}

2.26 ± 0.29 {23 ± 3}

mm Rear

B

Front MPa {kg/cm2}

Pressure Rear

Operating force (Turning speed for steering wheel: 30 rpm)

• Oil temperature: 60 – 80°C • When machine stopped (empty) (If it is impossible when the machine stopped, travel at low speed with engine at low idle)

N {kg}

14.7 – 29.4 {1.5 – 3.0}

Max. 35.3 {Max. 3.6}

Play

• Length at circumference of steering wheel • Engine stopped, until tires start to move

mm

Max. 135

Max. 135

No. of turns

• Lock o lock

Turns

3.5 ± 0.3

3.5 ± 0.6

Max. 4

Max. 5

Max. 4

Max. 5

20.2 – 21.1 {206 – 215}

20.1 – 23.5 {205 – 240}

20.2 – 21.1 {206 – 215}

20.1 – 23.5 {205 – 240}

Turning time Steering valve

See Brake

Relief pressure

Left o right Right o left • Oil temperature: 45 – 55°C

• Oil temperature: 60 – 80°C • Engine speed: Whole range • Lock o lock At high idle (2,270 rpm) At low idle (750 rpm) (Reference value)

sec.

MPa {kg/cm2}

*1. Cylinder with buffer ring

HD465-7, HD605-7

20-5 (10)


Component


Unit

Standard value

Permissible value

Operating force (Full)

N {kg}

233 ± 29.4 {23.8 ± 3}

234 ± 29.4 {23.8 ± 3}

Travel (Start of depressing o Full)

mm

40 ± 5

40 ± 10

N {kg}

5.9 – 9.8 {0.6 – 1.0}

3.0 – 14.7 {0.3 – 1.5}

deg

0 – 78

N {kg}

296 ± 29.4 {30.2 ± 3}

296 ± 29.4 {30.2 ± 3}

Max. 22.3

Max. 22.3

Max. 17.0

Max. 17.0

17.6 ± 1.2 {180 ± 12}

17.6 ± 1.2 {180 ± 12}

9.8 ± 0.7 {100 ± 7}

9.8 ± 0.7 {100 ± 7}

8.7 ± 0.6 {88.5 ± 6.5}

8.7 ± 0.6 {88.5 ± 6.5}

0.98 9.85 +– 0.49

0.98 9.85 –+ 0.49

Item


Retarder control lever

Brake pedal

• Measure at position a (Position at 150 mm from fulcrum of pedal)

Operating force

• At point 10 mm from tip of lever

Travel

0 –2

0 – 78

0 –4

Emergency brake pedal



Service brake braking distance

46 ton payload

Empty

Front

Brakes

Brake actuating pressure

• Initial speed: 32 km/h • Distance from starting to lose speed to stopping • Max. hydraulic pressure Rear: 9.8 MPa {100 kg/cm2} Front: 17.6 MPa {180 kg/cm2} • On flat, dry road surface • Engine: Stopped • When first operated

Rear (service) MPa {kg/cm2}

Rear (retarder) Parking brake releasing pressure Stopping distance when emergency brake is applied

Brake oil pressure

• Engine: Stopped

{100.4 +– 510 • Carrying 46 ton payload • Initial speed: 32 km/h • On flat, dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder

20-6 (10)

m

m

MPa {kg/cm2}

}

{100.4 +– 510 }

Max. 52.1

Max. 52.1

17.6 ± 1.2 {180 ± 12}

17.6 ± 1.2 {180 ± 12}

9.8 ± 0.7 {100 ± 7}

9.8 ± 0.7 {100 ± 7}

8.7 ± 0.6 {88.5 ± 6.5}

8.7 ± 0.6 {88.5 ± 6.5}

HD465-7, HD605-7


Component

Item Service brake Retarder brake Parking brake

Brakes


Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually. Measure the engine speed when the truck starts moving

Left side

Rear brake (Disc wear gauge )

Left side

Must not move at 1,400 rpm rpm

mm

Right side

—

Right side HOLD o RAISE

FLOAT o HOLD

N {kg}

LOWER o FLOAT • Engine: stopped • Center of control lever knob

Dump valve Dump EPC valve

• Oil temperature: 45 – 55°C

RAISE o HOLD

Body

Lowering speed

Hydraulic drift

HD465-7, HD605-7

3.0

19.5

3.0

Must be in wear gauge range Must be in wear gauge range Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Must return smoothly when engine is running at 2,000 rpm 44.8 ± 1.9

44.8 ± 1.9

44.8 ± 1.9

44.8 ± 1.9

At high idle (2,270 rpm)

20.1 – 21.1 {205 – 215}

19.6 – 22.6 {200 – 230}


18.6 – 19.6 {190 – 200}

18.6 – 19.6 {190 – 200}

3.4 ± 0.49 {35 ± 5}

3.4 ± 0.49 {35 ± 5}

2.6 ± 0.49 {27 ± 5}

2.6 ± 0.49 {27 ± 5}

11.5 ± 1.5

11.5 ± 1.5

10.5 ± 1.5

2.0 10.5 +– 1.0

Max. 85

170

HOLD o LOWER


Lifting speed

19.5

Must return smoothly when engine is running at high idle

FLOAT o LOWER

Relief pressure ( root pressure)

Must not move at 1,670 rpm

Max. 29.4 {Max. 3.0}

RAISE o HOLD HOLD o FLOAT

Operating force

Relief pressure

Permissible value

Must not move until torque converter stall speed

Front brake (Pad thickness )

Travel

Standard value


Emergency brake

• Engine: stopped • Center of control lever knob

Dump lever

Unit

mm

MPa {kg/cm2}

At low idle (750 rpm) (Reference value) • Oil temperature: 45 – 55°C • Engine speed: 2,000 rpm • Use FLOAT when lowering

sec.

• Oil temperature: 45 – 55°C • Set with No. 2 cylinder extended 200 mm • Hydraulic drift after 5 minutes

mm

20-7 (11)




Item

Model


Engine

SAA6D170E-3


Unit

Power mode High idle

2,270 ± 50

2,270 ± 50

+0 – 50

(empty)

2,270 ± 50 (loaded) 2,100 rpm

Hi

Permissible value

2,100

Economy mode Stationary mode (*1)

Engine Speed

Standard value

+0 – 50

2,200 ± 50 2,100

+0 – 100

945 ± 50

945 ± 50

750 ± 50

750 ± 50

2,000 ± 50

2,000 ± 50

1,900 ± 50 (empty) 2,100 ± 50 (loaded)

1,900 ± 50

Min. 106.6 {Min. 800}

Min. 93.3 {Min. 700}

Max. 670

Max. 700

Max. 670

Max. 700

Max. 3.5

Max. 6.0

Max. 1.0

Max. 2.5

0.32

—

0.62

—

Min. 2.9 {30}

Min. 1.96 {20}

Max. 5.4 {550}

Max. 8.8 {900}

0.392 – 0.539 {4.0 – 5.5} 0.343 – 0.539 {3.5 – 5.5}

Min. 0.206 {2.1}

At low idle (SAE30)

Min. 0.118 {1.2}

Min. 0.080 {0.8}

At low idle (SAE10W)

Min. 0.098 {1.0}

Min. 0.069 {0.7}

Low idle Lo Power mode Rated speed Economy mode Boost pressure


Exhaust temperature


kPa {mmHg} # 1, 2, 3 °C # 4, 5, 6

At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature)

Bosch index

Intake valve mm Exhaust valve

Compression pressure (SAE30 oil)

Oil temperature: 40 – 60°C (Engine speed: 210 – 250 rpm)

MPa {kg/cm2}

Blow-by pressure

(Coolant temperature: Operating range) kPa • Power mode {mmH2O} • Torque convertor stall (Coolant temperature: Operating range) At high idle (SAE30)

Oil pressure

At high idle (SAE10W)

MPa {kg/cm2}

Min. 0.177 {1.8}

Oil temperature

Whole speed range (Inside oil pan)

°C

90 – 110

120

Belt tension (Alternator)

Deflection when pressed with finger force of approx. 58.8 N {6 kg}

mm

15

15

*1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position. When measuring the high idle speed in the power mode or economy mode, set the hoist lever in the "HOLD" position.

20-8 (12)

HD465-7, HD605-7



STANDARD VALUE TABLE FOR CHASSIS HD465-7 Serial No.: 7484 and up HD605-7 Serial No.: 7182 and up Component

Standard value

Permissible value

11.5 ± 5 %

11.5 ± 5 %

16.0 ± 5 %

16.0 ± 5 %

21.5 ± 5 %

21.5 ± 5 %

29.5 ± 5 %

29.5 ± 5 %

F5

39.0 ± 5 %

39.0 ± 5 %

F6

52.5 ± 5 %

52.5 ± 5 %

F7

70.0 ± 5 %

70.0 ± 5 %

R

12.0 ± 5 %

12.0 ± 5 %

2,100 ± 50

2,100 ± 50

Item

Measurement conditions F1 F2

Performance

F3 F4

Travel speed

High power mode

• Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Machine unloaded • Travel resistance: 3.3 % • Standard tires • High power mode km/h

Shift up Shift down

Empty


Full throttle

Engine speed

Unit

• Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C

1,400 ± 50 1,400 ± 50 1,325 ± 35 1,325 ± 35 (F2 o F1 only) (F2 o F1 only) 1,800/1,935 ± 50 1,800/1,935 ± 50 2,000 ± 50 2,000 ± 50 (F1 o F2 only) (F1 o F2 only) 1,750 ± 50

1,750 ± 50

2,000 ± 50 2,000 ± 50 (F1 o F2 only) (F1 o F2 only)

Half throttle

1,800 ± 50 1,800 ± 50 (F2 o F3 only) (F2 o F3 only) Economy mode

Accelerator OFF (Slow travel)

Shift up

rpm 2,450 ± 50

2,450 ± 50

1,935/2,070 ± 50 1,935/2,070 ± 50

Loaded

Full throttle

2,100 ± 50 2,100 ± 50 (F1 o F2 only) (F1 o F2 only) 1,750 ± 50

Half throttle

1,750 ± 50

2,100 ± 50 2,100 ± 50 (F1 o F2 only) (F1 o F2 only) 1,800 ± 50 1,800 ± 50 (F2 o F3 only) (F2 o F3 only)


HD465-7, HD605-7

2,450 ± 50

2,450 ± 50

20-9 (12)


Component


Item


Empty

Full throttle

Half throttle

Unit

• Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C

Standard value

Permissible value

1,300 ± 35

1,300 ± 35

1,250 ± 35 1,250 ± 35 (F2 o F1 only) (F2 o F1 only) 1,200 ± 35

1,250 ± 35 1,250 ± 35 (F3oF2,F2oF1) (F3oF2,F2oF1) 1,200 ± 35


1,200 ± 35


Economy mode

Shift down

1,350 ± 35 Full throttle

Engine speed

1,350 ± 35

1,325 ± 35 1,325 ± 35 (F2 o F1 only) (F2 o F1 only) 1,200 ± 35

Loaded


1,200 ± 35

1,200 ± 35

1,250 ± 35 1,250 ± 35 (F3 o F2 only) (F3 o F2 only)

Half throttle

1,325 ± 35 1,325 ± 35 (F2 o F1 only) (F2 o F1 only) 1,200 ± 35 Accelerator OFF (Slow travel)

rpm

1,200 ± 35


Shift up

2,450 ± 50

2,450 ± 50

Shift down

1,550 ± 50

1,550 ± 50

Torque converter speed ratio is minimum 0.85 at minimum of 1,500 rpm or 1,300 rpm.

Torque converter speed ratio is minimum 0.85 at minimum of 1,500 rpm or 1,300 rpm.

F3 – F7: 1,050 ± 50

F3 – F7: 1,050 ± 50

F1, F2: 1,100 ± 50

F1, F2: 1,100 ± 50

Set

2,600 ± 10

2,600 ± 10

Reset

2,350 ± 10

2,350 ± 10

1,910 ± 10

1,910 ± 10

1,800 ± 100

1,800 ± 100

1,875 ± 100

1,875 ± 100

Torque converter

Overrun prevention

Auto lock-up

Braking mode

20-10 (12)

Set

Reset

Power mode Engine speed at torque Empty conEconverter omy stall mode Loaded

• Transmission oil temperature: 85 – 110°C • Hydraulic oil temperature: 45 – 55°C • Engine coolant temperature: Within operating range

HD465-7, HD605-7


Accelerator pedal

Component

Item

Operating force

Travel


Starting to depress

• Operating effort at a point 150 mm from pedal fulcrum

Fully Starting to depress i o fully

Unit

N {kg}

Standard value

Permissible value

22.5 ± 4.9 {2.3 ± 0.5}

22.5 ± 4.9 {2.3 ± 0.5}

2.0 42.1 +– 7.8

2.0 42.1 –+ 7.8

{4.3

+ 0.3 – 0.8

}

{4.3

+ 0.3 – 0.8

}

• Travel at a point 150 mm from pedal fulcrum

mm

45 ± 5

45 ± 5

• At center of lever knob

N {kg}

21.6 ± 3.9 {2.2 ± 0.4}

Max. 29.4{3}

mm

24.5 ± 1

24.5 ± 2


0.74 ± 0.05 {7.5 ± 0.5}

0.74 ± 0.05 {7.5 ± 0.5}


0.88 ± 0.05 {8.9 ± 0.5}

0.88 ± 0.05 {8.9 ± 0.5}


0.17 ± 0.05 {1.7 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}


0.59 ± 0.05 {6.0 ± 0.5}

0.59 ± 0.05 {6.0 ± 0.5}


0.71 ± 0.05 {7.2 ± 0.5}

0.71 ± 0.05 {7.2 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


1.67 ± 0.20 {17 ± 2}

1.67 ± 0.20 {17 ± 2}


3.68 ± 0.15 {37.5 ± 1.5}

3.68 ± 0.15 {37.5 ± 1.5}


3.77 ± 0.15 {38.5 ± 1.5}

3.77 ± 0.15 {38.5 ± 1.5}


3.33 ± 0.15 {34 ± 1.5}

3.33 ± 0.15 {34 ± 1.5}

1.67 ± 0.2 {17 ± 2}

1.67 ± 0.2 {17 ± 2}

1.82 ± 0.2 {18.5 ± 2}

1.82 ± 0.2 {18.5 ± 2}

1.77 ± 0.2 {18 ± 2}

1.77 ± 0.2 {18 ± 2}

2nd clutch

3.33 ± 0.2 {34 ± 2}

3.33 ± 0.2 {34 ± 2}

1st clutch

3.58 ± 0.2 {36.5 ± 2}

3.58 ± 0.2 {36.5 ± 2}

Operating force Transmission shift lever


R–N N–D Travel

D–5 5–4 4–3 3–L

Torque converter

Inlet oil pressure

Outlet oil pressure • Oil temperature: 75 – 85°C Lock-up oil pressure

Main relief oil pressure

Transmission

H, 4th clutch

At low idle (750 rpm) (Reference value) At engine speed 2,000 rpm

MPa {kg/cm2}

• Oil temperature: 60 – 80°C • Engine: at rated speed

L clutch Control valve set pressure

HD465-7, HD605-7

3rd clutch

MPa {kg/cm2}

20-11 (12)


Parking brake

Tires (Inflation pressure)

Transmission

Component

Item

Lubricating oil pressure

Standard tires

Tire (If equipped)


• Oil temperature: 60 – 80°C (When using EO10-CD) or Oil temperature: 80 – 100°C (When using EO30-CD) 24.00-35-36PR (Front and rear tires)

Standard value

Permissible value

0.15 ± 0.05 {1.5 ± 0.5}

0.15 ± 0.05 {1.5 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}

0.17 ± 0.05 {1.7 ± 0.5}

0.09 ± 0.05 {0.9 ± 0.5}

0.09 ± 0.05 {0.9 ± 0.5}

0.46 {4.75}

0.46 {4.75}

0.69 {7.0}

0.69 {7.0}

%

Min. 25

Min. 25

rpm

Min. 1,540

Min. 1,540

Unit

At engine speed 2,000 rpm At high idle (2,270 rpm) (Reference value)

MPa {kg/cm2}


• Machine unloaded MPa {kg/cm2}

24.00-R35 (Front and rear tires)

Braking capacity

• With 46ton payload

Starting test

• F2 • Torque converter stall

Releasing pressure

See Brake

Front Suspension cylinder


A

MPa {kg/cm2}

• On flat road surface • When empty

Installed length

mm Rear

B

Front MPa {kg/cm2}

Pressure

Steering wheel

Rear

249 ± 10

249 ± 20

249 ± 10 (*1)

249 ± 20 (*1)

220 ± 10

220 ± 20

204 ± 10 (*1)

204 ± 20 (*1)

3.82 ± 0.39 {39 ± 4}

3.82 ± 0.39 {39 ± 4}

2.26 ± 0.29 {23 ± 3}

2.26 ± 0.29 {23 ± 3}

Operating force (Turning speed for steering wheel: 30 rpm)

• Oil temperature: 60 – 80°C • When machine stopped (empty) (If it is impossible when the machine stopped, travel at low speed with engine at low idle)

N {kg}

14.7 – 29.4 {1.5 – 3.0}

Max. 35.3 {Max. 3.6}

Play

• Length at circumference of steering wheel • Engine stopped, until tires start to move

mm

Max. 135

Max. 135

No. of turns

• Lock o lock

Turns

3.5 ± 0.3

3.5 ± 0.6

Max. 4

Max. 5

Max. 4

Max. 5

20.2 – 21.1 {206 – 215}

20.1 – 23.5 {205 – 240}

20.2 – 21.1 {206 – 215}

20.1 – 23.5 {205 – 240}

Turning time Steering valve

See Brake

Relief pressure

Left o right Right o left • Oil temperature: 45 – 55°C

• Oil temperature: 60 – 80°C • Engine speed: Whole range • Lock o lock At high idle (2,270 rpm) At low idle (750 rpm) (Reference value)

sec.

MPa {kg/cm2}

*1. Cylinder with buffer ring

20-12 (12)

HD465-7, HD605-7


Component


Unit

Standard value

Permissible value


N {kg}

233 ± 29.4 {23.8 ± 3}

234 ± 29.4 {23.8 ± 3}

Travel (Start of depressing o Full)

mm

40 ± 5

40 ± 10

N {kg}

5.9 – 9.8 {0.6 – 1.0}

3.0 – 14.7 {0.3 – 1.5}

deg

0 – 78

N {kg}

296 ± 29.4 {30.2 ± 3}

296 ± 29.4 {30.2 ± 3}

Max. 22.3

Max. 22.3

Max. 17.0

Max. 17.0

17.6 ± 1.2 {180 ± 12}

17.6 ± 1.2 {180 ± 12}

9.8 ± 0.7 {100 ± 7}

9.8 ± 0.7 {100 ± 7}

8.7 ± 0.6 {88.5 ± 6.5}

8.7 ± 0.6 {88.5 ± 6.5}

0.98 9.85 +– 0.49

0.98 9.85 –+ 0.49

Item


Retarder control lever

Brake pedal


Operating force

• At point 10 mm from tip of lever

Travel

0 –2

0 – 78

0 –4

Emergency brake pedal



Service brake braking distance

46 ton payload

Empty Front

Brakes

Brake actuating pressure

• Initial speed: 32 km/h • Distance from starting to lose speed to stopping • Max. hydraulic pressure Rear: 9.8 MPa {100 kg/cm2} Front: 17.6 MPa {180 kg/cm2} • On flat, dry road surface • Engine: Stopped • When first operated

Rear (service)

MPa {kg/cm2}

Rear (retarder) Parking brake releasing pressure Stopping distance when emergency brake is applied

Brake oil pressure

• Engine: Stopped

{100.4 +– 510 • Carrying 46 ton payload • Initial speed: 32 km/h • On flat, dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder

HD465-7, HD605-7

m

m

MPa {kg/cm2}

}

{100.4 +– 510 }

Max. 52.1

Max. 52.1

17.6 ± 1.2 {180 ± 12}

17.6 ± 1.2 {180 ± 12}

9.8 ± 0.7 {100 ± 7}

9.8 ± 0.7 {100 ± 7}

8.7 ± 0.6 {88.5 ± 6.5}

8.7 ± 0.6 {88.5 ± 6.5}

20-13 (12)


Component

Item Service brake Retarder brake Parking brake

Brakes


Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually. Measure the engine speed when the truck starts moving

Left side

Rear brake (Disc wear gauge )

Left side

Must not move at 1,400 rpm rpm

mm

Right side

—

Right side HOLD o RAISE

FLOAT o HOLD

N {kg}

LOWER o FLOAT • Engine: stopped • Center of control lever knob

Dump valve Dump EPC valve

• Oil temperature: 45 – 55°C

Body

Lowering speed

Hydraulic drift

(12)

3.0

19.5

3.0

Must be in wear gauge range Must be in wear gauge range Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Max. 29.4 {Max. 3.0}

Max. 35.3 {Max. 3.6}

Must return smoothly when engine is running at 2,000 rpm 44.8 ± 1.9

44.8 ± 1.9

44.8 ± 1.9

44.8 ± 1.9


20.1 – 21.1 {205 – 215}

19.6 – 22.6 {200 – 230}


18.6 – 19.6 {190 – 200}

18.6 – 19.6 {190 – 200}

3.4 ± 0.49 {35 ± 5}

3.4 ± 0.49 {35 ± 5}

2.6 ± 0.49 {27 ± 5}

2.6 ± 0.49 {27 ± 5}

11.5 ± 1.5

11.5 ± 1.5

10.5 ± 1.5

2.0 10.5 +– 1.0

Max. 85

170

HOLD o LOWER


Lifting speed

20-14

RAISE o HOLD

19.5

Must return smoothly when engine is running at high idle

FLOAT o LOWER

Relief pressure ( root pressure)


Max. 29.4 {Max. 3.0}

RAISE o HOLD HOLD o FLOAT

Operating force

Relief pressure

Permissible value

Must not move until torque converter stall speed

Front brake (Pad thickness )

Travel

Standard value


Emergency brake

• Engine: stopped • Center of control lever knob

Dump lever

Unit

mm

MPa {kg/cm2}

At low idle (750 rpm) (Reference value) • Oil temperature: 45 – 55°C • Engine speed: 2,000 rpm • Use FLOAT when lowering

sec.

• Oil temperature: 45 – 55°C • Set with No. 2 cylinder extended 200 mm • Hydraulic drift after 5 minutes

mm

HD465-7, HD605-7

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

20-101 (11)

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING


TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Symbol

Part No.

Air supply pressure (boost pressure)

A

799-201-2202

Boost gauge KIT

1

-101 – 200 kPa {-760 – 1,500 mmHg}

Wear level of front brake pad

b

566-98-41410

Gauge

1

Attached tool

799-101-1502

Digital temperature gauge

1

-99.9 – 1,299 °C

6215-11-8170

Sensor

1

Wire length: 490 mm

799-201-1110

Wiring harness

1

799-101-5002

Oil pressure gauge KIT (Analog)

1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (Digital)

1

Pressure gauge: 58.8 MPa {600 kg/cm2}

799-401-2320

Oil pressure gauge

1


799-101-5002


1


790-261-1204


1


799-101-5002


1


790-261-1204


1


799-101-5002


1


790-261-1204


1


799-101-5230

Nipple

1

14 × 1.5

799-401-3100

Adapter

1

Face seal type (# 02) (Female: PT 1/8)

02896-11008

O-ring

1

799-101-5002


1


799-261-1204


1


566-35-43561

Nipple

1

18 × 1.5 (Female: PT 1/8)

795-502-1590

Compression gauge

1

0 – 6.9 MPa {0 – 70 kg/cm2}

795-611-1210

Adapter

6

6560-11-8410

O-ring (TOP)

6

6560-11-8310

O-ring (2nd)

6

6560-11-8210

O-ring (3rd)

6

6560-11-8510

O-ring (4th)

6

6560-11-7310

Gasket

6

795-799-5410

Adapter

1

795-799-5420

Remover

1

Measurement item

Coolant, exhaust, and oil temperatures

B

1 Engine oil pressure 2 Steering, hoist oil pressure circuit

1

Power train oil pressure

1 C 1

Dump EPC oil pressure circuit

3

Part Name

Q’ty

4

1 Brake oil pressure J 1

Remarks

2 Compression pressure

D

3

20-101-1 (11)

Injector pull out

HD465-7, HD605-7



Measurement item

Symbol

Part No.

Part Name

Q’ty

Remarks

799-101-5002


1


790-261-1204


1


1

795-799-5460

Cable

1

K 2

Commercially available

Tester

1

3

795-799-5550

Adapter

1

799-101-5002


1


790-261-1204


1


1

795-799-5550

Adapter

1

2

795-799-5560

Negative pressure gauge

1

0 – -0.1 MPa {0 – -1 kg/cm2}

799-201-1504

Blow-by checker

1

0 – 4.9 kPa {0 – 500 mmH2O}

1

6162-23-4500

Barring device

1

2


Thickness gauge

1

6162-23-4500

Barring device

1

1

799-201-9001

Handy smoke checker

1

2

795-502-1350

Smoke meter

1

1

792-610-1000

Suspension tool

1

2

• 792-610-1130

• Pump assembly

1

3

• 792-610-1110

• Hose

1

4

• 792-610-1120

• Joint

1

5

• 07020-21732

• Fitting

1

6

• 792-610-1140

• Joint

1

H 7

• 792-610-1250

• Valve assembly

1

8

• 792-610-1260

• Nipple

1

9

• 792-610-1480

• Stem

1

10 • 792-610-1640

• Joint

1

11 • 792-610-1400

• Regulator assembly

1

12 • 792-610-1430

• Gauge

1

24.5 MPa {250 kg/cm2}

13 • 792-610-1440

• Gauge

1

9.81 MPa {100 kg/cm2}

C 1

Fuel pump outlet pressure

C 1 Fuel pump inlet pressure M

Blow-by pressure

Valve clearance

Injector set load

Exhaust color

Suspension cylinder of adjustment

HD465-7, HD605-7

E

F

F1

Bosch index: 0 – 9

G

H2 – H6 Pump assembly KIT part No. 792-610-1100

H7 – H13 Charging tool assembly KIT part No. 792-610-1200

20-101-2 (11)



Measurement item

Symbol

Part No.

Troubleshooting of injector

J

795-799-5510

Heat gun

1

At raise of emergency dump body

K

792T-491-1110

Plug

1

799-608-3101

Service KIT

1

799-608-3211

• Discket

1

799-608-3220

• Harness

1


Lap top type personal computer

1

OS: Windows 98/2000

79A-264-0021

Push-pull scale

1

0 – 294 N {0 – 30 kg}

79A-264-0091

Push-pull scale

1

0 – 490 N {0 – 50 kg}

1

Initial set up of VHMS controller and, at repair set up L

2

Operating effort

Part Name

Q’ty

Remarks

P

Travel, hydraulic drift

Q


Scale

1

Work equipment speed

R


Stopwatch

1

Voltage, resistance

S


Tester

1

799-601-7400

T-adapter assembly

1

799-601-3450

Adapter

1

For MS-5

799-601-7330

Adapter

1

For S-16 (White)

799-601-7340

Adapter

1

For M-8

799-601-7360

Adapter

1

For relay (5 pins)

799-601-7370

Adapter

1

For relay (6 pins)

799-601-7510

Adapter

1

For AMP070-10

799-601-7520

Adapter

1

For AMP070-12

799-601-7530

Adapter

1

For AMP070-14

799-601-7540

Adapter

1

For AMP070-18

799-601-7550

Adapter

1

For AMP070-20

2

799-601-9000

T-adapter assembly

1

For DT connector

3

799-601-9300

T-adapter assembly

1

For DT connector (For 24, 40 pin)

4

795-799-5520

Socket (S)

1

For speed sensor

5

795-799-5530

Socket (C)

1

For fuel temperature sensor For engine coolant temperature sensor

6

795-799-5540

Socket (A)

1

For intake temperature sensor

1

Sensor, wiring harnesses

20-101-3 (11)

T

HD465-7, HD605-7



Measurement item

Sensor, wiring harnesses

Symbol

Part No.

Part Name

Q’ty

7

795-799-5460

Cable (Cummins Part No.: 3824774)

1

T 8

795-799-5470


1

9

795-799-5480


1

Remarks Atmosphere pressure sensor Fuel rail pressure sensor Timing rail actuator Fuel pump actuator Fuel rail actuator Engine oil pressure sensor Timing rail pressure sensor Boost pressure sensor Fuel pump pressure sensor

SKETCH OF SPECIAL TOOL Note: Komatsu cannot accept any responsibility for special tools manufactured according to these drawings. K Plug

HD465-7, HD605-7

20-101-4 (11)


MEASURING ENGINE SPEED Stop the machine on flat ground, turn the parking brake switch PARKING, and block the tires. a Measure the engine speed under the following condition. • Engine coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C 1. Preparation work Turn the starting switch ON and set the machine monitor (EMMS) in the "Monitoring function of service mode 1" to prepare for measurement of the engine speed. a For the operating method, see "Special functions of machine monitor (EMMS)". • Monitoring code: 01001 (Engine speed) a The unit of displayed engine speed is 1 rpm.

2. Measuring low idle speed 1) Set the shift lever N and dump lever in HOLD. 2) Start the engine and set the accelerator pedal in the low idle position and measure the engine speed. 3. Measuring high idle speed 1) Set the shift lever N and dump lever in HOLD. 2) Start the engine and set the accelerator pedal in the high idle position and measure the engine speed.

MEASURING ENGINE SPEED

4. Measuring torque converter stall speed 1) Switch the machine monitor display to the monitoring function of service mode 1 and display the following 2 items at the same time with the monitoring function. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 30100: Torque converter oil temperature a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.

2) Start the engine and raise the temperature of the hydraulic oil and torque converter oil. a Torque converter oil temperature: 60 – 80°C a Hydraulic oil temperature: 45 – 55°C 3) Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. a If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4) Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter to raise the torque converter oil temperature. There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any position other than the D position during the stall operation. 5) When the torque converter oil temperature goes above 90°C, run the engine immediately at low idle and return the gearshift lever to the N position. Never operate the gearshift lever with the accelerator pedal depressed. It will cause a big shock and will also lead to a reduction in the service life of the machine.

20-102 (10)

HD465-7, HD605-7


MEASURING ENGINE SPEED

6) Run the engine at a mid-range speed, and when the torque converter oil temperature goes down to approx. 80°C, run at low idle. a Keep the gearshift lever at the N position. 7) Repeat Steps 3 – 6 and equalize the oil temperature in the torque converter and transmission. 8) At the same time as repeating Steps 3 and 4, measure the stall speed when the torque converter oil temperature is 80°C. a Measure the stall speed 2 or 3 times. a The stall speed may vary according to the following conditions, so always measure the stall speed at the time of delivery. i) Variations according to the engine serial number ii) Variations in engine output due to atmospheric pressure and temperature iii) Variations due to consumption torque of accessories iv) Variations due to features of the torque converter v) Variations according to the method of measuring the stall

HD465-7, HD605-7

20-103 (10)


ADJUSTING ENGINE SPEED SENSOR a If the engine speed sensor has been removed and installed or the flywheel has been removed or installed, adjust as follows. 1. Remove engine speed sensor (1). a Before adjusting, remove the engine speed sensor, check that the tip of the sensor is not scratched and that there are no iron particles sticking to it, then install it again.

ADJUSTING ENGINE SPEED SENSOR

5. After completing the adjustment, switch the machine monitor to the display of "Monitoring function of service mode 1", and check that the engine speed is displayed normally. a For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: 01001 (Engine speed)

2. Screw in sensor (1) until the tip of the sensor contacts the tip of the tooth of flywheel ring gear (2). Thread: Loctite hydraulic sealant (No. 21028) 3. Return sensor (1) by the specified angle from that position. a Angle to return: 1/2 – 3/4 turns a Clearance a of 0.75 – 1.25 mm is made between the tip of the sensor and the tip of the gear tooth. 4. Fix engine speed sensor (1) and tighten locknut (3). Nut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}

20-104 (10)

HD465-7, HD605-7

MEASURING ENGINE OIL PRESSURE


MEASURING ENGINE OIL PRESSURE

(Measuring with measuring instruments) 1. Remove engine oil pressure measurement plug (1).

Special tool list Symbol 1 C

2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital type hydraulic tester

799-401-2320

Hydraulic tester (1.0MPa {10kg/cm2})

a Measure the engine oil pressure under the following conditions. • Engine oil temperature: Min. 80°C • Coolant temperature: Within operating range (Measuring with monitor panel) a It is also possible to check the engine oil pressure with the "Monitoring function of service mode 1" of the machine monitor (EMMS). For details of the method of operation, see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). • Monitoring code: 37200 (Engine oil pressure) a The engine oil pressure is displayed in units of 1 kPa. a For the method of measurement, see MEASURING WITH MEASURING INSTRUMENTS.

2. Fit nipple [1] of hydraulic tester C1, then connect to hydraulic tester C2.

3. Start the engine, and measure the oil pressure at low idle and high idle. 4. After completing the measurement, remove the measuring equipment and set to the original condition.

HD465-7, HD605-7

20-105 (11)

MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)



(Measuring with measuring tool) 1. Remove air supply pressure measurement plug (1).

Special tool list Symbol

Part No.

Part Name

Remarks

A

799-201-2202

Boost gauge kit

–101 – 199.9kPa {–760 – 1,500mmHg}

Be careful not to touch any hot parts when removing or installing the measuring tools. a Measure the air supply pressure (boost pressure) under the following conditions. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C

2. Fit nipple of boost gauge kit A, then connect gauge.

(Measuring with monitor panel) 1. Change the machine monitor to Service mode 1 and display the following 2 items simultaneously with the monitoring function. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 36500: Boost pressure

a For the method of measurement, see MEASURING WITH MEASURING INSTRUMENTS.

20-106 (1)

3. Run the engine at a mid-range speed or above to bleed the oil from the hose. a Insert the connection of the hose and pressure gauge about half way, repeat the action to open the self-seal portion at the hose end, and bleed the oil. a If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. a If there is oil inside the hose, the gauge will not work, so always bleed the oil.

HD465-7, HD605-7



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

HD465-7, HD605-7

20-107 (9)

MEASURING EXHAUST TEMPERATURE


MEASURING EXHAUST TEMPERATURE Special tool list Symbol

B

Part No.

Part Name

Remarks

799-101-1502

Digital temperature gauge

–99.9 – 1,299°C

6215-11-8170

Sensor

Wire length: 490 mm

799-201-1110

Wiring harness

Wait for the temperature of the exhaust pipe to go down before removing or installing the measuring equipment. a Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C Method using measuring equipment 1. Remove exhaust temperature measurement plug (1).

2. Install sensor [1], then connect to digital temperature gauge B. a Clamp the wiring harness of the temperature gauge at a suitable place to prevent it from touching any hot part.

20-108 (10)

3. Method of periodic measurement for preventive maintenance service. a To prevent the torque converter from overheating, use the full stall (torque converter stall + hydraulic relief) to stabilize the exhaust temperature, then stall only the torque converter and measure the temperature. 1) Turn the power mode switch to the HIGH POWER position. 2) Start the engine and raise the temperature of the coolant to the operating range. 3) Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4) Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter. At the same time, operate the dump lever to the LOWER position and relieve the oil pressure (full stall). a Continue until the exhaust temperature reaches the standard value of 670°C. There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any position other than the D position during the stall operation.

HD465-7, HD605-7


5) When the temperature stabilizes at near the target temperature, return the dump lever to FLOAT and measure the temperature with only the torque converter stalled. a The exhaust temperature will start to go down from the full stall condition, so measure the temperature when it stabilizes. a If the exhaust temperature does not go down but rises, make the set temperature at full stall higher. a After completing the measurement, lower the engine speed to low idle, then return the gearshift lever to the N position. 4. When measuring the maximum value for the exhaust temperature during troubleshooting, do as follows. Carry out actual work and record the maximum exhaust temperature during operation. a Use the PEAK mode of the digital temperature gauge. (Set the temperature gauge to the PEAK mode. The maximum temperature automatically recorded.) a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. • Corrected value [°C] = Measured value + 2 x (20 – ambient temperature)

MEASURING EXHAUST TEMPERATURE

Method using monitoring a This method applies only to the VHMS specification machine. 1. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. a Monitoring items (1) Code No. 01001 : Engine speed (2) Code No. 42600 : Exhaust temperature (front)

(1) Code No. 01001 : Engine speed (2) Code No. 42601 : Exhaust temperature (rear)

5. After completing the measurement, remove the measuring equipment and set to the original condition.

a For details of the method of measuring, see METHOD USING MEASURING EQUIPMENT.

HD465-7, HD605-7

20-109 (10)

MEASURING BLOW-BY PRESSURE


MEASURING BLOW-BY PRESSURE Special tool list Symbol

Part No. 799-201-1504

Part Name

Remarks

Blow-by checker 0 – 4.9 MPa {0 – 500 mmH2O}

Method using measuring equipment 1. Install nozzle and hose [1] to blow-by hose (1), then connect to blow-by checker E.

5. After completing the measurement, remove the measuring equipment and set to the original condition.

2. Start the engine and raise the temperature of the coolant to the operating range.

Method using monitoring a This method applies only to the VHMS specification machine. 1. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. a Monitoring items (1) Code No. 01001: Engine speed (2) Code No. 42800: Blow-by pressure

3. Depress the parking brake pedal, turn the parking brake switch TRAVEL, then set the gearshift lever to the D position. If the gearshift lever is operated to any position other than the D position, the machine may move off even if the brake is being depressed, so always measure at the D position. 4. Depress the accelerator pedal gradually, run the engine at high idle and stall the torque converter, and measure the blow-by pressure. There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any position other than the D position during the stall operation. a After completing the measurement, run the engine at low idle, then return the gearshift lever to the N position.

20-110 (10)

a For details of the method of measuring, see METHOD USING MEASURING EQUIPMENT.

HD465-7, HD605-7

TROUBLESHOOTING OF INJECTOR


TROUBLESHOOTING OF INJECTOR Special tool list Symbol

Part No.

J

795-799-5510

Part Name Heat gun

a If the engine output drops or there is any other problem, if there is the possibility of defective combustion due to defective injection by the injector, carry out troubleshooting of injector. 1. Stop the engine and leave it to cool down. a When cooling the engine down, as a guideline, wait for the temperature of the exhaust manifold to cool down to a temperature of "ambient temperature +20°C". 2. Make marks a for measurement to the exhaust manifolds of the all cylinders. a Make marks to the same points on the upper side or lower side of the exhaust manifolds of the all cylinders.

6. Adjust the temperature of each cylinder measured 12 minutes after by the compensation value and find out the abnormal cylinder. a Compensation value Cylinder No.1 Compensa- +20 tion value

4. Run the engine at low idle. 5. Using the heat gun J, measure the exhaust manifold outlet temperature of each cylinder 3, 6, 9, and 12 minutes after starting the engine. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point.

HD465-7, HD605-7

No.3

No.4

No.5

Unit:°C No.6

+5

0

0

+5

+20

a Method of judgment Add up the temperatures after compensating, then calculate the average temperature. If the temperature of any cylinder is more than 20°C lower than the average, judge that the cylinder is abnormal. 1) Measurement and judgment example 1: No.2 cylinder is more than 20°C lower than the average value, so judge that No.2 cylinder is abnormal. Cylinder No.1 Measured 85 value Compensation value 105 Average value

3. Using the heat gun J, measure the exhaust manifold outlet temperature of each cylinder before starting the engine. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point.

No.2

No.2

No.3

No.4

No.5

Unit:°C No.6

62

79

112

89

82

67

79

112

94

102

93

2) Measurement and judgment example 2: No.3 cylinder is more than 20°C lower than the average value, so judge that No.3 cylinder is abnormal. Cylinder No.1 Measured 86 value Compensa- 106 tion value Average value

No.2

No.3

No.4

No.5

Unit:°C No.6

96

73

91

94

103

101

73

91

99

123

99

3) Measurement and judgment example 3: No cylinder is more than 20°C lower than the average value, so judge that all cylinders are normal. Cylinder No.1 Measured 70 value Compensa- 90 tion value Average value

No.2

No.3

No.4

No.5

Unit:°C No.6

88

88

93

86

72

93

88

93

91

92

91

20-111 (10)

MEASURING COMPRESSION PRESSURE



4. Remove injector push rods (2) and injectors (3). a Using tool D3, pull out each injector (See DISASSEMBLY AND ASSEMBLY).

a Special tools list Symbol 1

F

2

3

Part No.

Part Name

795-502-1590

Compression gauge

795-611-1210

Adapter

6560-11-8410

O-ring (Top)

6560-11-8310

O-ring (2nd)

6560-11-8210

O-ring (3rd)

6560-11-8510

O-ring (4th)

6560-11-7310

Gasket

795-799-5410

Adapter

795-799-5420

Remover

When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 – 60°C). a Since adapter assemblies D2 of the all cylinders should be removed and installed simultaneously for efficiency, prepare 6 sets of them.

5. Install adapter assemblies D2 to the all cylinders and secure them with the holders. a Install the adapter assemblies with the drain holes in the diagonal direction of the holders. a Secure the adapter assemblies with the injector holders. 3 Holder mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

1. Open the right side cover and left side cover of the engine. 2. Remove all cylinder head covers. 3. Remove rocker arm assemblies (1) of all the cylinders.

20-111-1 (7)

HD465-7, HD605-7


6. Install rocker arm assemblies (1) and adjust the valve clearance. 2 Threads and seat of mounting bolt: Engine oil (EO30CD) 3 Mounting bolt: 235.2 – 254.8 Nm {24 – 26 kgm}

7. Disconnect 2 connectors (4) (POW) and (SIG) of the engine. a After this step, the fuel pump does not supply fuel to the injectors.


10. After finishing measurement, remove the measuring instruments and return the removed parts. a Measure the stem length of the injector holder mounting bolt. If it is longer than 80 mm, replace the bolt. 2 Threads and seat of holder mounting bolt: Engine oil (EO30CD)

3 Holder mounting bolt: 1st time: 24.5 – 34.3Nm {2.5 – 3.5kgm} 2nd time: Tighten by 90 – 120°

2 Threads and seat of rocker arm assembly mounting bolt: Engine oil (EO30CD)

3 Rocker arm assembly mounting bolt: 235.2 – 254.8 Nm {24 – 26 kgm} a Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. a Adjust the set load of the injector. For details, see ADJUSTING SET LOAD OF INJECTOR.

3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm}

8. Connect compression gauge D1 to adapter assembly D2 of the cylinder to be measured.

9. Crank the engine with the starting motor and measure the compression pressure. a Read the gauge when its pointer is stabilized.

HD465-7, HD605-7

20-111-2 (10)


HANDLING EQUIPMENT IN FUEL SYSTEM MEASURING FUEL PUMP OUTLET PORT PRESSURE

HANDLING EQUIPMENT IN FUEL SYSTEM

MEASURING FUEL PUMP OUTLET PORT PRESSURE

a Precautions for inspection and maintenance of fuel system The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so problems may occur if dirt or dust get in. When carrying out inspection and maintenance of the fuel system, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely. a Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel filter cartridge. The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.

Special tool list Symbol C

K

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

1

795-799-5460

Cable

2


Tester

3

795-799-5550

Adapter

1

1. Measuring pressure sensor signal voltage 1) Disconnect connector CN-PMPR (1) of the fuel pump pressure sensor, then connect cable K1 to the male and female ends.

2) Start the engine, switch the machine monitor to the display of "Monitoring function of service mode 1", and prepare to measure the engine speed. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). • Monitoring code: 01001 (Engine speed) a The engine speed is displayed in units of 1 rpm.

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HD465-7, HD605-7

MEASURING FUEL PUMP OUTLET PORT PRESSURE


3) Run the engine at low idle and check that the source voltage of the fuel pump pressure sensor is in the following range. a Source voltage of sensor (CN-PMPR connector between (A) – (B)): 4.75 – 5.25 V 4) Run the engine at each speed in the following table and check that the signal voltage of the fuel pump pressure sensor is in the corresponding range shown in the same table. a Signal voltage of sensor (CN-PMPR connector between (C) – (D)): Table 1 Engine speed and signal voltage Engine speed

Fuel pump outlet port Signal voltage pressure (Reference)

1,000 rpm 1.68 ± 0.21 V

1.23 ± 0.14 MPa {12.6 ± 1.43 kg/cm2}

1,300 rpm 3.00 ± 0.21 V

1.57 ± 0.14 MPa {16.0 ± 1.43 kg/cm2}

1.78 ± 0.14 MPa 1,500 rpm 3.26 ± 0.21 V {18.15 ± 1.43 kg/cm2}

2. Measuring with pressure gauge (directly) 1) Fit adapter K3 to nipple (2) for measuring the pump outlet port pressure. 2) Install nipple [1] of hydraulic tester C1 to nipple (2) and connect them to hydraulic tester H1.

HD465-7, HD605-7

3) Start the engine, switch the machine monitor to the display of "Monitoring function of service mode 1", and prepare for measuring the engine speed. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR. • Monitoring code: 010 (Engine speed) a The engine speed is displayed in units of 1 rpm. 4) Run the engine at the speed shown in Table 1 and check that the pump outlet port pressure is in the range shown in the table 1.

20-113 (10)

MEASURING FUEL PUMP INLET PORT PRESSURE VISUAL INSPECTION OF RETURN FUEL


MEASURING FUEL PUMP INLET PORT PRESSURE Special tool list Symbol C

1 1

M

2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

795-799-5550

Adapter

795-799-5560

Negative pressure gauge (0 – -0.1 MPa{0 – -1.02 kg/cm2})

1. Fit adapter M1 to pump inlet port pressure measuring nipple (1). 2. Fit nipple [1] of hydraulic tester C1 and hose [2] to adapter M1 and connect them to negative pressure gauge M2.

3. Run the engine at a medium speed to bleed the oil from the hose. a Insert the connection of the negative pressure gauge and hose about halfway, repeat the action to open the self-seal portion at the hose end to bleed the oil. a If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be used. a If there is oil inside the hose, the gauge will not work, so always bleed the oil. 4. Run the engine at full throttle and measure the pump inlet port pressure (See Table 1). Table 1 Fuel filter

Fuel pump inlet port pressure

New

Max. – 13.60 kPa {Max. – 102 mmHg}

Used

Max. – 27.10 kPa {Max. – 203 mmHg}

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

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HD465-7, HD605-7

ADJUSTING INJECTOR SET LOAD


ADJUSTING INJECTOR SET LOAD Special tool list Symbol

Part No.

F1

6162-23-4500

Part Name Barring device

1. Open the engine hood cover.

a The cylinder where the injector is adjusted is different from the cylinder at compression top dead center, so check the chart below when carrying out the operation. • Cylinder at compression top dead center and cylinder where injector is inspected. Compression top dead center

1

5

3

6

2

4

Injector to adjustment

2

4

1

5

3

6

2. Remove all cylinder head covers (1).

3. Rotate the crankshaft in the normal direction, align [1.6TOP] line a on the damper with pointer (2), and set the No.1 cylinder at compression top dead center. a Remove the flywheel housing cover and install barring device F1 to rotate the crankshaft.

4. Loosen locknut (2) of the injecter to be adjusted and adjustment screw (1) completely, and then tighten the adjustment screw with your fingers. a Check that the socket at the tip of the rocker arm and the ball of the push rod are both fitted securely into the injector and push rod, respectively. 5. Tighten adjustment screw (1), repeat the loosening operation, then tighten finally. Adjustment screw: 1st time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 2nd time : Loosen fully 3rd time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 4th time : Loosen fully 5th time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

a At compression top dead center, the rocker arm of the No.1 cylinder can be moved by hand and amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn.

HD465-7, HD605-7

20-115 (7)


ADJUSTING INJECTOR SET LOAD

6. Hold adjustment screw (1) in position, then tighten locknut (2). Locknut: 205.8 – 245 Nm {21 – 25 kgm}

7. After completing the adjustment, set to the original position. Cylinder head mounting bolt : 9.8 ± 1.0 Nm {1 ± 0.1 kgm}

20-116 (4)

HD465-7, HD605-7

BLEEDING AIR FROM FUEL CIRCUIT



a If the engine does not start or is difficult to start after the following operations or conditions, bleed the air from the fuel circuit as follows. • When starting the engine for the first time • After cleaning the fuel tank • After adding fuel when the engine has stalled • After replacing the fuel filter (only when the air is not bled easily)

a Add fuel from the inlet port a (8 places). Portion b is the outlet port after filterinig (clean side), so never add fuel from portion b.

1. Check that there is ample fuel in the fuel tank. 2. Remove fuel filter (1), fill it with fuel, then install it again. a Carry out this operation only if the fuel filter has been replaced. a If the fuel filter is not to be replaced, there is danger of dirt getting in, so do not remove the fuel filter.

HD465-7, HD605-7

20-117 (1)



3. Crank the engine with the starting motor, push air bleed the valve (1), and bleed the air from the vent circuit. a There is no problem with starting even if some air is in the circuit, so if the fuel flows out the bleeding operation is completed. 4. Start the engine and run at low idle. a The injector is an open circuit, so while the engine is running the air remaining in the circuit is released from the injector to the inside of the engine or the fuel tank. a After the engine is started, the engine rotation will be slightly unstable until the air remaining in the circuit is completely bled, so continue to run the engine at low idle until it stabilizes. a If the engine will still not start after the above operation, fill the fuel pump with fuel as follows. 1) Remove air bleeding valve (1). 2) Fill with clean fuel through the hole in the valve until it overflows. a Amount of fuel to add: Approx. 30 cc (reference) 3) Install air bleeding plug (1). Air bleeding plug: 12.7 Nm {1.3 kgm} 4) Crank the engine with the starting motor.

20-118 (10)

HD465-7, HD605-7

MEASURING EXHAUST COLOR


MEASURING EXHAUST COLOR Special tool list Symbol G

Part No.

Part Name

1

799-201-9001

Handy smoke checker

2

795-502-1350

Smoke meter

Remarks Bosch index: 0 – 9

Be careful not to touch any hot parts when removing or installing the measuring tools. When measuring with a handy smoke meter, avoid standing against the exhaust gas and insert the exhaust gas suction port into the exhaust pipe. a When measuring in the field where there is no air or electric power supply, use handy smoke checker G1; when recording formal data, use smoke meter G2.

2. Measuring with Smoke Meter G2 1) Keep the dump body raised and insert the probe of smoke meter G2 in the joint of the exhaust pipe and dump body and fix it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose and accelerator switch to smoke meter G2. a Keep the pressure of the air supply below 1.5 MPa (15 kg/cm2). 3) Connect the power cord to the AC socket. a Before connecting the cord, check that the power switch of the smoke meter is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. 5) Turn the power switch of smoke meter G2 ON.

1. Measuring with Handy Smoke Checker G1 1) Install filter paper to handy smoke checker G1. 2) Insert the exhaust gas suction port into the exhaust pipe. 3) Start the engine and raise the temperature of the coolant to the operating range. 4) Keep the dump body raised and set handy smoke checker G1 to the joint of the exhaust pipe and dump body.

5) Accelerate the engine suddenly, and operate the handle of handy smoke checker G1 while running at high idle to collect the exhaust gas on the filter paper. 6) Remove the filter paper and compare it with the scale supplied to judge the condition.

HD465-7, HD605-7

20-119 (11)

ADJUSTING VALVE CLEARANCE


ADJUSTING VALVE CLEARANCE Special tool list Symbol 1 F

Part No.

4. Insert feeler gauge F2 into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw (5). a Insert the feeler gauge and turn the adjustment screw until the clearance is a sliding fit.

Part Name

6162-23-4500

Barring device


Feeler gauge

1. Open the engine hood. 2. Remove all cylinder head covers (1).

3. Rotate the crankshaft in the normal direction, to set the No.1 cylinder at compression top dead center, and align [1.6TOP] line a on the damper with pointer (2). a Use a barring device F1 on the flywheel housing to carry out cranking. a At compression top dead center, the rocker arm of the No.1 cylinder can be moved by hand an amount equal to the valve clearance. If the rocker arm does not move, it is not at compression top dead center, so rotate the crankshaft one more turn.

5. Hold adjustment screw (5) in position, then tighten locknut (6). Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm} a After tightening the locknut, check the valve clearance again.

6. Rotate the crankshaft 120° each time in the normal direction and repeat the procedure in Steps 3 – 5. You may adjust the valves marked with q when the No. 1 cylinder is at the compression top dead center and adjust the valves marked with Q when the No. 6 cylinder is at the compression top dead center, referring to the following valve arrangement. • Firing order: 1–5–3–6–2–4 a Valve clearance (at cold). Intake valve : 0.32 ± 0.2 mm Exhaust valve: 0.62 ± 0.2 mm

7. After completing the adjustment, set to the original condition. Cylinder head cover mounting bolt: 9.8 ± 1.0Nm {1.0 ± 0.1 kgm}

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HD465-7, HD605-7


TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION Testing • Measure deflection a when a point midway between the alternator pulley and idler pulley is pressed with a finger. a Pushing force: Approx. 98 N {approx. 10 kg}

Adjusting a If the deflection is not correct, adjust as follows. 1. Loosen the 2 alternator (1) mounting bolts and 1 lock bolt (2) for the adjustment rod. 2. Loosen locknut (3), then turn adjustment nut (4) to move alternator (1) and adjust the belt tension. 3. Tighten the 2 alternator mounting bolts and 1 lock bolt for the adjustment rod. Alternator mounting bolt (4): 65 – 85 Nm {6.7 – 8.7 kgm} Alternator locknut (1): 147 – 247 Nm {15 – 25 kgm}

HD465-7, HD605-7

20-121 (1)


TESTING AND ADJUSTING, AIR CONDITIONER COMPRESSOR BELT TENSION

TESTING AND ADJUSTING, AIR CONDITIONER COMPRESSOR BELT TENSION Testing • Measure deflection a when a point midway between the air conditioner compressor pulley and idler pulley is pressed with a finger. a Pushing force: Approx. 98 N {approx. 10 kg}

Adjusting a If the deflection is not correct, adjust as follows. 1. Loosen the mounting bolts (2) of air conditioner compressor bracket (1). 2. Loosen locknut (3), then turn adjustment nut (4) to move air conditioner compressor bracket (1) and adjust the belt tension. 3. After completing the adjustment, tighten air conditioner compressor mounting bolts.

20-122 (10)

HD465-7, HD605-7

MEASURING POWER TRAIN OIL PRESSURE



Special tool list Symbol

Part No.

Part Name

Remarks

799-101-5002

Pressure gauge Analog hydraulic 2.5, 5.9, 39.2, meter 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Digital hydraulic Pressure gauge 58.8 MPa meter {600 kg/cm2}

C1

a Table of oil pressure measurement port positions and gauges to use No. 1

Measurement location Main relief pressure

Gauge (MPa{kg/cm2}) 5.9{60}

2

Torque converter inlet port pressure

2.45{25}

3

Torque converter outlet port pressure

2.45{25}

4

Torque converter lock-up clutch pressure

5.9{60}

5

Transmission Lo clutch pressure

5.9{60}

6

Transmission Hi clutch pressure

5.9{60}

7

Transmission 1st clutch pressure

5.9{60}

8

Transmission 2nd clutch pressure

5.9{60}

9

Transmission 3rd clutch pressure

5.9{60}

10 Transmission 4th clutch pressure

5.9{60}

11

5.9{60}

Transmission R clutch pressure

5A- Each clutch pilot pressure 11A

5.9{60}

a The transmission lubrication pressure is represented by the torque converter outlet port pressure, so there is no need to measure it.

HD465-7, HD605-7

20-123 (11)


Stop the machine on a level ground, turn the parking brake switch PARKING, and put chocks under the tires. Stop the engine and wait until the oil temperature lowers sufficiently before installing and removing the measuring instruments. When measuring the oil pressure while the machine is traveling, secure a wide travel area and take care of the safety around the machine.

Whole power train 1. Measuring main relief pressure Raise the dump body and lock it with the safety pin. Take care not to "get burned", since the oil temperature is high. When removing and installing a plug or an oil pressure gauge, stop the engine. 1) Raise the transmission oil temperature. a Oil temperature for measurement: 60 – 80°C 2) Remove plug (1) and install tool C (5.88 MPa {60 kg/cm2}) (including C1, [1]).


Items related to torque converter 2. Measuring torque converter inlet oil pressure Raise the dump body and lock it with the safety pin. Take care not to "get burned", since the oil temperature is high. When removing and installing a plug or an oil pressure gauge, stop the engine. 1) Referring to TESTING MAIN RELIEF OIL PRESSURE, check that there is not abnormality. 2) Remove plug (2) and install tool C (2.45 MPa {25 kg/cm2}) (including C1, [1]).

3) Start the engine and measure the oil pressure at high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.

3) Start the engine and set the gear shift lever in the "N", and then measure the oil pressure at low idle and high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.

20-124 (10)

HD465-7, HD605-7


3. Measuring torque converter outlet oil pressure Raise the dump body and lock it with the safety pin. Take care not to "get burned", since the oil temperature is high. When removing and installing a plug or an oil pressure gauge, stop the engine. 1) Referring to TESTING MAIN RELIEF OIL PRESSURE, check that there is not abnormality. 2) Remove plug (3) and install tool C (2.45 MPa {25 kg/cm2}) (including C1, [1]).


4. Measuring torque converter lock-up clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (4), (4A) and install the nipple and hoses [1] for measurement.

3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position L. 7) Release the brake, travel at high idle, and measure the oil pressure when the lock-up pilot lamp lights up. In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.

3) Start the engine and measure the oil pressure at high idle. 4) After completing the measurement, remove the measuring equipment and set to the original condition.

8) After completing the measurement, remove the measuring equipment and set to the original condition.

HD465-7, HD605-7

20-125 (10)


Transmission related a Table of gearshift lever positions, speed ranges, and clutches actuated Gearshift lever Clutches Speed R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R F1


5. Measuring transmission Lo clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (5), (5A) and install the nipple and hoses [1] for the measurement.

F2 F3 F4 F5 F6 F7 N R

a The mark indicates the speed ranges that are actuated for each position of the gearshift lever. a The mark and mark indicate the clutches that are actuated for each travel speed. a The mark indicates the speed range when measuring the oil pressure for each clutch.

3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position L. 7) Release the brake and measure the oil pressure when traveling at high idle. In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.


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HD465-7, HD605-7



6. Measuring transmission Hi clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (6), (6A) and install the nipple and hoses [1] for the measurement.

7. Measuring transmission 1st clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (7), (7A) and install the nipple and hoses [1] for the measurement.

3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position 3. 7) Release the brake, travel at high idle, and measure the oil pressure when the shift indicator shows "3".

3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position L. 7) Release the brake and measure the oil pressure when traveling at high idle.

In F3, a maximum travel speed of approx. 21.5 km/h is reached, so check carefully that the surrounding area is safe. 8) After completing the measurement, remove the measuring equipment and set to the original condition.

In F1, a maximum travel speed of approx. 11.5 km/h is reached, so check carefully that the surrounding area is safe.


HD465-7, HD605-7

20-127 (10)



8. Measuring transmission 2nd clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (8), (8A) and install the nipple and hoses [1] for the measurement.

9. Measuring transmission 3rd clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (9), (9A) and install the nipple and hoses [1] for the measurement.




In F4, a maximum travel speed of approx. 29.5 km/h is reached, so check carefully that the surrounding area is safe.


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HD465-7, HD605-7



10. Measuring transmission 4th clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (10), (10A) and install the nipple and hoses [1] for the measurement.

11. Measuring transmission R clutch and pilot pressure 1) Raise the dump body, then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (11), (11A) and install the nipple and hoses [1] for the measurement.


3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL, depress the parking brake pedal, then set the gearshift lever to position R. 7) Release the brake and measure the oil pressure when traveling at high idle.


In R, a maximum travel speed of approx. 12.0 km/h is reached, so check carefully that the surrounding area is safe.


HD465-7, HD605-7

20-129 (10)


ADJUSTING TRANSMISSION SPEED SENSOR

ADJUSTING TRANSMISSION SPEED SENSOR

a There are 3 speed sensors installed to the transmission. Adjust each sensor as follows. CN3: Input shaft speed sensor CN4: Intermediate shaft speed sensor CN5: Output shaft speed sensor

3. Secure nut (3) with sensor (1). Nut: 49.0 – 68.6Nm {5 – 7 kgm}

1. Screw in until the tip of sensor (1) contacts the face or tip of the tooth of gear (2). a Before installing, check that the tip of the sensor is not scratched and that there are no iron particles sticking to the sensor tip. Thread portion: Gasket sealant (LG-5) 2. Turn back sensor (1) 1/2 – 1 turn from this position. a Adjust clearance a between the tip of the sensor and the tip of the gear tooth to 0.75 – 1.0 mm.

20-130 (1)

4. After completing the adjustment, check that the each transmission shaft speed is displayed normally by using the monitoring function of the machine monitor. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.

HD465-7, HD605-7

INSPECTING BRAKE OIL PRESSURE


INSPECTING BRAKE OIL PRESSURE Special tool list Symbol

Part No.

Remarks

799-101-5002

Pressure gauge Analog hydraulic 2.5, 5.9, 39.2, meter 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Pressure gauge Digital hydraulic 58.8 MPa meter {600 kg/cm2}

566-35-43561

Nipple

C1

J

Part Name

4) Measure the cut-out pressure at high idle. • Read the ACC oil pressure (front or rear) when it stops rising at the highest point (Approx. 20.6 MPa {Approx. 210 kg/ cm2}) after the cut-in pressure. (Measuring with diagnosing devices) 1) Stop the engine and remove plug (4) (18, P: 1.5). Connect nipple J and hose [1] and install oil pressure gauge C1 (Oil pressure gauge: 39.2 MPa {400 kg/cm2}).

18 × 1.5 (female: PT 1/8)

Stop the machine on a level place, apply the parking brake, and set chocks under the tires securely. 1. Measuring ACC charge oil pressure (Measuring with monitor) 1) Set the machine monitor in service mode 1 and display the following 2 items simultaneously with the monitoring function. a Monitoring items (1) Code No. 35500: ACC oil pressure (Front) (2) Code No. 35501: ACC oil pressure (Rear)

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

HD465-7, HD605-7

20-131 (11)


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

INSPECTING BRAKE OIL PRESSURE

4. Front brake operating pressure 1) Remove air bleeder (3) and install tool C1 [Oil pressure gauge: 39.2 MPa {400 kg/ cm2}]. 2) Operate the brake pedal and measure the oil pressure. a After finishing measurement, bleed air, r efe rr ing to B LEEDING AIR FROM BRAKE CIRCUIT on the next page.

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

20-132 (1)

HD465-7, HD605-7


BLEEDING AIR FROM BRAKE CIRCUIT

BLEEDING AIR FROM BRAKE CIRCUIT a If any brake circuit device was removed and installed or if the transmission and brake cooling oil was replaced, bleed air from the brake circuit according to the following procedure. Stop the machine on a level ground and set chocks under the tires securely. 1. Rear brake a Bleed air from the slack adjuster side first, then bleed air from the wheel brake side. 1) Using a vinyl tube for bleeding air, depress the brake pedal and loosen air bleeder screw (1) or (2) by 3/4 turns. Keep depressing the brake pedal until bubbles do not come out of the bleeder any more. When bubbles do not come out any more, tighten (close) the bleeder and release the pedal. 2) Pull the retarder control lever and loosen air bleeder screw (1) or (2) by 3/4 turns. Keep pulling the retarder control lever until bubbles do not come out of the bleeder any more. When bubbles do not come out any more, tighten (close) the bleeder and release the retarder control lever.

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

3) Bleed air from bleeder (3) on the wheel side similarly to step 1) above. a After finishing bleeding air, tighten (close) the bleeder and put the cap.

HD465-7, HD605-7

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TESTING WEAR OF FRONT BRAKE PAD


TESTING WEAR OF FRONT BRAKE PAD Special tool list Symbol

Part No.

b

566-98-41410

Part Name Gauge

Remarks Tools on truck

Stop the machine on level ground, apply the parking brake, and put chocks under the tires. 1. Visual check Check visually, and if the pad has reached the wear limit line, replace the pad.

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

20-134 (10)

HD465-7, HD605-7


TESTING WEAR OF REAR BRAKE DISC

TESTING WEAR OF REAR BRAKE DISC Stop the machine on level ground, turn the parking brake switch PARKING, and put chocks under the tires. Carry out the inspection when the brake oil temperature is less than 60°C. When the disk comes close to the wear limit, carry out the inspection more frequently. Be sure to carry out inspection of the retarder braking performance at the same time. 1. Check that the brakes other than parking brake are not being actuated. 2. Stop the engine. 3. Remove cap nut (1) of the gauge.

6. Install cap nut (1) of the gauge. Cap nut: 19.6 Nm {2.0 kgm}

4. Push in the rod (2) of the gauge until it contacts the piston and judge the amount of wear. a With a new machine, adjust so that inner (deeper) end a of groove D on the rod (2) is aligned with the end face of guide (3). The adjustment position will move out of alignment, so do not loosen locknut (4) of guide (3) except when replacing the disc. a Outer end b of groove D indicates the wear limit for the disc. If it is inside guide (3) totally [If it reaches the end face of guide (3)], the disc has reached the wear limit.

HD465-7, HD605-7

20-135 (10)


METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY

METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY a If the parking brake cannot be released because of a trouble in its electric or hydraulic system, release it tentatively according to the following procedure. If the hydraulic system has a trouble, the wheel brake probably does not work normally. Accordingly, be sure to tow the machine at low speed after releasing the parking brake. When releasing the parking brake, stop the machine on a level place and make sure of the safety around it. If it is obliged to release the parking brake on a slope in an emergency, put chocks under the tires securely. When releasing the parking brake, stop the engine. 1. Remove plugs (1) (10 pieces). a Prepare a container to receive the oil flowing out of the plug holes. Tightening torque for plug: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

2. Prepare 10 sets of bolt (2) (01017-51230), washer (3), and nut (4) for releasing the parking brake manually and tighten the bolts alternately and evenly to release the parking brake. a Tighten nuts (4) to pull piston (5) and release the parking brake.

20-136 (10)

HD465-7, HD605-7

TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER


TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER Special tool list Symbol

H

Part No.

Part Name

Remarks

1

792-610-1000

Suspension tool

2

•792-610-1130

3

•792-610-1110

4

•792-610-1120

Pump assembly H2 – H6 : Pump assembly Hose Kit No. : 792-610-1100 Joint

5

•07020-21732

Fitting

6

•792-610-1140

Joint

7

•792-610-1250

Valve assembly

8

•792-610-1260

Nipple

H7 – H13 : Charging tool assembly Kit No. : 792-610-1200

9

•792-610-1480

Stem

10

•792-610-1640

Joint

11

•792-610-1400

Regulator assembly

12

•792-610-1430

Gauge

24.5 MPa {250 kg/cm2}

13

•792-610-1440

Gauge

9.81 MPa {100 kg/cm2}

a Stop the machine empty on level ground. 1. Testing length of cylinder 1) Check that the bottom of the cylinder cover is within the range e marked by arrows for the cylinder level.

2) Before adjusting the oil level, check the condition of the variable damper valve. S posision : soft mode H posision: hard mode M posision: medium mode

HD465-7, HD605-7

a With the truck empty, starting switch ON, parking brake OFF, and hoist control lever at the FLOAT position, check that the cylinder of the variable damper valve is in the soft mode. a If the cylinder of the variable damper valve is not in the soft mode when checking, operate as follows to switch to the soft mode. i) Use the retarder brake (Note 1) and drive the machine several times repeatedly forward and in reverse to set to the soft mode. Note 1: If the foot brake pedal is used, the automatic suspension is automatically set to the medium mode, and the resistance of the cylinder increases, so it takes time to adjust. 2. Releasing nitrogen gas 1) Front suspension cylinder i) Set hydraulic jack [1] (50ton) under the main frame. ii) Disconnect pressure sensor connector (2) of valve (1), then loosen the valve (1) 2 – 3 turns. a When releasing the nitrogen gas, there is danger that releasing the gas from the valve core of feed valve (3) will damage the valve core, so remove the gas at the valve (1). a When loosening the valve (1), loosen only the valve itself. Do not loosen the pressure sensor or nipple.

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a When the valve (1) is loosened, and oil and gas spurt out together, tighten the valve slightly, and allow time for the gas to escape slowly. iii) Operate the hydraulic jack so that dimension a of the cylinder is the specified dimension for the oil level. Dimension a:79 ± 3 mm (Standard) 79 ± 3 mm (With buffer ring)

7) After completion of supplying the oil, remove the volume pump, then install feed valve (3). 3 Feed valve: 39.2 – 49.0 Nm {4 – 5 kgm}

3. Adjusting of oil level a Release the nitrogen gas before adjusting the oil level. 1) Remove feed vavle (3), and install joint H6. 2) Install fitting H5 to joint H4, then connect hose H3 and volume pump H2. 3) Loosen air bleeding valve (4), then operate volume pump H2 until no more bubbles come out with the oil from air bleed side hole b. 4) When no more bubbles come out with the oil, tighten air bleeding valve (4). 3 Air bleeding valve: 39.2 – 49.0 Nm {4 – 5 kgm}

5) Remove valve (1), then operate volume pump H2 until no more bubbles come out with the oil from the valve (1) mount. 6) When no more bubbles come out with the oil, tighten the valve (1). 3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}

20-138 (10)

HD465-7, HD605-7



4. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). 2) Set tool H as shown in the diagram. a Before installing regulator H11, blow the connector filter with nitrogen gas at 0.981 MPa {10 kg/cm2} or more to blow out all dirt or dust. (Dirt or dust in the system causes failures.) 3) Open valve [2] of the gas cylinder [1], and check the pressure reading of gauge H12 (internal pressure of gas cylinder). a The pressure indicated must be at least 0.981 MPa {10 kg/cm2 } higher than the pressure inside the suspension cylinder (max. pressure inside suspension cylinder: 4.31 MPa {44 kg/cm2}). 4) Turn handle H11a of regulator H11 slowly clockwise, set the pressure reading of gauge H13 to 0.981 MPa {10 kg/cm 2 } above the internal pressure of the suspension cylinder, then operate valves H7 and H10 to fill the suspension cylinder with nitrogen gas. a Fill the left and right cylinders in the same way. 5) When dimension a of the left and right cylinders reaches the standard value, turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas. a Standard dimension a: 249 ± 10 mm 6) Turn handle H10a of H10 fully back counterclockwise, loosen air bleeding plug H7a of valve H7, release the gas inside the hose, then remove tool H. a Be careful not lose the O-ring of the feed valve.

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20-139 (10)



5. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine-empty and on level ground. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing), drive the machine forward approx. 15 m and stop suddenly, then drive in reverse to the original position and stop again suddenly. Repeat this cycle 3 – 4 times, and finally, allow the machine to stop slowly without depressing the brake. Then measure the installed length. a Do not use the foot brake when braking the machine. Use the retarder control lever to brake the machine, and check that the suspension is in the soft mode. 2) If the result of the check shows that the installed length is too long, release nitrogen gas to adjust the length. a Loosen the valve (1) slightly to release the nitrogen gas. When doing this, release only a small amount of gas; do not make the cylinder move. a If too much nitrogen gas is released and the cylinder moves, the installed length may be below the specified length. a Do not press the tip of the valve core. If the tip of the valve core is pressed, the valve core may be damaged. 3) After releasing nitrogen gas and adjusting the installed length, repeat Step 1) to check the installed length again. 4) Repeat the above Steps 1) – 3) to adjust the cylinder to the specified length. 5) Finally, check that there is no leakage of gas from the valve core (6), valve (1), and piston rod gland. a Use soapy water to check for leakage of gas. a If there is any leakage of gas from the valve core, use tool [3] and remove the valve core.

20-140 (10)

Note:1. Checking after changing oil and gas After the oil and gas have been changed, operation of the machine causes the gas to dissolve in the new oil inside the cylinder until it is saturated, so the volume of gas is reduced and the installed length of the suspension goes below the specified limit. Therefore, 48 hours after changing the oil and gas, check the installed length of the suspension and adjust the gas if the length is not within the specified value. 2. Checking for changes in installed length caused by variation in ambient temperature. Depending on the ambient temperature when the machine is working, the gas in the suspension may expand or contract, so the installed length will also change. In territories where there are big differences in temperature throughout the year, inspect daily and adjust to keep the installed length within the specified range.

HD465-7, HD605-7


TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER a Stop the machine empty on level ground. 1. Testing length of cylinder Check that dimension "a" of the rear suspension cylinder is within the specified value. Specified value for dimension "a" : 220 ± 10 mm (Standard) : 204 ± 10 mm (With buffer ring) Thickness of frange b a For the standard dimensions, see the decal stuck to the cylinder. Standard

With buffer ring

49 mm

65 mm

TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER

ii) Disconnect pressure sensor connector (2) of valve (1), then loosen the valve 2 – 3 turns. a When releasing the nitrogen gas, there is danger that releasing the gas from the valve core of feed valve (3) w il l d am a g e t he v a lv e c o r e , s o remove the gas at the valve (1). a When loosening the valve (1), loosen only the valve itself. Do not loosen the pressure sensor or nipple. k When loosening the valve (1), gradually loosen only valve (1) itself, and do not remove the valve until all the nitrogen gas has been released from the slit.

k If the nitrogen gas has not all been released, pressure sensor (5) are still under high pressure, so do not loosen them under any circumstances. a When the valve (1) is loosened, and oil and gas spurt out together, tighten the valve slightly, and allow time for the gas to escape slowly.

2. Releasing nitrogen gas 1) Rear suspension cylinder i) Set block [2] between the stopper and axle housing. Thickness of block: 19 mm Dimension a : 140 ± 3 mm (Standard) : 124 ± 3 mm (With buffer ring)

HD465-7, HD605-7

20-141 (11)


3. Adjusting oil level a Release the nitrogen gas before adjusting the oil level. 1) Remove feed valve (3), and install joint H6. 2) Install fitting H5 to joint H4, then connect hose H3 and volume pump H2. 3) Loosen air bleeding valve (1), then operate volume pump H2 until no more bubbles come out with the oil from air bleeding valve (1). 4) When no more bubbles come out with the oil, tighten air bleeding valve (1). 5) After adding oil, remove the volume pump, then install feed valve (3).


H13 to 0.981 MPa {10kg/cm 2 } above the internal pressure of the cylinder, then operate valves H7 and H10 to fill the cylinder with nitrogen gas. a Fill the left and right cylinders in the same way. 5) When dimension "a" of the left and right cylinders reaches the standard value, turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas. a Standard dimension a : 220 ± 10 mm (Standard) : 204 ± 10 mm (With buffer ring) 6) Turn handle H10a of H10 fully back counterclockwise, loosen air bleeding plug H7a of valve H7, release the gas inside the hose, then remove tool H. a Be careful not to lose the O-ring of the feed valve.

4. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). 2) Set tool H to the feed valve supply as shown in the diagram. a Before installing regulator H11, blow the filter in the connector with nitrogen gas at 0.981 MPa {10 kg/cm2} or more to blow out all dirt or dust. (Dirt or dust in the system causes failures.) 3) Open valve [2] of the gas cylinder [1], and check the pressure reading of gauge H12 (internal pressure of gas cylinder). a The pressure indicated must be at least 0.981 MPa {10kg/cm 2 } higher than the pressure inside the cylinder (max. pressure inside cylinder: 2.74 MPa {28 kg/ cm2}). 4) Turn handle H11a of regulator H11 slowly clockwise, set the pressure reading of gauge

20-142 (10)

HD465-7, HD605-7


5. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine empty and on level ground. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing), drive the machine forward approx. 15 m and stop suddenly, then drive the machine forward approx. 15 m and stop suddenly, then drive in reverse to the original position and stop again suddenly. Repeat this cycle 3 – 4 times, and finally, allow the machine to stop slowly without depressing the brake. Then measure the installed length. a Do not use the foot brake when braking the machine. Use the retarder control lever to brake, the machine, then check that the suspension is in the soft mode. 2) If the result of the check shows that the installed length is too long, release nitrogen gas to adjust the length. a Loosen the valve slightly to release the nitrogen gas. When doing this, release only a small amount of gas; do not make the cylinder move. a If the nitrogen gas is so released that the cylinder may move, the installed length may be below the specified length. a Do not press the tip of the valve core. If the tip of the valve core is pressed, the valve core may be damaged. 3) After releasing nitrogen gas and adjusting the installed length, repeat Step 1) to check the installed length again. 4) Repeat the above Steps 1) – 3) to adjust the cylinder to the specified length. 5) Finally, check that there is no leakage of gas from the valve core (6), valve, and piston rod gland. a Use soapy water to check for leakage of gas. a Replace valve core (6) if there is any leakage of gas from the valve core.


6. Testing and adjusting dust cover a To protect the rear suspension from stones and other objects thrown up by the tires when the machine is traveling, carry out inspection of the cover and repair or replace it as necessary. 1) Check visually that there are no cracks or breaks in cover (1). a If the cover is damaged, replace it with a new part. 2) Check that hooks (2) are not missing. (3 places) a If any hooks are missing, remove all mud and dirt, then install hooks. 3) Check that band (3) is not loose or missing. a If the band is loose or missing, tighten to the following torque. Band: 6.8 ± 0.49 Ncm {69 ± 5 kgcm}

V a l v e c o r e :

HD465-7, HD605-7

20-143 (10)


TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER)

TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER) 1. Testing 1) Check that length "a" of hydraulic cylinder (1) is as specified under the following condition. a Condition (Mode S) (1) Machine is empty. (2) Starting switch is ON. (3) Parking brake switch is ON. (4) Work equipment control lever is at FLOAT. a Specified length "a": 352 ± 1 mm 2) Shift the hoist lever from the FLOAT position to another position and check that hydraulic cylinder length "a" is not (is longer than) 352 ± 1 mm. 2.

Adjusting 1) Remove mounting bolt (2) of hydraulic cylinder (1) and disconnect hydraulic cylinder (1). 2) Loosen locknut (3) and adjust mounting length "a" with rod end. a Specified length "a": 352 ± 1 mm 3) Install (Return) hydraulic cylinder (1) with mounting bolt (2). 4) Turn the starting switch to the ON position and shift the hoist lever from the FLOAT position to another position and check that length "a" of hydraulic cylinder (1) is not (is longer than) 352 ± 1 mm. (Reference) • "b" in hard mode : 383 ± 1 mm • "d" in medium mode : 414 ± 1 mm

20-144 (1)

5) Check that the hole of bracket (5) is in the slit (part "e") in modes S and M.

10858

HD465-7, HD605-7

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT


TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT a Special tool list Symbol

Part No.

Part Name

Remarks

799-101-5002

Analog hydraulic meter


790-261-1204

Digital hydraulic meter


C1

Stop the machine on level ground, apply the parking brake, and put chocks under the tires. Lower the body to the frame, stop the engine, then remove the cap from the hydraulic tank and release the pressure inside the cylinder circuit.

Steering circuit 1. Measuring hydraulic pressure in steering circuit 1) Raise the hydraulic oil temperature. a Oil temperature when measuring : 45 – 55°C 2) Remove plug (1) and install tool C1 (39.22 MPa {400 kg/cm2}). 3) Operate the steering wheel fully to the left or right, and measure the hydraulic pressure when the circuit is relieved.

HD465-7, HD605-7

2. Adjusting hydraulic pressure in steering circuit If the hydraulic pressure is not within the standard value, adjust as follows. • Steering pressure (adjust with demand valve) 1) Remove cap (2), then loosen locknut (3) and turn adjustment screw (4) to adjust. a To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 2.45 MPa {25 kg/cm2}.

10860

20-145 (11)


2) After adjusting, hold the adjustment screw with a screwdriver to prevent it from turning, then tighten the locknut and install the cap. cap: 29.4 – 39.2 Nm {3 – 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value. For details, see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT. a The pressure of crossover relief valve (5) cannot be adjusted when it is installed on the machine, so do not adjust the pressure.


Hoist circuit 1. Measuring hydraulic pressure in hoist circuit 1) Raise the hydraulic oil temperature. a Oil temperature when measuring : 45 – 55°C 2) Remove oil pressure measurement plug (1) and install tool C1 (39.22 MPa {400 kg/cm2}). 3) Operate the hoist control lever, and move the dump body to the maximum dump position to relieve the circuit, then measure the hydraulic pressure with the engine at full throttle.

3. Measuring steering valve charge pressure 1) Remove plug (6) and install tool C1 (39.2 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit. 4. Measuring hydraulic pressure in steering cylinder 1) Remove pressure measurement plug (7) (when turning the steering to the left) or pressure measurement plug (8) (when turning the steering to the right), and install tool C1 (39.2 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit.

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HD465-7, HD605-7



2. Adjusting hydraulic pressure in hoist circuit If the hydraulic pressure is not within the standard value, adjust as follows. Hoist cylinder pressure (adjust with hoist valve) 1) Loosen locknut (2) and turn adjustment screw (3) to adjust. a To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 4.2 MPa {42.8 kg/cm2}. 2) After adjusting, hold the adjustment screw with a screwdriver to prevent it from turning, then tighten the locknut. Lock nut: 29.4 – 39.2 Nm {3 – 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value. For details, see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT.

3. Measuring hoist cylinder pressure 1) Remove plug (4) and install tool C1 (39.22 MPa {400 kg/cm2}). 2) Measure in the same way as when measuring the hydraulic pressure in the hoist circuit.

HD465-7, HD605-7

20-147 (10)

TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT


TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT

2) Install nipple C3 and hose [2] and connect oil pressure gauge C1 [5.9 MPa {60 kg/cm2}]. 3) Start the engine and measure the oil pressure when the dump lever is in neutral.

a Special tool list Symbol

Part No.

Part Name

Remarks

799-101-5002

Analog hydraulic meter


790-261-1204

Digital hydraulic meter


799-101-5230

Nipple

14 × 1.5

799-401-3100

Adapter

Face seal type (#02) (Female: PT 1/8)

02896-11008

O-ring

1 C

3 4

—

Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank.

2. Measuring dump EPC valve output pressure 1) Disconnect EPC hose (3) or (4) to be measured. (3): Dump raise side (Port PB) (4): Dump lower side (Port PA)

Measuring 1. Measuring dump EPC valve main pressure 1) Remove oil pressure pickup plug (2) (M14 x 1.5) from dump EPC valve (1) inside the hydraulic tank (inside the machine).

2) Install adapter C4 to hoist valve and connect the hose. 3) Install nipple [1] and hose [2] and connect oil pressure gauge C1 [5.9 MPa {60 kg/cm2}]. 4) Start the engine and raise or lower the dump lever and measure the circuit oil pressure.

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HD465-7, HD605-7


AIR BLEEDING FROM STEERING CYLINDER

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

HD465-7, HD605-7

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PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY


PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY a Special tool list Symbol

Part No.

K

792T-491-1110

Part Name Plug

Remarks —

a If the dump body cannot be raised because of a failure in the controller or electric system, raise it to dump the load according to the following procedure.

When performing this procedure, be sure not to go under the dump body but stand on the ground. a The dump body lowers by itself. Keep it at safe lowering speed by adjusting the tightening depth tool [K]. 5. After the dump body lowers completely, remove tool [K] and install plug (2). Tightening torque of plug: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}

1. Stop the engine and remove the hydraulic tank cap to release the residual pressure from the hoist circuit. 2. Remove plug (1) and tighten tool [K] fully. a If tool [K] is tightened in fully, the spool is moved to the rising stroke end.

1) If the engine can be started, start the engine under this condition, and the dump body rises. 2) If the engine cannot be started, turn the emergency steering switch "ON" and raise the dump body with the hydraulic pressure of the emergency steering pump. a Do not operate the emergency steering pump for more than 90 seconds continuously. If the load cannot be dumped in 90 seconds, cool down the steering pump, and then operate it again. 3. Stop the engine and remove tool [K] and install plug (1). Tightening torque of plug: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 4. When lowering the dump body, remove plug (2) and tighten tool [K] slowly.

20-150 (10)

HD465-7, HD605-7


ADJUSTING BODY POSITIONER SENSOR a If the body positioner rod has been disconnected and connected again or the body positioner sensor has been removed and installed again, inspect and adjust the body positioner sensor as follows. a HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 • If the positioner link is changed, adjust it to the same value with following model. HD465-7 #7057 and up HD605-7 #7021 and up 1. Checking sensor input voltage 1) Switch the machine monitor display to the monitoring function of service mode 1 and display the body positioner sensor input voltage. a Monitoring item Code No. 34400: BODY POSITION a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.

ADJUSTING BODY POSITIONER SENSOR

2. Adjusting link length a If the monitoring voltage is not within the normal range, adjust the length of the link as follows. 1) Loosen locknut (1). 2) Remove mounting bolt (2). 3) Turn rod end (3) to adjust the length of the link (4). a Standard installing length a: 433 mm. a Do not set installing length a less than 430 mm. HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 a Standard installed length "a" of link: 440 mm a Do not reduce length "a" to below 436 mm. HD465-7 #7057 and up HD605-7 #7021 and up a Adjust the input voltage as follows. • INCREASE link length to DECREASE voltage • DECREASE link length to INCREASE voltage 4) Install mounting bolt (2). 5) Tighten locknut (1). 6) Repeat the checking procedure above to check that the input voltage is within the normal range.

2) Start the engine. 3) Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position and RAISE position. a When operated fully to LOWER: 0.35 – 0.40 V: HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 0.38 – 0.44 V: HD465-7 #7057 and up HD605-7 #7021 and up a When operated fully to RAISE: 3.80 – 4.70 V

HD465-7, HD605-7

20-151 (8)


ADJUSTING BODY POSITIONER SENSOR

3. Calibrating system Stop the machine on a level ground, apply the parking brake, then put chocks under the tires securely. a Hydraulic oil temperature: 80 – 90°C 1) With the body seated perfectly, start the engine. 2) Keep the dump control lever in the FLOAT position for at least 5 seconds. a Check that the FLOAT caution lamp is turned off. 3) With the body raised to the cylinder stopper, run the engine at low idle and keep the dump control lever in the RAISE position for at least 5 seconds. 4) Run the engine at high idle and raise the body to the stroke end. Then, lower the engine speed to low idle and set the dump control lever in the FLOAT position to lower the body to the seating position. a Repeat the operations of 3) and 4) above 5 – 10 times. 5) Run the engine at high idle and raise the body to the stroke end. Then, keep the engine speed at high idle and set the dump control lever in the LOWER position to lower the body to the seating position. a Repeat this operation 5 – 10 times.

20-151-1 (10)

HD465-7, HD605-7

METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM


METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM If any problem occurs in the electrical system of the engine control system or transmission control system, it may become impossible to start the engine or to move the machine off. If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system, move the machine to a safe place, then carry out troubleshooting. 1. When problem occurs in engine control system and engine cannot be started a Decide the escape method according to the following flowchart. a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MONITOR. 2

1 Did [Engiine system caution NO lamp] on machine monitor flash when engine stopped? YES

3

NO

Is there fuel in fuel tank?

YES

Tow machine to safe place (see note)

4

Is following service code YES displayed or recorded? C441KK (ENG) 442KG (ENG)

Does engine start when following fuse is replaced? NO FUA (30A) BT2 --- No.3 (10A) BT2 --- No.15 (20A) BT4 --- No.10 (10A)

NO

YES

5 Does engine start when folNO lowing relay is replaced? R01 (engine start relay)

If there is no relay to replace or engine does not start, tow machine to safe place (see note)

YES

Start engine and move machine (do not turn electric power ON except when absolutely necessary) 6 Is following service code YES displayed or recorded? C111KT C346KT (ENG) NO

10

Does engine start when folYES lowing relay is replaced? R02 (transmission neutral relay)

7

Does engine start when en- NO gine controller is replaced?

8

Is following service code YES displayed or recorded? C115KZ (ENG) C121LC (ENG) NO

YES

If there is no controller to replace, tow machine to safe place (see note)

9 Does engine start when following speed sensor is replaced? NO Master speed sensor (SP1) Back-up speed sensor (SP2)

If there is no speed sensor to replace or engine does not start, tow machine to safe place (see note)

YES Start engine and move machine (do not turn electric power ON except when absolutely necessary)

NO

Tow machine to safe place (see note)

Note: If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE.

20-152 (11)

HD465-7, HD605-7



2. When problem occurs in transmission control system and machine cannot be started a Check the service code and determine the escape method from the following chart. a For details of the method of checking the failure code, see SPECIAL FUNCTIONS OF MACHINE MONITOR. Failure code

Condition when failure occurred

1380MW

Occurrence condition 1

Escape procedure 1 D – L : F2, R : R

1500L0


Escape procedure 2 —

15G0MW


Escape procedure 3 D – L : F2

15H0MW



15J0MW



15K0MW



15L0MW



15M0MW



15N0MW



15SBL1


Escape procedure 1

Escape method

Lever position for speed range to move off after escape operation

R:R

15SBMA



15SCL1



15SCMA



15SDL1



15SDMA



15SEL1



15SEMA



15SFL1



15SFMA



15SGL1



15SGMA



15SHL1



15SHMA



15SJL1



15SJMA



D1B0KZ


Normal travel possible if display Escape procedure 4 returns to normal (Note 1)

DAQ0KK



DAQ2KK



DAQ9KM



DAQ9KQ



DAQAKQ



DAQSMA



DDTGKA



DDTHKA



DDTJKA



DDTKKA



DDTLKA



DDTMKA



DDTNKA


Escape procedure 1

DDTPKA



HD465-7, HD605-7

Remarks Occurrence condition 1: Speed range remains fixed; when the machine is moved off again, speed range does not shift. a When lever is returned to N, transmission shifts to neutral. Occurrence condition 2: Transmission suddenly shifts to neutral when the machine is traveling; after machine is stopped, transmission stays in neutral even when lever is operated, and machine does not move off. Occurrence condition 3: Transmission suddenly shifts to neutral. Occurrence condition 4: After engine is started, transmission stays in neutral even when lever is operated, and machine does not move off. Occurrence condition 5: Response of lever becomes abnormal; lever does not work as operated When lever is operated, transmission shifts to neutral. Occurrence condition 6: Speed range remains fixed; when the machine is moved off again, speed range does not shift. a When lever is returned to N, transmission shifts to neutral, but after that, transmission does not shift to any speed range. Note 1: Even when the machine condition is restored after a failure, the neutral condition is maintained until the lever is returned to the N position. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller.

R:R

20-153 (10)



Failure code

Condition when failure occurred

DF10KA



DF10KB



DLE2KA



DLE2LC



DLF1KA



DLF1LC



DLF2KA



DLF2LC



DLT3KA



DLT3LC



DXH1KB



DXH2KA



DXH2KB



DXH3KA



DXH3KB



DXH4KA



DXH4KB



DXH5KA



DXH5KB



DXH6KA



DXH6KB



DXH7KA



DXH7KB



DXHHKA



DXHHKB



– (Note 2)



Escape method

Escape procedure 1: 1) Stop traveling and return the gearshift lever to the N position. 2) Operate the gearshift lever again and move the machine OFF. a When operating the gearshift lever, release the accelerator pedal. a N o D – L or N o R Escape procedure 2: Tow the machine. a If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE.

20-154 (10)

Lever position for speed range to move off after escape operation

Remarks Note 1: Even when the machine condition is restored after a failure, the neutral condition is maintained until the lever is returned to the N position. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller.

Escape procedure 3: 1) Stop traveling and return the gearshift lever to the N position. 2) Connect and disconnect emergency escape connectors A1 (female) and A2 (male), and switch to the emergency escape mode. a Connectors A1 and A2 are installed to near the fuse box. a Connect and disconnect the connectors with the starting switch at ON or with the engine started. 3) Operate the gearshift lever again and move the machine OFF. a When operating the gearshift lever, release the accelerator pedal. a N o D – L or N o R a The emergency escape mode is maintained until the starting switch is turned OFF.

HD465-7, HD605-7



Escape procedure 4: Replace the transmission cut relay. • Transmission cut relay: R15 Escape procedure 5: Check the circuit breaker and fuse, and if they are normal, replace the transmission controller. • Circuit breaker: No. 23 (80A) • Fuse: BT3-No. 14 (10A) Escape procedure 6: Check the fuse unit and fuse, and if they are normal, replace the transmission controller. • Fuse unit: Inside battery housing (30A) • Fuse: BT2-No. 22 (10A) Escape procedure 7: Check the model selection setting, and if it is normal, replace the transmission controoler. a For details of checking the model selection setting, see ADJUSTING TRANSMISSION CONTROLLER. Escape procedure 8: Check the fuse, and if it is normal, replace the gearshift lever. • Fuse: BT3-No. 10 (10A) Escape procedure 9: Check the transmission controller harness, and if it is normal, replace the transmission controller.

HD465-7, HD605-7

20-155 (1)


ADJUSTING MACHINE MONITOR

ADJUSTING MACHINE MONITOR (EMMS) • EMMS: Equipment Management Monitoring System Machine monitor (EMMS) rotary switches (SW1, SW2, SW3), dipswitches (SW5, SW6), and option setting connectors (OP1 – OP7)

20-156 (1)

HD465-7, HD605-7



•

In the following cases, check the settings of the rotary switches, dipswitches, and option setting connectors at the rear face of the machine monitor (EMMS), and change the settings as necessary. • When the machine monitor has been removed and installed again. • When machine monitor (EMMS) have been replaced with new parts (service meter, odometer, reverse travel odometer setting) a When carrying out of these settinigs, it is necessary to use the special operation of the character display and mode switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). • When service code [DAFOKM] is displayed a There is probably mistaken connection of the option setting connector, so see TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE) for details. • When the specification is changed as shown in Table 1, change the setting.

Table 1: Condition of switch setting functions and option setting connectors. Switch

Position

SW1

0–F

Correction of travel speed (Correction of tire size)

Unnecessary

0–F

• Setting of max. speed • Setting of max. speed when body is raised

Unnecessary

0–F

Setting of specification

Unnecessary

OFF

Unit of speed meter: km/h

Unnecessary

SW2

SW3 1

ON OFF

Purpose of switch

Unit of speed meter: MPH Exhaust brake: Not installed

2 SW5

Connector

Unnecessary

Remarks Standard tire is set to position 7.

Only in area where MPH is used as unit

Open (Not connected)

ON

Exhaust brake: Installed

Connected

OFF

Spare

ON

Spare

OFF

Front brake cut: Not installed

ON

Front brake cut: Installed

OFF

Maintenance function: Not installed

ON

Maintenance function: Installed

OFF

Setting of caution when body is raised: Not installed

Open (Not connected)

ON

Setting of caution when body is raised: Installed

Connected

OFF

Spare

ON

Spare

OFF

Spare

ON

Spare

3

4

1

Open (Not connected) Connected Open (Not connected) Connected

2 SW6

3

4

• •

The condition of each switch and connector can be checked with the special function of the machine monitor (EMMS) (monitoring function). Connector OP7 is used for the special function of the machine monitor. a For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).

HD465-7, HD605-7

20-157 (10)



a All setting operations are carried out with the starting switch OFF and the monitor panel removed. a Always set each switch and connector as instructed. a Be careful not to touch anything inside the grommet except for the switch. a When turning the rotary switch, use a precision cross-head screwdriver and turn slowly. a The protruding triangular part of the rotary switch is the setting arrow. a When changing the dipswitch, use a precision flat-headed screwdriver and turn slowly. a When setting, always avoid foreign matters or dust. a After setting, be sure to install grommet.

1. Setting rotary switch SW1 Rotary switch SW1 is used to set the travel speed compensation. The machine monitor uses the size of the standard tire to calculate the travel speed. If the tire size is changed, adjust the position of the switch to compensate for the speed display. a Tire size and setting position. Tire size

SW1

Connector

Remarks

24.0 – 35PR

7

Not needed

HD465-7 standard tire

a The connector in the table indicates the number of the connector to be connected or released when changing the setting. (In the case of SW1, there is no need to connect or release the connector.) a Travel speed compensation using SW1 Position 0 1 2 3 4 5 6 7

Speed compensation +7% +6% +5% +4% +3% +2% +1% 0%

Position 8 9 A B C D E F

Speed compensation 0% –1% –2% –3% –4% –5% –6% –7%

2. Setting rotary switch SW2 Rotary switch SW2 is used to set the maximum speed and the maximum speed when the body is raised. Position of SW2 0 1 2 3 4 5 6 7 8 9 A B C D E F

Setting of max. speed F7 (Default) F5 F4 F6 F5 F4 F6 F5 F4 F6 F5 F4

Setting of max. speed when body is raised F2 (Default) F2 F2 F2 F3 F3 F3 F3 N N N N

Connector OP3 • Setting is made: Connected • Setting is not made: Open (Not connected)

20-158 (10)

HD465-7, HD605-7



3. Setting rotary switch SW3 Rotary switch SW3 is used for setting when the functions of (ASR), ASRC, AUTO SUS, (ABS), etc. are changed. Position of SW3 0 1 2 3 4 5 6 7 8 9 A B C D E F

Function Not set (ASR) ARSC AUTO SUS (ABS) (ASR, ARSC) (ASR, AUTO SUS) (ARS, ABS) (ARSC, AUTO SUS) (ARSC, ABS) (AUTO SUS, ABS) (ASR, ARSC, AUTO SUS) (ASR, ARSC, ABS) (ASR, AUTO SUS, ABS) (ASRC, AUTO SUS, ABS) (ASR, ARSC, AUTO SUS, ABS)

Connector OP2 • Setting is made: Connected • Setting is not made: Open (Not connected)

4. Setting dipswitch SW5-1 Dipswitch SW5-1 is set as follows. The setting must not be changed. a Turn ON this switch only in an area where MPH is used as the unit. SW5-1

Connector

OFF ON

Unnecessary Unnecessary

Remarks Unit of speedometer: km/h Unit of speedometer: MPH

5. Setting dipswitch SW5-2 Use dipswitch SW5-2 to set the exhaust brake. When the exhaust brake has been installed or removed, set as follows. Exhaust brake Not installed Installed ON

SW5-2 OFF ON

Connector OP1

7. Setting dipswitch SW5-4 Use dipswitch SW5-4 to set the front brake cut. When the front brake cut has been installed or removed, set as follows. Front brake cut

SW5-4

Connector OP4

Not installed

OFF

Released (Not installed)

Installed

ON

Connected

Remarks

8. Setting dipswitch SW6-1 Dip switch SW6-1 is used for setting when the maintenance function is changed. Maintenance function Not installed Installed

SW6-1

Connector OP5

OFF ON

Open Installed

Remarks

9. Setting dipswitch SW6-2 Dip switch SW6-2 is used for setting when the caution for raising the body is changed. Setting caution for raising body Not installed Installed

SW6-2

Connector OP6

OFF ON

Open Connected

Remarks

10. Setting dipswitch SW6-3 Dipswitch SW6-3 is set as follows. The setting must not be changed. • Set position of dipswitch SW6-3: OFF • Connector operation: Not needed 11. Setting dipswitch SW6-4 Dipswitch SW6-4 is set as follows. The setting must not be changed. • Set position of dipswitch SW6-4: OFF • Connector operation: Not needed

Remarks

Open Connected

6. Setting dipswitch SW5-3 Dipswitch SW5-3 is set as follows. The setting must not be changed. • Set position of dipswitch SW5-3: OFF • Connector operation: Not needed

HD465-7, HD605-7

20-159 (10)


ADJUSTING TRANSMISSION CONTROLLER

ADJUSTING TRANSMISSION CONTROLLER

2. Setting machine body wiring harness a If the transmission controller is replaced, set the connector for selecting the model as shown below.

1. Setting rotary switch a If the transmission controller has been replaced, set the rotary switches for the network data and model selection as follows. a Use a precision cross-head screwdriver and turn the rotary switch slowly. a The e mark on the rotary switch is the guideline for setting. 1) Remove 2 grommets at the top of the controller. 2) Align the SW1 rotary switch and SW2 rotary switch with the set position. a Set rotary switches 1 and 2 (SW1 and SW2) to only the following positions (1) Contents of setting and set position of rotary switch 1 (SW1) Table 1 Switch

Contents of setting

Position

SW1

Model information

4

HD465, 605-7 MS11 – MS12 MS21 – MS22 MS31 – MS32

Connected Open Connected

3. Adjusting transmission a After carrying out any of the following operations, adjust the transmission in order to adjust the fitting between the transmission and the transmission controller. • When the transmission has been overhauled or replaced • When the transmission control valve has been repaired or replaced • When the transmission controller has been replaced • When the power train speed sensor has been repaired or replaced • When the transmission oil temperature sensor has been repaired or replaced • When the transmission oil filter has become clogged and has been cleaned a When adjusting the transmission, use the service function of the machine monitor. a For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.

(2) Contents of setting and set position of rotary switch 2 (SW2) (See table 2)

Table 2 Switch

SW2

Card-type payload meter (PLM- )

Function of payload meter (PLM) function

Position

— —

Not installed

Not installed

F

Installed

Installed

F

Installed Installed

Not installed Not installed



B B

Installed

Installed

Not installed

Installed

9

VHMS controller

PLM function in VHMS controller

Not installed Not installed

a The transmission controller switch (SW2) is used to notify the monitor panel "whether the VHMS is installed", "whether the PLM function in the VHMS is turned on", and "whether PLM- is installed".

20-160 (7)

HD465-7, HD605-7

INITIAL SETTING OF PAYLOAD METER


INITIAL SETTING OF PAYLOAD METER In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to Table 1. 1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time 2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller (PLM ) is changed Table 1

VHMS controller


Not installed

—

Not installed

—


Payload meter (PLM) function

Not installed Not installed Installed

Installed

Setting with VHMS initial setting manual (tool) (*2)

Set position of rotary switch 2 (SW2) of transmission controller (*1)

Model

Type

Variation code

Date Time Time difference (GMT) Summer time

F

—

—

—

—

F

—

—

—

—

Installed

Not installed Not installed Not installed

B

Installed

Not installed

Installed

Installed

F

Installed

Installed

Installed

Installed

9

HD465 or HD605

ST –7

P2

Set properly

PV

(*1) For the set position of rotary switch 2 (SW2) of the transmission controller, see the section of adjustment of the transmission controller. (*2) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool) When there is not a problem in installation and wiring of the payload meter but there are the following problems, check the above setting again. 1. Items related to the payload meter are not displayed on the machine monitor. "The payload is not displayed when the machine is loaded and stopped", "There are not the manus related to the payload meter on the match marks", etc. a Wrong setting of rotary switch 2 (SW2) of transmission controller 2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on the machine monitor. a Wrong setting of rotary switch 2 (SW2) of transmission controller 3. While the payload meter in the VHMS is set, the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 4. The storage place of the data file made by the download software is not found. a Wrong setting of the model and serial No. with the VHMS initial setting tool. 5. Data cannot be downloaded. a Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool. 6. Date and time of the downloaded data are wrong. a Wrong setting of the date and time with the VHMS initial setting tool.

HD465-7, HD605-7

20-160-1 (10)

SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT


SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT In the following cases, set the rotary switches and DIP switches on the side of the card-type payload meter and set the threshold value of turning on the external indicator lamp and option code with the switches on the front. • •

When card-type payload meter is installed for the first time When card-type payload meter is replaced

1. Setting of switches 1) Remove cover (1) from the left side of the card-type payload meter.

2) Set the following switches. (See view Z in the above figure.) • Set the model selector switch (No. 4).

•

Model

7

HD465-7

A

HD605-7

Set weight unit setting switch (No. 7).

20-160-2 (11)

Position of rotary switch

Position of switch

Model

Upper

Metric ton

Lower

American ton (Short ton)

HD465-7, HD605-7



•

Set buzzer volume switch (No. B) and switch forcible prohibition switch (No. 8), if necessary. When changing these switches from the initial positions, be sure to check with the Operation and Maintenance Manual.

•

Do not change the load weight correction trimmer (No. 1) from the initial position.

•

Do not change the speed correction switch (No. 2), distance correction switch (No. 3), memory card using switch (No. 5), and clinometer using switch (No. 6) from the initial positions. Switch

Initial setting

Speed correction switch (No. 2)

Switch position: 7

Distance correction switch (No. 3)

Switch position: 7

Memory card using switch (No. 5)

Switch position: Lower (Use)

Clinometer using switch (No. 6)

Switch position: Lower (Use)

Switch forcible prohibition switch (No. 8)

Switch position: Upper (Permission)

a You can carry out the operations of calibration, clearing all data, dumping card, and setting date by turning switches No. 5 and No. 8 ON or OFF. (See the Operation and Maintenance Manual.) 2. Setting of option code a Required for communication with personal computer The option code is set to zero (0) initially. For HD465-7 and HD605-7, check that the option code is zero by the following method. When the power is turned ON, "OP: 0" is indicated before the normal operation display starts. (See Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indication.) Optional setting

Option code

Transmission baud rate (bit/sec)

Execution of automatic transmission function

Setting of TALKS

Setting of PMC

Type of transmission of data when dumping is finished (when PMC is set)

0

9600

NO

NO

NO

—

1

9600

YES

NO

NO

—

2

1200

NO

NO

NO

—

3

1200

YES

NO

NO

—

4

9600

NO

YES

NO

—

5

9600

YES

YES

NO

—

6

1200

NO

YES

NO

—

7

1200

YES

YES

NO

—

8

9600

NO

YES

YES

Z1

9

9600

NO

YES

YES

Z2

10

9600

NO

NO

YES

Z1

11

9600

NO

NO

YES

Z2

HD465-7, HD605-7

20-160-3 (11)



Method of changing option code 1) Set the gearshift lever in "N" and the dump lever in FLOAT. Operation switches to be used • MODE (2) • LIGHT/INC (3) • TOTAL/SFT (4) • CAL/CLR (5) Screen (6) a While watching the screen, operate switches (2) – (5) to set values.

20-160-4 (11)

HD465-7, HD605-7



2) Display the option code screen according to the following procedure. Press MODE switch (2). Press MODE switch (2) for 2 seconds.

Display

Cd: dp (Cd lights up and dp blinks)

Display

0. XXX (0. XX lights up and X at ones place blinks)

XXX = Currently set operator ID

O O Press MODE switch (2). Press MODE switch (2).

Display

A. CLE (A lights up and CLE blinks)

Display

SP: XX (SP: X lights up and X at ones place blinks)

XX = Current set limit speed (km/h)

O O Press MODE switch (2). Press MODE switch (2).

Display

F. CHE (F. CHE blinks)

Display

OP: XX (OP: X lights up and X at ones place blinks)

XX = Current set option code

O

Press MODE switch (2).

Display

d. XXX (d. XX lights up and X at ones place blinks)

XXX = Currently set machine ID

O

HD465-7, HD605-7

20-160-5 (11)



3) Changing set value of option code a You can change the digit at the blinking place. •

Press LIGHT/INC switch (3).

Changing ones digit Display

OP: XX (OP: X lights up and X at tens place blinks)

XX = Tens digit of currently set option code is increased by 1.

•

Changing place to be changed a Press TOTAL/SFT switch (4). o The blinking point moves to the ones place.


Display

OP: XX (OP: X lights up and X at ones place blinks)

XX = Ones digit of currently set option code is increased by 1.

•

Changing tens digit

4) Finishing setting

a Press TOTAL/SFT switch (4).

a Press MODE switch (2).

o The blinking point moves to the tens place.

20-160-6 (11)

HD465-7, HD605-7



3. Setting threshold value of external indicator lamp a When installing the card-type payload meter to a machine having the 3-bulb external indicator lamp (HD465-7, HD605-7), be sure to set the threshold value of the external indicator lamp.

Press CAL/CLR switch (5).

Display

PL: XX (PL: lights up and XX blinks)

1) Set the gearshift lever in "N" and the dump lever in FLOAT. 2) Set the threshold value of the external indicator lamp according to the following procedure. a For the setting switches, see "2. Setting of option code", Method of changing option code.

O Press CAL/CLR switch (5).

Display

O. SEL (O. SEL lights up)

Press MODE switch (2) and LIGHT/INC switch (3) simultaneously for 3 seconds.

O Display

CHEC (CHEC blinks) Press CAL/CLR switch (5).

Display

P. SEL (P. SEL lights up)

O Press TOTAL/SFT switch (4) and LIGHT/INC switch (3) simultaneously for 2 seconds.

O Display

S. SEL (S. SEL lights up) Press CAL/CLR switch (5).

Display

H. SEL (H. SEL lights up)

O


O Display

UP: XX (UP: lights up and XX blinks)


Display

E. SEL (E. SEL lights up)

O

O HD465-7, HD605-7

20-160-7 (11)



Press TOTAL/SFT switch (4).

Display

A. XXX (A. lights up and XXX blinks)

XXX = Currently set display level of external lamp 1

O


Display

c. XXX (c. lights up and XXX blinks)

XXX = Set to 050.

a If LIGHT/INC switch (3) is held, XXX increases to 255 and then returns to 0. O


Display

b. XXX (b. lights up and XXX blinks)


O


Display

d. XXX (d. lights up and XXX blinks)


O


Display

c. XXX (c. lights up and XXX blinks)


O


Display

d. XXX (d. lights up and XXX blinks)

XXX = Set to 090.


20-160-8 (11)

HD465-7, HD605-7




Display

E. XXX (E. lights up and XXX blinks)


O

4. Check of setting For 30 seconds after the card-type payload meter is turned ON, the model selection code, setting of memory card using switch, setting of clinometer using switch, setting of weight unit setting switch, setting of switch forcible prohibition switch, and setting of option code are displayed. Check that they are correct. a For contents of indication made when the power is turned ON, see Operation and Maintenance Manual, Handling of payload meter (card type), Contents of indication.


Display

E. XXX (E. lights up and XXX blinks)

XXX = Set to 105. (HD465-7) XXX = Set to 100. (HD605-7)



Display

CHEC (CHEC blinks)

O


End of setting

HD465-7, HD605-7

20-160-9 (11)

SPECIAL FUNCTIONS OF MACHINE MONITOR


SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) •

EMMS: Equipment Management Monitoring System

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

i o

Service mode

1

Service meter, odometer display function (default) (*1)

9

Electric system fault history display function

2

Reverse travel distance display function

10

Mechanical system fault history display function

3

Filter replacement, oil change interval display function

4

Telephone number input function

5

Language selection function

6

PLM setup function

7

Action code display function

8

Failure code display function

11

Machine data monitoring function

12

Adjustment function

13

Filter replacement, oil change interval display function

14

Snapshot function

15

PLM setting function

16

Initialize function (factory use only)

*1: PLM (payload meter) display function when receiving VHMS data

HD465-7, HD605-7

20-161 (10)



FLOW MODES AND FUNCTION

20-162 (10)

HD465-7, HD605-7


HD465-7, HD605-7


20-163 (2)


20-163-1 (5)


HD465-7, HD605-7


HD465-7, HD605-7


20-163-2 (5)



Operator mode a [>], [<], [ ], [t], give an endless display according to the operation of the switch. a When a failure occurs, the screen changes automatically to ACTION CODE DISPLAY FUNCTION, regardless of the display screen. a Regardless of the display screen, if no switch is operated for more than 30 seconds, the screen automatically changes as follows. • Goes to SERVICE METER, ODOMETER DISPLAY FUNCTION: If there is no failure • Goes to ACTION CODE DISPLAY FUNCTION: If there is a failure a From FAILURE CODE DISPLAY FUNCTION the screen changes to SERVICE METER, ODOMETER DISPLAY FUNCTION with the switch operation, and if no switch is operated for more than 10 seconds, the screen automatically changes to ACTION CODE DISPLAY FUNCTION. Service mode a For selection of each function, [>], [<], [ ], [t],give an endless display according to the operation of the switch. a Once the ID is input and confirmed, it remains effective until the starting switch is turned OFF.

Character display The character display consists of a top line and bottom line with 16 characters each. A combination of the following characters (alphabet and numerals) and symbols is displayed according to the content. 1) Numerals: 1, 2, 3 . . . 2) Small letters: a, b, c . . . 3) Capital letters: A, B, C . . . 4) Katakana: Japanese display only 5) Symbols: @, ¥, $ . . . 6) Special characters Control switches Control of the machine monitor display is all carried out with machine monitor mode selector switches (1) and (2). The following functions are provided for the buttons of each switch. 1) : Select, Run 2) t: Cancel, Release, Select (YES/NO only) 3) >: Right, Next, Continue 4) <: Left, Previous, Return

20-164 (9)

HD465-7, HD605-7



Operation and displays for operator mode 1. Service meter, odometer display function When the starting switch is turned ON, the top line shows the service meter and the bottom line shows the odometer (Fig. 1) a For details, see STRUCTURE AND FUNCTION, Machine monitor system.

2. Reverse travel distance display function Use the switch to display the total distance traveled in reverse of the machine monitor (Fig. 2) a For details, see STRUCTURE AND FUNCTION, Machine monitor system.

3. Filter, oil replacement interval display function 1) Filter, oil replacement time display (automatic display) When the replacement interval for the filters or oil approaches, this information is automatically displayed on the machine monitor to recommend the operator to carry out maintenance (Fig. 3: example).

2) Resetting replacement time (selection menu) When the maintenance operation for the filters and oil replacement has been completed, the switches on the machine monitor can be used to reset the interval (Fig. 4) a For details, see STRUCTURE AND FUNCTION, Machine monitor system. a The replacement time can be set using Service mode.

HD465-7, HD605-7

20-165 (10)



4. Telephone number input function The telephone number set inside the machine monitor can be input, corrected, or canceled by operating the switches (Fig. 5). a When action code [E03] is displayed, the telephone number is displayed at the same time as [CALL]. a For details, see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR".

5. Language selection function The language used for the machine monitor display can be selected by operating the switches (Fig. 6) a The functions of Service mode is not included in the functions for display selection, so it is always displayed in English. a For details, see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR".

6. PLM setting function a This function is applied to the "PLM in VHMS" (Only when the option is set). • Various functions of the "PLM in VHMS" are displayed and set (FIG. 10). a For details, see the operation manual for the "PLM in VHMS".

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

20-166 (10)

HD465-7, HD605-7



Action code

CALL+ Telephone number

E01

Not displayed

E02

Not displayed

E03

Displayed

Action recommended to operator •

Carry out testing and adjusting after completion of operations or when changing shifts between operators

•

When overrun related display is shown: Reduce engine speed and machine speed while continuing operations. When overheat related display is shown: Stop machine and keep engine running at mid-range speed under no load.

•

•

Stop engine and machine immediately and contact serviceman.

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

HD465-7, HD605-7

20-167 (10)



FAILURE CODES LIST Failure code

Failed section

Failure phenomenon (Phenomenon/Contents of failure)

Controller

Action code

1380MW

Lockup clutch

Slip (MW)

TM

E03

1500LO

Detection of double engagement

* See separate list (L0)

TM

E03

15B0NX

Clogging of steering oil filter

Clogging (NX)

TM

E01

15E0KM

R o F gear shifting abuse 1

Mistake in operation or setting (KM)

TM

—

15E7KM

R o F gear shifting abuse 2


TM

—

15G0MW

R clutch

Slip (MW)

TM

E03

15H0MW

Hi clutch

Slip (MW)

TM

E03

15J0MW

Lo clutch

Slip (MW)

TM

E03

15K0MW

1st clutch

Slip (MW)

TM

E03

15L0MW

2nd clutch

Slip (MW)

TM

E03

15M0MW

3rd clutch

Slip (MW)

TM

E03

15N0MW

4th clutch

Slip (MW)

TM

E03

15SBL1

R clutch ECMV


TM

E03

15SBMA

R clutch ECMV

Malfunction (MA)

TM

E03

15SCL1

Hi clutch ECMV


TM

E03

15SCMA

Hi clutch ECMV

Malfunction (MA)

TM

E03

15SDL1

Lo clutch ECMV


TM

E03

15SDMA

Lo clutch ECMV

Malfunction (MA)

TM

E03

15SEL1

1st clutch ECMV


TM

E03

15SEMA

1st clutch ECMV

Malfunction (MA)

TM

E03

15SFL1

2nd clutch ECMV


TM

E03

15SFMA

2nd clutch ECMV

Malfunction (MA)

TM

E03

15SGL1

3rd clutch ECMV


TM

E03

15SGMA

3rd clutch ECMV

Malfunction (MA)

TM

E03

15SHL1

4th clutch ECMV


TM

E03

15SHMA

4th clutch ECMV

Malfunction (MA)

TM

E03

15SJL1

Lockup clutch ECMV


TM

E03

15SJMA

Lockup clutch ECMV

Malfunction (MA)

TM

E03

2F00KM

Parking brake


TM

—

2G42ZG

Accumulator (Front)

Lowering of oil pressure (ZG)

BK

E03

2G43ZG

Accumulator (Rear)

Lowering of oil pressure (ZG)

BK

E03

989AOO

Engine overrun prevention command signal

Operation (OO)

TM

E02

989AKZ

Engine overrun prevention command signal

Disconnection or short circuit (KZ)

TM

E01

989OO

Rear part tipping signal

Operation (OO)

BK

—

20-168 (10)

HD465-7, HD605-7


Failure code

Failed section



Controller

Action code

AA10NX

Air cleaner element

Clogging (NX)

TM

E01

AB00MA

Alternator

Malfunction (MA)

TM

E03

B@BCZK

Radiator coolant

Lowering of level (ZK)

TM

E01

B@C7NS

Rear brake oil

Overheating (NS)

MON

E02

B@CENS

Torque converter

Overheating (NS)

MON

E02

C111KT

Failure in controller memory

Internal defect of controller (KT)

ENG

E03

C112LK

Timing actuator defective

* See separate list (LK)

ENG

E03

C113KZ

Abnormal current in timing actuator


ENG

E03

C115KZ

Error in engine speed sensor 2 system


ENG

E03

C116KX

Abnormality in timing rail pressure sensor

Clogging (NX)

ENG

E03

C117KX

Abnormality in timing rail pressure sensor

Out of input signal range (KX)

ENG

E03

C118KX

Abnormality in fuel pump pressure sensor


ENG

E01

C119KX

Abnormality in fuel pump pressure sensor


ENG

E01

C121LC

Error in engine speed sensor 1 system

* See separate list (LC)

ENG

E03

C122KX

Abnormality in boost pressure sensor


ENG

E03

C123KX

Abnormality in boost pressure sensor


ENG

E03

C131KX

Abnormality in throttle sensor


ENG

E03

C132KX

Abnormality in throttle sensor


ENG

E03

C135KX

Abnormality in oil pressure sensor


ENG

E01

C141KX

Abnormality in oil pressure sensor


ENG

E01

C143ZG

Lowering of oil pressure (Engine protection)


ENG

E03

C144KX

Abnormality in coolant temperature sensor


ENG

E01

C145KX

Abnormality in coolant temperature sensor


ENG

E01

C148KX

Abnormality in FM throttle


ENG

E03

C151NS

Rise of coolant temperature (Engine protection)

Overheating (NS)

ENG

E02

C153KX

Abnormality in intake air temperature sensor


ENG

E01

C154KX

Abnormality in intake air temperature sensor


ENG

E01

C221KX

Abnormality in atmospheric pressure sensor


ENG

E03

C222KX

Abnormality in atmospheric pressure sensor


ENG

E03

C234N1

Engine over-speed

Overrun (N1)

ENG

E02

C254KZ

Abnormality in FSOV circuit


ENG

E03

C259FS

Abnormality in FSOV circuit

Fixing (FS)

ENG

E03

C261NS

Rise of fuel temperature (Engine protection)

Overheating (NS)

ENG

E02

C263KX

Abnormality in fuel temperature sensor


ENG

E01

HD465-7, HD605-7

20-169 (10)


Failure code

Failed section



Action code

ENG

E01

C265KX

Abnormality in fuel temperature sensor

C316KZ

Abnormal current in fuel injection pump actuator Disconnection or short circuit (KZ)

ENG

E01

C318LK

Pump actuator defective


ENG

E01

C346KT

ECM power-down error

Internal defect of controller (KT)

ENG

E03

C423L6

Timing rail pressure in-range error


ENG

E03

C431L4

Abnormality in idle validation switch


ENG

E01

C432L5

Idle validation process error


ENG

E03

C441KK

Abnormality in battery voltage

Lowering of source/input voltage (KK)

ENG

E01

C442KG

Abnormality in battery voltage

High source voltage (KG)

ENG

E03

C451KX

Abnormality in fuel rail pressure sensor


ENG

E03

C452KX

Abnormality in fuel rail pressure sensor


ENG

E03

C455KZ

Abnormality in fuel rail actuator circuit


ENG

E03

C467LK

Timing actuator control error


ENG

E03

C468LK

Fuel rail actuator control error


ENG

E03

C514LK

Fuel rail actuator defective


ENG

E03

C554L6

Fuel rail pressure sensor in-range error


ENG

E03

D1B0KZ

Transmission cut-out relay


TM

E03

D1C0KZ

Brake cut-out relay


BK

E03

D5ZMKZ

Disconnection/Grounding fault/Short circuit in engine output mode command line Failure in front brake cut-out output system (Disconnection, grounding fault, short circuit) (OPT)


TM

E01


BK

E01

DAF0KM

Monitor panel


MON

E03

DAF9KM

Monitor panel


MON

E03

DAFSKQ

Monitor panel

Disagreement of model selection signals (KQ)

MON

E03

DAQ0KK

Transmission controller


TM

E03

DAQ1KK

Transmission controller main power source line


TM

E03

DAQ2KK

Transmission controller load power source line


TM

E03

DAQ3KK

Transmission controller battery direct power source line


TM

E03

DAQ9KM

Transmission controller wiring harness


TM

E03

DAQ9KQ

Transmission controller wiring harness

TM

E03

DAQAKQ

Transmission controller rotary switch

TM

E03

DAQSKR

Transmission controller S-NET line

Disagreement of model selection signals (KQ) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR)

MON

E03

DAQSMA


Malfunction (MA)

TM

E03

DASRKR

COMMUNICATION ERROR ENG

Communication defective/Abnormality in objective component (KR)

MON

E03

DB10KK

Retarder controller


BK

E03

D5ZNKZ

20-170 (10)


Controller

HD465-7, HD605-7


Failure code

Failed section



Controller

Action code

DB11KK

Retarder controller main power source line


BK

E03

DB12KK

Retarder controller load power source line


BK

E03

DB13KK

Retarder controller battery direct power source line


BK

E03

DB19KM

Retarder controller wiring harness


BK

E03

DB1SKR

Retarder controller S-NET line

MON

E03

DB1SKQ

Wrong information on model selection

BK

E03

DBBSKR

Communications error VHMS

Communication defective/Abnormality in objective component (KR) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR)

MON

E01

DDD7KX

Failure in travel speed setting switch system (OP)


BK

E03

DDD8KA

Disconnection ARSC system switch (OP)

Disconnection (KA)

BK

E03

DDD8KB

Short circuit ARSC system switch (OP)

Short circuit (KB)

BK

E03

DDDAKA

Disconnection ASR system switch (OP)

Disconnection (KA)

BK

E01

DDDAKB

Short circuit ASR system switch (OP)

Short circuit (KB)

BK

E01

DDTGKA

Fill switch for lockup clutch

Disconnection (KA)

TM

E03

DDTHKA

Fill switch for Hi clutch

Disconnection (KA)

TM

E03

DDTJKA

Fill switch for Lo clutch

Disconnection (KA)

TM

E03

DDTKKA

Fill switch for 1st clutch

Disconnection (KA)

TM

E03

DDTLKA

Fill switch for 2nd clutch

Disconnection (KA)

TM

E03

DDTMKA

Fill switch for 3rd clutch

Disconnection (KA)

TM

E03

DDTNKA

Fill switch for R clutch

Disconnection (KA)

TM

E03

DDTPKA

Failure in flow sensor valve for 4th clutch

Disconnection (KA)

TM

E03

DF10KA

Gear shift lever

Disconnection (KA)

TM

E03

DF10KB

Gear shift lever

Short circuit (KB)

TM

E03

DGF1KX



TM

E03

dGR2L8

Failure in retarder oil temperature sensor system


BK

E03

DGR2L8

Brake oil temperature sensor (Rear)


BK

E01

DGT1KX



TM

E01

dHP4KX

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


BK

E03

DhP4KX

Suspension pressure sensor (FR)


PLM

E01

DHP4KX

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


BK

E01


BK

E03

DhP5KX

Suspension pressure sensor (FL)


PLM

E01

DHP5KX

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


BK

E03

DHP6KX

Suspension pressure sensor (RR)


PLM

E01

DHP7KX

Suspension pressure sensor (RL)


PLM

E01

dHP5KX

HD465-7, HD605-7

20-171 (10)


Failure code

Failed section



Controller

Action code

DHT5KX



TM

E01

DHT5L6



TM

E01

DHU2KX

Accumulator oil pressure sensor (Front)


BK

E01

DHU3KX

Accumulator oil pressure sensor (Rear)


BK

E01

DJF1KA

Fuel level sensor

Disconnection (KA)

TM

E01

DK11KX

Throttle angle sensor


TM

E03

dK11KX

Failure in acceleration sensor system (OPT)


BK

E03

Dk11KX

Failure in acceleration sensor system (OPT)


BK

E01

DK30KX

Failure of steering angle potentiometer (OP)


BK

E01

DK51L5

Retarder lever potentiometer


BK

E03

DK52KX

Dump lever potentiometer 1


BK

E03

DK53L8

Dump lever potentiometer 2


BK

E03

DK54KX

Body positioner sensor


BK

E03

DKD0L6

Failure in steering speed sensor (OPT)


BK

E01

DKH1KX

Abnormality in angle sensor


PLM

E01

DLE2KA

Engine speed sensor

Disconnection (KA)

TM

E03

DLE2LC

Engine speed sensor


TM

E03

DLF1KA


Disconnection (KA)

TM

E03

DLF1LC



TM

E03

DLF2KA


Disconnection (KA)

TM

E03

DLF2LC



TM

E03

DLF8KA

Disconnection in wheel speed sensor (RR) (OP)

Disconnection (KA)

BK

E01

DLF8LC

Failure in wheel speed sensor (RR) system (OP)


BK

E01

DLF9KA

Disconnection in wheel speed sensor (RL) (OP)

Disconnection (KA)

BK

E01

DLF9LC

Failure in wheel speed sensor (RL) system (OP)


BK

E01

DLT3KA


Disconnection (KA)

TM

E03

dLT3KA

Disconnection in transmission output shaft speed sensor Disconnection in transmission output shaft speed sensor

Disconnection (KA)

BK

E01

Disconnection (KA)

BK

E03

DLT3LC



TM

E03

DLT3LC



BK

E01

dLT3LC

Failure in transmission output shaft speed sensor

Disconnection (LC)

BK

E01

DV00KB

Short circuit in buzzer output

Short circuit (KB)

MON

E01

DW35KZ

Failure in auto suspension solenoid 1 output system (Disconnection, grounding fault, short circuit) (OPT) Failure in auto suspension solenoid 2 output system (Disconnection, grounding fault, short circuit) (OPT)


BK

E01


BK

E01

dLt3KA

DW36KZ

20-172 (10)

HD465-7, HD605-7


Failure code

Failed section



Controller

Action code


BK

E01

DW73KZ

Failure in kick-out solenoid output system (D_OUT3) (Disconnection, grounding fault, short circuit) Failure in hoist select valve output system (D_OUT5) (Disconnection, grounding fault, short circuit)


BK

E03

DWNBK4

Shut-off valve

Not control (K4)

BK

E01

DWNBKA Disconnection in shut-off valve system

Not control (KA)

BK

E01

DWNBKB Grounding fauit in shut-off valve system

Short circuit (KB)

BK

E01

DWNBKY Short circuit in shut-off valve system

Short circuit with power line (KY)

BK

E01

DWNBMA Shut-off valve

Malfunction (MA)

BK

E01

Electromagnetic proportional pressure reducing valve Disconnection in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Short circuit in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Grounding fault in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Electromagnetic proportional pressure reducing valve Disconnection in output circuit of hoist EPC valve (A_OUT3) Grounding fault in output circuit of hoist EPC valve (A_OUT3) Short circuit in output circuit of hoist EPC valve (A_OUT3) ASR proportional solenoid pressure reducing valve (Right) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) ASR proportional solenoid pressure reducing valve (Right) ASR proportional solenoid pressure reducing valve (Left) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP)

Disconnection (K4)

BK

E03

Disconnection (KA)

BK

E03

Short circuit (KB)

BK

E03


BK

E03

Malfunction (MA)

BK

E03

Disconnection (KA)

BK

E03

Short circuit (KB)

BK

E03


BK

E03

Not control (K4)

BK

E01

Disconnection (KA)

BK

E01

Short circuit (KB)

BK

E01


BK

E01

Malfunction (MA)

BK

E01

Not control (K4)

BK

E01

Disconnection (KA)

BK

E01

Short circuit (KB)

BK

E01


BK

E01

Malfunction (MA)

BK

E01

DXH1KA

Disconnection in output circuit of lockup clutch solenoid

Disconnection (KA)

TM

E03

DXH1KB

Short circuit in output circuit of lockup solenoid

Short circuit (KB)

TM

E03

DXH2KA

Disconnection in output circuit of H clutch solenoid

Disconnection (KA)

TM

E03

DXH2KB

Short circuit in output circuit of H clutch solenoid

Short circuit (KB)

TM

E03

DXH3KA

Disconnection in output circuit of L clutch solenoid

Disconnection (KA)

TM

E03

DXH3KB

Short circuit in output circuit of L clutch solenoid

Short circuit (KB)

TM

E03

DXH4KA

Disconnection in output circuit of 1st clutch solenoid

Disconnection (KA)

TM

E03

DXH4KB

Short circuit in output circuit of 1st clutch solenoid

Short circuit (KB)

TM

E03

DW72KZ

DX11K4 DX11KA DX11KB DX11KY DX11MA DX13KA DX13KB DX13KY DX17K4 DX17KA DX17KB DX17KY DX17MA DX18K4 DX18KA DX18KB DX18KY DX18MA

HD465-7, HD605-7

20-173 (10)


Failure code

Failed section

DXH5KA

Disconnection in output circuit of 2nd clutch solenoid

DXH5KB



Controller

Action code

Disconnection (KA)

TM

E03

Short circuit in output circuit of 2nd clutch solenoid

Short circuit (KB)

TM

E03

DXH6KA

Disconnection in output circuit of 3rd clutch solenoid

Disconnection (KA)

TM

E03

DXH6KB

Short circuit in output circuit of 3rd clutch solenoid

Short circuit (KB)

TM

E03

DXH7KA

Disconnection in output circuit of R clutch solenoid

Disconnection (KA)

TM

E03

DXH7KB

Short circuit in output circuit of R clutch solenoid

Short circuit (KB)

TM

E03

DXHHKA

Disconnection in output circuit of 4th clutch solenoid

Disconnection (KA)

TM

E03

DXHHKB

Short circuit in output circuit of 4th clutch solenoid

Short circuit (KB)

TM

E03

a For details of the VHMS controller related failure codes not displayed on the machine monitor, see Troubleshooting VHMS control system. a Separate table: Detailed phenomena of L Series phenomenon codes (L*) Problem code

Nature

L0

Fill signals on 2 or more channels for clutches not forming a set are input at same time

L1

Fill signal is ON when command current to ECMV is OFF

L2

Fuel pressure is higher than maximum set pressure

L3

Corresponding component cannot be controlled

L4

ON/OFF signals for 2 systems do not match

L5

Potentiometer signal and switch signal do not match

L6

Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch, etc. do not match operating condition or stopped condition of machine

L8

Analog signals for 2 systems do not match

LC

Speed signals for 2 systems do not match

LH

Fill signal is OFF when command current to ECMV is ON

a Failure codes with ( ) These failure codes are not recorded as fault history for either the electrical system or the mechanical system. a Controller codes and troubleshooting mode names The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting section are linked, so check the controller code for the failure code displayed, then go to the applicable troubleshooting mode. ENG: Troubleshooting of engine controller system (ENG MODE) TM: Troubleshooting of transmission controller system (TM MODE) BK: Troubleshooting of retarder controller system (BK MODE) MON: Troubleshooting of machine monitor system (MON MODE) VHMS: Troubleshooting for VHMS controller system (including payload meter system in VHMS) (VHMS mode)

20-174 (10)

HD465-7, HD605-7



Procedure for switching to Service mode and screen display a When using Service mode, carry out the following special operation to switch the screen display. 1) Checking screen display With the machine monitor in the operator mode, check that the screen is one of the following displays: Service meter/odometer, action code, or failure code. 2) Initial screen display for ID input Press the following 2 buttons at the same time for at least 5 seconds to display the initial screen display for the ID input (Fig. 1). • [t] button and [<] button a If the buttons are held pressed for at least 5 sec, the whole screen will give no display, so check this condition, then release the buttons. 3) Inputting ID, confirming Operate the buttons to input the ID (Fig. 2). a ID: 6491 • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to initial screen (see Note) Note: When the cursor is at the left side, the screen returns to the normal screen (operator mode). If the cursor is not at the left side, the cursor returns to the left side. a If the switch on the ID input screen is not operated for more than 60 seconds, the screen returns automatically to the normal screen. 4) Displaying menu initial screen After confirming all four digits of the ID, the menu initial screen of Service mode is displayed (Fig. 3). a Once the ID has been input and confirmed, it remains effective until the starting switch is turned OFF.

HD465-7, HD605-7

20-175 (9)



5) Menu selection in Service mode Press the [>] or [<] buttons on the menu screen and the menus of Service mode are displayed endlessly in the following order (Fig. 4). a The menu is displayed in the places marked with [*]. • [>] button: Goes on to next menu • [<] button: Goes back to previous menu (1) ELECTRICAL FAULT: Fault history display function for electrical system (2) MACHINE FAULT: Fault history display function for mechanical system (3) REAL-TIME MONITOR: Machine data monitoring function (4) CYLINDER CUT-OUT: Reduced cylinder mode (5) TUNING: Adjustment function (6) MAINTENANCE MONITOR: Filter, oil replacement time setting function (7) INITIALIZE: Initialize function (exclusive function for factory) 6) Completion of mode, function When operating at any point in any function, it is possible to finish the mode or function by using any of the following methods. (1) When continuing operations in another mode or function: Press the [t] button and return to the mode screen to be used or menu screen to be used. a Note that if the [t] button is pressed on the YES/NO screen, the function will be executed. a If you return to the normal screen (operator mode) by mistake, repeat the procedure from Step 1) above (there is no need to input the ID again). (2) When completing all operations: Turn the starting switch OFF.

20-176 (10)

HD465-7, HD605-7



9. Electrical system fault history display function (ELECTRIC FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. 1). a The total number of fault history items recorded in memory is displayed in the [ ] portion. 2) Fault history display With the menu selected, press the [ ] button and display the fault history recorded in memory (Fig. 2: example). • [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the electrical system, the following data can be displayed (Fig. 3). 1: Record number (recorded up to a maximum of 20 items) A: Failure code (4-digit location code + 2-digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. a For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. a Note that with the fault history display function and failure code display function for the electrical system, the displayed data are partially different. a If no fault history are recorded, [0] is displayed on the display portion for 1, and [–] is displayed on the display portion for A, 2, 3, and 4.

HD465-7, HD605-7

20-177 (10)



4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history, the display switches to the other recorded fault history. • [>] button: Goes on to data for next record number • [<] button: Goes back to data for last record number 5) Deleting individual fault history i) Display the fault history to be deleted, then press the [ ] button once to display the individual item CLEAR screen (Fig. 4). • [ ] button: Display CLEAR screen ii) Operate the buttons according to the explanation on the screen (Fig. 4). • [<] button: Select YES • [>] button: Select NO • [t] button: Run a The data for an existing problem (flashing display) cannot be deleted. 6) Deleting all fault history i) Display the fault history, then press the [>] button or [<] button to display the ALL CLEAR menu (Fig. 5). ii) Press the [ ] button once to display the ALL CLEAR screen (Fig. 6). • [ ] button: Run ALL CLEAR menu iii) Operate the buttons according to the explanation on the screen (Fig. 6). • [<] button: Select YES • [>] button: Select NO • [t] button: Run a The data for an existing problem (flashing display) cannot be deleted.

20-178 (10)

HD465-7, HD605-7



10. Mechanical system fault history display function (MACHINE FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. They can be displayed as follows. 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. 1). a The total number of fault history items recorded in memory is displayed in the [**] portion. 2) Fault history display With the menu selected, press the [ ] button and display the fault history recorded in memory (Fig. 2: example). • [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the mechanical system, the following data can be displayed (Fig. 3). 1: Record number A: Failure code (4-digit location code + 2digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. a For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display function. a Note that with the fault history display function and failure code display function for the mechanical system, the displayed data are partially different. a If no fault history are recorded, [0] is displayed on the display portion for 1, and [–] is displayed on the display portion for A, 2, 3, and 4.

HD465-7, HD605-7

20-179 (10)



4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history, the display switches to the other recorded fault history. • [>] button: Goes on to data for next record number • [<] button: Goes back to data for last record number 5) Deleting fault history (not permitted) a The fault history for the mechanical system cannot be deleted.

20-180 (10)

HD465-7, HD605-7



11. Machine data monitoring function (REALTIME MONITOR) The machine monitor can monitor the condition of the machine in real time through the signals from the sensors installed to various parts of the machine. In the machine data monitoring function, the following 2 types of display can be shown. • 1st item independent display (for each controller) • 2nd item simultaneous display (code input) 1) Menu selection Select the machine data monitoring function on the menu screen of Service mode (Fig. 1). 2) Display sub menu With the menu selected, press the [ ] button and display the initial screen of the sub menu (Fig. 2). • [ ] button: Runs menu 3) Select sub menu If the [>] button or [<] button is pressed on the sub menu screen, the sub menu displays endlessly in the following order (Fig. 3). a The sub menu is displayed in the [*] portion. • [>] button: Goes on to next menu • [<] button: Goes back to last menu (1) MONITOR PANEL: Machine monitor system (2) TRANSMISSION: Transmission controller system (3) ENGINE: Engine controller system (4) BRAKE: Retarder controller system (5) 2 ITEMS: 2-item display

HD465-7, HD605-7

20-181 (10)



4) Setting 1st item individual monitoring i) Select the controller system for monitoring on the sub menu screen (Fig. 4: example). ii) With the menu selected, press the [ ] button and display the monitoring data initial screen. • [ ] button: Runs sub menu iii) Press the [>] button or [<] button to select the item for monitoring (Fig. 5: example). • [>] button: Goes on to next item • [<] button: Goes back to last item a Scroll the monitoring items to display in the internally set order. a If the button is kept pressed, the items will scroll at high speed. a To hold or cancel monitoring data: If the [ ] button is pressed during monitoring, the monitor data is held and the [ ] mark flashes. If the [ ] button is pressed again, it becomes active again. 5) Display data for 1st item individual monitoring On the 1st item individual monitoring screen, the following data are displayed (Fig. 6). A: Item display B: Monitoring code (5-digit) 1: Monitoring data (including unit) a For details, see MONITORING CODE TABLE.

20-182 (10)

HD465-7, HD605-7



6) Setting 2nd item simultaneous monitoring i) Select the 2nd item display on the sub menu screen (Fig. 6). ii) With the menu selected, press the [ ] button and display the monitoring code input screen (Fig. 7). • [ ] button: Runs sub menu

iii) Operate each button and input the monitoring code for the 2nd monitoring item directly. • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to code input screen

iv) When both of the monitoring codes have been confirmed, the screen switches to the 2nd item display screen (Fig. 9: example). a To hold or cancel monitoring data: If the [ ] button is pressed during monitoring, the monitor data is held and the [ ] mark flashes. If the [ ] button is pressed again, it becomes active again.

7) Display data for 2nd item simultaneous monitoring On the 2nd item simultaneous monitoring screen, the following data are displayed (Fig. 10). A: Monitoring code 1 1: Monitoring data 1 (including unit) B: Monitoring code 2 2: Monitoring data 2 (including unit) a For details, see MONITORING CODE TABLE.

HD465-7, HD605-7

20-183 (1)



Monitoring Code Table MONITOR PANEL (Monitor panel system) Monitoring item

No.

Item display

Monitoring code

Display range

Unit

1

Engine speed

ENG SPEED

01001

0 – 65535

rpm

2

Engine coolant temperature (for high temperature)

COOLANT TEMP H

04104

0 – 160

°C

3

Torque converter oil temperature

T/C OIL TEMP

30100

0 – 160

°C

4

Brake oil temperature

BRAKE OIL TEMP

30200

0 – 160

°C

5

Fuel level sensor input resistance value

FUEL SENSOR

04201

0 – 150

z

6

Rheostat input voltage

RHEOSTAT

30300

0.0 – 51.0

V

7

Operation status of front brake cut-out switch

F BK CUT SW

37600

ON/OFF

Status display

8

Operation status of ARSC switch

ARSC SW

37700

ON/OFF

Status display

9

(Operation status of ABS switch)

ABS SW

37800

ON/OFF

Status display

10 (Operation status of ASR switch)

ASR SW

37900

ON/OFF

Status display

11 Input status of connector check (1 & 2)

CONN CHK 1, 2

30700

12 Setting status of rotary switch (SW1 & SW2 & SW3)

SW1, SW2, SW3

30800

13 Setting status of dip switch (SW5-1 & SW5-2)

SW5-1, SW5-2

30900

ON/OFF, ON/OFF Status display


SW5-3, SW5-4

30901



SW6-1, SW6-2

30902



SW6-3, SW6-4

30903


17 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2

31000



31001



31002


ON/OFF, ON/OFF Status display 0 – F, 0 – F, 0 – F,

Status display

a Note: The following monitoring items display data for 2 or 3 systems at the same time. • No. 11: Input status of connector check (displays 2 items) • No. 12: Setting status of rotary switch (displays 3 items at same time) • No. 13: Setting status of dipswitch (displays 2 items at same time) • No. 14: Setting status of dipswitch (displays 2 items at same time) • No. 15: Setting status of dipswitch (displays 2 items at same time) • No. 16: Setting status of dipswitch (displays 2 items at same time) • No. 17: Setting status of option selection connector (displays 2 items at same time) • No. 18: Setting status of option selection connector (displays 2 items at same time) • No. 19: Setting status of option selection connector (displays 2 items at same time)

20-184 (10)

HD465-7, HD605-7



TRANSMISSION (Transmission controller system) Monitoring item

No.

Item display

Monitoring code

Display range

Unit

1

Transmission service meter

SERVICE METER

31100

0 – 65535

h

2

Transmission input shaft speed

T/M SPEED: IN

31200

0 – 65535

rpm

3

Transmission intermediate shaft speed

T/M SPEED: MID

31300

0 – 65535

rpm

4

Transmission output shaft speed

T/M SPEED: OUT

31400

0 – 65535

rpm

5

Operation status of fill switch for Lo clutch

FILL SW (L)

31510

ON/OFF

Status display

6

Operation status of fill switch for Hi clutch

FILL SW (H)

31511

ON/OFF

Status display

7

Operation status of fill switch for 1st clutch

FILL SW (1st)

31512

ON/OFF

Status display

8

Operation status of fill switch for 2nd clutch

FILL SW (2nd)

31513

ON/OFF

Status display

9

Operation status of fill switch for 3rd clutch

FILL SW (3rd)

31514

ON/OFF

Status display

10 Operation status of fill switch for 4th clutch

FILL SW (4th)

31515

ON/OFF

Status display

11 Operation status of fill switch for R clutch

FILL SW (R)

31516

ON/OFF

Status display

12 Operation status of fill switch for lockup clutch

FILL SW (L/U)

31519

ON/OFF

Status display

13 Command value of solenoid output current for Hi clutch

ECMV H DIR

31600

0 – 1020

mA

14 Sensed value of solenoid output current for Hi clutch

ECMV H

31610

0 – 1020

mA

15 Command value of solenoid output current for Lo clutch

ECMV L DIR

31601

0 – 1020

mA

16 Sensed value of solenoid output current for Lo clutch

ECMV L

31611

0 – 1020

mA

17 Command value of solenoid output current for 1st clutch

ECMV 1 DIR

31602

0 – 1020

mA

18 Sensed value of solenoid output current for 1st clutch

ECMV 1

31612

0 – 1020

mA

19 Command value of solenoid output current for 2nd clutch

ECMV 2 DIR

31603

0 – 1020

mA

20 Sensed value of solenoid output current for 2nd clutch

ECMV 2

31613

0 – 1020

mA

21 Command value of solenoid output current for 3rd clutch

ECMV 3 DIR

31604

0 – 1020

mA

22 Sensed value of solenoid output current for 3rd clutch

ECMV 3

31614

0 – 1020

mA

23 Command value of solenoid output current for 4th clutch

ECMV 4 DIR

31605

0 – 1020

mA

24 Sensed value of solenoid output current for 4th clutch

ECMV 4

31615

0 – 1020

mA

25 Command value of solenoid output current for R clutch

ECMV R DIR

31606

0 – 1020

mA

26 Sensed value of solenoid output current for R clutch

ECMV R

31616

0 – 1020

mA

value of solenoid output current for lockup 27 Command clutch

ECMV LU DIR

31609

0 – 1020

mA

28 Sensed value of solenoid output current for lockup clutch

ECMV LU

31619

0 – 1020

mA

29 Fill time of Hi clutch

FILL TIME H

41801

0 – 2550

ms

30 Fill time of Lo clutch

FILL TIME L

41800

0 – 2550

ms

31 Fill time of R clutch

FILL TIME R

41806

0 – 2550

ms

32 Fill time of 1st clutch

FILL TIME 1

41802

0 – 2550

ms

HD465-7, HD605-7

20-185 (10)



No.

Monitoring item

Item display

Monitoring code

Display range

Unit

33 Fill time of 2nd clutch

FILL TIME 2

41803

0 – 2550

ms

34 Fill time of 3rd clutch

FILL TIME 3

41804

0 – 2550

ms

35 Fill time of 4th clutch

FILL TIME 4

41805

0 – 2550

ms

36 Fill status of Hi clutch

FILL H

31501

0–2

Status display

37 Fill status of Lo clutch

FILL L

31500

0–2

Status display

38 Fill status of R clutch

FILL R

31506

0–2

Status display

39 Fill status of 1st clutch

FILL 1

31502

0–2

Status display

40 Fill status of 2nd clutch

FILL 2

31503

0–2

Status display

41 Fill status of 3rd clutch

FILL 3

31504

0–2

Status display

42 Fill status of 4th clutch

FILL 4

31505

0–2

Status display

43 Input voltage of acceleration sensor

THROTTLE POS

31700

0.00 – 5.10

V

44 Operation status of emergency steering (1 & 2)

ENERG STRG 1,2

32100

45 Input status of alternator terminal R

ALTERNATOR R

04301

ON/OFF

Status display

46 Input status of starting switch terminal C

KEY SW C

32300

ON/OFF

Status display

47 Setting status of emergency escape switch

ENERG TRAVEL

32400

ON/OFF

Status display

48 ECMV oil temperature

ECMV OIL TEMP

32500

0 – 160

°C

49 Torque converter oil pressure

T/C OIL PRESS

32600

0.00 – 5.02

MPa

50 Steering oil temperature

STRG OIL TEMP

32700

51 Output status of overrun prevention brake

OVERRUN BK DIR

35001

ON/OFF

Status display

52 Output status of DROOP MODE 2 (P/E)

DROOP MODE 2

38100

ON/OFF

Status display

53 Connector check input status (1 & 2)

CONN CHK 1,2

30701


54 Hydraulic tank level

HYD OIL LEVEL

33000

LOW/NORMAL Status display

55 Engine oil tank level

ENG OIL LEVEL

38200


56 Transmission oil tank level

TM OIL LEVEL

38300


57 Electrolyte level

BATT LIQ LEVEL

40302


58 Radiator coolant level

COOLANT LEVEL

33100


59 Clogging status of air cleaner

AIR CLEANER

33200

60 Clogging status of transmission filter

T/M FILTER

33300

61 Clogging status of hydraulic oil filter

HYD OIL FILTER

33400

CLOGGED/NOR- Status display MAL CLOGGED/NORStatus display MAL CLOGGED/NOR- Status display MAL

62 Clogging status of engine oil filter

ENG OIL FILTER

38400

CLOGGED/NOR- Status display MAL

63 Judgment of acceleration at gear shifting point

ACCELERATON

38500

QUICK/NRMAL Status display

64 Holding status of skip-shift

TM SKIP SHIFT

38600

KEEP/NORMAL Status display

65 Gear shift mode status

TM SHIFT MODE

38700

20-186 (10)


OVERHEAT/NORStatus display MAL

0–F

Status display

HD465-7, HD605-7



Item display

Monitoring code

Display range

Unit

66 Setting status of rotary switch (SW1 & SW2)

ROTARY SW 1,2

30801

0 – F, 0 – F

Status display

67 Input status of model select wiring harness 1

MACHINE SEL1

02701

GND/OPEN

Status display


MACHINE SEL2

02702

GND/OPEN

Status display


MACHINE SEL3

02703

GND/OPEN

Status display

70 1st update status for model rotary switch

TM STATE CHECK

38800

00 – FF

Status display

71 Correction value of Hi clutch trigger

TRIGER MOD H

38901

00000000 – FFFFFFFF Status display

72 Correction value of Lo clutch trigger

TRIGER MOD L

38900


73 Correction value of 1st clutch trigger

TRIGER MOD 1

38902


74 Correction value of 2nd clutch trigger

TRIGER MOD 2

38903


75 Correction value of 3rd clutch trigger

TRIGER MOD 3

38904


76 Correction value of 4th clutch trigger

TRIGER MOD 4

38905


77 Correction value of R clutch trigger

TRIGER MOD R

38906


No.

Monitoring item

78 Part No. of software (For main CPU)

79 Part No. of software (For sub-CPU)

TRANSM ROM 1

TRANSM ROM 2

20204

XXXXRYYY [3rd – 10th digits of part No. from left are displayed] Example: If part No. is 7831-46R110, 3146R110 is displayed.

Status display

20205


Status display

a Note: The following monitoring items display data for 2 systems at the same time. • No. 44: Actuation condition of emergency steering (displays 2 systems at same time) • No. 53: Input status of connector check (displays 2 systems at same time) • No. 66: Setting status of rotary switch (displays 2 items at same time)

HD465-7, HD605-7

20-187 (10)



ENGINE (Engine controller system) Monitoring item

No.

Item display

Monitoring code

Display range

Unit

1

Engine speed

ENG SPEED

01002

0 – 8032

rpm

2

Opening rate of acceleration sensor

THROTTLE POS

31701

0.0 – 100

%

3

Fuel temperature

FUEL TEMP

04203

-40 – 210

°C

4

Fuel (rail) pressure

METRING PRESS

37000

0.00 – 9.99

MPa

5

Fuel consumption

FUEL RATE

37300

0.0 – 999.9

L/h

6

Timing rail pressure

TIMING PRESS

37100

0.00 – 9.99

MPa

7

Boost pressure

BOOST PRESS

36500

0 – 300

kPa

8

Engine coolant temperature

COOLANT TEMP

04104

-40 – 210

°C

9

Engine oil pressure

ENG OIL PRESS

37200

0 – 1000

kPa

10 Temperature in intake manifold

AIR TEMP

37500

-273.0 – 1735.0

°C

11 Atmospheric pressure

AIR PRESS

37400

0.0 – 125.0

kPa

20-188 (10)

HD465-7, HD605-7



BRAKE (Retarder controller system)

Monitoring item

No.

Item display

Monitoring code

Display range

Unit

1

Brake service meter

SERVICE METER

31101

0 - 65535

h

2

Command value of rear retarder EPC solenoid output current

F BK OUTP DIR

33800

0 – 1020

mA

3

Sensed value of rear retarder EPC solenoid output current F BRAKE OUTPUT

33801

0 – 1020

mA

4

Retarder lever input (Voltage & conversion quantity)

RETARD LEVER

33900

0.00 – 5.10 (0 – 100)

V (%)

5

Input status of retarder lever validation switch (1 & 2)

RLV SW 1,2

34000

6

Operation status of retarder lever switch

RETARDER

34100

WORKING/ RELEASE

Status display

7

Input voltage of dump lever potentiometer 1

DUMP LEVER 1

34300

0.00 – 5.10

V

8

Input voltage of dump lever potentiometer 2

DUMP LEVER 2

34301

0.00 – 5.10

V

9

Input voltage of body positioner sensor

BODY POSITION

34400

0.00 – 5.10

V

10 Input status of body seating switch

BODY SEATING

34600

ON/OFF

Status display

11 Output status of dump lever kick-out solenoid

KICKOUT SOL

34700

ON/OFF

Status display

12 Output status of dump select solenoid

SWV FOR HOIST

34800

ON/OFF

Status display

13 Command value of dump EPC solenoid output current EPC HOIST DIR

34900

0 – 1020

mA

14 Output current detection value for dump EPC solenoid EPC HOIST

34901

0 – 1020

mA

15 Input status of overran command

OVERRUN SIG

35000

ON/OFF

Status display

16 Input status of service brake oil pressure switch

SERVICE BRAKE

35100

ON/OFF

Status display

17 Input status of starting switch terminal C

KEY SW C

32300

ON/OFF

Status display

18 Connector check input status (1 & 2)

CONN CHK 1,2

30702

19 Front accumulator oil pressure

ACC OIL PRE F

35500

0.00 – 50.26

MPa

20 Rear accumulator oil pressure

ACC OIL PRE R

35501

0.00 – 50.26

MPa

21 Clogging status of brake cooling filter

RETARD FILTER

35700

22 Inclination angle switch

INCLINATION SW

39000

ON/OFF

Status display

23 Command of front brake cut

FBK CUT DIR

39100

ON/OFF

Status display

24 Hoist lower pressure

HOIST PRESS

34501

0.00 – 50.26

MPa

25 Auto suspension mode

AUTO SUS MODE

39200

26 Auto suspension solenoid 1 output

AUTO SUS DIR 1

39300

ON/OFF

Status display

27 Auto suspension solenoid 2 output

AUTO SUS DIR 2

39301

ON/OFF

Status display

28 Front suspension pressure (right)

SUS PRESS (FR)

32802

0.00 – 20.10

MPa

29 Front suspension pressure (left)

SUS PRESS (FL)

32803

0.00 – 20.10

MPa

30 Judgment of load

EMPTY OR LOAD

39400

EMPTY/LOAD

Status display

31 Accelerator sensor

THROTTLE POS

31704

0.00 – 3.10

V

32 Travel speed set with ARSC switch

ARSC SET SP SW

37701

0.00 – 3.10

V

HD465-7, HD605-7



CLOGGED/NORStatus display MAL

MEDIUM/SOFT/ Status display HARD

20-189 (10)



BRAKE [Retarder controller system] No.

Monitoring item

Item display

Monitoring code

Display range

Unit

33 ARSC command

ARSC STATUS

39500

ON/OFF

Status display

34 Travel speed set with ARSC

ARSC SET SPEED

39501

0 – 255

km/h

35 ASR command

ASR STATE

39600

ON/OFF

Status display

36 (ASR output (L) (Command value))

ASR OUTP DIR L

39601

0 – 1020

mA

37 (ASR output (L) (Sensed value))

ASR OUTPUT (L)

39602

0 – 1020

mA

38 (ASR output (R) (Command value))

ASR OUTP DIR R

39603

0 – 1020

mA

39 (ASR output (R) (Sensed value))

ASR OUTPUT (R)

39604

0 – 1020

mA

40 (ASR switch (R))

ASR SW (R)

39605

ON/OFF

Status display

41 (ASR switch (L))

ASR SW (L)

39606

ON/OFF

Status display

42 Steering angle

STRG ANGLE

35400

0.00 – 5.10

V

43 Steering angle speed

STRG ANG SPEED WHEEL SPEED RL WHEEL SPEED RR

35401

0.0 – 99.99

rad/s

39700

0.0 – 65535

rpm

39701

0.0 – 65535 [0000 – FFFF]

rpm

20206


Status display

20207


Status display

44 Wheel speed (RL) 45 Wheel speed (RR)

46 Part No. of software (For main CPU)

47 Part No. of software (For sub-CPU)

BRAKE ROM 1

BRAKE ROM 2

a Note: The following monitoring items display data for 2 systems at the same time. • No. 4: Retarder lever input (displays 2 types at same time; does not display unit for conversion %) • No. 5: Input status of retarder lever validation switch (displays 2 systems at same time) • No. 18: Connector check input status (displays 2 systems at same time)

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VHMS (VHMS controller system)

Monitoring item

No.

Item display

Monitoring code

Display range

Unit

1

Exhaust temperature (F)

EXHAUST TEMP F

42600

200 – 950

°C

2

Exhaust temperature (R)

EXHAUST TEMP R

42601

200 – 950

°C

3

Engine oil temperature

ENG OIL TEMP

42700

0 – +180

°C

4

Ambient temperature

AIR TEMP

37501

-30 – +100

°C

5

Blow-by pressure

BLOW PRESS

42800

0.0 – 20.0

kPa

6

Payload

PAYLOAD

42200

t (metric ton or short ton)

7

Suspension pressure (FR)

SUS PRESS (FR)

32804

8

Suspension pressure (FL)

SUS PRESS (FL)

32805

9

Suspension pressure (RR)

SUS PRESS (RR)

32806

10 Suspension pressure (RL)

SUS PRESS (RL)

32807

11 Angle sensor

INCLINOMETER

32901

12 FLOAT signal

FLOAT SIG

42300

13 Gearshift lever N signal

SHIFT LEVER N

42500

14 Machine status

TRUCK STATUS

42400

0.0 – 6553.5 – – – – (*) 0.0 – 20.10 – – – – (*) 0.0 – 20.10 – – – – (*) 0.0 – 20.10 – – – – (*) 0.0 – 20.10 – – – – (*) -0.42 – +0.44 – – – – (*) ON/OFF – – – – (*) ON/OFF – – – – (*) 0–8 – – – – (*)

MPa MPa MPa MPa rad Status display Status display Status display

a The (*) mark in the data display range column shows the case when the PLM is not set up.

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12. Adjustment function (TUNING) Through the transmission controller, the machine monitor can carry out the the adjustment function to correct the difference in operating feeling to a constant level caused by the the individual differences in the ECMV. It can also carry out the selfadjusting learning function so that a constant gearshifting feeling is maintained in accordance with the wear of the transmission clutch. When the following operations related to the power train have been carried out, perform the adjustments. • When the transmission has been overhauled or replaced • When the transmission valve has been replaced • When the transmission controller has been replaced • When an abnormality has occurred in the power train speed sensor and it has been repaired (for details, see the failure code in the chart on the right) • When an abnormality has occurred in the transmission oil temperature sensor and it has been repaired (for details, see the failure code in the chart on the right) • When the transmission oil filter has become clogged and it has been repaired (for details, see the failure code in the chart on the right)


Failure code DLF1KA DLF1LC DLF2KA DLF2LC DLT3KA DLT3LC

Component name Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission output shaft R speed sensor

DGF1KA


15B0NA

Transmission oil filter

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

HD465-7, HD605-7

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Preparatory work: Adjusting ECMV oil temperature a It is necessary to carry out the adjustment operation at the specified oil temperature, so check that there is no abnormality on the machine and adjust the ECMV oil temperature as follows. 1) Start the engine. 2) Display [ECMV oil temperature] with machine data monitoring function. (Fig. 1). • TRANSMISSION No. 48

the

3) Raise ECMV oil temperature to 70 – 80°C by raising engine speed. 4) Keep engine speed in low idle for 3 minutes. Before carrying out adjustment, be sure to check that ECMV oil temperature is kept within 70 – 80°C.

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Adjustment operation (1): Adjusting individual difference of valve a See Preparatory work and check that the ECMV oil temperature is at the specified temperature. a The adjustment operation is carried out automatically four times for the Lo, Hi, R, 1st, 2nd, 3rd and 4th valves. 1) Set the machine to the following conditions. • Parking brake switch: PARKING • AISS LOW switch: LOW • Gearshift lever: N position • Engine: Low idle • Accelerator pedal: OFF (released) 2) Operate the machine monitor and display the adjustment menu screen (Fig. 4). • Adjustment menu: 02: ECMV TUNING AUTO 3) Check the condition of the machine again, press the [ ] button, and start the adjustment operation (Fig. 5). • [ ] button: Runs adjustment menu a The adjustment is carried out consecutively four times for the applicable clutches and displays a screen like the one shown on the right. a For each adjustment operation, the result is displayed as normal or abnormal, so take action according to the display (Fig. 6). • If [4-4 OK] is displayed: The adjustment operation has been completed correctly. (When the starting switch is turned OFF, the adjusted value is recorded in the controller.) • If [NG 1] (Outside compensation condition) is displayed: Adjust the ECMV oil temperature correctly, check the set conditions of the machine again, then repeat from Step 1). • If [NG 2] (No fill) is displayed: Carry out troubleshooting for failure codes [15S[ ]MA] [DDT[ ]KA], and if it is found to be normal, repeat from Step 1). • If [NG 3] (Compensation value over] is displayed: Carry out troubleshooting for failure code [15S[ ]L1], and if it is found to be normal, repeat from Step 1).

HD465-7, HD605-7


No.

Valve

1st time 2nd time 3rd time 4th time

1

Lo

IP L-1

IP L-2

IP L-3

IP L-4

2

Hi

IP H-1

IP H-2

IP H-3

IP H-4

3

R

IP R-1

IP R-2

IP R-3

IP R-4

4

1st

IP 1-1

IP 1-2

IP 1-3

IP 1-4

5

2nd

IP 2-1

IP 2-2

IP 2-3

IP 2-4

6

3rd

IP 3-1

IP 3-2

IP 3-3

IP 3-4

7

4th

IP 4-1

IP 4-2

IP 4-3

IP 4-4

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Adjustment operation (2): Resetting gearshifting feeling stabilized learning data 1) Operate the machine monitor and display the initial menu screen (Fig. 7). • Initial menu: 01: TM TRIGGER a The present initial status is displayed on the bottom line of the screen. • Initializing completed: INITIAL STATUS • Initializing not performed: TUNED a With the transmission adjustment, the learning data is initialized from the following operation, regardless of the present initial status. 2) With the menu selected, press the [ ] button and display the initial screen of the sub menu (Fig. 7). • [ ] button: Runs initialize menu 3) Operate the buttons according to the screen display (Fig. 8). • [<] button: Select YES • [>] button: Select NO • [t] button: Run a After carrying out initializing, check that INITIAL STATUS is displayed on the bottom line of the screen.

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Adjustment work (3): Initial learning of stabilization of gear shifting feel a Referring to PREPARATION WORK, check that the ECMV oil is at the specified temperature. Perform the adjustment work in a place wide sufficiently for travel, taking care of the safety around the machine. a When performing the adjustment work by driving the vehicle actually, perform it on finished flat ground, as long as possible. 1) Display R CLUTCH FILL STATE with the machine monitoring function (Fig. 10). • No. 38 of TRANSMISSION FILL R: Fill state of R clutch 2) Run the engine at low idle and hold the gearshift lever in the N position for 10 seconds, and then operate the gearshift lever in the following order. a Operation of gearshift lever: N o R o N 3) Check the fill state with the monitoring display. a If "0" is displayed, go the next step. a If "1" is displayed, repeat step 2) until "0" is displayed. a After Step 2) is repeated 3 times, if "0" is still not displayed, display R CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 250 msec or shorter, go to 4). (2) If the fill time is 900 msec or longer, return to 1) and repeat step 2) until the fill state of the R clutch becomes "0". • No. 31 of TRANSMISSION • FILL TIME R: Fill time of R clutch (Fig. 11) a If the above condition is still not satisfied after the steps are repeated 5 times, the ECMV may be defective. In this case, replace the ECMV.

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4) Set the gearshift lever in the 6 position. Run the engine at full throttle and shift up the gear to F6. 5) Drive the machine in F6 for 10 seconds, and then release the accelerator pedal and shift down the gear to F1 by coasting run. a Shifting down: F6 o F5 o F4 o F3 o F2 o F1 a Do not operate the brake during coasting run. 6) Display 4TH CLUTCH FILL STATE, 2nd CLUTCH FILL STATE, and 1st CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. 12, Fig. 13, and Fig. 14). • No. 42 of TRANSMISSION FILL 4: Fill state of 4th clutch • No. 40 of TRANSMISSION FILL 2: Fill state of 2nd clutch • No. 39 of TRANSMISSION FILL 1: Fill state of 1st clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 4) and 5) until "0" is displayed for the all clutches. a After steps 4) and 5) are repeated 3 times, if "0" is still not displayed as the fill state of the 1st clutch, display 1ST CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 250 msec or shorter, go to 7). (2) If the fill time is 550 msec or longer, return to 4) and repeat steps 4) and 5) until the fill state of the 1st clutch becomes "0". • No. 32 of TRANSMISSION FILL TIME 1: Fill time of 1st clutch (Fig. 15) a If the above condition is still not satisfied after the steps are repeated 6 times, the ECMV may be defective. In this case, replace the ECMV.

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HD465-7, HD605-7



7) Set the gearshift lever in the 3 position. Run the engine at full throttle and shift up the gear to F3. 8) Stop the machine and display HI CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 16). • No. 36 of TRANSMISSION FILL H: Fill state of Hi clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 7) and 8) until "0" is displayed. a After steps 7) and 8) are repeated 3 times, if "0" is still not displayed as the fill state of the Hi clutch, display HI CLUTCH FILL TIME with the machine monitoring function. (1) If the fill time is 200 msec or shorter, go to 9). (2) If the fill time is 550 msec or longer, return to 7) and repeat steps 7) and 8) until the fill state of the Hi clutch becomes "0". • No. 29 of TRANSMISSION FILL TIME H: Fill time of Hi clutch (Fig. 17) a If the above condition is still not satisfied after the steps are repeated 5 times, the ECMV may be defective. In this case, replace the ECMV.

HD465-7, HD605-7

20-195-2 (7)



9) Display LO CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 18). • No. 37 of TRANSMISSION FILL L: Fill state of Lo clutch 10) Set the gearshift lever in the 4 position. Run the engine at full throttle and shift up the gear to F3. a Take care not to shift up the gear to F4. If the gear has been shifted to F4, repeat the step from starting. 11) Drive the machine in F3 for 5 seconds, and then shift up the gear to F4 with the engine at full throttle. 12) While the machine is traveling in F4, press control switch [U] to keep displaying the machine monitoring function. 13) Stop the machine and display LO CLUTCH FILL STATE and 3RD CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. 19). a Judge the fill state of the Lo clutch by the value displayed and held during travel at F4. Once holding is reset, the value is updated. • No. 41 of TRANSMISSION FILL 3: Fill state of 3rd clutch a If "0" is displayed, correction is completed. a If "1" is displayed, repeat steps 9) – 13) until "0" is displayed for both clutches. a After steps 9) – 13) are repeated 6 times, if "0" is still not displayed, the ECMV may be defective. In this case, replace the ECMV. a The display keeping function of the machine monitoring function is reset automatically when any switch is operated. a If the starting switch is turned OFF or control switch [t] is pressed 3 times, the machine monitoring function screen disappears and the ordinary screen appears.

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HD465-7, HD605-7



13. Filter, oil replacement time setting function (MAINTENANCE MONITOR) The machine monitor can set the maintenance interval for filters and oil, which form the base for the filter and oil replacement time and display. 1) Menu selection Select Filter, oil replacement time setting function on the menu screen of Service mode (Fig. 1). 2) Selecting filter, oil replacement time setting item i) With the menu selected, press the [ ] button and display the initial screen of the set item (Fig. 2). • [ ] button: Runs menu ii) Press the [>] or [<] buttons to select the item to be set. • [>] button: Goes on to next item • [<] button: Goes back to last item a The set items are displayed endlessly in the internal set order (for details, see Table of filter and oil replacement time set items). 3) If the maintenance items in the display for the filter and oil replacement time set items are selected, the following content is displayed (Fig. 3). 1: Code (2 digits) A: Filter and oil replacement time set items 2: Remaining time to set replacement time 3: Number of times of replacement up to present 4) Changing replacement interval i) With the set items selected, press the [ ] button and display the interval input screen (Fig. 4: example). • [ ] button: Executes change function a The presently set interval is displayed on the screen.

20-196 (9)

HD465-7, HD605-7



i)

ii)

Operate the buttons to input the interval (Fig. 4). • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to item selection screen a The time must always be input with four digits. For numbers of less than four digits, input 0s at the beginning. When all the interval times are confirmed, the change confirmation screen is displayed, so operate the buttons according to the screen display (Fig. 5). • [<] button: Select YES • [>] button: Select NO • [t] button: Run

Table of filter and oil replacement time set items No.

Item

Code

Display

Replacement time

1

Fuel filter

03

FUEL FILT

0500

2

Engine oil filter

02

ENG FILT

0500

3

Engine oil

01

ENG OIL

0500

4

Transmission oil filter

13

TM FILT

0500

5

Corrosion resistor

06

CORR RES

1000

6

Torque convertor, transmission, brake oil

24

TC/TM/BK OIL

1000

7

Brake oil filter

14

BK OIL FIL

1000

8

Brake cooling oil filter

16

BK C FIL

1000

9

Hydraulic filter

04

HYD FILT

2000

10

Differential case oil

11

DIFF OIL

2000

11

Final drive oil

08

FNL OIL

2000

12

Hydraulic oil

10

HYD OIL

4000

HD465-7, HD605-7

20-197 (1)



14. Snap shot function a For this function, see "Execution of PM clinic using manual snap shot (Another name: Quick PM)" (Drawing No. WJ021D060) (Fig. 1).

15. PLM setting function a This function is applied to "PLM having VHMS" (only when the option is set). • Various items of the "PLM having VHMS" are displayed and set with this function.

1) Setting of travel distance to recognize completion of loading Input a travel distance to recognize completion of loading by pressing the following buttons (Fig. 3). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Stop inputting number. a The setting range is 0 – 255 m (0.0 – 0.158 miles). If the set value is too small, the system may recognize that loading is completed while the dump truck is still being loaded. 2) Correction of calculation of payload Since this function affects the accuracy directly, execute the following procedure securely. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. Accordingly, secure travel distance for this purpose.

20-197-1 (10)

HD465-7, HD605-7


i)

ii)


The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment. Accordingly, perform the following procedure very carefully. This function is used to match the calculation result to the indication of the load meter to be used. It does not always heighten the absolute accuracy. Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper, etc.) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. (1) Select "EMPTY WEIGHT" (Fig. 4). • [>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". • [U] button: Enter the selection. (After selecting, go to Fig. 5.) • [t] button: Return to the previous screen. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected (See Fig. 11). • Check the unit of the input value. a The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC) --- metric ton (SHORT) ---- short ton (2) Check that measurement of the weight of the empty dump truck has been completed. a Display on the screen (Fig. 5) • [U] button: Check that measurement has been completed and go to the next step. • [t] button: Return to the previous screen.

HD465-7, HD605-7

20-197-2 (5)



(3) Input the measured weight of the empty dump truck (Fig. 6). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. a Inputtable range HD465-7: 43.6 [t] (Operating weight) ± 15% (metric ton) HD605-7: 46.8 [t] (Operating weight) ± 15% (metric ton) (4) Check the input value (Fig. 7). • [>] button: Select "YES". • [<] button: Select "NO". • [t] button: Enter.

(5) Move the dump truck to a place where you can drive it. a Display on the screen (Fig. 8) • [U] button: After getting ready for drive, press this button and start driving the dump truck. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. • [t] button: Return to the screen for inputting values.

20-197-3 (5)

HD465-7, HD605-7



(6) Display the progress of measurement (Fig. 9). • [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. a As measurement is executed, the number of " * " increases. When measurement is finished, the next screen appears automatically. iii) Load the dump truck to measure the weight of the fully loaded dump truck (Fig. 10). • [t] button: Return to the menu screen. a When loading is started, the menu s cr een app ears automati cal ly. When indicating the current load for reference while the dump truck is being loaded, go out of "Service mode" temporarily and return to "Display of load/integrated odometer". On this screen, you can check the current load. iv) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper, etc.) v) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes. (1) Select "LOADED WEIGHT" (Fig. 11). a For the method of displaying the following screen, see the steps up to ii) - (1). • [>], [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". • [U] button: Enter the selection. • [t] button: Return to the previous screen. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes, "LOADED WEIGHT" is displayed when the menu is selected (See Fig. 11). • Check the unit of the input value. a The unit is indicated in the ( ) on the right side of WEIGHT. (METRIC) --- metric ton (SHORT) ---- short ton

HD465-7, HD605-7

20-197-4 (9)



(2) Check that measurement of the weight of the fully loaded dump truck has been completed. a Display on the screen (Fig. 5) • [U] button: Check that measurement has been completed and go to the next step. • [t] button: Return to the previous screen.

(3) Input the measured weight of the fully loaded dump truck (Fig. 6). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Return to the largest position of the number to input the value again. If this button is pressed again, inputting of the value is stopped and the previous screen appears. a Inputtable range HD465-7: A1 ± (A1 x 0.25) (metric ton) However, A1 = {43.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 ± (A2 x 0.25) (metric ton) However, A2 = {46.8 [t] (Operating weight) + 63 [t] (Load capacity)} (4) Check the input value (Fig. 7). • [>] button: Select "YES". • [<] button: Select "NO". • [t] button: Enter.

20-197-5 (5)

HD465-7, HD605-7



(5) Move the dump truck to a place where you can drive it. a Display on the screen (Fig. 8) • [U] button: After getting ready for drive, press this button and start driving the dump truck. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. • [t] button: Return to the screen for inputting values. (6) Display the progress of measurement (Fig. 9). • [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. a As measurement is executed, the number of " * " increases. When measurement is finished, the next screen appears automatically. vi) Dump the load in the dump area (Fig. 12). • [t] button: Return to the menu screen. a If the load is dumped with the dump lever, the menu screen appears automatically. If the load is dumped normally, correction is finished. 3) Correction of level of inclination sensor i) Move the dump truck to a level place. ii) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. (1) Enter value of (F) (Fig. 13). • [U] button: Enter the flashing value. • [t] button: Return to the menu screen. a The current standard level value is displayed on the upper line. The clinometer value (F) at the current position flashes. Enter it when it is stabilized.

HD465-7, HD605-7

20-197-6 (5)



(2) Turn the dump truck 180 degrees (Stop it in the opposite direction). (3) Enter value of (R). • [U] button: Enter the flashing value. • [t] button: Return to the menu screen. a The current standard level value is displayed on the upper line. The clinometer value at the current position flashes. Enter it when it is stabilized.

(4) Enter the standard level value (Fig. 15). • [>] button: Select "YES". • [<] button: Select "NO". • [t] button: Enter.

4) Setting of criterion of maximum travel speed Input a criterion of the maximum travel speed by pressing the following buttons (Fig. 16). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Stop inputting number. a The setting range is 0 – 99 km/h (0 – 62 MPH). (Default: 99 km/h)

5) Setting of payload to recognize start of loading Input a payload to recognize start of loading by pressing the following buttons (Fig. 17). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Stop inputting number. a The setting range is 0 – 25.5%. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below (on the next page).

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HD465-7, HD605-7



•

If the value is reduced, start of loading may be recognized wrongly. • If the value is increased and a loader having a small-capacity bucket is used, the forecast function of the outside indicator lamps and the MMS communication may not operate normally. 6) Setting of indication range of outside indicator lamps Input an indication range of the outside indicator lamps by pressing the following buttons (Fig. 19). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Stop inputting number. a The setting range is 0 – 130% of the load capacity. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp), however. 7) Setting of OFFSET function Input an offset range by pressing the following buttons (Fig. 20). • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. • [t] button: Stop inputting number. a The setting range is -5.0 – +5.0 [t]. • Check the unit of the input value on the previous menu screen (Fig. 21). a The unit is indicated in the ( ) on the right side of the input value [t]. (METRIC) --- metric ton (SHORT) ---- short ton

HD465-7, HD605-7

20-197-8 (5)



8) Selection of method of entering saved payload i) Select the method of entering the saved payload (Fig. 22). • [>], [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". • WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. • WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped. • [U] button: Enter the selected method. • [t] button: Return to the menu screen. ii) Enter the selected method (Fig. 23). • [>] button: Select "YES". • [<] button: Select "NO". • [t] button: Enter.

16. Initialize function (INITIALIZE) (exclusive function for factory) a This is a special function for the factory and is not used for service.

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HD465-7, HD605-7


BASIC PRECAUTIONS 1. Handling machine, safety, inspection and maintenance For details of safety items, operation, inspection, and maintenance of the machine, see the Operation and Maintenance Manual for the machine. 2. Handling monitoring system Always obey the following precautions when handling the monitoring system. 1) When disassembling, repairing, or modifying the machine or system, follow the instructions in the manual. 2) Do not touch the system (equipment) when operating the machine. 3) Do not damage or get the wiring harnesses, connectors, or sensors of the system (equipment) caught or pulled by force. This may cause short circuits or disconnections that will lead to failure or fire on the machine or system (equipment). 4) Do not get water, dirt, or oil on the system (equipment). 3. Permanent power source for VHMS (battery direct power source) 1) Meaning and need of permanent power source The VHMS has the function of checking and collecting data on the condition of the machine from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Therefore, its power supply is differentfrom many of the electronic equipment and electrical parts. For the system to provide the above functions, it is necessary to have a power supply

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BASIC PRECAUTIONS

that is connected directly to the battery and always supplies electricity (permanent power source) in addition to the power source (switch power source) that is cut when the starting switch is turned OFF or the engine is stopped. Because this switch power source and permanent power source are provided, the period needed for collecting data is clearly known and it becomes possible to store this data in the internal memory. In other words, the VHMS uses the permanent power source to save to memory the data accumulated from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Then the VHMS controller itself turns off the permanent power source. 2) Precautions when turning the permanent power source OFF When the starting switch is turned OFF, the power supply is maintained for at least 3 minutes (the VHMS system shut-down time: the time taken for the VHMS system to save the data to memory and switch off), and then the permanent power source is turned OFF. If the VHMS system shut-down time is shorter than 3 minutes, the accumulated data may be damaged. i) When removing VHMS from permanent power source When removing the VHMS from the permanent power source (for example, when carrying out repairs), check that the monitor display (7-segment LED in the diagram below) of the VHMS controller is out.

HD465-7, HD605-7


BASIC PRECAUTIONS

ii) When installing battery isolator or other battery shut-down device a) Basic connections It is a basic assumption that the engine stop switch is a type that will not shut off the permanent power source when the engine is stopped. b) When safety regulations for user make it impossible to avoid shutting down all electric power • Install a battery isolator so that the permanent power source is kept in the specified condition for at least 3 minutes after the starting switch is turned OFF before the permanent power source is shut down. • If there is no timer, wait for at least 3 minutes before turning off the permanent power source. • If the above shut-down time is shorter than 3 minutes, the accumulated data may be damaged. 4. Precautions when VHMS power source is ON • For the first few seconds after the power is switched ON, the VHMS controller carries out the initial check (LEDs flash). Do not carry out any of the following operations until the initial check is completed. • Operation of manual snapshot switch • Downloading from PC (Check that the LEDs are displaying the aggregate numerals in turn before operating.) 5. Precautions when replacing VHMS and transmission controller 1) Before starting replacement i) Download VHMS data When the VHMS controller is replaced, the data collected up to that point is lost, so be sure to download the accumulated data before starting the replacement operation. Next, send the accumulated data to web care. For details of the method of downloading, see the separate instruction manual for the technical analysis tool box.

HD465-7, HD605-7

ii) Specified method of shutting down VHMS power source a) Use the starting switch to turn the normal power source OFF b) Maintain the permanent power source in the specified condition for at least 3 minutes. c) Turn the permanent power source (battery direct) OFF.

20-203-2 (10)


BASIC PRECAUTIONS

2) Method of replacement, action after replacement When replacing the VHMS controller, be careful not to subject the VHMS controller or wiring harnesses to any excessive force or impact, and carry out the initial setup. For details, see the separate instruction manual for the technical analysis tool box. 6. Handling communications controller (ORB • • • Orbcomm) 1) The ORB controller must be used. If the ORB controller is not used, it is impossible to carry out the request to open communications before starting to use. If the control power is turned on before completing the request, the transmission will be unauthorized and there will be problems with the communications system. If there are any problems or any part is unclear, please contact Komatsu or the person responsible for operation. 2) Finally, turn on the ORB power ON (connect the connector). After the VHMS controller confirmation is completed, connect the ORB controller connector (ORB-A, ORB-B).

20-203-3 (2)

HD465-7, HD605-7


OUTLINE

OUTLINE a It is also possible to add this system to a machine that has already been shipped. 1. Basic structure (1)

HD465-7, HD605-7

20-203-4 (2)


OUTLINE

2. Basic structure (2)

20-203-5 (2)

HD465-7, HD605-7


HD465-7, HD605-7

OUTLINE

20-203-6 (2)


OUTLINE

3. Position of equipment Install monitoring controller (VHMS controller) (1) on the machine, and collect the operation data for the engine, transmission, and PLM. 1) Data collection function i) Data from connected sensors • Blow-by pressure {sensor (2)} • Engine oil temperature {sensor (3)} • Exhaust gas temperature {sensor (4)} • Ambient temperature {sensor (5)} ii) Data from controller mounted on machine • Engine speed • Fuel injection amount • Engine oil pressure • Data from transmission controller • Data from retarder controller • Data from PLM II controller • SMR (service meter) 2) Saving data • The above data is saved to memory.

20-203-7 (2)

HD465-7, HD605-7


OUTLINE

3) External communication function • Connect the PC (personal computer) to the VHMS controller, download the data, and transmit the data through the Internet. • Send the data automatically from remote areas through the communications satellite (ORB). (6): Ground level download connector (7): Download connector inside cab (8): Communications antenna/pole Antenna mount: Thread tightener (LT-2)

HD465-7, HD605-7

20-203-8 (2)


SETTING UP VHMS CONTROLLER

SETTING UP VHMS CONTROLLER 1. Setting up VHMS controller • In the following cases, always carry out the setup. 1) When making the initial installation of the VHMS system 2) When replacing or overhauling the following components • VHMS controller • Engine • Transmission • PLM II (option) • When carrying out the setup, the following are needed 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) • For details of the setup method, see the instruction manual for the technical analysis tool box (for service). • The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. • Or contact Komatsu.

2. Setting items • VHMS: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Calendar (date, time, time difference from GMT, summer time (daylight saving time)) 2) Machine model, Serial No., variation code 3) Engine model, Serial No. 4) Transmission Serial No. • For details of the method of setting PLM II and VHMS with PLM function, see the separate PLM instruction manual. 1) Time of the start of data collection 2) Data collection unit (day) • Opening communications with Orbcomm: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Communications method (stop/start, interval, transmission time) 2) Time of PLM data collection 3) Country code for communications controller (GCC)

3. Setup flow (outline) Procedure 1

Turn starting switch ON (starting switch ON)

• Check for generation of errors • Start setup tool

Method (specific content, points to remember, etc.) Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal

• Calendar (data, time, time difference from GMT, summer time (daylight saving time))

2

Setting up VHMS

• Machine model, Serial No., variation code • Engine model, Serial No. • Transmission Serial No.

3

Setting up PLM function or PLM II (when the PLM function is available or machine is PLM II specification)

• Time of start of data collection • Data collection unit (day)

4

Starting switch OFF (starting switch OFF)

• Saving settings

5

Starting switch ON (starting switch ON)

• Checking VHMS functions

6

Start engine Test (quick PM) Starting switch OFF

• Performing test (quick PM) • Downloading • Checking data (content of data)

7

• Check for errors • Start setup tool

Starting switch ON (starting switch ON)

• Checking operation of Orbcomm • Setting up communications

8

Starting switch OFF (starting switch OFF)

20-203-9 (12)

(need for communications file, communications frequency, GCC code)

• Setup completion report, content of setup (data), sending checksheet • Sending download data

HD465-7, HD605-7


SETTING UP VHMS CONTROLLER

4. Checking operation, actuation a Check the functions of the VHMS system as follows. Start

Turn starting switch to [ON] position Display

Display Normal

Engine, transmission controllers show past errors, then give [00] display (no error exists)

VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists)

No display

Normal

No display

Turn starting switch [OFF], then check connection of wiring harnesses again

Turn starting switch again to [ON] position Display

Display Normal

Engine, transmission controllers show past errors, then give [00] display (no error exists) No display Abnormality in machine syastem See machine shop manual

VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists)

Normal

No display Possible abnormality in VHMS controller

5. Collection of data a If there is no abnormality in the system, the machine will operate and the operation data for the machine will automatically be saved by the VHMS controller.

HD465-7, HD605-7

20-203-10 (2)

COLLECTION, TRANSMISSION OF DATA


COLLECTION, TRANSMISSION OF DATA 1. Collection of data 1) Downloading with PC (personal computer) • PC (personal computer) • VHMS analysis tool (software) (799-608-3211) • Download cable (799-608-3220) When using a PC to download the collected data, send the data to the file server in the computer center by e-mail (Internet). (There are limitations to the capacity of satellite communications, so use this method to send all the data.)

a For details of downloading and sending the data, see the instruction manual for the technical analysis tool box (for service). 2) Automatic transmission by communications satellite (machines with Orbcomm specification) • Error data and other specified data are automatically sent by communications satellite to the file server in the computer center.

2. Setup flow (outline) Procedure

Method (specific content, points to remember, etc.)

1

Turn starting switch ON (starting switch ON) • Check for generation of errors • Start setup tool

Check that no error is generated by VHMS controller or other controller If there is any error, repair or correct to return condition to normal

2

Setting up communications

• Checking satellite communications data, setting communications frequency • Setting GCC code

3

Starting switch OFF (turn key to OFF) • Saving set values • Reporting completion of setup

3. Carrying out quick PM a For details, see TESTING AND ADJUSTING, Performing PM clinic using manual snapshot. • To collect data under the normal working conditions, and to collect data when operating under such conditions as torque converter stall or high idle, carry out the quick PM (equivalent to PM clinic) before downloading with the PC. 4. Method of downloading with PC (personal computer) To ensure safety, stop the machine on level ground and put chocks under the tires to prevent the machine from moving. When turning the starting switch ON, check that the parking brake is ON and that the gearshift lever is at the N position. Sound the horn to warn people in the surrounding area before starting the engine. a For details of the method of using the PC, see the instruction manual for the technical analysis tool box (for service). • Prepare a PC for downloading and a download wiring harness. a The download connectors are provided in 2 places: rear of assistant's seat inside cab (7) and behind front left tire of machine (6).

20-203-11 (10)

HD465-7, HD605-7


1) Remove the connected wiring harness and install the download cable. 2) Connect the other end of the download wiring harness to the PC. 3) Turn the machine starting switch ON, check that the monitor controller is working, then download to the PC. a To check that the VHMS controller is working, check that the VHMS controller starts up, LEDs flash (see diagram below), and aggregate numerals are displayed in order. 4) When [complete] is displayed on the download PC, the download operation is completed. 5) Turn the machine starting switch OFF, then turn the PC power OFF, remove the download cable, and return the wiring harness to its original condition.


1) Remove the clamp at the top of the download box. 2) Use the engine key to open the cover at the front of the box. 3) Remove the cap of the download connector and install the download cable. 4) When turn (wake-up) switch (10) is turned, the VHMS is actuated and pilot lamp (11) lights up. 5) Check that pilot lamp (11) is lighted up, then carry out the PC download. 6) When [complete] is displayed on the download PC, the download operation is completed. 7) Return the turn switch to its original position, remove the download cable, then install the cap. 8) Check that pilot lamp (11) is out, then close the box cover. If the turn switch is not off, the cover will not close. 9) Turn the engine key and lock the front cover. Close the clamps at the top of the box also.

4. Types of data collection files 1) Index file : This records the common data for the machine model, serial No., and service meter (SMR). 2) VHMS history : This records changes in the VHMS. 3) Machine history : This records the actual engine operation data. 4) Fault history : This records errors that occurred in order of occurrence. 5) Trend analysis : This records the maximum or minimum values for each measurement device at the specified intervals. (See Table 1) 6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures. (see Table 2) 7) Snapshot : This records the data for a specified time before and after the occurrence of an error (see Table 3.1, 2) 8) Load map : This records the frequency of the applicable area, taking the engine speed and fuel injection amount as the axes 9) Cycle interval : This records the aggregate frequency of the changes in engine speed 10) Running area : This records the operation distribution for each area on the engine performance graph 11) Running direction : This records the track of movement for each area on the engine performance graph 12) Transmission shift change map: This records the transmission gearshift data 13) Transmission fill time trend : This records the transmission clutch engagement time data (See table 4) 14) Payload data (if equipped) : This records the payload meter data 15) Payload data cycle (if equipped) : This records the operating cycle data for the machine

HD465-7, HD605-7

20-203-12 (10)



TREND DATA ITEMS Table 1: Trend analysis data No.

Item

Content

1

SMR

Service meter

2

Calendar

Calendar

3

Engine speed max.

Engine speed (max.)

Unit

Data collection point

Remarks

h y/m/d h:m:s rpm

Engine controller

Maximum value within set trend data

4

Blow-by press. max.

Blow-by pressure (max.)

mmAq

5

F. Exh. temp. max.

Front engine exhaust temperture (max.)

deg.C

6

R. Exh. temp. max.

Rear engine exhaust temperture (max.)

deg.C

Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor

7

E. oil press. max.

Engine oil pressure (max.)

kg/cm2

Engine controller

8

E. oil P. L min.

Engine oil pressure at low idle (min.)

kg/cm2

Engine controller

9

E. oil P. H min.

Engine oil pressure at high idle (min.)

kg/cm2

Engine controller

10

Eng. oil temp. max.

Engine oil temperature (max.)

deg.C

Engine oil temperature sensor

11

Fuel rate

Fuel consumption rate (average)

Liter/h

Engine controller

12

Cool temp. max.

Engine coolant temperature (max.)

deg.C

Engine controller

13

Cool temp. min.

Engine coolant temperature (min.)

deg.C

Engine controller

14

Ambient temp. max.

Ambient temperature (max.)

deg.C

15

Ambient temp. ave.

Ambient temperature (average)

deg.C

16

Ambient temp. min.

Ambient temperature (min.)

deg.C

17

Atmos. press. ave.

Atmospheric pressure (average)

hPa

(Every 20 hours) See as below

Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller

2

Retarder controller Retarder controller

18

F. brake P. max.

Front brake oil pressure (max.)

kg/cm

19

R. brake P. max.

Rear brake oil pressure (max.)

kg/cm2

Table 2: Machine trend data No.

Item

Content

Unit

1

SMR

Service meter

2

Calendar

Calendar

T/C oil temp. 120– T/C oil temp. 130– T/C oil temp. 140– Rtrdr. oil temp. T120– Rtrdr. oil temp. T130– Rtrdr. oil temp. T140–

Time of use for each torque converter oil temperature

3 4


Remarks

h y/m/d h:m:s Transmission controller sec.

Time of use for each retarder oil temperature

Retarder controller

Table 3.1 Observation items (trigger items) for auto snapshot No.

Content

Failure code

2

No. 1,2,3 cylinder exhaust temperature is high F@BYNS(n361) (stage 1) No. 4,5,6 cylinder exhaust temperature is high F@BZNS(n371) (stage 1)

3

Blow-by pressure is high

1

No.

Content

Failure code

11

Problem with No. 2 clutch

15L0MW(b025)

12


15M0MW(b026)

F@BBZL(n338)

13


15N0MW(b027)

14

Problem with engine speed senser

C115KZ

5

No. 1,2,3 cylinder exhaust temperature is high F@BYNR(n362) (stage 2) No. 4,5,6 cylinder exhaust temperature is high F@BZNR(n372) (stage 2)

15

Overheating of water

C151NS

6

Double meshing of transmission clutch

1500L0(b005)

16

Overheating of fuel

C261NS

7

Problem with lock-up clutch

1380MW(b021)

17

Overheating of torque converter

B@CENS(A0d2)

8

Problem with High clutch

15H0MW(b022)

18

Overheating of rear brake oil

B@C7NS(A0d4)

9

Problem with Low clutch

15J0MW(b023)

19

Overrun

A00N1(n201)

15K0MW(b024)

20

Abnormal drop in engine oil pressure

C143ZG

4

10 Problem with No. 1 clutch

20-203-13 (12)

HD465-7, HD605-7



Table 3.2 Data items for manual snapshot No.

Item

Content

Unit


1

Time

Elapsed time

sec.

VHMS

2

Eng. speed

Engine speed

rpm

Engine controller

3

Fuel inject

Fuel injection amount

mm3/st

Engine controller

4

Blow-by press.

Blow-by pressure

mmAq

5

F. exh. temp.

deg. C

6

R. exh. temp.

Exhaust temperature (No. 1,2,3 cylinders) Exhaust temperature (No. 4,5,6 cylinders)

Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor

7

Eng. oil. press.

Engine oil pressure

kg/cm2

Engine controller

8

Eng. oil. temp.

Engine oil temperature

deg. C

Oil temperature sensor

9

Eng. cool. temp.

Engine coolant temperature

deg. C

Engine controller

10

Ambient temp.

Ambient temperature

deg. C

Engine controller (ambient temperature sensor)

11

Boost press.

Engine boost pressure

mmHg

Engine controller

12

Accelerator pos.

Accelerator angle

%

Engine controller

13

Hoist lev. pos.

Hoist lever position

—

Retarder controller

14

T/C oil temp.

Torque converter oil temperature

15

T/M out. speed

Transmission output speed

16

Shift indicator

Gearshift range (position)

17

Lockup signal

Lock-up clutch

18

Retarder temp.

Retarder oil temperature

deg. C

Retarder controller

19

F. brake press.

Front brake oil pressure

kg/cm2

Retarder controller

20

R. brake press.

Rear brake oil pressure

kg/cm2

Retarder controller

21

Retarder position

Retarder brake use

ON-OFF

Retarder controller

22

Foot brake position

Foot brake use

ON-OFF

Retarder controller

deg. C

deg. C rpm

Remarks

FLOAT = 0, HOLD = 1, LOWER = 2, RAISE = 3, Max height = 4, Other = 5

Transmission controller Transmission output shaft speed sensor

—


ON-OFF


R = 10, N = 0, F1 = 1, ••• F7= 7

Table 4: Transmission trend data No.

Item

Content

1

SMR

Service meter

2

Calendar

Calendar

3

Trig. time Low (fill time) Trig. time High (fill time) Trig. time Rev. (fill time) Trig. time 4th (fill time) Trig. time 3rd (fill time) Trig. time 1st (fill time) Trig. time 2nd (fill time)

Transmission fill-up time

HD465-7, HD605-7

Unit


Remarks

h y/m/d h:m:s

msec.


(Every 200 h)

20-203-14 (12)


5. Confirming data For details of the method of confirming the data, see the instruction manual for the technical analysis tool box. a Check that each file has been saved. Check also that there is no abnormal data. a Compare the quick PM data and the PM clinic data to check that there are no abnormal values. a After downloading, if there is no problem with the data, clear only the snapshot data. For details of the method of clearing, see the instruction manual for the technical analysis tool box (for service).

20-203-15 (9)


• Engine speed (high idle, torque converter stall) • Blow-by pressure (high idle, torque converter stall) • Exhaust temperature (torque converter stall) • Engine oil pressure (low idle, high idle, torque converter stall) • Engine oil temperature (no PM data ••• reference value)

HD465-7, HD605-7


INSPECTION AND MAINTENANCE, REPLACING PARTS

INSPECTION AND MAINTENANCE 1. Inspection interval: Inspection and maintenance interval for machine Check the system at the same time as carrying out maintenance on the machine. 2. Inspection items a Carry out inspection and maintenance, and take the necessary action if there are any abnormalities. 1) Checks before starting (ask the customer also to carry out this inspection) i) Check that the sensors are installed properly. (Check that there are no loose, damaged, or dirty mounts) • Blow-by sensor • Engine oil temperature sensor • Exhaust temperature sensor • Ambient temperature sensor • Communications antenna ii) Check that there are no disconnected or damaged wiring harnesses, cables, or connectors. iii) Check that there is no leakage of oil or gas from the sensor mounts. 2) Every 1000 hours service i) Communications antenna • Check that there is no looseness at the antenna mount. • Check that there is no damage or looseness of the antenna itself. • If there is any abnormality, replace the antenna. 3) When required i) If there is any abnormality in the downloaded values, check all sensors.

REPLACING PARTS If initial setup of VHMS system has been made or VHMS controller has been replaced If the system has been newly installed or the VHMS controller or other components (transmission, engine, etc.) have been replaced, it is necessary to carry out the initial setup of the system. • Necessary tools 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) • For details of the setup method, see the instruction manual for the technical analysis tool box (for service). • The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. Or contact Komatsu. When replacing communications controller • In the following cases, there are important procedures to be carried out, such as opening and closing of the communications controller, so follow the instruction of the person in charge at your company. Or contact Komatsu. 1) When replacing the controller installed on the machine with another controller. 2) When removing the controller installed on one machine and installing it on another machine. 3) When disposing of the controller. 4) When giving away or selling the machine with the controller installed. 5) When disposing of a machine with a controller installed.

3. Remedy If there is any abnormality, repair, replace, or reinstall (tighten).

HD465-7, HD605-7

20-203-16 (2)

PROCEDURE FOR INITIAL SETUP OF VHMS


PROCEDURE FOR INITIAL SETUP OF VHMS (Applicable machine models: HD465/605-7 Dump Truck) Timing

Before starting operation

Operation step

Operation step

• Prepare necessary parts, tools, and check sheet.

• Contact Komatsu before starting the setup operation. (Contact at least 3 days before)

* There are download connectors in two places (inside cabin, ground level download box), but the setting operation must be carried out inside the cab. 799-608-3220 Download cable Program for setting(VHMS technical analysis tool box) 799-608-3211 Portable PC

1. Check machine and component nameplates

Check the serial No. first from the following nameplates and enter the serial No. on the check sheet. • Machine • Engine • Transmission • VHMS controller

2. Connect PC and VHMS controller

Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). Connect the other end to the RS232C port of the

Starting switch OFF

portable PC.

Starting switch ON

3. Check that VHMS controller works properly Do not start engine yet.

Check the 7-segment display window of the VHMS controller to see that the LED operation is normal. With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.

*

Start up the personal computer and click the VHMS initial setup tool icon.

4. Start VHMS initial setup tool (VHMS technical tool box)

Icon

For details of the method of installing the VHMS initial setup program, see the separate program operation instructions.

(automatic updating of definition data)

If the definition data for the connected machine is not in the technical analysis tool box on the personal computer, download automatically from the VHMS controller and update the technical analysis tool box. Press the YES button to update. Note: This program will not start if the VHMS controller and PC are not connected.

5. Initial setup of VHMS controller After starting up, first input the ID (Service ID). Select "Data Clear and Set up". The ID is the part No. for the VHMS controller. It differs according to the machine model.

5-1 Setting up machine data This sets the basic data for the machine in the VHMS controller.

Starting switch OFF

6. Saving of contents of setting Turn the starting switch OFF to save the data in the VHMS controller.

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

Starting switch ON ** When using the payload meter as shipped (default), the following setting is not necessary **

7. Setting of payload meter 7-1 Check of operation of VHMS controller

7-2 Starting of VHMS initial setting tool

(Default setting) • Time when collection is started: 12 o'clock (Midnight) • Unit of collection (Day) : 1 day Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller.

* The normal operation of the LED means that the 7 segments flash in the rotation state after the starting switch is turned to the ON position and then they count up in hexadecimal notation. For details, see the Shop Manual. Start the personal computer and click the icon of "VHMS initial setting tool". For the method of installing the program for setting the VHMS initially,

Icon

see the separate operation manual for the program.

If the definition information of the connected machine is not in "Analysis tool" of the personal computer, it is downloaded automatically from the VHMS controller and "Analysis tool" is updated.

Press the "yes" button to update. After the personal computer starts, input the ID (Service ID) first. Select "Set up".

Note: This program will not start if the VHMS controller and PC are not connected.

The ID is the part No. for the VHMS controller. It differs according to the machine model.

(Cont'd)

20-203-17 (12)

(Cont'd)

HD465-7, HD605-7



Operation step

Timing

Operation step

7-3 Setting up payload meter

Click the PLT tag to 1) Setting start time and interval (days) for

(Machine with PLM II or VHMS with PLM function

data collection

• In the example on the right, the start time is set at 11 PM and the interval at 2 days.

(For details of setting up PLM, see the separate PLM instruction manual)

Click Apply to register the setting

Starting switch OFF

8. Saving of contents of setting Turn the starting switch OFF to save the data in the VHMS controller. Starting switch ON

9. Check of normal operation of VHMS controller

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

[Outline of procedure]

Start engine

10. Execution of quick Pm clinic Execute the quick Pm clinic according to the procedure shown in the Shop Manual.

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

converter stall.

Starting switch OFF

11. Saving in VHMS

Check lighting of the 7 segments in the inspection window of the VHMS controller.

Turn the starting switch OFF to save the data in the VHMS controller. Starting switch ON

• The segments keep lighting for several seconds after the starting switch is turned off. (Saving operation) Check that the segments go off perfectly.

Check that the VHMS controller is connected to the portable personal computer by the cable.

12. Download

Start the "VHMS analysis tool" (VHMS technical analysis tool box) on the personal computer display. Download all files. For details, see the instruction manual for the technical analysis tool box.

After downloading is finished, check the VHMS data with the "VIEW" function. • Check that the set contents are displayed correctly. (Date, time, service meter, machine serial No., etc.) • Check that the data of the quick Pm executed in [8] are saved in "Snap Shot".

13. Check of downloaded data

14. Saving in VHMS Turn the starting switch OFF to save the data in the VHMS controller.

1) After the starting switch is turned to the OFF position, the LED of the VHMS displays SF and SH (Processing time of memory), and then the all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.

Starting switch OFF

After returning to office

Finish setting of the VHMS and notify to KOMATSU

This completes the initial setup of the VHMS. The setup of the database (Web server) is carried out by Komatsu, so after you have completed the operation, inform Komatsu as follows. [1] Send the check sheet by fax. [2] Send the downloaded VHMS data by Notes or E-mail to the following address.

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

TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: [email protected]

Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM controller VHMS controller



Payload meter (PLM) function

Set position of rotary switch 2 (SW2) of transmission controller

Not installed

—

Not installed

Not installed

Setting with VHMS initial setting manual (tool) (*1) Date Time Time difference (GMT) Summer time

Model

Type

Set variation code

F

—

—

—

—

—

—

—

—

Not installed

—

Installed

Installed

F

Installed

Not installed

Not installed

Not installed

B

Installed

Not installed

Installed

Installed

F

Installed

Installed

Not installed

Installed

9

HD465 or HD605

ST –7

P2

Set properly

PV

a A variation code is an item among the model, date, etc. that are set with the personal computer software when the VHMS is set initially. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV), whether PLM is connected (Code: P2), and whether the machine has the payload meter (PLM) function (Code: ST)". a Since A and B of the short connector to be connected to connector No. HM-50 are not used, connect them normally. (*1) The transmission controller switch 2 (SW2) is used to notify the monitor panel "whether the VHMS is installed", "whether the PLM function in the VHMS is turned on", and "whether PLM- is installed". (See the section of adjustment of the transmission controller.)

HD465-7, HD605-7

20-203-18 (12)



To: VHMS/WebCARE Support Center (R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)

Date of setup Date of fax

Month Month

Day Day

Year Year

Name of distributor/branch Name of person filling in check sheet

FAX: 81-3-5561-4766

VHMS INITIAL SET-UP CHECK SHEET (For HD465/605-7 Dump Truck) Steps for setup

Check items Name of machine Serial No. Service meter Engine serial No. Transmission serial No. VHMS controller serial No.

Results

1.

Check machine and component nameplates

2.

Connect PC and VHMS controller

Are they are properly connected?

yes

no

3.

Check that operation of VHMS controller is normal

Does it work properly? (After rotation, hexadecimal count-up display)

yes

no

4.

Start VHMS initial setup tool

Is selection of mode for setup tool "Data Clear and Set up" ?

yes

no

5.

Initial setup of VHMS controller

Is model name same as name of machine? Has machine serial No. been input correctly? Was selection of variation code set correctly? Has engine serial No. been input correctly? Has date been set to today's date? Has time been set to correct time?

yes yes yes yes yes yes

no no no no no no

After saving operation, did LED (7 segments) go off?

yes

no

7–1 Check of operation of VHMS controller

Did LED operate normally?

yes

no

7–2 Starting of VHMS initial setting tool

Is selection of mode of setting tool "Set up"?

yes

no

7–3 Setting of payload meter

Enter set value of PLM collection Time to start collection

5–1 Set machine data This sets the basic data for the machine in the VHMS controller.

6.

Save settings

7.

Setting of payload meter

(When PLM II or PLM function is installed)

Collection interval (day)

day

8.

Save settings


yes

no

9.

Check of normal operation of VHMS controller


yes

no

10. Perform quick PM clinic

Were service mode and "SNAPSHOT" selected and was switch pressed?

yes

no

11. Save to VHMS memory


yes

no

12. Download


yes

no

13. Check downloaded data

Have all files been downloaded? Time of download (use wrist watch) [Check data] Is there any MFAO error in Fault History? In Fault History, do set values for SMR and time match? Are there any data missing in Snapshot? Are there any data in Transmission Shift Change Map?

yes

no

yes

no

yes

no

yes yes

no no


yes

no

14. Save to VHMS memory

Point of Contact

VHMS/WebCARE Support Center (R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)


20-203-19 (12)

HD465-7, HD605-7

PROCEDURE FOR OPENING ORBCOMM SERVICE


PROCEDURE FOR OPENING ORBCOMM SERVICE (Applicable machine models: HD465/605-7 Dump Truck) a Make a communications contract with Orbcomm before performing this work. Timing

Before starting operation

Operation step

• Prepare the necessary tools and check sheet. • Contact Komatsu before starting the setup operation. (Contact at least 3 days before)

Operation step * There are download connectors at two places (inside cabin, ground level download box), but the setup operation must be carried out inside the cab. 799-608-3220 Download cable 799-608-3211 VHMS technical analysis tool box Portable PC

1. Check machine and component nameplates

Check the serial No. first from the following nameplates and enter the serial No. on the check sheet. • Machine • Engine • Transmission • VHMS controller • Orbcomm controller


Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). Connect the other end to the RS232C port of the

Starting switch OFF

portable PC.

Starting switch ON

Check the 7-segment display window of the VHMS controller to see that the LED operation is normal.

3. Check that VHMS controller works properly (Check that the Orbcomm controller works properly) (When an Orbcomm controller is installed)

* With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual. When checking that the operation of the Orbcomm controller is normal, wait for 3 minutes after starting the VHMS, then check the condition of the decimal point on the VHMS monitor (7-segment). • OFF : ORBCOMM controller cannot communicate with ORBCOMM terminal. • ON : Communication with ORBCOMM terminal is OK. Terminal does not have communication data. • Quick flash : Communication with ORBCOMM terminal is OK. Terminal has communication data and has captured satellite. • Slow flash : Communication with ORBCOMM terminal is OK. Terminal has communication data and has not captured satellite. Start up the personal computer and click the VHMS initial setup tool icon.

4. Start VHMS initial setup tool (VHMS technical tool box) (automatic updating of definition data)

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

5. Initial setup of VHMS controller

Note: This program will not start if the VHMS controller and PC are not connected.

After starting, input the ID (Service ID) first. Select "Set up". The ID is the part No. for the VHMS controller. It differs according to the machine model.

5-1 Setting up communications (For machines with Orbcomm controller specifications) This sets up the selection of VHMS data to be sent by satellite communications

1) Selecting data to send – – There are 3 types of data that can be sent. With this operation is possible to set acceptance /refusal of satellite communications and the frequency of change. – – Decide the data to change, then click on * Edit to change it.

and the frequency of communications.

* (The setting of the machine data and PLM is already completed)

*1: The default for the number of items in the Fault History is 8. For details, see the instruction manual for the setup tool.

5-2 Set start of communications 2) Setting up GCC code – – Click Edit and select 130 (if Japan) for the GCC code.

Finally, click Apply to register the setting.

(Cont'd)

HD465-7, HD605-7

GCC code 1 120 121 122 123 130

Territory (country) USA ITALY MALAYSIA KOREA BRAZIL JAPAN

20-203-20 (12)



Timing Starting switch OFF

Operation step 6. Save to VHMS memory Turn the starting switch OFF to save the data in the VHMS controller.

Operation step Check the 7-segment display in the VHMS controller inspection window. • The display continues for several seconds after the starting switch is turned OFF. Check that the saving-to-memory display goes out completely. 1) After the starting switch is turned to the OFF position, the LED of the VHMS displays SF and SH (Processing time of memory), and then the all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.

After returning to office

Completing operation to set up VHMS and contacting Komatsu

This completes the setup for Orbcomm. The setup of the reception inside of the satellite communications is carried out by Komatsu, so after you have completed the operation, inform Komatsu as follows. 1) Send the check sheet by fax. 2) Send the downloaded VHMS data by Notes or E-mail to the following address.

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

20-203-21 (12)


HD465-7, HD605-7



To: VHMS/WebCARE Support Center (R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)

Date of setup Date of fax

Month Month

Day Day

Year Year

Name of distributor/branch Name of person filling in check sheet

FAX: 81-3-5561-4766

VHMS INITIAL SET-UP CHECK SHEET (For HD465/605-7 Dump Truck) Steps for setup 1. Check machine and component nameplates

Check items Name of machine Serial No. Service meter Engine serial No. Transmission serial No. VHMS controller serial No. Orbcomm controller serial No.


Are they are properly connected?

3. Check that operation of VHMS controller is normal (Check operation of Orbcomm)

Does it work properly? (After rotation, count-up display) Does VHMS monitor (7-segment) display decimal point? (OFF, ON, Slow/Quick flash)

4. Start VHMS initial setup tool

Is selection of mode for setup tool "Data Clear and Set up"?

Results

yes

no

yes

no

yes

no

yes

no

5. Initial setup of VHMS controller 5–1 Set up communications * (The setting of the machine data and PLM is already completed)

5–2 Set start of communications

6. Save settings Point of Contact

Input set value of short Fault History Condition of communications Number of items (default value: 8) Input set value of short Trend Analysis Condition of communications Interval (default value: 20 hrs) Input set value of short Payload data Condition of communications Time of start of data collection Data collection interval (day) Is GCC code set to 130 (if Japan)

yes

no


yes

no

On

Off items

On

Off Hrs

On

Off day

VHMS/WebCARE Support Center (R&M Engineering Team, R&M department, Product Support Division, Komatsu LTD)


HD465-7, HD605-7

20-203-22 (12)


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

PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) What is quick Pm? If a serious error occurs, the VHMS snapshot function saves all the data for a period of 5 minutes 30 seconds before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds). This snapshot function can be studied by pressing the manual switch. After the button is pressed, all data is automatically saved for seven minutes 30 seconds. All data can be automatically collected in cases such as torque converter stall, so it is possible to reduce the time taken for measurements in the Pm Clinic. However, the data sampling interval is one time every 10 seconds for the first 5 minutes and one time every 1 second for the next 2 minutes 30 seconds. To raise the precision of the data, it is necessary to create the conditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.

Necessary tools • Personal computer • VHMS technical analysis toolbox (software) 799-608-3211 • Download cable 799-608-3220 To ensure safety, stop the machine on level ground and put chocks under the tires to prevent the machine from moving. 1. Start the engine. 2. Select SNAPSHOT with the monitor panel (EMMS). a For details of the method of selecting, see Special functions of vehicle monitor (EMMS).

20-204 (10)

HD465-7, HD605-7



3. Press the [ ] button. "READY" is displayed. (Waiting status) 4. When the [ ] button is pressed, Snapshot is started and the time advances. (Running) If you want to stop, press the [ ] button to return to the Waiting status screen. 5. Run the engine at low idle and stabilize it for 2 minutes. a Check that the coolant temperature gauge and torque converter oil temperature gauge are in the white range. 6. After starting, operate the machine as shown in Table 1.

Table 1 Measurement conditions Start

Finish

Time

Operation of machine

1

0 : 00

2 : 00 120 sec Low idle (Low)

Auto

Economy

N

2

2 : 00

3 : 00

60 sec Low idle (Hi)

Auto

Economy

N

3

3 : 00

4 : 00

60 sec High idle (Stationary mode)

Auto

Economy

N

ON

mode Shift lever AISS switch Power setting

Parking brake

Retarder

Dump lever

ON

ON

Hold

OFF

OFF

Hold

ON

Float

4

4 : 00

5 : 00

60 sec Low idle (Hi)

Auto

Economy

N

ON

ON

Hold

5

5 : 00

5 : 30

30 sec High idle (Economy mode)

Auto

Economy

N

ON

ON

Hold

6

5 : 30

6 : 00

30 sec Torque converter stall (Economy mode)

Auto

Economy

D

OFF

ON

Hold

7

6 : 00

6 : 30

30 sec High idle (Power mode)

Auto

Power

N

ON

ON

Hold

8

6 : 30

7 : 00

30 sec Torque converter stall (Power mode)

Auto

Power

D

OFF

ON

Hold

7 : 30

High idle (Power mode) 30 sec + 20 pumping operations of foot brake

Auto

Power

N

ON

ON

Hold

9

(*1) (*2)

(*3)

7 : 00

Remarks

(*1)

(*2, *3) (*2, *3)

Press the foot brake. When stalling the torque converter [Portion marked with (*)], do not overheat it. [Stall of torque converter for 30 seconds is only a reference. When the oil temperature gauge reaches the top of the white range while the torque converter is stalled, return the transmission (gearshift) lever to the N position.] When setting the gearshift lever in the D position, return the engine speed to low idle temporarily (to prevent the machine from running out).

HD465-7, HD605-7

20-204-1 (10)



7. After 7 minutes 30 seconds, the screen on the right is displayed for 5 seconds, and then it returns to the opening screen. (Completion of Snapshot)

8. Download the snapshot data to the personal computer. For details, see Procedure for downloading VHMS data to personal computer. NOTICE The quick PM data is only recorded once. If the operation is carried out again, the data is overwritten, so after performing the quick PM, always download the data to the personal computer. 9. Use the technical analysis tool box to read the quick PM data. a For details of the method of using the technical analysis tool box, see the instruction manual. • Open the quick PM data and make a graph • For the X-axis, select Time and for the Yaxis, select 1) Engine Speed 2) Blowby Press 3) Exhaust Temp 1, 2 & 3 4) Exhaust Temp 4, 5 & 6 5) Engine Oil Press and put a check mark against Graph value display at click position (marked by ).

20-204-2 (2)

HD465-7, HD605-7



•

If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph.

(Example of graph display)

•

Enter these values on the Pm Clinic check sheet. The relationship between the measurement conditions and the necessary data in the Pm Clinic is as shown below. Conditions

1 2 3 4 5 6 7 8

9

Measurement items

Engine speed

Mode

Low idle Low idle High idle Low idle High idle Torque converter stall High idle Torque converter stall High idle + 20 pumping operations of foot brake

Low High Stationary mode Economy mode Economy mode

Engine speed

Blow-by pressure

Lubricating oil Exhaust pressure temperature

Brake oil pressure (*1)

Economy mode Power mode Power mode

Power mode

(*1) Cut OUT oil pressure and brake cut IN.

HD465-7, HD605-7

20-204-3 (10)


HD465-7, HD605-7

PM-CLINIC SERVICE

20-205 (10)


20-206 (10)

PM-CLINIC SERVICE

HD465-7, HD605-7


HD465-7, HD605-7

PM-CLINIC SERVICE

20-207 (10)

TROUBLESHOOTING Points to remember when troubleshooting ............................................................................................... 20Sequence of events in troubleshooting ..................................................................................................... 20Points to remember when carrying out maintenance................................................................................ 20Checks before troubleshooting ................................................................................................................. 20Categories, procedure, and method of using troubleshooting charts........................................................ 20Connection table for connector pin numbers ............................................................................................ 20T-adapter table .......................................................................................................................................... 20Types and locations of connectors ........................................................................................................... 20Connector arrangement location............................................................................................................... 20-

302 303 304 312 313 318 341 344 356

Troubleshooting of engine controller system (ENG mode) ....................................................................... 20- 401 Troubleshooting for transmission controller system (TM mode) ............................................................... 20- 501 Troubleshooting for retarder controller system (BK mode) ....................................................................... 20- 701 Troubleshooting for payload meter system (card type) (LC mode) ........................................................... 20- 801 Troubleshooting for monitor system (MON mode) .................................................................................... 20- 901 Troubleshooting of VHMS controller system (VHMS mode) ..................................................................... 20-1001 Troubleshooting of ASR controller system (ASR mode) ........................................................................... 20-1051 Troubleshooting of hydraulic and mechanical systems (H mode) .............................................................20-1101 Troubleshooting of engine system (S mode) ............................................................................................20-1151 Troubleshooting of electrical system (E mode) ........................................................................................ 20-1201 Troubleshooting of ABS controller system (ABS mode) (If equipped) ...................................................... 20-1251

HD465-7, HD605-7

20-301 (12)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level ground, and check that the safety pin, chocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the ma chine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. 2) Check the CHECKS BEFORE STARTING items.

20-302 (10)

3) 4)

4.

5.

6.

Other inspection items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. W hen operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that ma y make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

HD465-7, HD605-7

SEQUENCE OF EVENTS IN TROUBLESHOOTING

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING TEW00180

TEW00181

Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.

Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.

Step 3 Preparation of troubleshooting

tools

1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.

Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take

TEW00186

1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.

TEW00187

Step 6 Re-enacting failure •

Step 4 Go to jobsite

Step 5 Ask operator questions to confirm details of failure. • • • TEW00189

HD465-7, HD605-7

Drive and operate the machine to confirm the condition and judge if there is really a failure.

Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure?

20-303 (2)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.

Main failures occurring in wiring harness • Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

•

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-304 (10)

HD465-7, HD605-7

TROUBLESHOOTING


•

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

•

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

•

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

HD465-7, HD605-7

20-305 (10)

TROUBLESHOOTING


2) Removing, installing, and drying connectors and wiring harnesses i)

Disconnecting connectors a) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. b) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. a If the connector is twisted up and down or to the left or right, the housing may break.

c) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-306 (10)

HD465-7, HD605-7

TROUBLESHOOTING


ii) Connecting connectors a) Check the connector visually. • Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). • Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. • Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. b) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. c) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. d) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

HD465-7, HD605-7

20-307 (10)

TROUBLESHOOTING


iii) Connecting DT connectors Since the DT 8-pole and 12-pole heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. Male connector (1). Female conector (2). Normal locking state (Horizontal): a, b, d Incomplete locking state (Diagonal): c

iv) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. a) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.

b) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

c) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with contact restorer and reassemble.

20-308 (10)

HD465-7, HD605-7

TROUBLESHOOTING


3) Handling control box i) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. ii) Do not open the cover of the control box unless necessary.

iii) Do not place objects on top of the control box. iv) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. v) During rainy weather, do not leave the control box in a place where it is exposed to rain.

vi) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). vii) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

HD465-7, HD605-7

20-309 (10)

TROUBLESHOOTING

3. POINTS TO REMEMBER HYDRAULIC EQUIPMENT


WHEN

HANDLING

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.

3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-310 (1)

HD465-7, HD605-7

TROUBLESHOOTING


5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

HD465-7, HD605-7

20-311 (1)

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING (1. Check before starting and 2. Other check items) Item

Hydraulic oil, lubricating oil,coolant

1. Check fuel level 2. Water, sediment in fuel tank

Air, hydraulic, mechanical components Electrical components

Check before starting items

20-312 (10)

Fuel level —

Action Add fuel Drain

3. Check oil level in transmission case

Sight gauge

Add oil

4. Check oil level in hydraulic tank

Sight gauge

Add oil

5. Check oil level in engine oil pan

Oil level gauge

Add oil

6. Check coolant level

—

7. Check dust indicator

Dust indicator

Clean, replace

8. Check that steering wheel play is correct

Max. 135 mm

Adjust

Actuation 20 sec

Repair

Label

Repair

9. Check emergency steering

1

Judgement value

10. Check length of suspension cylinder 11. Check tire inflation pressure, check for damage

—

Add coolant

Inflate or replace

Torque (see DISASSEMBLY AND ASSEMBLY)

Tighten

13. Check foot brake effect

—

Adjust

14. Check parking brake effect

—

Adjust or repair

15. Check that emergency brake works properly

—

Adjust or repair

16. Check that there is no abnormality in operation of steering

—

Adjust or repair

17. Check that direction of rear view mirror and under mirror is correct

—

Adjust

18. Check that there is no abnormality in exhaust color or sound

—

Adjust or repair

19. Check that retarder brake works properly

—

Adjust or repair

20. Check that body mount rubber is normal

—

Replace

21. Check that horn sounds

—

Repair

22. Check that lamps flash properly

—

Repair or replace

23. Check that gauges work properly during operation

—

Adjust or repair

24. Check monitor panel

—

Adjust or repair

25. Check mechanical monitor system

—

Repair or replace

26. Check central warning lamp

—

Adjust or repair

27. Check for looseness, corrosion of battery terminal wiring

—

Retighten or clean

28. Check for looseness, corrosion of alternator terminal wiring

—

Retighten or clean

29. Check for looseness, corrosion of starting motor terminal wiring

—

Retighten or clean

12. Check hub nuts

HD465-7, HD605-7

CHECKS BEFORE TROUBLESHOOTING


Hydraulic, mechanical equipment

Item

Electrics, electrical components

Other check items

Action

30. Check for abnormal noise or smell

—

Repair

31. Check for oil leakage

—

Repair

32. Air bleed operation

—

Bleed air

33. Check battery voltage (engine stopped)

2

Judgement value

24V

Charge or replace

34. Check battery electrolyte level

—

Add distilled water

35. Check wiring for discoloration, burn marks, peeling of cover

—

Replace

36. Check for loose wiring clamps, hanging wiring

—

Repair

37. Check for wet wiring (be particularly careful to check connectors and terminals)

—

Dry

38. Check for blown fuses, defective contact

—

Replace

27.5 – 29.5 V

Replace

—

Replace

39. Check alternator voltage after several minutes of running (engine at 1/2 throttle or above) 40. Check for actuation sound from battery relay (when starting switch is turned ON-OFF)

HD465-7, HD605-7

20-312-1 (10)

TROUBLESHOOTING

CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS

CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code a If the machine monitor displays a failure code, it also displays the controller name at the same time, so the troubleshooting codes are categorized to match each controller name. (This may also include the electrical system, where some failure codes are not displayed). a The hydraulic and mechanical system, for which the machine monitor cannot display a failure code, is categorized as H Mode. Troubleshooting Code ENG

Troubleshooting System Troubleshooting of engine controller system

TM

Troubleshooting for transmission controller system

BK

Troubleshooting for retarder controller system

LC

Troubleshooting for payload meter system (card type)

MON HM

Troubleshooting for monitor system Troubleshooting VHMS controller system

H

Troubleshooting of hydraulic and mechanical systems

S

Troubleshooting of engine body

E

Troubleshooting of electrical system

2. Troubleshooting procedure a If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows. 1) When machine monitor displays failure code If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the content of the display, then go to the applicable troubleshooting chart for the failure code. 2) When machine monitor does not display failure code, but fault history is recorded If a problem occurs but the failure code display cannot be checked on the machine monitor, use the fault history display function in the machine monitor service mode to check for a failure code. If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable troubleshooting chart. 3) When machine monitor does not display failure code and fault history is also not recorded If a problem occurs but the failure code display cannot be checked on the machine monitor, and the problem is also not recorded by the fault history display function in the machine monitor service mode, there is a probability that is a problem in the electrical system that cannot be detected by a controller or that a problem has occurred in the hydraulic and mechanical system. In this case, check the nature of the problem and go to the applicable troubleshooting chart.

HD465-7, HD605-7

20-313 (11)


TROUBLESHOOTING

Phenomena considered to be failures and troubleshooting No. q go to troubleshooting No. on failure code display Troubleshooting No.

Phenomena considered to be failures

Error code

ENG mode

TM mode

BK mode

LC mode

MON mode

VHMS mode

H mode

S mode

Error code related 1

Error code is displayed in error code display mode

q

Engine related 2

Starting performance is poor (starting always takes time)

3 Engine does not start

4 5

ENG-1

S-1

Engine does not turn

S-2 a)

Engine turns but no exhaust smoke comes out Exhaust smoke comes out but engine does not start

S-2 b) S-2 c)

6

Engine does not pick up smoothly (follow-up is poor)

S-3

7

Engine stops during operations

S-4

8

Engine does not rotate smoothly (hunting)

S-5

9

Engine lacks output (or lacks power)

S-6

10

Exhaust smoke is black (incomplete combustion)

S-7

11

Oil consumption is excessive (or exhaust smoke is blue)

S-8

12

Oil becomes contaminated quickly

S-9

13

Fuel consumption is excessive

S-10

14

Oil is in coolant, or water spurts back, or coolant level goes down Oil pressure caution lamp lights up (drop in oil pressure)

S-11

15

S-12

16

Oil level rises

S-13

17

Coolant temperature becomes too high (overheating)

S-14

18

Abnormal noise is made

S-15

19

Vibration is excessive

S-16

20

Failure in preheating

21 22

AISS function does not work normally

Engine is not preheated

ENG-2a)

Engine is still preheated after preheating time When AISS switch is set in AUTO, LOW SPEED control is selected When AISS switch is set in LOW SPEED, AUTO control is selected

ENG-2b)

Not error code is displayed in error code display mode

ENG-3a) ENG-3b) TM1 – 27

Transmission controller related 23 24 25 26 27

Fuel level gauge does not operate normally (It always indicates "FULL") When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON Abnormality in Backup lamp is not turned ON backup lamp (Backup buzzer is normal) and backup Backup buzzer is not turned ON buzzer (Backup lamp is normal) While shift lever is not operated, backup lamp and backup buzzer

20-314 (10)

TM-1 TM-2a) TM-2b) TM-2c) TM-2d)

HD465-7, HD605-7


TROUBLESHOOTING

Troubleshooting No.


Error code

ENG mode

TM mode

BK mode

LC mode

MON mode

VHMS mode

H mode

S mode

Retarder controller related

28

29 30 31

When the parking brake switch is set in the OFF position, the parking brake s not released When the parking brake switch is set in the PARK position, the parking brake does not work Retarder brake oil temperature gauge does not operate normally Inclination alarm is turned ON when dump body is raised (When chassis is not inclined laterally more than 15°) Parking brake does not operate normally

Touch up/down and cancellation cannot be performed

BK-1a) BK-1b) BK-2 BK-3 BK-4

Payload meter related

34

When starting switch is turned ON, any item is not displayed After starting switch is turned ON, all external pilot lamps do not light up External lamps light up while condition for lighting is not set

LC-3

35

Lighting level of external pilot lamps is abnormal

LC-4

32 33

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Cycle data and engine ON/OFF data not recorded (charge level signal system: judges that engine is stopped) Calibration cannot be performed and displayed clock does not conform to condition (shift lever "N" position signal system) When loaded dump truck starts traveling, "0" is kept displayed After loaded dump truck start traveling, display of odometer does not increase Displayed logic When travel speed exceeds limit is abnormal speed, "SP:SP" does not go off Integrated pay load is not displayed Displayed and saved pay load is not correct Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in "FLOAT" position while truck is not dumping) Payload meter displays "F:09" (lowering of internal backup battery voltage) Payload meter displays " :FULL" (data saving memory is full) Payload meter displays "F-20" :failure in power source of suspension pressure sensor and clinometer system Payload meter displays "F-21" – "F-24" : disconnection or grounding fault in suspension pressure sensor signal system Payload meter displays "F-25" – "F-28" : short circuit with power source in suspension sensor signal system Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) Payload meter displays "F:43" – "F:45" (short circuit with power source in external pilot lamp relay system) Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck travels for 160 m after it is loaded Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal system Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal system Payload meter displays "F:18" (disconnection in charge level signal system)

HD465-7, HD605-7

LC-1 LC-2

LC-5 LC-6 LC-7a) LC-7b) LC-7c) LC-7d) LC-7e) LC-8 LC-9 LC-10 LC-11 LC-12 LC-13 LC-14 LC-15 LC-16 LC-17 LC-18 LC-19 LC-20

20-315 (10)


TROUBLESHOOTING

Troubleshooting No.


Error code

ENG mode

TM mode

BK mode

LC mode

MON mode

VHMS mode

H mode

S mode

Monitor related 56

When starting switch is turned ON, machine monitor does not display any item

MON-1

57

When starting switch is turned OFF and machine monitor does not operate normally

MON-2

58

Alarm buzzer defective

Alarm buzzer does not sound

MON-3a)

Alarm buzzer does not stop sounding

MON-3b)

Items displayed by gauges are different from machine condition

MON-4

Items displayed by caution lamps are different from machine condition

MON-4

Character display does not display any item or it displays abnormally

MON-4

60

Operation of machine monitor cannot be checked normally

MON-5

61

Display of character display cannot be selected normally

59

62

63

64

65

Items displayed by gauges, caution lamps, and character display of machine monitor are abnormal

Machine monitor mode select switch 1 system is abnormal

MON-6

Machine monitor mode select switch 2 system is abnormal

MON-6

Power mode select function does not work normally

MON-7

Lamp lights up while seat belt is fastened

MON-8a)

Lamp does not light up while seat belt is unfastened

MON-8b)

When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash

MON-9a)

When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up

MON-9b)

When turn signal lever is operated, turn signal lamps on either or both sides do not flash (When hazard lamp switch is operated, however, turn signal lamps flash normally)

MON-9c)

W h e n h a z a r d l a m p s w it c h i s turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally)

MON-9d)

W h e n h a z a r d l a m p s w it c h i s turned OFF, turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally)

MON-9e)

Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however)

MON-9f)

When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up

MON-10a)

When lamp switch is set in 1st position, small lamp and night lamp do not light up

MON-10b)

When lamp switch is OFF, small lamp and night lamp light up

MON-10c)

When dimmer switch is operated, brightness of night lighting does not change

MON-10d)

Head lamp "Hi" beam does not light up

MON-10e)

Seat belt caution lamp does not operate normally

Turn signals and hazard lamp do not operate normally

Night lighting is abnormal

20-316 (10)

HD465-7, HD605-7


TROUBLESHOOTING

Troubleshooting No.

65

66


Night lighting is abnormal

Power window does not operate normally

Head lamp "Lo" beam does not light up Head lamp cannot be set to "Hi" or "Lo" When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up Left window does not work Right window does not work Air conditioner does not operate Air is not blown out or airflow cannot be adjusted Air is not cooled or temperature cannot be adjusted (Electric system)

67

Defective air conditioner

Inside air and fresh air cannot be selected Air outlet cannot be selected Cooling capacity is low (Mechanical system) Heating capacity is low (Defective hot water circuit) Abnormal noise comes out Water leaks

Error code

ENG mode

TM mode

BK mode

LC mode

MON mode

VHMS mode

H mode

S mode

MON-10f) MON-10g) MON-10h) MON11a) MON11b) MON12a) MON12b) MON12c) MON12d) MON12e) MON12f) MON12g) MON12h) MON12i)

VHMS

68

Abnormality in satellite data communication

Satellite communication data are not transmitted

VHMS-1

Downloading into PC

69

Abnormality in saving in VHMS controller (Data are not saved)

VHMS-2

70

Engine blow-by pressure of monitoring display is low (when measurement equipment shows blow-by pressure is normal)

VHMS-3

Hydraulic and mechanical related 71

Machine does not start

H-1

72

Machine does not travel smoothly

H-2

73

Lock-up clutch cannot be disengaged

H-3

74

Excessive shock when starting or shifting

H-4

75

Transmission does not shift up

H-5

76

Machine lacks power or speed when traveling

Abnormality at all speed ranges

H-6a)

Torque converter lock-up does not engage Abnormality at specific speed ranges

H-6b) H-6c)

77

Time lag is excessive when starting or shifting gear

H-7

78

Torque converter oil temperature is high

H-8

79

Torque converter oil pressure is low

H-9

80

Front brake is ineffective, or effective only on one side

H-10

81

Rear brake is ineffective, or effective only on one side

H-11

HD465-7, HD605-7

20-317 (10)


TROUBLESHOOTING

Troubleshooting No.


Error code

ENG mode

TM mode

BK mode

LC mode

MON mode

VHMS mode

H mode

82

Steering wheel is heavy

H-12

83

Steering wheel does not work

H-13

84

Steering wheel vibrates

H-14

85

Hoist cylinder lacks lifting force (lifting speed)

H-15

86

Hoist cylinder does not work

H-16

87

Excessive hydraulic drift of dump body

H-17

20-317-1 (9)

S mode

HD465-7, HD605-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins while the terms male housing and female housing refer to the mating portion of the housing. X-type connector

No. of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

1

Part No.: 08055-00181

Part no.: 08055-00191

799-601-7010

2

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

3

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

4

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

—

Terminal part no.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: black • Quantity: 20

Terminal part no.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: black • Quantity: 20

—

—

Terminal part no.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: red • Quantity: 20

Terminal part no.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: red • Quantity: 20

—

20-318 (10)

HD465-7, HD605-7

TROUBLESHOOTING

No. of pins


SWP-type connector Male (female housing)


6

T-adapter Part No.

799-601-7050

Part No.: 08055- 10681

Part No.: Part No.: 08055- 10691

8

799-601-7060

Part No.: 08055-10881

Part No.: 08055- 10891

12

799-601-7310

Part No.: 08055- 11281

Part No.: 08055- 11291

14

799-601-7070

Part No.: 08055- 11481

HD465-7, HD605-7

Part No.: 08055-11491

20-319 (1)

TROUBLESHOOTING


SWP-type connector

No. of pins



16

T-adapter Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

—

Terminal part no.: • Electric wire size: 0.85 • Grommet: black • Quantity: 20

Terminal part no.: • Electric wire size: 0.85 • Grommet: black • Quantity: 20

—

—

Terminal part no.: • Electric wire size: 1.25 • Grommet: red • Quantity: 20

Terminal part no.: • Electric wire size: 1.25 • Grommet: red • Quantity: 20

—

20-320 (10)

HD465-7, HD605-7

TROUBLESHOOTING


M-type connector

No. of pins



T-adapter Part No.

1

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

2

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

3

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

4

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

6

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

8

799-601-7340

Part No.: 08056-00871

HD465-7, HD605-7

Part No.: 08056-00881

20-321 (7)

TROUBLESHOOTING

No. of pins


S-type connector Male (female housing)


8

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10 (white)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12 (white)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16 (white)

799-601-7330

Part No.: 08056-11671

20-322 (10)

T-adapter Part No.

Part No.: 08056-11681

HD465-7, HD605-7


TROUBLESHOOTING

No. of pins

S-type connector Male (female housing)


10 (blue)

T-adapter Part No.

—

—

—

12 (blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16 (blue)

799-601-7170

Part No.: 08056-11672

HD465-7, HD605-7

Part No.: 08056-11682

20-323 (1)

TROUBLESHOOTING

No. of pins


MIC type connector Male (female housing)


T-adapter Part No.

7

Housing part No.: 79A-222-2640 Qty.: 5


—

11



—

5

799-601-2710



9

799-601-2950



13

799-601-2720


20-324 (10)


HD465-7, HD605-7

TROUBLESHOOTING

No. of pins


MIC type connector Male (female housing)


17

T-adapter Part No.

799-601-2730



21

799-601-2740





HD465-7, HD605-7

—

20-325 (1)


TROUBLESHOOTING

No. of pins

AMP040-type connector Male (female housing)

T-adapter Part No.


8

799-601-7180

—


12

799-601-7190

—


16

799-601-7210

—


20

799-601-7220

—


aTerminal part No.: 79A-222-3470 (no relation with number of pins)

20-326 (1)

HD465-7, HD605-7


TROUBLESHOOTING

No. of pins

AMP070-type connector Male (female housing)


10

799-601-7510

—

Part No.: 7821-92-7330

12

799-601-7520

—

Part No.: 7821-92-7340

14

799-601-7530

—

Part No.: 7821-92-7350

18

799-601-7540

—

Part No.: 7821-92-7360

20

799-601-7550

—

HD465-7, HD605-7

T-adapter Part No.

Part No.: 7821-92-7370

20-327 (9)


TROUBLESHOOTING

No. of pins

L type connector Male (female housing)


—

2

—

No. of pins

T-adapter Part No.

—

—

PA type connector Male (female housing)


—

—

T-adapter Part No.

9

No. of pins

Bendix MS connector Male (female housing)


10

799-601-3460

—

20-328 (10)

T-adapter Part No.

—

HD465-7, HD605-7


TROUBLESHOOTING

No. of pins

KES 1 (Automobile) connector Male (female housing)


2

T-adapter Part No.

—

Part No.: 08027-10210 (natural color) 08027-10220 (black)


3

—

Part No.: 08027-10310

Part No.: 08027-10360

4

—



6

—


HD465-7, HD605-7


20-329 (1)


TROUBLESHOOTING

No. of pins

KES 1 (Automobile) connector Male (female housing)

T-adapter Part No.


8

—


20-330 (1)


HD465-7, HD605-7


TROUBLESHOOTING

No. of pins

Connector for relay (socket type) Male (female housing)


5

799-601-7360

—

—

6

799-601-7370

—

HD465-7, HD605-7

T-adapter Part No.

—

20-331 (10)


TROUBLESHOOTING

No. of pins

F-type connector Male (female housing)


4

—

—

20-332 (1)

T-adapter Part No.

—

HD465-7, HD605-7


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 series connector

Type (shell size code)

18-8 (1)

18-14 (2)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106


Pin (male terminal)

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206

Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106

Pin (male terminal)


Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206

Part No.: 08191-24101, 08191-24102 08191-24105, 08191-24106


Pin (male terminal)

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

HD465-7, HD605-7

T-adapter Part No.

799-601-9210

799-601-9220

20-333 (10)


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

18-20 (3)

18-21 (4)

20-334 (10)

HD30 series connector Body (plug)

Body (receptacle)

Pin (male terminal)


Part No.: 08191-31201, 08191-31202

Part No.: 08191-34101, 08191-34102


Pin (male terminal)

Part No.: 08191-32201, 08191-32202

Part No.: 08191-33101, 08191-33102

Pin (male terminal)


Part No.: 08191-41201, 08191-42202

Part No.: 08191-44101, 08191-44102


Pin (male terminal)

Part No.: 08191-42201, 08191-42202

Part No.: 08191-43101, 08191-43102

T-adapter Part No.

799-601-9230

799-601-9240

HD465-7, HD605-7


TROUBLESHOOTING



24-9 (5)

24-16 (6)

Body (plug)

Body (receptacle)

Pin (male terminal)


Part No.: 08191-51201, 08191-51202

Part No.: 08191-54101, 08191-54102


Pin (male terminal)

Part No.: 08191-52201, 08191-52202

Part No.: 08191-53101, 08191-53102

Pin (male terminal)


Part No.: 08191-61201, 08191-62202 08191-61205, 08191-62206

Part No.: 08191-64101, 08191-64102 08191-64105, 08191-64106


Pin (male terminal)

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

T-adapter Part No.

799-601-9250

799-601-9260

HD465-7, HD605-7

20-335 (10)


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

24-21 (7)

24-22 (8)

20-336 (10)

HD30 series connector T-adapter Part No.

Body (plug)

Body (receptacle)

Pin (male terminal)


Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106


Pin (male terminal)

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206

Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106

Pin (male terminal)


Part No.: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-81206

Part No.: 08191-84101, 08191-84102, 08191-84103, 08191-84104, 08191-84105, 08191-84106


Pin (male terminal)

Part No.: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206

Part No.: 08191-83101, 08191-83102, 08191-83103, 08191-83104, 08191-83105, 08191-83106

799-601-9270

799-601-9280

HD465-7, HD605-7


TROUBLESHOOTING



24-31 (9)

Body (plug)

Body (receptacle)

Pin (male terminal)


Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106


Pin (male terminal)

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

T-adapter Part No.

799-601-9290

HD465-7, HD605-7

20-337 (10)


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)]

No. of pins

DT series connector Body (plug)

T-adapter Part No.

Body (receptacle)

2

799-601-9020

Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)


3

799-601-9030



4

799-601-9040



6

799-601-9050


20-338 (10)


HD465-7, HD605-7


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] DT series connector

No. of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

8Gr: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8Br: 799-601-9090

8

Part No.: 08192-1820 08192-2820

(normal type) (fine wire type)


12Gr: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12Br: 799-601-9140

12


HD465-7, HD605-7


20-339 (10)


TROUBLESHOOTING


No. of pins

DTM series connector Body (plug)

Body (receptacle)

2

T-adapter Part No.

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100


No. of pins

DTHD series connector T-adapter Part No.

Body (plug)

Body (receptacle)

Part No.: 08192 - 31200 (contact size #12) 08192 - 41200 (contact size #8) 08192 - 51200 (contact size #4)

Part No.: 08192 - 31100 (contact size #12) 08192 - 41100 (contact size #8) 08192 - 51100 (contact size #4)

1

20-340 (10)

HD465-7, HD605-7


TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins

DRC26 Series connector Body (plug)

Body (receptacle)

24

799-601-9360

—

Part No.: 7821-93-3110

40 (A)

799-601-9350

—

Part No.: 7821-93-3120

40 (B)

799-601-9350

—

HD465-7, HD605-7

T-adapter Part No.

Part No.: 7821-93-3130

20-340-1 (9)

T-ADAPTER TABLE

TROUBLESHOOTING

T-ADAPTER TABLE

799-601-2600

For measuring box

Econo-21P

799-601-3100

For measuring box

MS-37P

799-601-3200

For measuring box

MS-37P

799-601-3300

For measuring box

Econo-24P

799-601-3360

Plate

For MS box

799-601-3370

Plate

For MS box

799-601-3380

Plate

For MS box

799-601-3410

BENDIX(MS)

24P

799-601-3420

BENDIX(MS)

24P

799-601-3430

BENDIX(MS)

17P

799-601-3440

BENDIX(MS)

17P

799-601-3450

BENDIX(MS)

5P

799-601-3460

BENDIX(MS)

10P

799-601-3510

BENDIX(MS)

5P

799-601-3520

BENDIX(MS)

14P

799-601-3530

BENDIX(MS)

19P

799-601-2910

BENDIX(MS)

14P

799-601-3470

CASE

799-601-2710

MIC

5P

799-601-2720

MIC

13P

799-601-2730

MIC

17P

799-601-2740

MIC

21P

799-601-2950

MIC

9P

799-601-2750

ECONO

2P

799-601-2760

ECONO

3P

799-601-2770

ECONO

4P

799-601-2780

ECONO

8P

799-601-2790

ECONO

12P

799-601-2810

DLI

8P

799-601-2820

DLI

12P

799-601-2830

DLI

16P

799-601-2840

Extension cable

799-601-2850

CASE

799-601-7010

X

1P

799-601-7020

X

2P

799-601-7030

X

3P

799-601-7040

X

4P

799-601-7050

SWP

6P

799-601-7060

SWP

8P

799-601-7310

SWP

12P

799-601-7070

SWP

14P

HD465-7, HD605-7

Q

Q Q

Q Q

Q

Q Q Q Q Q Q Q Q Q

Q Q Q

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

Q Q Q

Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q

Q

Q

Q Q Q Q Q

Q Q Q Q Q

Q Q Q Q Q Q

Q Q Q Q

Q

Q

Q

20-341 (12)

T-ADAPTER TABLE

TROUBLESHOOTING

M

1P

799-601-7090

M

2P

799-601-7110

M

3P

799-601-7120

M

4P

799-601-7130

M

6P

799-601-7340

M

8P

799-601-7140

S

8P

799-601-7150

S

10P-White

799-601-7160

S

12P-Blue

799-601-7170

S

16P-Blue

799-601-7330

S

16P-White

799-601-7350

S

12P-White

799-601-7180

AMP040

8P

799-601-7190

AMP040

12P

799-601-7210

AMP040

16P

799-601-7220

AMP040

20P

799-601-7230

Short connector

X-2

799-601-7240

Case

799-601-7270

Case

799-601-7510

070

10P

799-601-7520

070

12P

799-601-7530

070

14P

799-601-7540

070

18P

799-601-7550

070

20P

799-601-7360

Relay connector

5p

799-601-7370

Relay connector

6p

799-601-7380

JFC connector

2P

799-601-9010

DTM

2P

799-601-9020

DT

2P

799-601-9030

DT

3P

799-601-9040

DT

4P

DT

6P

799-601-9060

DT

8P-Gray

799-601-9070

DT

8P-Black

799-601-9080

DT

8P-Green

799-601-9090

DT

8P-Blown

799-601-9110

DT

12P-Gray

799-601-9120

DT

12P-Black

799-601-9130

DT

12P-Green

799-601-9140

DT

12P-Blown

799-601-9210

HD30

18-8

799-601-9220

HD30

18-14

(12)

—

799-601-9300

799-601-9200

Q Q Q Q

799-601-9100

Q Q Q Q

799-601-9000

Q Q Q Q

799-601-8000

Q Q Q Q

799-601-7500

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

Q Q Q Q

Q Q Q Q Q

Q

16P

799-601-9050

20-342

799-601-7400

SWP

799-601-7080

799-601-7100

799-601-7320

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

Q Q Q Q Q Q Q

Q

Q Q Q

Q Q Q Q Q Q Q Q Q Q Q Q Q Q

Q Q Q Q

Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q Q Q Q

HD465-7, HD605-7

T-ADAPTER TABLE

TROUBLESHOOTING

18-20

HD30

18-21

799-601-9250

HD30

24-9

799-601-9260

HD30

24-16

799-601-9270

HD30

24-21

799-601-9280

HD30

24-23

—

Q Q Q Q Q Q Q Q Q

799-601-9300

Q Q Q Q Q Q Q Q Q Q

799-601-9200

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-9100

HD30

799-601-9240

799-601-9000

799-601-9230

799-601-2900

Pin No.

799-601-2800

Connector type

799-601-2700

Port No.

799-601-2500

KIT No.

799-601-9290

HD30

24-31

799-601-9310

Plate

For HD30

799-601-9320

For measuring box

For DT, HD

799-601-9330

Case

799-601-9340

Case

799-601-9350

DRC26

40P

799-601-9360

DRC26

24P

799-601-9410

For NE, G sensor

2P

Q

799-601-9420

For boost pressure, fuel

3P

Q

799-601-9430

PVC socket

2P

Q

HD465-7, HD605-7

Q Q

Q Q Q

20-343 (12)

TYPES AND LOCATIONS OF CONNECTORS

TROUBLESHOOTING

TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. connector of pin

Address Location

3-dimensional wiring diagram ENG

System diagram TM

BK

PLM

MON VHMS

01

Terminal

1

Battery relay (B)

B9

J-1

K-8

H-9

K-9

N-9

02

Terminal

1

Battery relay (M)

B9

J-1

K-8

H-8

K-8

N-8

03

Terminal

1

Battery relay (B)

B9

J-1

K-8

H-8

K-8

N-8

04

Terminal

1

Battery relay (M)

B9

J-1

K-8

H-8

K-8

N-8

05

Terminal

1

Emergency steering relay (B)

A8

K-9

06

Terminal

1

Emergency steering relay (M)

A8

K-9

07

Terminal

1


A8

K-9

08

Terminal

1


A9

K-9

11

Terminal

1

Battery relay (E)

B8

J-1

K-8

H-9

K-9

N-9

12

Terminal

1

Battery relay (BR)

B8

J-1

K-8

H-8

K-8

N-8

12

KES0

2

Washer tank motor

—

J-1

K-8

13

Terminal

1

Battery relay (E)

C8

J-1

K-8

H-8

K-8

N-8

14

Terminal

1

Battery relay (BR)

C8

H-8

K-8

N-8

15

Terminal

1

Emergency steering relay (E)

A8

K-9

16

Terminal

1

Emergency steering relay (BR)

A7

K-9

17

Terminal

1


B7

K-9

18

Terminal

1


B7

K-8

20

—

1

Circuit breaker

A9

L-8

N-8

21

—

1

Circuit breaker

A9

L-8

N-7

22

—

1

Circuit breaker

A9

J-2

K-8

I-8

L-8

N-8

23

—

1

Circuit breaker

B9

I-2

K-8

I-8

L-8

N-7

1939

HD30

9

Connector for connecting J1939 device

—

G-9

A

1

Lamp (Optional for payload meter)

—

J-9

A

One-pin connector One-pin connector

1


—

H-1

A1

M

1

Emergency reset connector

X6

B-7

A2

M

1


V8

B-7

3

Air pressure sensor

AH5

AAPR PACKARD

A-3

B-1

ABS

M

6

ABS system switch

O2

E-9

AC1

One-pin connector

1

Air conditioner wiring harness

M3

C-7

ACBM

YAZAKI

2

Air conditioner blower motor

T2

A-9

ACCF

DT-T

3

ACC oil pressure sensor (Front)

L4

L-2

K-4

ACCR

DT-T

3

ACC oil pressure sensor (Rear)

K3

L-2

K-4

ACM1

AMP

5

Temperature regulation servomotor

V3

A-8

ACM2

AMP

5

Air outlet mode selection servomotor

M6

B-9

20-344 (10)

ASR

HD465-7, HD605-7

TROUBLESHOOTING


Address

ConType Numnector of ber No. connector of pin

Location


System diagram TM

BK

PLM

MON VHMS

ASR

ACM3

AMP

5

Recirculated/Fresh air selection servomotor

ACP1

AMP

16

Air conditioner control panel

O7

B-9

ACP2

AMP

12


O7

B-9

ACPS SUMITOMO

2

Air conditioner pressure switch

U2

A-8

ACR1

Relay

4

Blower main relay

W3

A-8

ACR2

Relay

4

Blower Hi relay

W4

A-8

ACR3

Relay

4

Blower M2 relay

W4

A-7

ACR4

Relay

4

Blower M1 relay

W4

A-7

ACR5

Relay

4

Compressor clutch relay

W4

A-7

ACRE

AMP

4

Air conditioner blower resistor

U2

A-8

ACTH

YAZAKI

2

Thermistor

U3

A-8

AISS

M

6

AISS switch

M3

ARC

M

3

ARSC set switch

P8

F-9

ARSC

M

6

ARSC system switch

N3

C-1

AS1

SWP

6

Acceleration sensor

N2

AS2

X

3

Acceleration sensor

O2

ASR

M

6

ASR system switch

O2

ASR1

DT-T-T

2

Steering angle sensor

C2

C-9

ASR2

DT-T-T

2

Shut off valve

L2

D-9

ASR3

DT-T-T

2

ASR valve (R)

K3

D-9

ASR4

DT-T-T

2

ASR valve (L)

L3

E-9

ASR5

DT-T

2

ASR oil pressure switch (R)

K3

E-9

ASR6

DT-T

2

ASR oil pressure switch (L)

L2

F-9

ASR7

DT-T

2

ASR oil ptessure switch (Main)

K1

F-9

ASS

DT-T

2

Air suspension seat

T2

ATC1

MIC

17


Z1

ATC2

MIC

21


Z1

ATC3A AMP040

20


Z4

ATC3B AMP040

16


Z4

AMP040

12


AA4

ATC5A AMP040

20


AA1

ATC5B AMP040

16


AA4

A-4 A-3

ATC4

W3

A-7

L-5

F-9

L-2 C-8 F-9

L-8

A-7

E-1

E-1

A-6

E-1

E-1

A-6

E-1

L-7

A-5

E-1

L-7

A-5

H-1

A-7 L-8

F-1

I-1

ATC6

X

4

Software rewriting connector (Transmission controller)

W4

B01

DT-T

6

Intermediate connector

K9

M-5

B02

DT-T

6


K8

M-5

HD465-7, HD605-7

F-5

20-345 (5)


TROUBLESHOOTING

Address


Location


System diagram TM

BK

PLM

MON VHMS

B03

DT-T

6

Winker lamp, stop lamp, tail lamp

J9

B04

Terminal

1

Backup lamp

J9

F-9

M-6

B05

Terminal

1

Backup alarm buzzer

J9

F-9

M-6

B06

Terminal

1

Backup alarm buzzer

J9

F-9

M-6

B07

DT-T

3

Body position sensor

K9

B1

1

Lamp (Payload meter) (If equipped)

—

I-9

B1


1


—

H-1

B10

Terminal

1

Grounding

K8

B11

Terminal

1

Grounding

L8

B2

1


—

J-9

1


—

H-1

1


—

J-9

1


—

H-1

1

Beacon lamp

T9

8


F9

BL

One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector DT-T (Gray) One-pin connector

1


C7

BLS

M

6

Rotary lamp switch (If equipped)

N1

C-9

BR

One-pin connector

1


M4

C-7

BRC1

MIC

17

Retarder controller

Y2

BRC2

MIC

21

Retarder controller

Y2

BRC3A AMP040

20

Retarder controller

Y4

BRC3B AMP040

16

Retarder controller

Y4

AMP040

12

Retarder controller

Z4

BRC5A AMP040

20

Retarder controller

Y1

BRC5B AMP040

16

Retarder controller

Y2

B2 B3 B3 BCOM BK

BRC4

M-6

K-5

G-9

M-4 M-5

A-2 H-2

M-2

I-8

J-9

C-1

A-8

D-1

H-1

A-7 C-1

A-6

A-1 D-1

B-1

A-5 J-9

C-1

A-5

D-1

H-1

A-4 C-1

A-3

D-1

BRC6

X

4

Software rewriting connector (Retarder controller)

S9

BT

DT

6


C9

BT1

—

—

Fuse box

X5

BT2

—

—

Fuse box

X7

L-4

E-2

BT3

—

—

Fuse box

X6

L-4

E-2

BT4

—

—

Fuse box

X6

L-3

E-2

BZ2

M

2

Buzzer

R1

D-9

CAB1

8


Q9

F-1

CAB2

DT-T (Gray) DT-T (Black)

8


Q9

CAN

DT

3

CAN connector

AJ6

20-346 (10)

ASR

A-2 I-2

H-6

G-8

J-6

M-9

E-7

K-3

F-3

E-7

I-3

F-3

E-6

K-3

E-6

I-3

E-3

F-4

B-9 H-9

L-6

M-3

A-2

HD465-7, HD605-7

TROUBLESHOOTING


Address


Location


System diagram TM

BK

PLM

MON VHMS

CAN1

DT-T

3

VHMS CAN connector

T9

CAN2

DT-T

3

Resistor

Q1

CG1

One-pin connector

1

Cigarette lighter

M5

CG2

—

1

Cigarette lighter

M5

CH1

S

8

Machine monitor mode selector switch 1

M1

E-9

CH2

S

8


M1

E-9

CJA

DT-T

6

Joint connector

D8

L-9

CJB

DT-T (Black)

8

Joint connector

B7

CJB

DT-T

6

Joint connector

E8

CJC

DT-T

6

Joint connector

D8

CJD

DT

6

Joint connector

D8

CJE2

DT-T

6

Joint connector

AI9

G-1

M-1

CJE3

8

Joint connector

A12

G-1

M-1

L-3

CJH1

DT-T (Black) DT-T (Black)

8

Joint connector

—

I-9

J-1

CJH2

DT-T

6

Joint connector

—

CJK

DT

6

Joint connector

B8

CJL

DT-T

6

Joint connector

L7

CJN

DT (Black)

8

Joint connector

J3

I-1

CJP

DT-T

6

Joint connector

I9

I-1

CJP1

DT-T

6

Joint connector

H9

I-1

CJP2

DT-T

6

Joint connector

I9

H-1

CJPR

DT-T

6

Joint connector

C8

I-9

CJS

DT-T

6

Joint connector

L7

CJSL

DT-T

6

Joint connector

I9

CJT

8

Joint connector

L8

G-9

CJT1

DT (Black) DT-T (Black)

8

Joint connector

L7

G-1

CJT2

DT-T

6

Joint connector

H9

G-1

CJW

DT-T

6

Joint connector

CK1

YAZAKI

6

Bulb breakage check switch

M2

2

Coolant temperature sensor

AE8

CLTP PACKARD

C-9 F-9

D-9

I-1

M-9 L-9

G-8 H-9

I-1

H-9 H-9

M-9

K-1

N-7 M-1

J-1

J-1

J-9

H-9

J-9

H-9

I-1

M-9 M-1

J-1

N-5 I-1 N-5

F-7 F-9 A-1

CM

DT-T (Green)

8

Lighting switch, passing switch, turn switch

CN3

DT-T

2

Input shaft speed sensor

AC9

M-8

CN4

DT-T

2

Intermediate shaft speed sensor

AC9

M-8

CN5

DT-T

2

Output shaft speed sensor

AD7

M-8

CN6

DT-T

2

Solenoid for transmission 1st clutch

AB9

M-6

HD465-7, HD605-7

ASR

Q8

B-2

G-2

K-4

20-347 (10)


TROUBLESHOOTING

Address


Location


System diagram TM

CN7

DT-T

2

Fill switch for transmission 1st clutch

AB9

N-6

CN8

DT-T

2

Solenoid for transmission 2nd clutch

AB9

M-6

CN9

DT-T

2

Fill switch for transmission 2nd clutch

AA9

N-6

CN10

DT-T

2

Solenoid for transmission R clutch

AA9

M-6

CN11

DT-T

2

Fill switch for transmission R clutch

AA9

N-6

CN12

DT-T

2

Solenoid for transmission 3rd clutch

AA9

M-6

CN13

DT-T

2

Fill switch for transmission 3rd clutch

AA9

N-6

CN14

DT-T

2

Solenoid for transmission 4th clutch

AA9

M-5

CN15

DT-T

2

Fill switch for transmission 4th clutch

Z9

M-5

CN16

DT-T

2

Solenoid for transmission L clutch

Z8

M-7

CN17

DT-T

2

Fill switch for transmission L clutch

Z8

N-6

CN18

DT-T

2

Solenoid for transmission H clutch

Y8

M-7

CN19

DT-T

2

Fill switch for transmission H clutch

Y7

N-7

Solenoid for torque converter lockup clutch Fill switch for torque converter lockup clutch Torque converter intermediate pressure sensor Torque converter oil temperature sensor Transmission valve oil temperature sensor Intermediate connector (Power window switch) Intermediate connector (Gear shift lever) Intermediate connector (Parking brake switch)

Z8

M-7

Z8

N-7

Z5

M-8

AA5

M-7

AC5

M-7

CN20

DT-T

2

CN21

DT-T

2

CN22

DT-T

3

CN23

DT-T

2

CN24

DT-T

2

CNS1

12

COM

DT-T (Brown) DT-T (Green) DT-T (Black) One-pin connector

1


M3

D01

DT-T

2

Diode

W8

D02

DT-T

2

Diode

W8

D03

DT-T

2

Diode

W8

D04

DT-T

2

Diode

M6

A-8

D05

DT-T

2

Diode

V8

A-1

D07

DT-T

2

Diode

P2

D08

DT-T

2

Diode

W8

DL

DT-T (Black)

12


X6

DPC1

AMP070

20

Machine monitor

P8

DPC2A AMP070

18

Machine monitor

P1

DPC2B AMP070

12

Machine monitor

P1

DPC3A AMP070

18

Machine monitor

P8

12

Machine monitor

Q1

CNS2 CNS3

DPC4

AMP070

20-348 (10)

12 12

BK

PLM

MON VHMS

ASR

H-8 B-9 A-9

B-2

H-8

E-7 C-7

L-5

C-9

F-8

F-8

A-1

I-9 F-1 F-1

E-1 I-9

K-5

C-9

F-8

I-9

E-9

C-1

F-8

I-9

A-7 A-6

C-1

A-6

F-1

A-5 I-9

E-9

D-9

A-5

HD465-7, HD605-7

TROUBLESHOOTING


Address


Location


System diagram TM

DPC6

AMP040

8

Machine monitor

O7

DPC7

X

4

Software rewriting connector (Machine monitor)

N3

DSL

—

1

Door switch (Left)

F1

DSR

—

1

Door switch (Right)

T2

DT7

DT-T

12


T2

DT8

DT-T

4


J2

E

Terminal

1

Emergency steering motor

E01

Terminal

1

Alternator

AE7

H-1

N-3

E02A

DT-T

2

Starting motor

AH1

H-2

M-3

E02B

DT-T

2

Starting motor

AH1

G-2

M-2

E03

DT-T

2

Engine speed sensor

AF1

N-3

E04

DT-T

2

Oil level switch (If equipped)

AH5

M-3

E05

Terminal

1

Oil filter switch

C2

H-9

E06

Terminal

1

Alternator

AE6, AF1

E07

DT-T

2

Compressor

AF8

E08

DT-T

2

Diode

AG9

E09

Terminal

1

Alternator

AE6

E10

Terminal

1

Grounding

AG9

E11A

Terminal

1

Heater relay

E11B

Terminal

1

E12A

Terminal

E12B E13A

BK

PLM

D-2

MON VHMS

F-1

L-9

H-1

L-4

K-3

N-7

N-4 N-7

H-1

N-3

AJ9

F-3

N-5

Ribbon heater

AH9

F-2

N-4

1

Heater relay

AJ9

F-3

N-4

Terminal

1

Ribbon heater

AG9

F-1

N-4

1


AG1

I-2

K-5

E13B

DTHD (#4) DTHD (#4)

1


AG1

H-2

K-5

E15

Terminal

1

Grounding

AI2

G-1

M-3

E16A

Terminal

1

Grounding

AI9

F-3

N-5

E16B

Terminal

1

Grounding

AH9

F-2

N-4

E17A

DT-T

2

Diode

AJ8

F-3

N-5

E17B

DT-T

2

Diode

AJ8

F-2

N-4

E2B

DT

2

Diode

AE5

A-3

ECM A

DRC26

40

Engine controller

AG5

A-8

L-1

K-8

M-4

ECM B

DRC26

40

Engine controller

AG9

C-8

L-1

K-8

M-4

EG4

12


V9

ENG

DT-T (Brown) DT-T (Gray)

8


AJ7

H-2

H-3

J-7

J-3

M-7

ER

Terminal

1

Grounding

C9, C8, E9, G9

I-1

J-8

H-8

J-7

M-8

HD465-7, HD605-7

ASR

B-3

20-349 (10)


TROUBLESHOOTING

Address


Location


System diagram TM

BK

D-8

F-7

A-8

C-1

PLM

MON VHMS

ER1

Terminal

1

Grounding

P1

ER2

Terminal

1

Grounding

X7

ER3

Terminal

1

Grounding

O2

FBC

M

6

Front brake cutting switch

N3

FL01

DT-T

2

Radiator coolant level sensor

B3

FL04

YAZAKI

2

Washer motor

B3

M-1

FL05

DT-T

2

Air conditioner dual switch

B2

L-1

FLB

—

1

Flasher

R1

A-4

FLL

—

1

Flasher

R1

A-4

FLTP PACKARD

2

Fuel temperature sensor

AF9

FOG

M

6

Fog lamp switch (If equipped)

N1

FR01

DT-T

2

Air cleaner clogging sensor

B7

FS2

2

Spare terminal

X6

2

Spare terminal

X7

2

Spare terminal

X7

2

Spare terminal

X7

FS8

One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector

2

Spare terminal

X6

J-4

FSO–

Terminal

1

Fuel shut-off valve –

AE7

E-1

FSO+

Terminal

1

Fuel shut-off valve +

AE7

E-1

FUA

Terminal

—

Fuse box (30 A)

C9

K-2

L-9

FUB

Terminal

—

Fuse box (120 A x 2)

C9

K-1

L-9

G

1


—

I-9

G


1


—

H-1

G21

Terminal

1

Grounding

S1

GND

Terminal

1

Engine block GND

AF8

H01

DT-T

2

Steering flow switch

K3

H10

1

Heater unit

M4

H20


1

Heater unit

M4

HAZ

M

6

Hazard switch

O7

HEAT

DT

2

Heater control

AJ7

HEPC

DT-T

2

Hoist EPC valve

L5

HES

Terminal

1

Grounding

—

HN

One-pin connector

1

Horn switch

Q8

D-9

HN1A

—

1

Horn valve

A4

L-9

HN1B

—

1

Horn valve

A4

L-9

FS3 FS4 FS5

20-350 (10)

H-6

B-7

ASR

F-1

G-9 H-9

A-1 C-9 G-9

I-9

L-9

N-8

B-7 E-2

K-1

L-8

M-4

G-9 F-6

J-2 L-2

HD465-7, HD605-7

TROUBLESHOOTING


Address


Location


System diagram TM

BK

PLM

MON VHMS

HN2A

—

1

Horn valve

A4

HN2B

—

1

Horn valve

A3

HSL

DT-T

4


V3

D-1

HSL

DT-T

4

Hoist lever potentiometer

V3

D-1

HSOL

DT-T

3

Hoist selector valve

L5

L-2

HTA

8


L6

I-8

J-3

HTB

DT-T (Gray) DT-T (Black)

8


L6

I-8

K-3

J-4

M-2

IMPR

PACKARD

3

Intake air pressure sensor

AF8

B-1

IMTP

PACKARD

2

Intake air temperature sensor

AF8

B-1

J01

HD30

9


I2

G-4

F-6

H-7

G-7

I-6

J02

HD30

31


I2

G-3

F-6

H-7

G-6

I-6

C-7

J03

HD30

31


I2

F-6

H-6

G-5

I-5

C-7

J04

HD30

31


H-5

G-4

I-5

C-6

J05

HD30

31


H1, AN6 H1, AN6

F-5

H-4

G-4

J07

HD30

14


H1

F-5

H-3

G-4

J08

HD30

31


G1

F-5

J09

HD30

31


G1

G-6

F-4

H-4

J10

HD30

31


G1

G-4

F-4

H-3

JC01

DT

6

Joint connector

AI6

A-4

JC02

DT (Black)

8

Joint connector

AI5

A-5

JC03

DT (Black)

8

Joint connector

AH5

A-5

JC04

DT (Black)

8

Joint connector

AG5

A-6

K-1

L-7

JC11

DT

6

Joint connector

AG5

E-9

K-1

JC12

DT

6

Joint connector

AH5

E-9

JC13

DT (Black)

8

Joint connector

AI5

F-9

K-1

L-7

JC14

DT (Black)

8

Joint connector

AI6

G-9

K-1

L-7

M-3

JC15

DT

6

Joint connector

AI6

H-9

L-1

L-6

M-3

JCA

8

Joint connector

X5

8

Joint connector

X5

K-6

C-1

A-1

C-1

G-1

8

Joint connector

X5

K-6

B-1

A-2

C-1

G-1

8

Joint connector

X4

K-6

B-1

A-1

C-1

G-1

8

Joint connector

X4

K-7

B-1

A-2

C-1

G-1

8

Joint connector

S9

J-8

D-1

A-3

E-1

H-1

JCG

DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black)

8

Joint connector

V3

K-8

A-3

F-1

F-1

I-1

JT1

DT-T

6

Joint connector

AD7

JCB JCC JCD JCE JCF

HD465-7, HD605-7

ASR

C-5 C-4

G-3

I-5

C-4

I-5

C-3

M-4

A-2

E-1

J-1

20-351 (10)


TROUBLESHOOTING

Address


Location


System diagram TM

BK

PLM

MON VHMS

JT2

DT-T

6

Joint connector

AD7

LINK

DT

6

Data link crossover

AJ6

LKO

DT-T

2


U3

D-1

LKO

DT-T

2

Lever kick-out solenoid

V3

D-1

LP

DT (Gray)

12


I2

LS

M

3

Rheostat

M1

M

Terminal

1


MON1

One-pin connector One-pin connector One-pin connector

1

Rear view monitor (If equipped)

N7

I-9

1


N7

I-9

1


O7

I-9

U9

A-4

U9

A-4

U9

A-4

U9

A-4

U9

A-4

V3

A-4

MON2 MON3

J-1 F-7

J-3

K-7

H-8

K-2 D-9

K-9

MS11

M

1

MS12

M

1

MS21

M

1

MS22

M

1

MS31

M

1

MS32

M

1

Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller)

3

Engine oil pressure sensor

AE5

OLPR PACKARD

B-1

OP1

M

1

Machine monitor setting connector

OP2

M

1


OP3

M

1


OP4

M

1


OP5

M

1


OP6

M

1


OP7

M

1


M8, N9 M8, N9 M8, O9 M8, O9 M8, O9 N8, O8 N8, O8

OPS

DT-T

2

Seat heater

T2

PL01

M

2

Left head lamp (LOW)

D1

J-1

PL02

M

2

Left head lamp (HIGH)

D2

J-1

PL03

1

Clearance lamp

E1

K-1

1

Clearance lamp

E1

K-1

1

Turn signal

E1

K-1

PL06

One-pin connector One-pin connector One-pin connector One-pin connector

1

Fog lamp (If equipped)

D1

J-1

PL07

Terminal

1

Grounding

D2

K-1

PM1

MIC

21

VHMS wiring harness

T9

PM3

DT-T

3

Pitch angle sensor

X7

PM4

S (Natural color)

16

VHMS wiring harnes

T9

PL04 PL05

20-352 (10)

ASR

A-5 A-5 A-5 A-5 A-5 A-5 A-4

D-8, E-9

D-7

F-7, H-7

A-4 I-8

E-7

D-8

C-8

F-6, H-6

HD465-7, HD605-7

TROUBLESHOOTING


Address


Location


System diagram TM

BK

MON VHMS

PM5

MIC

13

Payload meter controller

T9

PM6

AMP040

12


U9

PM7

AMP

9

VHMS wiring harnes

PM7

AMP

9


N7

PM8

BENDIX

5

Connector

N7

PM9

MIC

21

VHMS wiring harness

T9

E-9

H-7

PM10

S (Natural

color)

16

VHMS wiring harnes

T9

E-9

H-6

PM11

MIC

21


V9

PMLA

DT-T (Gray)

12


H9

PMPR PACKARD

3

Fuel pump pressure sensor

AF5

PMRA

DT-T

6


D8

POW

HD30

21


AJ7

PR01

M

2

Right head lamp (LOW)

A5

K-9

PR02

M

2

Right head lamp (HIGH)

A4

J-9

PR03

1

Clearance lamp

A5

K-9

1

Clearance lamp

A5

K-9

1

Turn signal

A5

K-9

PR06

One-pin connector One-pin connector One-pin connector One-pin connector

1

Fog lamp (Optional)

A6

J-9

PR07

Terminal

1

Grounding

A4

K-8

PSOL

DT-T

2

Parking brake solenoid

L6

L-3

PSW

DT-T

2


K3

L-3

3

Fuel pump actuator

PR04 PR05

PUMP PACKARD

E-9

PLM

I-8

E-9

D-9

A-9

G-8

A-9

G-8 H-8

AF5

K-5

I-3 C-1

F-4

I-7

H-4

J-7

D-1

PWL

One-pin connector

1

Power window motor (Left)

I2

F-1

PWM

M

6

Power mode switch

M4

G-9

PWR

1

Power window motor (Right)

C7

F-1

1


J-9

R


1


H-1

R01

Relay

5

Engine starting relay

AB4

R02

Relay

5

Transmission Neutral relay

AB3

R03

Relay

5

Parking brake relay

AB3

R04

Relay

5

Brake lamp relay (RL)

AB3

R05

Relay

6

Backup lamp, buzzer relay

AB2

R06

Relay

6

Fog lamp relay

AC4

R07

Relay

5

AISS relay

AB4

R08

Relay

5

Brake lamp relay (CTR)

AB3

R

HD465-7, HD605-7

ASR

G-7

B-2 B-2

A-8 A-9 D-1

B-1

D-1 D-1

H-8 E-1

20-353 (10)


TROUBLESHOOTING

Address


Location


System diagram TM

BK

PLM

R09

Relay

5

Brake lamp timer relay

AB2

R10

Relay

5

PLM GDL relay

AC4

R11

Relay

5

Horn relay

AC4

R14

Relay

5

Brake cutting relay

AB4

R15

Relay

5

Transmission cutting relay

R16

Relay

6

Hazard relay 1

AB1

C-1

R17

Relay

5

Hazard relay 2

AC1

C-1

R19

Relay

5

Parking brake safety relay

AC4

R21

Relay

6

Side lamp relay

AC4

R22

Relay

5

Rotary lamp relay

AD3

B-1

R25

YAZAKI

11

Power window relay

AC1

B-1

R29

Relay

5

Head lamp Hi relay

AD2

C-1

R30

Relay

5

Head lamp Lo relay

AD1

B-1

R32

Relay

5

Dust indicator relay

AC1

R33

Relay

6

Parking brake manual switch

R9

R34

YAZAKI

7

Power window switch (Left)

S1

H-9

R35

YAZAKI

7

Power window switch (Right)

S9

H-9

R37

Relay

5

Auto preheater relay

AD3

R40

Relay

6

Payload meter relay (If equipped)

AD2

A-6

R43

Relay

5

AD2

A-5

R44

Relay

5

AD2

A-5

R45

Relay

5

Green outside pilot lamp relay of payload meter Yellow outside pilot lamp relay of payload meter Red outside pilot lamp relay of payload meter

AD1

A-5

RAD

YAZAKI

9

AM/FM radio

O2

RAIL

PACKARD

3

Fuel rail actuator

AF5

RDC

YAZAKI

9

Cassette stereo

O2

RE1

YAZAKI

2

Resistor

S9

RE2

YAZAKI

2

Resistor

S9

RE3

YAZAKI

2

Resistor

P8

F-9

RE4

YAZAKI

2

Resistor

P8

F-9

RESW

DT-T

2

Retarder switch

L4

L-1

RETV

DT-T

2

Retarder valve

L4

L-1

RL

YAZAKI

2

Room lamp

E9

RL2

One-pin connector

1

Room lamp 2

G9

RP

DT-T

6


A6

RPR

PACKARD

3

Fuel rail pressure sensor

AI6

20-354 (10)

A-9

MON VHMS

ASR

E-1 A-7 D-1

A-8

A2

B-2

A-8 A-6

B-3 E-8

G-8

B-3

D-1

C-9

A-8

A-7

N-1

K-8 C-1

HD465-7, HD605-7

TROUBLESHOOTING


Address


Location


System diagram TM

BK

PLM

MON VHMS

RT2

Terminal

1

Emergency steering timer

M4

RT6

Terminal

1


M5

RT7

Terminal

1


M5

RT8

Terminal

1


M4

RTL

DT-T

6

Retarder potentiometer

P8

C-9

S01

DT-T

2

Service brake switch

B7

G-2

N-2

S02

DT-T

2

Secondary brake switch

E9

G-2

N-2

E9

G-2

F9

H-2

F9

H-1

C-8

S03

DT-T

2

S04

DT-T

2

S05

DT-T

2

Front brake cutting solenoid (If equipped) Auto suspension solenoid 1 (If equipped) Auto suspension solenoid 2 (If equipped)

SBS

DT-T

2

Seat belt switch

U2

SDE

M

6

Side lamp switch (If equipped)

N2

SF1

DT-T (Green)

12

Shift lever

R9

SF2

DT-T

2

Shift lever

Q9

SIG

HD30

31


AJ7

SLG

Terminal

1

Grounding

C8

I-8

SLG

Terminal

1

Grounding

J2

I-2

SLL

M

1

Side lamp (If equipped)

J2

G-2

SLR

M

1


C7

J-9

5

S-NET monitor

T1

S-NET MS3102A 14S

F-1 A-7 B-9

F-6

H-4

B-2

J-7

H-9

J-5

B-3

A-9

SP1

PACKARD

2

Engine speed sensor (Master)

AJ8

A-1

SP2

PACKARD

2

Engine speed sensor (Backup)

AJ8

A-1

SPA1

DT-T

4

Spare connector 1

C-6

SPA2

DT-T

12

Spare connector 2

C-5

SPA3

DT-T

6

Spare connector 3

F1

SPL

YAZAKI

2

Speaker (Left)

G9

SPR

YAZAKI

2

Speaker (Right)

F9

SR2

X

3

Steering speed sensor

P1

F-9

SR3

X

2

Pitch angle sensor

X7

B-1

SUFL

DT-T

3

H1

H-1

K-5

SUFR

DT-T

3

B7

G-9

K-6

SURL

DT-T

3

L8

K-5

K-5

SURR

DT-T

3

Suspension oil pressure sensor(FL) (If equipped) Suspension oil pressure sensor(FR) (If equipped) Suspension oil pressure sensor(RL) (If equipped) Suspension oil pressure sensor(RR) (If equipped)

J9

K-5

K-5

T01

DT-T

2

Fuel level gauge sensor

G9

T02

DT-T

6


H9

HD465-7, HD605-7

ASR

I-9 J-8

20-355 (10)


TROUBLESHOOTING

Address


Location


T05

Terminal

1

Grounding

I9

T1

Terminal

1

Grounding

AC9

TEST


1

TEST switch

V8

1

Tachograph

S9

1

Tachograph

S9

3

Timing rail actuator

AG9

TG TG2

TIMG PACKARD

System diagram TM

BK

PLM

MON VHMS

ASR

K-1 I-3 F-5

D-1

TM2

HD30

21


AD8

H-5

J-4

TM3

HD30

31


AD8

H-5

TMF

DT-T

2

Transmission oil filter sensor

J3

I-9

TPR

PACKARD

3

Timing rail pressure sensor

AI6

TR

—

6

Brake lamp timer

X7

VHM

DT-T (Black)

8


C2

WFM

M

6

Front wiper motor

Q1

A-4

WFR

Relay

6

Front wiper relay

R1

A-3

WPS

DT-T (Black)

12

Wiper switch

Q8

B-3

WSRL

DT-T

2

Wheel speed sensor (RL)

K1

B-9

WSRR

DT-T

2

Wheel speed sensor (RR)

K1

C-9

C-1 E-1

VHMS controller related CAN1

DT-T

3

VHMS intermediate connector

AU2

E-5

DLSW

Terminal

1

Ground level download box

AO1

A-7

EG4

DT-T

12


AV3

E-6

GDL

DT-T

12

Ground level download box intermediate connector

AP4

A-6

GR1

Terminal

1


AP2

A-7

GR2

Terminal

1


AP2

A-7

HM-12

DT-T

3

Blow-by sensor

AM6

B-4

HM-21A

DT

2

Exhaust temperature sensor

AN8

B-2

HM-21B

DT

2


AN7

B-2

HM-22A

DT

2

AR8

J-2

HM-22B

DT

2

AQ7

J-2

HM-23A

DT-T

3

AR8

J-2

HM-23B

DT-T

3

Exhaust temperature sensor - amp intermediate connector Exhaust temperature sensor - amp intermediate connector VHMS - exhaust temperature amp intermediate connector VHMS - exhaust temperature amp intermediate connector

AQ7

J-2

HM-31

DT

2


AN1

B-4

HM-35

DT

2

Ambient temperature sensor

AM1

B-8

HM50

DT-T

3

Short connector

AU2

H-8

HM55

DT-T

3

Short connector

AQ6

I-8

20-355-1 (10)

HD465-7, HD605-7


TROUBLESHOOTING

Address


Location


System diagram TM

BK

PLM

MON VHMS ASR

8

VHMS - Orbcomm controller intermediate connector

AT2

L-3

HM-2130 YAZAKI

2

Resistor

AQ2

H-8

HM-2140 YAZAKI

2

Resistor

AR2

H-8

HM-CN1 AMP070

20

VHMS controller

AS8

I-8

HM-CN2A AMP070

18

VHMS controller

AT7

J-8

HM-CN2B AMP070

12

VHMS controller

AU7

J-8

HM-CN3A AMP070

18

VHMS controller

AT8

J-8

HM-CN3B AMP070

12

VHMS controller

AS8

K-8

HM-CN4A AMP070

14

VHMS controller

AU7

K-8

HM-CN4B AMP070

10

VHMS controller

AT8

L-8

Ground level download box lamp terminal Ground level download box lamp terminal

AP3

B-7

AP3

B-7

Orbcomm controller

AS2

K-2

HM81

M

LM1

Terminal

1

LM2

Terminal

1

ORB-A

AMP070

14

ORB-B

AMP070

10

Orbcomm controller

AS2

L-2

AP2

A-7

PDL

MS

5

Ground level download box PLM connector

PLM

MS

5

PLM II download connector

AQ6

K-4

PM1

MIC

21

PLM II intermediate connector

AV3

PM4

S

16


AU7

F-7, H-7 F-6, H-6

PM11

MIC

21


AV6

E-5

Ambient temperature sensor intermediate connector Ground level download box intermediate connector

AO6

C-6

AO6

C5

Ground level download box VHMS connector Blow-by, oil temperature sensor intermediate connector

AP3

A-7

AM6

B-4

SPA1

DT-T

4

SPA2

DT-T

12

VDL

MS

5

VHM

DT-T

8

VHMS

MS

5

VHMS download connector

AT2

K-4

WAKE

Terminal

1


AP2

A-7

HD465-7, HD605-7

20-355-2 (10)


TROUBLESHOOTING

ABS control related Address

Connec- Type Numtor of ber No. connector of pin

Location


System diagram TM

BK

PLM MON VHMS ASR

O2

E-9

ABS

ABS

M

6

ABS system switch

ABS1

MIC

17

ABS controller

BK7

ABS1

DT-T

6

Joint connector

BF9

ABS2

MIC

21

ABS controller

BR3

ABS2

DT-T

8

Joint connector

BD2

ABS3

DT-T

6

Joint connector

BE2

ABS3A

040

20

ABS controller

BR8

ABS3B

040

16

ABS controller

BQ9

ABS4

040

12

ABS controller

BR8

ABS4

DT-T

6

Joint connector

BE2

ABS5

DT

6

Joint connector

BF3

ABS5A

040

20

ABS controller

BR8

ABS6

DT-T

6

Joint connector

BG8

ABS7

DT-T

6

Joint connector

BH8

BR3

ABS8

DT-T

6

Joint connector

BE9

ABSFL

DT-T

2

ABS valve

AX9

ABSFR

DT-T

2

ABS valve

AX9

ABSRL

DT-T

2

ABS valve

BH7

ABSRR

DT-T

2

ABS valve

BF9 AW9

BPFL

DT-T

3

Brake oil pressure

BPFR

DT-T

3

Brake oil pressure

AX9

BPRL

DT-T

3

Brake oil pressure

BH8

BPRR

DT-T

3

Brake oil pressure

BRC3B

040

16

Retarder controller

BG9 Y4

BRC4

040

12

Retarder controller

Z4

BRC5A

040

20

Retarder controller

Y1

CHK

Yazaki

6

System check switch

A-5 J-9

C-1

A-5

BO9 D-1

H-1

BP9

A-4

BQ9 BL8

CVF

DT-T

2

ABS cut solenoid

AZ8

CVR

DT-T

2

ABS cut solenoid

BG9

CVSF

DT-T

3

ABS cut switch

AY8

CVSR

DT-T

3

ABS cut switch

BH8

DA1

DT-T

2

Diode

BE9

DPC2B AMP070

12

Machine monitor

FOGF

6

Fog lamp switch

M

P1

C-1

A-6

F-1

P1 BM1

FOGM

M

6

Fog lamp switch

BK8

J06

HD30

31


BD1

JABS

DT-T

12


BA9

RABS

KES1

6

ABS cut relay

BS7

RABS2

KES1

6

ABS cut valve relay

BS7 BC1

S01F

DT-T

3


S01M

DT-T

3


AZ1

S02F

DT-T

3


BC9

S02M

DT-T

3


BC9

WSFL

DT-T

2

Wheel speed sensor

BC1

WSFR

DT-T

2

Wheel speed sensor

AY7

WSRL2

DT-T

2

Wheel speed sensor

BG9

WSRR2

DT-T

2

Wheel speed sensor

BF9

20-355-3 (12)

HD465-7, HD605-7

TROUBLESHOOTING

CONNECTOR ARRANGMENT LOCATION

CONNECTOR ARRANGEMENT LOCATION

20-356 (5)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-357 (5)

TROUBLESHOOTING

20-358 (1)


HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-359 (1)

TROUBLESHOOTING

20-360 (1)


HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-361 (1)

TROUBLESHOOTING


VHMS control related (1/2)

20-362 (2)

HD465-7, HD605-7

TROUBLESHOOTING


(2/2)

HD465-7, HD605-7

20-363 (2)

TROUBLESHOOTING


ABS control related (1/2)

20-364 (12)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-365 (12)

TROUBLESHOOTING


(2/2)

20-366 (12)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-367 (12)

TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)

Electrical system diagram related engine control ...................................................................................... 20-404 Information in troubleshooting table ............................................................................................................ 20-406 [C111KT] Abnormality in engine controller memory ............................................................................ 20-408 [C112LK] Abnormality in timing rail actuator ....................................................................................... 20-408 [C113KZ] Abnormal current in timing rail actuator system .................................................................. 20-409 [C115KZ] Abnormality in engine speed sensor 2 systems .................................................................. 20-410 [C116KX] Abnormally high level in timing rail pressure sensor system ............................................... 20-412 [C117KX] Abnormally low level in timing rail pressure sensor system ................................................ 20-413 [C118KX] Abnormally high level in fuel pump pressure sensor system ............................................... 20-414 [C119KX] Abnormally low level in fuel pump pressure sensor system ................................................ 20-415 [C121LC] Abnormality in engine speed sensor 1 systems .................................................................. 20-415 [C122KX] Abnormally high level in boost pressure sensor system ...................................................... 20-416 [C123KX] Abnormally low level in boost pressure sensor system ....................................................... 20-417 [C131KX] Abnormally high level in throttle sensor system .................................................................. 20-418 [C132KX] Abnormally low level in throttle sensor system .................................................................... 20-420 [C135KX] Abnormally high level in engine oil pressure sensor system ............................................... 20-421 [C141KX] Abnormally low level in engine oil pressure sensor system ................................................ 20-422 [C143ZG] Lowering of engine oil pressure ........................................................................................... 20-422 [C144KX] Abnormally high level in engine coolant temperature sensor system .................................. 20-423 [C145KX] Abnormally low level in engine coolant temperature sensor system ................................... 20-424 [C148KX] Abnormality in FM throttle: Out of input signal range .......................................................... 20-425 [C151NS] Rise of engine coolant temperature ..................................................................................... 20-426 [C153KX] Abnormally high level in air intake temperature sensor system ........................................... 20-427 [C154KX] Abnormally low level in air intake temperature sensor system ............................................ 20-428 [C221KX] Abnormally high level in atmospheric pressure sensor system ........................................... 20-429 [C222KX] Abnormally low level in atmospheric pressure sensor system ............................................ 20-430 [C234NI] Over-speed .......................................................................................................................... 20-430 [C254KZ] Abnormal voltage of fuel shut-off valve................................................................................. 20-431 [C259FS] Abnormality in fuel shut-off valve ......................................................................................... 20-432 [C261NS] Abnormal rise of fuel temperature ....................................................................................... 20-432 [C263KX] Abnormally high level in fuel temperature sensor system ................................................... 20-433 [C265KX] Abnormally low level in fuel temperature sensor system ..................................................... 20-434 [C316KZ] Abnormal current of fuel pump actuator .............................................................................. 20-435 [C318LK] Abnormality in fuel pump actuator ....................................................................................... 20-436 [C346KT] Abnormality in power-down unit of engine controller ........................................................... 20-437 [C423L6] Abnormality in in-range of timing rail pressure sensor system ............................................ 20-439 [C431L4] Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed) ................................................................. 20-441 [C432L5] Error in idle validation process ( *See separate list (L5))...................................................... 20-443 [C441KX] Abnormally low level in battery voltage system .................................................................. 20-445 [C442KG] Abnormally high level in battery voltage system .................................................................. 20-445 [C451KX] Abnormally high level in fuel rail pressure sensor system ................................................... 20-446 [C452KX] Abnormally low level in fuel rail pressure sensor system .................................................... 20-447 [C455KZ] Abnormal current of fuel rail actuator .................................................................................. 20-448

HD465-7, HD605-7

20-401 (10)

[C467LK] [C468LK] [C514LK] [C551L4]

Abnormality in timing rail actuator control ........................................................................... 20-449 Abnormality in fuel rail actuator control ................................................................................ 20-449 Abnormality in fuel rail actuator .......................................................................................... 20-450 Abnormality in idle validation switch system: *See separate list (L4) (Either signal voltage of 2 systems is not sensed) ............................................................... 20-451 [C554L6] Abnormality in in-range of fuel rail pressure sensor system ................................................ 20-453 ENG-1 Engine does not start............................................................................................................ 20-455 ENG-2 Failure in preheating ............................................................................................................. 20-459 a) Engine is not preheated................................................................................................... 20-459 b) Preheating is actuated even under non-actuation conditions for preheating................... 20-462 ENG-3 AISS function does not work normally .................................................................................. 20-464 a) When AISS switch is set in AUTO, LOW SPEED control is selected.............................. 20-464 b) When AISS switch is set in LOW SPEED, AUTO control is selected.............................. 20-465

20-402 (10)

HD465-7, HD605-7

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL

ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL Engine serial No. : 310169 – 310414

20-404 (9)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-405 (2)

TROUBLESHOOTING


Engine serial No. : 310415 – 310798

20-405-1 (8)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-405-2 (8)

TROUBLESHOOTING


Engine serial No. : 310799 and up

20-405-3 (8)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-405-4 (8)

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code Display on panel

Failure code Controller code Display on panel

Display on panel

Trouble Trouble in machine

Contents of trouble Contents of trouble detected by monitor panel or controller Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble or monitor panel Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting

Cause

1

2

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment • Disconnection Connector is connected imperfectly or harness is broken. • Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent harnesses are in contact with each other abnormally.

Possible causes Possible causes of trouble and standard value (Given numbers are refer 3 in normal state ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter indicate priority) Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. 4 • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or harness entered on front side. 5 • Connect negative (–) lead to pin No. or harness entered on rear side.

20-406 (10)

HD465-7, HD605-7


TROUBLESHOOTING

Related electrical circuit diagram

Part of electric circuit diagram related to trouble • Connector No.: Indicates (Model – Number of pins) and (Color). • Arrows ( ): Indicate rough location of connector in machine.

PHENOMENON CODE TABLE a Regarding phenomenon code provided with instruction "Refer to table", check it against table below. Phenomenon code

Contents

Phenomenon code

Contents

KA

Disconnection in wiring

L0

Fill signals at two or more channels which are not set as combination are turned ON at the same time.

KB

Short circuit

L1

Fill signal is ON when command current to ECMV is OFF.

KK

Source voltage reduction/ input

L2

Fuel pressure is above maxim specified value.

KQ

Type select signal inconsistency

L3

Object part is uncontrollable.

KR

Defective communication

L4

ON and OFF signals at two systems are inconsistent.

KT

Abnormality in controller

L6

Engine rotation signal, terminal C signal, oil pressure switch signal, coolant temperature sensor signal, etc. are inconsistent with operation state or stop state.

KX

Outside input signal range

L8

Analog signals in two systems are inconsistent.

KY

Short circuit with power source (Hot short)

LC

rpm signals in two systems are inconsistent.

KZ

Disconnection or short circuit

LD

Switch is pressed for usually unthinkable long time.

MA

Malfunction

LH

Fill signal is OFF when command current to ECMV is ON.

MB

Performance reduction

MW

Sliding

NS

Overheat

ZG

Oil pressure reduction

ZK

Coolant level reduction

HD465-7, HD605-7

20-407 (10)

[C111KT], [C112LK]

TROUBLESHOOTING

[C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY Action code E03

Failure code Controller code C111KT

ENG

Trouble

Abnormality in engine controller memory (Engine controller system)

Contents of trouble • Memory in controller has trouble or processor in controller has communication trouble.

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that • Engine cannot be started. appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.

Cause

Standard value in normal state/Remarks on troubleshooting

Possible causes and standard value 1 Defective engine controller in normal state

Reset according to following procedure. If failure code E is displayed at this time, engine controller is defective. 1) Keep starting switch at OFF position for 5 seconds. 2) Run engine at low idle. 3) Check failure code.

[C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR Action code E03

Failure code Controller code C112LK

ENG

Trouble

Abnormality in timing rail actuator (Engine controller system)

• Displayed fuel value of timing rail is excessively different from actual timing fuel. Contents of trouble • Judgment value (for reference):

Error is above 400 mm3/st or below – 750 mm3/st (When coolant temperature is below 0°C). Action of controller

• Flashes warning lamp and turns on alarm buzzer. • Limits engine speed to 1,500 rpm.

Problem that • Engine speed lowers. appears on machine Related information • Method of reproducing failure code: Start engine.

Cause 1 Defective related systems

Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first.

Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping

Possible causes and standard value 3 Defective timing rail actuator Check timing rail actuator directly for defective operation. in normal state Clogging of timing rail actua4 Check timing rail actuator screen directly for clogging. tor screen

20-408 (10)

5 Breakage of injector O-ring

Check injector O-ring directly for breakage.

6 Defective engine controller

If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

HD465-7, HD605-7

[C113KZ]

TROUBLESHOOTING

[C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM Action code

Failure code Controller code

E03 Contents of trouble

C113KZ

ENG

Trouble

Abnormal current in timing rail actuator system (Engine controller system)

• Current in timing rail actuator is out of normal range. • Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)

Action of controller • Flashes warning lamp and turns on alarm buzzer. • Engine output lowers. Problem that appears on machine • Exhaust gas becomes white. Related information

• Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator. • Method of reproducing failure code: Turn starting switch ON (or start engine). Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

1

Possible causes and standard value in normal state

Defective timing rail actuator (Internal trouble)

TIMG (male)

Resistance

Between (A) – (C)

7–9z

Between (A), (C) – chassis ground

Min. 100 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (1) – 2 (Disconnection in wiring or Resistance Max. 10 z TIMG (female) (A) defective contact in connecWiring harness between ECMA (female) (20) – tor) Resistance Max. 10 z TIMG (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON Short circuit in wiring harness 3 (with another wiring harness)

Wiring harness between ECMA (female) (1) – TIMG (female) (A) with wiring harness around Resistance Min. 1 M z it Wiring harness between ECMA (female) (20) – TIMG (female) (C) with wiring harness around Resistance Min. 1 M z it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ECMA (female)

Resistance

Between (1) – (20)

7–9z

Wiring harness between (1), (20) – wiring harness around it

Min. 1 M z


Circuit diagram related to timing rail actuator

HD465-7, HD605-7

20-409 (11)

[C115KZ]

TROUBLESHOOTING

[C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS Action code


E03

C115KZ

ENG

Trouble

Abnormality in engine speed sensor 2 systems (Engine controller system)

Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems.

Action of controller

• Flashes warning lamp and turns on alarm buzzer. • Outputs speed signal of 0 rpm.

Problem that • Engine stops. appears on machine

• Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 01001, 01002: Engine speed) Related information • Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor. • Method of reproducing failure code: Start engine. Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON

Defective engine speed sen1 sor (Internal trouble)

2

Damage of engine speed sensor

SP (male)

Resistance

Between (2) – (1) and (3) – (4)

1 – 2 kz

Between (2) – (3)

Max. 10 z

Between (1) – (4)

Max. 10 z

Between (2), (3) – chassis ground

Min. 10 Mz

Check engine speed sensor directly. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between ECMA (female) (27) – Resistance Max. 10 z SP (female) (2) Wiring harness between ECMA (female) (28) – Resistance Max. 10 z SP (female) (1) Wiring harness between ECMA (female) (37) – Resistance Max. 10 z SP (female) (3) Wiring harness between ECMA (female) (38) – Resistance Max. 10 z SP (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness 4 (with another wiring harness)

Wiring harness between ECMA (female) (27) – Resistance Min. 1 Mz SP (female) (2) with wiring harness around it Wiring harness between ECMA (female) (28) – Resistance Min. 1 Mz SP (female) (1) with wiring harness around it Wiring harness between ECMA (female) (37) – Resistance Min. 1 Mz SP (female) (3) with wiring harness around it Wiring harness between ECMA (female) (38) – Resistance Min. 1 Mz SP (female) (4) with wiring harness around it aPrepare with starting switch OFF, then start engine and carry out troubleshooting. ECMA (female)


20-410 (10)

Resistance

Between (27) – (28)

1 – 2 kz


Min. 1 Mz

Between (37) – (38)

1 – 2 kz


Min. 1 Mz

HD465-7, HD605-7

TROUBLESHOOTING

[C115KZ]

Circuit diagram related to engine speed sensor

HD465-7, HD605-7

20-411 (8)

[C116KX]

TROUBLESHOOTING

[C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM Action code E03

Failure code Controller code C116KX

ENG

Trouble

Abnormally high level in timing rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4.78 V.

• Flashes warning lamp and turns on alarm buzzer. Action of controller • Opens and controls timing rail. • Limits engine speed to 1,500 rpm. • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to Problem that appears on machine 1,500 rpm. Related information

• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor. • Method of reproducing failure code: Start engine. Cause Defective timing rail pres1 sure sensor (Internal trouble)



Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TPR

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) – Resistance Max. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) – Resistance Max. 10 z TPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMA (female) (5)– Resistance Min. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) – Resistance Min. 1 Mz TPR (female) (C) with wiring harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between (5) – (18)

4.75 – 5.25 V

Between (33) – (18)

0.42 – 0.58 V

Circuit diagram related to timing rail pressure

20-412 (11)

HD465-7, HD605-7

[C117KX]

TROUBLESHOOTING

[C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM Action code


E03

C117KX

ENG

Trouble

Abnormally low level in timing rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.30 V

• Flashes warning lamp and turns on alarm buzzer. Action of controller • Opens and controls timing rail. • Limits engine speed to 1,500 rpm. • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to Problem that appears on machine 1,500 rpm. Related information • Method of reproducing failure code: Start engine.


HD465-7, HD605-7

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C116KX].

20-413 (10)

[C118KX]

TROUBLESHOOTING

[C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM Action code E01


ENG

Trouble

Abnormally high level in fuel pump pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.


• Flashes warning lamp and turns on alarm buzzer. • Opens and controls fuel pump.

Problem that appears on machine Related information

• Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor. • Method of reproducing failure code: Start engine. Cause Defective fuel pump pres1 sure sensor (Internal trouble)

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PMPR (male)

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (5) – Resistance Max. 10 z PMPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. 10 z PMPR (female) (B) Wiring harness between ECMA (female) (32) – Resistance Max. 10 z PMPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMA (female) (5) – PMPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (18) – PMPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (32) – PMPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA (female)

Resistance

Between (5) – (18)

4.75 – 5.25 V

Between (32) – (18)

0.42 – 0.58 V

Circuit diagram related to fuel pump pressure sensor

20-414 (11)

HD465-7, HD605-7

[C119KX], [C121LC]

TROUBLESHOOTING

[C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM Action code


E01

C119KX

ENG

Trouble

Abnormally low level in fuel pump pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.


• Flashes warning lamp and turns on alarm buzzer. • Opens and controls fuel pump.

Problem that appears on machine Related information • Method of reproducing failure code: Start engine.


Cause


[C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS Action code


E01

C121LC

ENG

Trouble

Abnormality in engine speed sensor 1 systems (Engine controller system)

Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems.

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information

• Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (Code 01001: Engine speed) • Method of reproducing failure code: Start engine.


HD465-7, HD605-7

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C115KZ].

20-415 (10)

[C122KX]

TROUBLESHOOTING

[C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM Action code E03


ENG

Trouble

Abnormally high level in boost pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.72 V.

Action of controller • When machine is accelerated suddenly, exhaust gas color is bad. Problem that appears on machine • Engine output rises. Related information

• Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor. • Method of reproducing failure code: Start engine. Cause Defective boost pressure 1 sensor (Internal trouble)

Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. IMPR (male)

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (6) – Resistance Max. 10 z IMPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max. 10 z IMPR (female) (B) Wiring harness between ECMA (female) (35) – Resistance Max. 10 z IMPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMA (female) (6) – IMPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) – IMPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (35) – IMPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between (6) – (17)

4.75 – 5.25 V

Between (35) – (17)

0.42 – 0.58 V

Circuit diagram related to boost pressure sensor

20-416 (11)

HD465-7, HD605-7

[C123KX]

TROUBLESHOOTING

[C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM Action code


E03

C123KX

ENG

Trouble

Abnormally low level in boost pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of boost pressure sensor circuit is below 0.30 V.

Action of controller Problem that • Engine output lowers. appears on machine Related information • Method of reproducing failure code: Start engine.


HD465-7, HD605-7

Cause


20-417 (10)

[C131KX]

TROUBLESHOOTING

[C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM Action code E03


ENG

Trouble

Abnormally high level in throttle sensor system (Engine controller system)

Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4.80 V.


• Flashes warning lamp and turns on alarm buzzer. • Keeps engine speed at constant level.

Problem that • Engine output and speed rise suddenly. appears on machine

• Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. Related information (Code 31701: throttle potentiometer voltage) • Method of reproducing failure code: Turn starting switch ON. Cause


Defective throttle potentiom1 eter (Internal trouble)

AS1 (male)

Resistance

Between (3) – (1)

4.0 – 6.0 kz

Between (3) – (2)

0.25 – 7.0 kz

Between (2) – (1)

0.25 – 7.0 kz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Wiring harness between ECMB (female) (26) – Resistance Max. 10 z AS1 (female) (3) Wiring harness between ECMB (female) (11) – Resistance Max. 10 z AS1 (female) (1) Wiring harness between ECMB (female) (29) – Resistance Max. 10 z AS1 (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Short circuit of wiring harness between ECMB (female) (26) – AS1 (female) (3) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (11) – AS1 (female) (1) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (29) – AS1 (female) (2) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


20-418 (10)

ECMB

Voltage

Between (29) – (11)

0.30 – 4.80 V

HD465-7, HD605-7

TROUBLESHOOTING

[C131KX]

Circuit diagram related to deceleration potentiometer

HD465-7, HD605-7

20-419 (1)

[C132KX]

TROUBLESHOOTING

[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM Action code E03


ENG

Trouble

Abnormally low level in throttle sensor system (Engine controller system)

Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.


• Flashes warning lamp and turns on alarm buzzer. • Keeps engine speed at constant level.

Problem that • Engine speed and output lower suddenly. appears on machine

• Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. Related information (Code 31701: throttle potentiometer voltage) • Method of reproducing failure code: Turn starting switch ON. Possible causes and standard value in normal state

20-420 (10)

Cause


HD465-7, HD605-7

[C135KX]

TROUBLESHOOTING

[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM Action code


E01

C135KX

ENG

Trouble

Abnormally high level in engine oil pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine oil pressure sensor circuit is above 4.88 V.


• Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor. • Method of reproducing failure code: Start engine. Cause Defective engine oil pres1 sure sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OLPR

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)

Wiring harness between ECMA (female) (6) – Resistance Max. 10 z OLPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max. 10 z OLPR (female) (B) Wiring harness between ECMA (female) (24) – Resistance Max. 10 z OLPR (female) (C)


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) (6) – OLPR (female) (A) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) – OLPR (female) (B) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (24) – OLPR (female) (C) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMA

Voltage

Between (6) – (17)

4.75 – 5.25 V

Between (24) – (17)

0.42 – 0.58 V


Circuit diagram related to engine oil pressure sensor

HD465-7, HD605-7

20-421 (10)

[C141KX], [C143ZG]

TROUBLESHOOTING

[C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM Action code E01


ENG

Trouble

Abnormally low level in engine oil pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.31 V.

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.


Cause


[C143ZG] LOWERING OF ENGINE OIL PRESSURE Action code E03

Failure code Controller code C143ZG

ENG

Trouble

Lowering of engine oil pressure (Engine controller system)

• Engine oil pressure sensor detected pressure lower than pressure set in controller. • Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm Contents of trouble Max. 0.15 MPa {1.5 kg/cm2} at 1,500 rpm Max. 0.18 MPa {1.85 kg/cm2} at 1,800 rpm Max. 0.21 MPa {2.1 kg/cm2} at 2,000 rpm Action of controller • Limits fuel injection rate to 50% after 10 seconds. Problem that appears on machine Related information • Method of reproducing failure code: Start engine.

Cause 1 Defective related systems Possible causes and standard value Defective engine oil presin normal state 2 sure sensor system 3 Defective engine

20-422 (10)

Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for failure codes [C135KX] and [C141KX]. See Shop Manual for engine (170-3 Series).

HD465-7, HD605-7

[C144KX]

TROUBLESHOOTING

[C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM Action code


E01

C144KX

ENG

Trouble

Abnormally high level in engine coolant temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.


• Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor. • Method of reproducing failure code: Start engine. Cause Defective engine coolant 1 temperature sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CLTP

Resistance

Between (A) – (B)

600 – 36 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (22) – Resistance Max. 10 z CLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. 10 z CLTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Short circuit of wiring harness between ECMA (female) (22) – CLTP (female) (A) with wiring Resistance Min. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) – CLTP (female) (B) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between (22) – (17)

600 – 36 kz

Circuit diagram related to engine coolant temperature sensor

HD465-7, HD605-7

20-423 (10)

[C145KX]

TROUBLESHOOTING

[C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM Action code E01


ENG

Trouble

Abnormally low level in engine coolant temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information • Method of reproducing failure code: Start engine.


20-424 (10)

Cause


HD465-7, HD605-7

[C148KX]

TROUBLESHOOTING

[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE Action code


E03

C148KX

ENG

Trouble Abnormality in FM throttle: Out of input signal range

Contents of trouble • The frequency of the FM throttle is below 150 Hz or above 400 Hz.


• Flashes warning lamp and turns on alarm buzzer. • The throttle sensor signal is conformed to the idle validation switch (In idle: 0%, Off idle: 35%).

Problem that • The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%). appears on machine Related information

Cause


1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector ECM. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between ECMB (female) (17) – contact) Resistance Max. 10 z ATC3A (female) (5)

2 Possible causes and standard value in normal state

Ground fault in wiring harness

1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and ATC3A. 3) Connect T-adapter. Wiring harness between ECMB (female) (17) – ATC3A (female) (5)

Resistance between ECMB (female) (17), ATC3A (feMin. 1 Mz male) (5) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 3 fective 5) Turn the starting switch ON. Between ATC3A (male) (5) – chassis ground

Frequency

170 – 380Hz

1) Connect all the connectors. 2) Turn the starting switch ON. 4 Engine controller defective

• Check that the failure code disappears. aIf the failure code does not disappear, replace the engine controller.

Circuit diagram related to engine abnormality in FM throttle

HD465-7, HD605-7

20-425 (10)

[C151NS]

TROUBLESHOOTING

[C151NS] RISE OF ENGINE COOLANT TEMPERATURE Action code E02 Contents of trouble

Failure code Controller code C151NS

ENG

Trouble

Rise of engine coolant temperature (Engine controller system)

• Engine coolant temperature sensor detected temperature higher than temperature set in controller. • Criterion (for reference): Min. 105°C

Action of controller • Limits fuel injection rate to 50% after 10 seconds. Problem that appears on machine Related information • Method of reproducing failure code: Start engine.

Cause


Check displayed failure codes. If code related to engine controller is 1 Defective related systems Possible causes displayed, carry out troubleshooting for it first. and standard value Defective engine coolant in normal state 2 Carry out troubleshooting for failure codes [C144KX] and [C145KX]. temperature sensor system 3 Defective engine

20-426 (10)

See Shop Manual for engine (170-3 Series).

HD465-7, HD605-7

[C153KX]

TROUBLESHOOTING

[C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM Action code


E01

C153KX

ENG

Trouble

Abnormally high level in air intake temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4.88 V.


• Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor. • Method of reproducing failure code: Start engine. Cause Defective air intake temper1 ature sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. IMTP (female)

Resistance

Between (A) – (B)

36 – 600 z

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (23) – Resistance Max. 10 z IMTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. 10 z IMTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Wiring harness between ECMA (female) (23) – IMTP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) – IMTP (female) (B) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between (23) – (17)

36 – 600 z

Circuit diagram related to air intake temperature sensor

HD465-7, HD605-7

20-427 (10)

[C154KX]

TROUBLESHOOTING

[C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM Action code E01


ENG

Trouble

Abnormally low level in air intake temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of air intake temperature sensor circuit is below 0.08 V.

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information • Method of reproducing failure code: Start engine.


20-428 (10)

Cause


HD465-7, HD605-7

[C221KX]

TROUBLESHOOTING

[C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM) Action code


E03

C221KX

ENG

Trouble

Abnormally high level in atmospheric pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is above 4.78 V


• Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor. • Method of reproducing failure code: Turn starting switch ON. Cause

Defective atmospheric pres1 sure sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting AAPR

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V


Wiring harness between ECMA (female) (6) – Resistance Max. 10 z AAPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max. 10 z AAPR (female) (B) Wiring harness between ECMA (female) (34) – Resistance Max. 10 z AAPR (female) (C)



Wiring harness between ECMA (female) (6) – AAPR (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) – AAPR (female) (B) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (34) – AAPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ECMA

Voltage

Between (6) – (17)

4.75 – 5.25 V

Between (34) – (17)

0.42 – 0.58 V


Circuit diagram related to atmospheric pressure sensor

HD465-7, HD605-7

20-429 (10)

[C222KX] , [C234NI]

TROUBLESHOOTING

[C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM Action code E03


ENG

Trouble

Abnormally low level in atmospheric pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.



Cause


[C234NI] OVER-SPEED Action code E02 Contents of trouble

Failure code Controller code C234NI

ENG

Trouble

Over-speed (Engine controller system)

• Engine speed sensor detected speed higher than speed set in controller. • Criterion (for reference): Min. 2,400 rpm

Action of controller • Closes fuel rail actuator fully (Cuts out fuel). Problem that appears on machine Related information • Method of reproducing failure code: Start engine.

Cause Possible causes and standard value 1 Defective related systems in normal state 2 Defective engine

20-430 (10)

Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. See Shop Manual for engine (170-3 Series).

HD465-7, HD605-7

[C254KZ]

TROUBLESHOOTING

[C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE Action code


E03

C254KZ

ENG

Trouble

Abnormal voltage of fuel shut-off valve (Engine controller system)

Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 z).

Action of controller • Turns off power for fuel shut-off valve. Problem that • Engine stops. appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.

Cause


1

Defective fuel shut-off valve (Internal trouble)

FSO (Valve side)

Resistance

Between (+) – (–)

23 – 40 z

Between (+) – chassis ground

100 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (30) – Resistance Max. 10 z FSO (wiring harness side) (+) defective contact in connecWiring harness between FSO (wiring harness Possible causes tor) Resistance Max. 10 z side) (–) – chassis ground and standard value in normal state aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harWiring harness between ECMA (female) (30) – ness FSO (wiring harness side) (+) with wiring har- Resistance Min. 1 Mz 3 ness around it (with another wiring harness) Wiring harness between FSO (wiring harness side) (–) – chassis ground with wiring harness Resistance Min. 1 Mz around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

ECMA

Resistance

Between (30) – chassis ground

23 – 40 z

Circuit diagram related to fuel shut-off valve

HD465-7, HD605-7

20-431 (10)

[C259FS], [C261NS]

TROUBLESHOOTING

[C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE Action code E03

Failure code Controller code C259FS

ENG

Trouble

Abnormality in fuel shut-off valve (Engine controller system)

Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).


• Flashes warning lamp and turns on alarm buzzer. • Turns off power for fuel shut-off valve.

Problem that • Engine cannot be stopped. appears on machine Related information • Method of reproducing failure code: Start engine.

Cause


1 Defective related systems

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly. Possible causes Clogging, looseness, breakand standard value Check fuel filter/piping directly for clogging, looseness, breakage, and 3 age, or leakage of fuel filter/ in normal state leakage. piping 4 Trouble in injector

Check inside of injector directly.



[C261NS] ABNORMAL RISE OF FUEL TEMPERATURE Action code E02 Contents of trouble

Failure code Controller code C261NS

ENG

Trouble

Abnormal rise of fuel temperature (Engine controller system)

• Fuel temperature sensor detected temperature lower than temperature set in controller. • Criterion (for reference): Min. 76°C

Action of controller • Limits engine speed to 800 rpm after 30 seconds. Problem that appears on machine Related information • Method of reproducing failure code: Start engine.

Cause 1 Defective related systems Possible causes and standard value Defective fuel temperature in normal state 2 sensor system 3 Defective engine

20-432 (10)

Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. If code related to engine controller is displayed, carry out troubleshooting for it first. Carry out troubleshooting for failure codes [C263KX] and [C264KX]. See Shop Manual for engine (170-3 Series).

HD465-7, HD605-7

[C263KX]

TROUBLESHOOTING

[C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM Action code


E01

C263KX

ENG

Trouble

Abnormally high level in fuel temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4.95 V.


• Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor. • Method of reproducing failure code: Turn starting switch ON. Cause Defective fuel temperature 1 sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FLTP (female)

Resistance

Between (A) – (B)

600 – 36 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (26) – Resistance Max. 10 z FLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. 10 z FLTP (female) (B) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Wiring harness between ECMA (female) (26) – FLTP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (17) – FLTP (female) (B) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between (26) – (17)

600 – 36 kz

Circuit diagram related to fuel temperature sensor

HD465-7, HD605-7

20-433 (10)

[C265KX]

TROUBLESHOOTING

[C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM Action code E01


ENG

Trouble

Abnormally low level in fuel temperature sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel temperature sensor circuit is below 0.21 V.



20-434 (10)

Cause


HD465-7, HD605-7

[C316KZ]

TROUBLESHOOTING

[C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR Action code



C316KZ

ENG

Trouble

Abnormal current of fuel pump actuator (Engine controller system)

• Current of fuel pump actuator circuit is out of normal range. • Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)


• Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator. • Method of reproducing failure code: Start engine. Cause


1


Defective fuel pump actuator (Internal trouble)

PUMP (male)

Resistance

Between (A) – (C)

7–9z


Min. 100 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (11) – 2 (Disconnection in wiring or Resistance Max. 10 z PUMP (female) (A) defective contact in connecWiring harness between ECMA (female) (40) – tor) Resistance Max. 10 z PUMP (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness)

Wiring harness between ECMA (female) (11) – PUMP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (40) – PUMP (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between (11) – (40)

7–9z

Between (11), (40) – another wiring harness

Min. 1 Mz

Circuit diagram related to fuel pump actuator

HD465-7, HD605-7

20-435 (10)

[C318LK]

TROUBLESHOOTING

[C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR Action code



C318LK

ENG

Trouble

Abnormality in fuel pump actuator (Engine controller system)

• Displayed pressure of fuel pump is excessively different from actual value. • Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when coolant temperature is 38°C)

Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that • Engine speed is unstable. appears on machine Related information • Method of reproducing failure code: Start engine.



Clogging, looseness, breakCheck fuel filter and piping directly for clogging, looseness, breakage, 2 age, or leakage of fuel filter/ and leakage. piping 3

Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level fuel level in tank gauge is in red range, supply fuel.

Possible causes and standard value Large suction resistance of 4 in normal state fuel filter

Suction resistance of fuel filter may be large. Check fuel filter directly. Negative suction pressure (Tank side)

27 kPa {203 mmHg}

5

Trouble in fuel pump actuaFuel pump actuator may malfunction. Check it directly. tor

6

Defective electric system of Carry out troubleshooting for failure codes [C118KX] and [C119KX]. fuel pump pressure sensor

7 Trouble in injector

Inside of injector may be defective. Check it directly.



Circuit diagram related to fuel pump actuator

20-436 (10)

HD465-7, HD605-7

[C346KT]

TROUBLESHOOTING

[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER Action code


E03

C346KT

ENG

Trouble

Abnormality in power-down unit of engine controller (Engine controller system)

Contents of trouble • Data recorded in power-down unit of engine controller has error.

Action of controller • Flashes warning lamp and turns on alarm buzzer. • Power-down data (maintenance information, current controller information, engine operating hours, Problem that appears on machine etc.) are lost. Related information

• Charge level of battery can be checked in monitoring mode. (Code: 04301) • Method of reproducing failure code: Turn starting switch ON. Cause 1 Defective fusible link (34 A) 2

Defective fuse (FS1-1, FS1-4)

Standard value in normal state/Remarks on troubleshooting If fusible link is broken, circuit probably has short circuit with chassis ground. If fuse is broken, circuit probably has short circuit with chassis ground. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMB (female) (3) – Resistance Max. 10 z BT2-(6) outlet Wiring harness between ECMA (female) (4), (5) – BT2-(30) outlet

Resistance Max. 10 z

Wiring harness between FS1 inlet – fusible link Resistance Max. 10 z (FUA) – battery relay terminal B



Wiring harness between ECMB (female) (3) – Resistance Min. 1 Mz BT2-(6) outlet with wiring harness around it Wiring harness between ECMA (female) (4), (5) – BT2-(30) outlet with wiring harness around it

Resistance Min. 1 Mz

Wiring harness between FS1 inlet – fusible link – battery relay terminal B with wiring harness Resistance Min. 1 Mz around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

HD465-7, HD605-7

ECMA, ECMB

Voltage

Between ECMB (3), (4), (5) – ECMA (7), (8)

17.3 – 34.7 V

20-437 (10)

TROUBLESHOOTING

[C346KT]

Circuit diagram related to engine controller power supply

20-438 (1)

HD465-7, HD605-7

[C423L6]

TROUBLESHOOTING

[C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM Action code


E03

C423L6

ENG

Trouble

Abnormality in in-range of timing rail pressure sensor system (Engine controller system)

Contents of trouble

• Timing rail pressure sensor detected abnormal pressure. • Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on


• Flashes warning lamp and turns on alarm buzzer. • Limits high idle speed to 1,500 rpm.


• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor. • Method of reproducing failure code: Turn starting switch ON. Cause Defective timing rail pres1 sure sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TPR (male)

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V


Wiring harness between ECMA (female) (5) – Resistance Max. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) – Resistance Max. 10 z TPR (female) (C)



Wiring harness between ECMA (female) (5) – Resistance Min. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) – Resistance Min. 1 Mz TPR (female) (C) with wiring harness around it

4

Large suction resistance of fuel filter


27 kPa {203 mmHg}

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

HD465-7, HD605-7

ECMA (female)

Resistance

Between (5) – (18)

4.75 – 5.25 V

Between (33) – (18)

0.42 – 0.58 V

20-439 (11)

TROUBLESHOOTING

[C423L6]

Circuit diagram related to timing rail pressure sensor

20-440 (1)

HD465-7, HD605-7

[C431L4]

TROUBLESHOOTING

[C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED) Action code


E01

C431L4

ENG

Trouble

Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed)

Contents of trouble • Both idle validation switch signals 2 and 3 are open (above 4.5 V).

Action of controller • (The controller displays action code E01, CHECK/REPAIR.) • None in particular. (Since the controller controls according to the throttle sensor signal (potentiometer), Problem that appears on machine no problems appear in the truck body. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AS1. 3) Connect T-adapter.

Between AS1 Idle validation switch defec(male) (4) – (5) 1 tive

Between AS1 (male) (4) – (6)

Release the accelerator pedal "Idle ON".


Press the accelerator pedal Resistance Min. 1 Mz "Idle OFF". Release the accelerator pedal "Idle ON".


Press the accelerator pedal Resistance Max. 100 z "Idle OFF".

1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter.


Disconnection in wiring har- Wiring harness between ECMB (female) (12) – Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) – Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter.

3


4 Engine controller defective

HD465-7, HD605-7

Wiring harness between ECMB (female) (12) – AS1 (female) (6)

Resistance between ECMB (female) (12), AS1 (female) Min. 1 M z (6) – chassis ground


Resistance between ECMB (female) (13), AS1 (female) Min. 1 Mz (5) – chassis ground



1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. • Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.

20-441 (10)

TROUBLESHOOTING

[C431L4]

Circuit diagram related to engine idle validation switch

20-442 (10)

HD465-7, HD605-7

[C432L5]

TROUBLESHOOTING

[C432L5] ERROR IN IDLE VALIDATION PROCESS ( *SEE SEPARATE LIST (L5)) Action code



C432L5

ENG

Error in idle validation process: *See separate list (L5) Trouble (Potentiometer signal and switch signal do not agree with each other)

• The throttle potentiometer signal of the accelerator pedal is not conformed to idle validation switch signal 2 and signal 3.

• Flashes warning lamp and turns on alarm buzzer. • The throttle is conformed to the idle validation switch (In idle: 0%, Off idle: 35%). Action of controller • If this failure is detected when the throttle sensor signal is on the low speed side (idle side), the throttle is conformed to the throttle sensor. Problem that • The engine speed is kept at low idle or 1,500 rpm (Throttle: 35%). appears on machine Related information

Cause









1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between ECMB (female) (12) – Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max. 1 z AS1 (female) (5) Possible causes and standard value in normal state

Wiring harness between ECMB (female) (21) – Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter.

3


4 Slottle sensor defective







1) Turn the starting switch OFF. 2) Disconnect connector AS1. 3) Connect T-adapter. 4) Connect connector. 5) Startin switch ON. Between AS1 (male) (1) – (2)

HD465-7, HD605-7


Voltage

0.35 – 0.55V

Press the accelerator pedal "Idle OFF".

Voltage

3.55 – 3.75V

20-443 (10)

[C432L5]

TROUBLESHOOTING

Cause Possible causes and standard value 5 Engine controller defective in normal state

Standard value in normal state/Remarks on troubleshooting 1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. • Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.

Circuit diagram related to engine idle validation process

20-444 (10)

HD465-7, HD605-7

[C441KX], [C442KG]

TROUBLESHOOTING

[C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM Action code


E01

C441KX

ENG

Trouble

Abnormally low level in battery voltage system (Engine controller system)

Contents of trouble • Voltage of controller power supply circuit is below 12 V.

Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.


Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT].

[C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM Action code


E01

C442KG

ENG

Trouble

Abnormally low level in battery voltage system (Engine controller system)

Contents of trouble • Voltage of controller power supply circuit is below 38 V.

Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.


HD465-7, HD605-7

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT].

20-445 (10)

[C451KX]

TROUBLESHOOTING

[C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM Action code E03


ENG

Trouble

Abnormally high level in fuel rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.


• Flashes warning lamp and turns on alarm buzzer. • Opens and controls fuel rail.


• Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. • Method of reproducing failure code: Start engine. Cause Defective fuel rail pressure 1 sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPR

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state

Wiring harness between ECMA (female) (5) – Resistance Max. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) – Resistance Max. 10 z RPR (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ECMA (female) (5) – Resistance Min. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) – Resistance Min. 1 Mz RPR (female) (C) with wiring harness around it aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.


ECMA

Voltage

Between (5) – (18)

4.75 – 5.25 V

Between (31) – (18)

0.42 – 0.58 V

Circuit diagram related to fuel rail pressure sensor

20-446 (10)

HD465-7, HD605-7

[C452KX]

TROUBLESHOOTING

[C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM Action code


E03

C452KX

ENG

Trouble

Abnormally low level in fuel rail pressure sensor system (Engine controller system)

Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.


• Flashes warning lamp and turns on alarm buzzer. • Reduces current for fuel rail actuator to 0 A.



HD465-7, HD605-7

Cause


20-447 (10)

[C455KZ]

TROUBLESHOOTING

[C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR Action code


E03

C455KZ

ENG

Trouble

Abnormal current of fuel rail actuator (Engine controller system)

Contents of trouble

• Current of fuel rail actuator circuit is out of normal range. • Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)




• Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator. • Method of reproducing failure code: Turn starting switch ON or start engine. Cause


1


Defective fuel rail actuator (Internal trouble)

RAIL (male)

Resistance

Between (A) – (C)

7–9z


Min. 100 kz

aPrepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ECMA (female) (3) – Resistance Max. 10 z 2 (Disconnection in wiring or RAIL (female) (A) defective contact in connecWiring harness between ECMA (female) (10) – tor) Resistance Max. 10 z RAIL (female) (C) Short circuit in wiring harness 3 (with another wiring harness)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ECMA (female) (3) – Resistance Min. 1 Mz RAIL (female) (A) with wiring harness around it Wiring harness between ECMA (female) (10) – Resistance Min. 1 Mz RAIL (female) (C) with wiring harness around it aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


ECMA (female)

Resistance

Between (3) – (10)

7–9z

Between (3), (10) – another wiring harness

Min. 1 Mz

Circuit diagram related to fuel rail actuator

20-448 (10)

HD465-7, HD605-7

[C467LK], [C468LK]

TROUBLESHOOTING

[C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL Action code


E03

C467LK

ENG

Trouble

Abnormality in timing rail actuator control (Engine controller system)

Contents of trouble

• Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot be obtained.





Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C112LK].

[C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL Action code


E03

C468LK

ENG

Trouble

Abnormality in fuel rail actuator control (Engine controller system)

Contents of trouble

• Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be obtained.


• Flashes warning lamp and turns on alarm buzzer. • Limits maximum injection rate to 217 mm3/st.




Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and 2 age, or leakage of fuel filter/ leakage. piping

Possible causes and standard value 3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly. in normal state Clogging of fuel rail actuator 4 Fuel rail actuator screen may be clogged. Check it directly. screen 5 Breakage of injector O-ring

Injector O-ring may be broken. Check it directly.



HD465-7, HD605-7

20-449 (10)

[C514LK]

TROUBLESHOOTING

[C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR Action code E03

Failure code Controller code C514LK

ENG

Trouble

Abnormality in fuel rail actuator (Engine controller system)

Contents of trouble

• Displayed injection rate of fuel rail is excessively different from actual injection rate. • Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.


• Flashes warning lamp and turns on alarm buzzer. • Limits maximum injection rate to 217 mm3/st.



20-450 (10)

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C468LK].

HD465-7, HD605-7

[C551L4]

TROUBLESHOOTING

[C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED) Action code


E01

C551L4

ENG

Trouble

Abnormality in idle validation switch system: *See separate list (L4) (Either signal voltage of 2 systems is not sensed)

Contents of trouble • Both of idle validation switch signals 2 and 3 are closed (connected to GND).


• Flashes warning lamp and turns on alarm buzzer. • Controller sets engine speed to low idle.

Problem that • Engine speed is kept at low idle. appears on machine Related information

Cause









1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter.


Disconnection in wiring har- Wiring harness between ECMB (female) (12) – Resistance Max. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) – Resistance Max. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. 2) Disconnect connectors ECMB and AS1. 3) Connect T-adapter.

3



HD465-7, HD605-7







1) Connect the all connectors. 2) Turn the starting switch ON. 3) Press the accelerator pedal 3 times repeatedly. • Check that the failure code disappears. a If the failure code does not disappear, replace the engine controller.

20-451 (10)

TROUBLESHOOTING

[C551L4]

Circuit diagram related to idle validation switch

20-452 (10)

HD465-7, HD605-7

[C554L6]

TROUBLESHOOTING

[C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM Action code


E03

C554L6

ENG

Trouble

Abnormality in in-range of fuel rail pressure sensor system (Engine controller system)

Contents of trouble

• Fuel rail pressure sensor detected abnormal pressure. • Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on


• Flashes warning lamp and turns on alarm buzzer. • Limits maximum injection rate to 270 mm3/st


• Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. • Method of reproducing failure code: Turn starting switch ON. Cause Defective fuel rail pressure 1 sensor (Internal trouble)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RPR

Voltage

Between (A) – (B)

4.75 – 5.25 V

Between (C) – (B)

0.42 – 0.58 V


Wiring harness between ECMA (female) (5) – Resistance Max. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) – Resistance Max. 10 z RPR (female) (C)



Wiring harness between ECMA (female) (5) – Resistance Min. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) – Resistance Min. 1 Mz RPR (female) (C) with wiring harness around it

4

Large suction resistance of fuel filter


27 kPa {203 mmHg}

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

HD465-7, HD605-7

ECMA

Voltage

Between (5) – (18)

4.75 – 5.25 V

Between (31) – (18)

0.42 – 0.58 V

20-453 (11)

TROUBLESHOOTING

[C554L6]

Circuit diagram related to fuel rail pressure sensor

20-454 (1)

HD465-7, HD605-7

ENG-1

TROUBLESHOOTING

ENG-1 ENGINE DOES NOT START Action code


Not set

Not set

ENG

Trouble Engine does not start

Contents of trouble • Engine does not start.

Action of controller • None in particular. Problem that • Engine does not start. appears on machine Related information

• If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it first. Cause 1 Battery defective

Standard value in normal state/Remarks on troubleshooting Specific gravity

Min. 1.26

Voltage

Min. 25 V

1) Turn the starting switch OFF. 2) Replace R01 with normal one. 3) Turn the starting switch ON. When engine starting relay (R01) No is replaced, is failure repaired? Yes

2

Engine starting relay (R01) defective

Relay (R01) normal Relay (R01) defective

1) Turn the starting switch OFF. 2) Disconnect connector R01. 3) Check R01. Between R01 (male) (1) – (2)

Resistance

200 – 400 z

1) Turn the starting switch OFF. 2) Disconnect connector R01. 3) Check R01. 4) Apply voltage between R01 (male) (1) – (2). Between R01 (male) (3) – (6) Possible causes and standard value in normal state

Apply 24 V between (1) – (2).


Do not apply voltage between (1) – (2).

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Replace R02 with normal one. 3) Turn the starting switch ON. When transmission neutral relay (R02) is replaced, is failure repaired?

3

Transmission neutral relay (R02) defective

No

Relay (R02) normal

Yes

Relay (R02) defective

1) Turn the starting switch OFF. 2) Disconnect connector R02. 3) Check R02. Between R02 (male) (1) – (2)

Resistance

200 – 400 z

1) Turn the starting switch OFF. 2) Disconnect connector R02. 3) Check R02. 4) Apply voltage between R02 (male) (1) – (2). Between R02 (male) (3) – (6)

4 Diode (D01) defective

HD465-7, HD605-7




Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Replace diode (D01). 3) Turn the starting switch to the START position. Failure is not repaired.

Diode (D01) is normal.

Failure is repaired.

Diode (D01) is defective.

20-455 (10)

ENG-1

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. Wiring harness between batVoltage between battery tertery – battery terminal 01 minal 01 (B), 03 (B), 02 (M), 20 – 30 V (B), 03 (B), 02 (M), and 04 and 04 (M) – chassis ground (M)

1) Turn the starting switch OFF. Disconnection of wiring har- 2) Disconnect fuse BT3 terminal (9) – battery relay terminal 02 (M) and 04 (M). 5 ness between battery relay and related wiring harness Wiring harness between bat- Resistance between battery tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) Max. 1 z (M) – fuse BT3 (9) – fuse BT3 (10) 1) Turn the starting switch OFF. 2) Disconnect the negative (-) terminal of the battery relay. Wiring harness between the negative (-) termiResistance Max. 1 z nal of the battery relay – chassis ground 1) Turn the starting switch to the START position.


Disconnection in wiring har- Wiring harness between bat6 ness related to starting mo- tery relay terminal 02 (M), 04 Voltage between starting motor terminal B – chassis tor terminal B (M) – starting motor terminal ground B


8

9

(10)

1) Turn the starting switch OFF. 2) Replace diode (D01). 3) Turn the starting switch to the START position. Failure is repaired.


Failure is not repaired.


1) Turn the starting switch OFF. 2) Disconnect connector ATC3B, diode (D01), alternator terminal R, and starting motor terminal R. 3) Turn the starting switch ON.

Hot short in wiring harness of starting motor terminal R Wiring harness between diode (D01), starting motor terminal R, – alternator terminal R

Voltage between diode (D01), starting motor termiMax. 12 V nal R (on the harness side), – chassis ground

1) Turn the starting switch ON. Alternator (Regulator) defecVoltage between starting motor terminal R – chassis tive ground


20-456

20 – 30 V

Max. 12 V

1) Turn the starting switch OFF. 2) Replace diode (D08). 3) Turn the starting switch to the START position. Failure is not repaired.


Failure is repaired.


HD465-7, HD605-7

ENG-1

TROUBLESHOOTING


Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R01, battery relay terminal 14 (BR), 12 (BR), and starting switch terminals BR and C.

11

Wiring harness between starting switch terminal B – Disconnection in wiring har- battery relay terminals 01 (B) and 03 (B). ness

Resistance between starting switch terminal B – battery Max. 1 z relay terminal 01 (B) and 03 (B)

(Disconnection or defective contact) • Wiring harness related to starting switch

Resistance between starting switch terminal BR – battery Max. 1 z relay terminal 14 (BR), 12 (BR)

Wiring harness between starting switch terminal BR – battery relay terminal 14 (BR), 12 (BR)

aMeasure at starting switch terminal BR (+ side of tester) with a tester in the diode range. Wiring harness between starting switch terminal C – R01 (female) (3)

Resistance between starting switch terminal C – R01 (fe- Max. 1 z male) (3)

1) Turn the starting switch OFF. 2) Disconnect connectors R01 and R02, fuse BT3 terminal (10), and starting motor terminal S. 3) Connect T-adapter. Disconnection in wiring harness Possible causes (Disconnection or defective and standard value 12 contact) in normal state • Wiring harness related to engine starting relay (R01)

Wiring harness between Resistance between fuse fuse BT3 terminal (10) – R01 BT3 terminal (10) – R01 (fe- Max. 1 z (female) (1) male) (1) Wiring harness between R01 (female) (2) – R02 (female) (6)

Resistance between R01 (female) (2) – R02 (female) (6)

Max. 1 z

Wiring harness between R01 (female) (6) – starting motor terminal S

Resistance between R01 (female) (6) – starting motor terminal S

Max. 1 z

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector R02 and S2 (connector of shift lever side). 3) Connect T-adapter. ness (Disconnection or defective 13 contact) • Wiring harness related to transmission neutral relay (R02)

14 Starting switch defective

Wiring harness between R02 (female) (1) – S2 (female) (4)

Resistance between R02 (female) (1) – S2 (female) (4)

Max. 1 z

Wiring harness between Resistance between R02 R02 (female) (2), (3) – chas- (female) (2), (3) – chassis sis ground ground

Max. 1 z

1) Disconnect the starting switch terminals. 2) Check the starting switch. Turn the starting switch to the START position.

Resistance between terminals B – C

Max. 1 z

1) Check the starting motor. 15 Starting motor defective

HD465-7, HD605-7

• If the check result of the starting motor is normal, the starting motor is normal.

20-457 (10)

TROUBLESHOOTING

ENG-1

Circuit diagram related to engine does not start

20-458 (1)

HD465-7, HD605-7

ENG-2

TROUBLESHOOTING

ENG-2 FAILURE IN PREHEATING a) Engine is not preheated Action code


Not set

Not set

ENG

Trouble

1. Failure in preheating a) Engine is not preheated

Contents of trouble • Engine is not preheated. (Engine coolant temperature is below 0°C.)

Action of controller • None in particular. Problem that • Engine is not preheated. appears on machine Related information

• If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors E11A, E12A, E11B, and E12B. 3) Check the disconnected connectors. Resistance 19 – 25 z

Between E11A – chassis ground Between E12A – opposite Intake air heater relay defec- terminal of relay switch 1 tive

When relay is ON

Resistance Max. 1 z

When relay is OFF

Resistance Min. 1M z Resistance 19 – 25 z

Between E11B – chassis ground Between E12B – opposite terminal of relay switch

2

Intake air heater (Ribbon heater) defective


When relay is ON

Resistance Max. 1 z

When relay is OFF


1) Turn the starting switch OFF. 2) Disconnect the heater terminal. 3) Check the heater. Between heater terminal – chassis ground

Resistance

0.17 – 0.27z

1) Turn the starting switch OFF. 2) Replace R37 with a normal relay. 3) Turn the starting switch ON. When the automatic preheater relay (R37) is replaced, is failure repaired?

3

Automatic preheater relay (R37) defective

No

Relay (R37) is normal.

Yes

Relay (R37) is defective.

1) Turn the starting switch OFF. 2) Disconnect connector R37. 3) Check connector R37. Between R37 (male) (1) – (2)

Resistance

200 – 400 z

1) Turn the starting switch OFF. 2) Disconnect connector R37. 3) Check connector R37. 4) Apply voltage between R37 (male) (1) – (2). Between R37 (male) (3) – (6)


Resistance Min. 1M z


Resistance Max. 1 z

1) Turn the starting switch OFF. Diode (E17A, E17B) defec- 2) Replace diode (E17A, E17B). 4 tive Failure is not repaired. Failure is repaired.

HD465-7, HD605-7

Diode (D01) is normal. Diode (D01) is defective.

20-459 (10)

ENG-2

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ECMA, R37, E11A, E11B, E12A, E12B, and fuse BT4 terminal (4). 3) Connect T-adapter. Wiring harness between ECMA (female) (2) – R37 (female) (1)


Wiring harness between Disconnection in wiring har- R37 (female) (2) – chassis ness ground 5 (Disconnection or defective Wiring harness between contact) R37 (female) (5) – E11A, E11B


Resistance between ECMA (female) (2) – R37 (female) (1)

Max. 1 z

Resistance between R37 (female) (2) – chassis ground

Max. 1 z

Resistance between R37 (female) (5) – E11A, E11B

Max. 1 z

Wiring harness between Resistance between fuse fuse BT4 terminal (4) – R37 BT4 terminal (4) – R37 (fe(female) (3) male) (3)

Max. 1 z

Wiring harness between bat- Resistance between battery tery relay terminal 02 (M), 04 relay terminal 02 (M), 04 (M) (M) – E12A, E12B – E12A, E12B

Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector ECMA. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Engine coolant temperature: Max. 0°C Between At the heater operation ECMA (2) – (7), (8) At the heater un operation

20-460 (10)

Voltage

20 – 30V

Voltage

Max. 1 V

HD465-7, HD605-7

TROUBLESHOOTING

ENG-2

Circuit diagram related to preheating

HD465-7, HD605-7

20-461 (1)

ENG-2

TROUBLESHOOTING

b) Preheating is actuated even under non-actuation conditions for preheating Action code Not set

Failure code Controller code Not set

ENG

Failure in preheating Trouble b) Preheating is actuated even under non-actuation conditions for preheating

Contents of trouble • Preheating is actuated even under non-actuation conditions for preheating.

Action of controller • None in particular. Problem that • Preheating is actuated even under non-actuation conditions for preheating. appears on machine Related information

• If any failure code related to the engine controller or transmission controller is indicated, perform troubleshooting for it. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors E11A, E12A, E11B, and E12B. 3) Check the disconnected connectors. Between E11A – chassis ground

Between E12A – opposite Intake air heater relay defec- terminal of relay switch 1 tive

Resistance Max. 1 z

When relay is OFF


Between E11B – chassis ground Between E12B – opposite terminal of relay switch

Resistance 19 – 25 z

When relay is ON


When relay is ON

Resistance Max. 1 z

When relay is OFF


1) Turn the starting switch OFF. 2) Disconnect the connector. 3) Connect T-adapter. 4) Turn the starting switch ON.

Possible causes and standard value in normal state 2 Hot short in wiring harness

Wiring harness between ECMA (female) (2) – R37 (female) (1)

Voltage between ECMA (female) (2), R37 (female) (1) – chassis ground

Max. 1 V

Wiring harness between R37 (female) (5) – E11A, E11B

Voltage between R37 (female) (5), E11A, E11B – chassis ground

Max. 1 V

Wiring harness between AC5A (female) (20) – HES (a)

Voltage between AC5A (female) (20), HES – chassis ground

Max. 1 V

Measure only on E12A side for wiring harness marked with (a).


1) Turn the starting switch OFF. 2) Disconnect connector ECMA. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Engine coolant temperature: Max. 0 °C Between At the heater operation ECMA (2) – (7), (8) At the heater un operation

20-462 (10)

Voltage

20 – 30V

Voltage

Max. 1 V

HD465-7, HD605-7

TROUBLESHOOTING

ENG-2

Circuit diagram related to preheating time

HD465-7, HD605-7

20-463 (1)

ENG-3

TROUBLESHOOTING

ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY a) When AISS switch is set in AUTO, LOW SPEED control is selected Action code Not set


Not set

When AISS switch is operated, AISS function does not work normally Trouble a) When AISS switch is set in AUTO, LOW SPEED control is selected

Contents of trouble • When AISS switch is set in AUTO, LOW SPEED control is selected

Action of controller • None in particular. Problem that • When AISS switch is set in AUTO, LOW SPEED control is selected appears on machine Related information • Failure code is not indicated.

Cause

1 AISS switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AISS. 3) Check the connector. Between AISS (male) (1) – (2)

Set the AISS switch in AUTO Resistance Max. 1 z Set the AISS switch in LOW. Resistance Min. 1 Mz

1) Turn the starting switch OFF. 2) Replace R07 with normal one. 3) Turn the starting switch ON. When AISS relay (R07) is replaced, is failure corrected?

2 AISS relay (R07) defective

No

Relay (R07) is normal

Yes

Relay (R07) is defective

1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay Between R07 (male) (1) – (2)

Resistance

200 – 400 z

1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay. 4) Apply voltage between R07 (male) (1) – (2).


Between R07 (male) (3) – (6)



Do not apply 24 V between (1) – (2).

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors AISS, R07, – fuse BT2 terminal (2). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (2) – AISS Resistance Max. 1 z ness (female) (1) 3 (Disconnection or defective Wiring harness between AISS (female) (2) – contact) Resistance Max. 1 z R07 (female) (1) Wiring harness between R07 (female) (2) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ECMB Set the AISS switch in AUTO. (33) – chassis ground Set the AISS switch in LOW.

20-464 (10)

Resistance Max. 1 z

Voltage

20 – 30 V

Voltage

Max. 1 V

HD465-7, HD605-7

ENG-3

TROUBLESHOOTING

b) When AISS switch is set in LOW SPEED, AUTO control is selected Action code


Not set

Not set

Not set

When AISS switch is operated, AISS function does not work normally Trouble b) When AISS switch is set in LOW SPEED, AUTO control is selected

Contents of trouble • When AISS switch is set in LOW SPEED, AUTO control is selected

Action of controller • None in particular. Problem that • When AISS switch is set in LOW SPEED, AUTO control is selected appears on machine Related information • Failure code is not indicated.

Cause

1 AISS switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector AISS. 3) Check the connector. Between AISS (male) (1) – (2)

Set the AISS switch in AUTO Resistance Max. 1 z Set the AISS switch in LOW Resistance Min. 1 Mz

1) Turn the starting switch OFF. 2) Replace R07 with normal one. 3) Turn the starting switch ON. When AISS relay (R07) is replaced, is failure corrected?

2 AISS relay (R07) defective

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the relay Between R07 (male) (1) – (2)

Resistance

200 – 400 z






Do not apply 24 V between (1) – (2).

Resistance Max. 1 z

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector R07. ness 3) Connect T-adapter. 3 (Disconnection or defective Wiring harness between R07 (female) (3) – contact) chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors AISS and R07. 3) Connect T-adapter.

4 Hot short in wiring harness

HD465-7, HD605-7

Wiring harness beWiring harness between AISS (female) tween AISS (female) (2), R07 (female) (1) – (2) – R07 (female) (1) chassis ground

Voltage

Max. 1 V

Wiring harness beWiring harness between ECMB (female) tween ECMB (female) (33), R07 (female) (6) (33) – R07 (female) (6) – chassis ground

Voltage

Max. 1 V

20-465 (10)

ENG-3

TROUBLESHOOTING

Cause

Possible causes and standard value 5 Engine controller defective in normal state

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ECMB Set the AISS switch in AUTO. (33) – chassis ground Set the AISS switch in LOW.

Voltage

20 – 30 V

Voltage

Max. 1 V

Circuit diagram related to low speed, auto control

20-466 (1)

HD465-7, HD605-7

TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE)

Electrical system diagram related to transmission control .......................................................................... 20-503 Information in troubleshooting table ....................................................................................................... 20-504 Phenomenon code table ........................................................................................................................ 20-505 [1380MW] Lockup clutch: Slip (MW)................................................................................................... 20-506 [1500L0] Detection of double engagement: *See separate list (L0) ................................................. 20-507 [15B0NX] Clogging of transmission oil filter: Clogging (NX) .............................................................. 20-508 [15E0KM] R to F gear shift abuse 1: Mistake in operation or setting (KM) ........................................ 20-509 [15E7KM] R to F gear shift abuse 2: Mistake in operation or setting (KM) ......................................... 20-509 [15G0MW] R clutch: Slip (MW)............................................................................................................ 20-510 [15H0MW] Hi clutch: Slip (MW) ........................................................................................................... 20-511 [15J0MW] Lo clutch: Slip (MW) ........................................................................................................... 20-513 [15K0MW] 1st clutch: Slip (MW).......................................................................................................... 20-515 [15L0MW] 2nd clutch: Slip (MW) ........................................................................................................ 20-516 [15M0MW] 3rd clutch: Slip (MW) ......................................................................................................... 20-517 [15N0MW] 4th clutch: Slip (MW) ......................................................................................................... 20-518 [15SBL1] R clutch solenoid: *See separate list (L1).......................................................................... 20-519 [15SBMA] R clutch solenoid: Malfunction (MA) .................................................................................. 20-520 [15SCL1] Hi clutch solenoid: *See separate list (L1)......................................................................... 20-521 [15SCMA] Hi clutch solenoid: Malfunction (MA) ................................................................................. 20-522 [15SDL1] Lo clutch solenoid: *Seee separate list (L1) ...................................................................... 20-523 [15SDMA] Lo clutch solenoid: Malfunction (MA)................................................................................. 20-524 [15SEL1] 1st clutch solenoid: *See separate list (L1) ....................................................................... 20-525 [15SEMA] 1st clutch solenoid: Malfunction (MA)................................................................................ 20-526 [15SFL1] 2nd clutch solenoid: *See separate list (L1) ...................................................................... 20-527 [15SFMA] 2nd clutch solenoid: Malfunction (MA)............................................................................... 20-528 [15SGL1] 3rd clutch solenoid: *See separate list (L1) ....................................................................... 20-529 [15SGMA] 3rd clutch solenoid: Malfunction (MA) ............................................................................... 20-530 [15SHL1] 4th clutch solenoid: *See separate list (L1) ....................................................................... 20-531 [15SHMA] 4th clutch solenoid: Malfunction (MA)................................................................................ 20-532 [15SJL1] Lockup clutch solenoid: 15SJ (L1)..................................................................................... 20-533 [15SJMA] Lockup clutch solenoid: 15SJ (MA) ................................................................................... 20-534 [2F00KM] Parking brake: Mistake in operation or setting (KM).......................................................... 20-535 [989A00] Engine overrun prevention command signal: Operation (00) ............................................ 20-537 [989AKZ] Engine overrun prevention command signal: Disconnection or short circuit (KZ) ............. 20-538 [AA10NX] Air cleaner element: Clogging (NX) ................................................................................... 20-539 [AB00MA] Alternator: Malfunction (MA).............................................................................................. 20-541 [B@BCZK] Lowering of radiator water: Lowering of level (ZK) ............................................................ 20-543 [D1BOKZ] Transmission controller cutout: Disconnection or short circuit (KZ) .................................. 20-544 [D5ZMKZ] Disconnection, grounding fault, or short circuit in engine output mode command line: Disconnection or short circuit (KZ) .................................................................................... 20-546 [DAQ0KK] Transmission controller: Lowering of source/input voltage (KK) ....................................... 20-547 [DAQ1KK] Main power line of transmission controller: Lowering of source/input voltage (KK) .......... 20-549 [DAQ2KK] Transmission controller load power line: Lowering of source/input voltage (KK) ............. 20-551 [DAQ3KK] Direct line of transmission controller battery: Lowering of source/input voltage (KK) ........ 20-553 [DAQ9KM] Transmission controller wiring harness: Mistake in operation or setting (KM) .................. 20-554 [DAQ9KQ] Transmission controller wiring harness: Disagreement of model selection signals (KQ) .. 20-555 [DAQAKQ] Transmission controller rotary switch: Disagreement of model selection signals (KQ) ..... 20-556 [DAQSMA] Transmission controller: Malfunction (MA) ........................................................................ 20-556

HD465-7, HD605-7

20-501 (10)

TROUBLESHOOTING

[DDTGKA] [DDTHKA] [DDTJKA] [DDTKKA] [DDTLKA] [DDTMKA] [DDTNKA] [DDTPKA] [DF10KA] [DF10KB] [DGF1KX] [DGT1KX] [DHT5KX] [DHT5L6] [DJF1KA] [DK11KX] [DLE2KA] [DLE2LC] [DLF1KA] [DLF1LC] [DLF2KA] [DLF2LC] [DLT3KA] [DLT3LC] [DXH1KA] [DXH1KB] [DXH2KA] [DXH2KB] [DXH3KA] [DXH3KB] [DXH4KA] [DXH4KB] [DXH5KA] [DXH5KB] [DXH6KA] [DXH6KB] [DXH7KA] [DXH7KB] [DXHHKA] [DXHHKB] TM-1 TM-2

20-502 (2)


Lockup clutch fill switch: Disconnection (KA) .................................................................... 20-557 Hi clutch fill switch: Disconnection (KA)............................................................................. 20-558 Lo clutch fill switch: Disconnection (KA) ............................................................................ 20-559 1st clutch fill switch: Disconnection (KA) ........................................................................... 20-560 2nd clutch fill switch: Disconnection (KA) .......................................................................... 20-561 3rd clutch fill switch: Disconnection (KA)........................................................................... 20-562 R clutch fill switch: Disconnection (KA) ............................................................................. 20-563 4th clutch fill switch: Disconnection (KA) ........................................................................... 20-564 Shift lever: Disconnection (KA) .......................................................................................... 20-565 Shift lever: Short circuit (KB) ............................................................................................. 20-569 Transmission valve oil temperature sensor: Out of input signal range (KX) ...................... 20-572 Torque converter oil temperature sensor: Out of inputsignal range (KX) .......................... 20-574 Torque converter oil pressure sensor: Out of input signal range (KX) .............................. 20-575 Torque converter oil pressure sensor: See separate list (L6) ........................................... 20-577 Fuel level sensor: Disconnection (KA) ............................................................................... 20-578 Throttle angle sensor: Out of input signal range (KX) ....................................................... 20-579 Engine speed sensor: Disconnection (KA) ........................................................................ 20-581 Engine speed sensor: *See separate list (LC) ................................................................... 20-582 Transmission input shaft speed sensor: Disconnection (KA) ............................................ 20-583 Transmission input shaft speed sensor: *See separate list (LC) ....................................... 20-584 Transmission intermediate shaft speed sensor: Disconnection (KA) ................................ 20-585 Transmission intermediate shaft speed sensor: *See separate list (LC) .......................... 20-586 Transmission output shaft speed sensor: Disconnection (KA) .......................................... 20-587 Transmission output shaft speed sensor: *See separate list (LC) ..................................... 20-588 Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA) .................. 20-590 Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB) ......................... 20-591 Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA) ......................... 20-592 Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB) ............................... 20-593 Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA) ........................ 20-595 Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB) ............................... 20-596 Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA) ....................... 20-598 Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB) ............................... 20-599 Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA) ...................... 20-600 Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB) ............................. 20-601 Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA) ....................... 20-602 Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB) .............................. 20-603 Disconnection in output circuit of R clutch solenoid: Disconnection (KA) .......................... 20-604 Short circuit in output circuit of R clutch solenoid: Short circuit (KB) ................................. 20-605 Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA) ....................... 20-606 Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB) .............................. 20-607 Fuel level gauge does not operate normally (It always indicates "FULL") ........................ 20-608 Abnormality in backup lamp and backup buzzer ............................................................... 20-609 a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON.......................................................................................................... 20-609 b) Backup lamp is not turned ON (Backup buzzer is normal)............................................ 20-610 c) Backup buzzer is not turned ON (Backup lamp is normal) ........................................... 20-610 d) While shift lever is not operated, backup lamp and backup buzzer are turned ON ...... 20-611

HD465-7, HD605-7

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL a For details of this page, see page 90-19.

HD465-7, HD605-7

20-503 (2)


TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code Display on panel


Display on panel


Contents of trouble Contents of trouble detected by monitor panel or controller

Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting

Cause

1

2



20-504 (10)

HD465-7, HD605-7

PHENOMENON CODE TABLE

TROUBLESHOOTING




Contents

Phenomenon code

Contents

KA


L0


KB

Short circuit

L1


KK


L2


KQ


L3


KR


L4


KT


L6


KX


L8


KY


LC


KZ


LD


MA

Malfunction

LH


MB


MW

Sliding

NS

Overheat

ZG


ZK


HD465-7, HD605-7

20-505 (10)

[1380MW]

TROUBLESHOOTING

[1380MW] LOCKUP CLUTCH: SLIP (MW) Action code


E03

1380MW

TM

Lockup clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

Contents of trouble

• When a signal is output to the lockup clutch ECMV, the value calculated from the signals of the engine speed sensor, transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.

• The lockup operation is reset and the gear cannot be shifted. Problem that appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619). Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-

sure control valve for a defect. Cause


1) Turn the starting switch OFF. 2) Disconnect connector CN20. Lockup clutch ECMV defec- 3) Connect T-adapter. 1 tive Between CN20 (male) (1) – (2)


Between CN20 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN10. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) – Resistance Max. 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) – Resistance Max. 1 z CN20 (female) (2) 3

Defective sensing by speed • Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor

1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (10) – Resistance 5 – 15 z ATC2 (female) (20)


20-506 (10)

HD465-7, HD605-7

[1500L0]

TROUBLESHOOTING

[1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0) Action code



1500L0

TM

Trouble Detection of double engagement: *See separate list (L0)

• The fill switch signals of abnormally combined 2 clutches are input.

Action of controller • The gear is set in Neutral during travel and the machine cannot start again. • The transmission cutout relay is turned OFF. Problem that appears on machine • The gear is set in Neutral. Related information

• Another failure (Clutch pressure control valve system failure code: 15S*L1) occurs simultaneously with this failure. Cause


Clutch pressure control Possible causes 1 valve system failure code • Perform troubleshooting by the indicated failure code. and standard value (15S*L1) is indicated. in normal state Transmission controller de2 • Perform troubleshooting by the indicated failure code. fective

HD465-7, HD605-7

20-507 (10)

[15B0NX]

TROUBLESHOOTING

[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER: CLOGGING (NX) Action code E01 Contents of trouble

Failure code Controller code 15B0NX

TM

Trouble Clogging of transmission oil filter: Clogging (NX)

• When the torque converter oil temperature is above 50°C, the signal circuit of the transmission clogging sensor is opened (disconnected from GND).

Action of controller • None in particular. Problem that • If the machine is used without repairing, dust may enter the transmission circuit. appears on machine

• This failure can be checked in the monitoring function (Code: 33300). Related information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the

transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor". Cause


Clogging of transmission fil1 • Clean or replace. ter 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A, TMF and CN10. Transmission filter clogging 3) Connect T-adapter. 2 sensor defective Resistance Max. 1 z Between TMF (male) Filter is normal. (1) – (2) Filter is clogged. Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A, TNF, and CN10. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 3 Wiring harness between ATC5A (female) (6) – in normal state Resistance Max. 1 z (Disconnection or defective TMF (female) (1) contact) Wiring harness between CJH1 (female) (5) – Resistance Max. 1 z TMF (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect conector. 4 fective 5) Turn the starting switch ON. Between ATC5A (6) – chassis ground

Filter is normal.

Voltage

Max. 1 V

Filter is clogged.

Voltage

20 – 30 V


20-508 (10)

HD465-7, HD605-7

[15E0KM], [15E7KM]

TROUBLESHOOTING

[15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM) Action code


Not set Contents of trouble

15E0KM

TM

Trouble R to F gear shift abuse 1: Mistake in operation or setting (KM)

• When the output shaft speed is 200 rpm – 300 rpm (approx. 5 – 7 km/h), the gear is shifted from reverse to forward.

Action of controller • None in particular. • If the machine is used without repairing, it may be broken. Problem that appears on machine • The failure is only recorded in the failure history. Related information • This failure can be checked in the monitoring function (Code: 31400).

Possible causes and standard value 1 Abuse in normal state

Cause

Standard value in normal state/Remarks on troubleshooting • Change the travel direction after the machine is stopped perfectly.

[15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM) Action code



15E7KM

TM

Trouble R to F gear shift abuse 2: Mistake in operation or setting (KM)

• When the output shaft speed is above 300 rpm (approx. 7 km/h), the gear is shifted from reverse to forward.

Action of controller • None in particular. • If the machine is used without repairing, it may be broken. Problem that appears on machine • The failure is only recorded in the failure history. Related information • This failure can be checked in the monitoring function (Code: 31400).

Possible causes and standard value 1 Abuse in normal state

HD465-7, HD605-7

Cause

Standard value in normal state/Remarks on troubleshooting • Change the travel direction after the machine is stopped perfectly.

20-509 (10)

[15G0MW]

TROUBLESHOOTING

[15G0MW] R CLUTCH: SLIP (MW) Action code E03 Contents of trouble

Failure code Controller code 15G0MW

TM

R clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.

Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. appears on machine

• This failure can be checked in the monitoring function (Code: 31516, 31606, 31616). Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure

control valve for a defect. Cause

1 R clutch ECMV defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN10. 3) Connect T-adapter. Between CN10 (male) (1) – (2)




1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (5) – ATC2 (female) (15)



20-510 (10)

HD465-7, HD605-7

[15H0MW]

TROUBLESHOOTING

[15H0MW] HI CLUTCH: SLIP (MW) Action code



15H0MW

TM

Hi clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.

Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in Neutral suddenly during travel. appears on machine

• This failure can be checked in the monitoring function (Code: 31511, 31600, 31610). Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure


1 Hi clutch ECMV defective






HD465-7, HD605-7


20-511 (10)

TROUBLESHOOTING

[15H0MW]


20-512 (7)

HD465-7, HD605-7

[15J0MW]

TROUBLESHOOTING

[15J0MW] LO CLUTCH: SLIP (MW) Action code



15J0MW

TM

Lo clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31510, 31601, 31611). Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure


1 Lo clutch ECMV defective






HD465-7, HD605-7


20-513 (10)

TROUBLESHOOTING

[15J0MW]


20-514 (7)

HD465-7, HD605-7

[15K0MW]

TROUBLESHOOTING

[15K0MW] 1ST CLUTCH: SLIP (MW) Action code



15K0MW

TM

1st clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 1st clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31512, 31602, 31612). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure


1 1st clutch ECMV defective








HD465-7, HD605-7

20-515 (10)

[15L0MW]

TROUBLESHOOTING

[15L0MW] 2ND CLUTCH: SLIP (MW) Action code



15L0MW

TM

2nd clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 2nd clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31513, 31603, 31613). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure



1) Turn the starting switch OFF. 2) Disconnect connector CN8. 1 2nd clutch ECMV defective 3) Connect T-adapter. Between CN8 (male) (1) – (2)







20-516 (10)

HD465-7, HD605-7

[15M0MW]

TROUBLESHOOTING

[15M0MW] 3RD CLUTCH: SLIP (MW) Action code



15M0MW

TM

3rd clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 3rd clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31514, 31604, 31614). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure


1 3rd clutch ECMV defective








HD465-7, HD605-7

20-517 (10)

[15N0MW]

TROUBLESHOOTING

[15N0MW] 4TH CLUTCH: SLIP (MW) Action code E03 Contents of trouble

Failure code Controller code 15N0MW

TM

4th clutch: Slip (MW) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 4th clutch ECMV, the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31515, 31605, 31615). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure


1 4th clutch ECMV defective








20-518 (10)

HD465-7, HD605-7

[15SBL1]

TROUBLESHOOTING

[15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code



15SBL1

TM

Trouble

R clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)

• When the output to the R clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.

Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in Neutral suddenly during travel. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN11. 3) Connect T-adapter.

1 R clutch fill switch defective Between CN11 (male) (1) – chassis ground

Possible causes and standard value Ground fault in wiring har2 in normal state ness

When disResistance Min. 1 Mz engaged When enResistance Max. 1 z gaged

1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN11. 3) Connect T-adapter. Wiring harness between ATC5A (female) (16) – CN11 (female) (1)

Resistance between ATC5A (female) (16), CN11 (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3

Transmission controller defective

When disResistance Min. 1 Mz Between ATC5A (female) (16) – engaged chassis ground When enResistance Max. 1 z gaged


HD465-7, HD605-7

20-519 (10)

[15SBMA]

TROUBLESHOOTING

[15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA) Action code



15SBMA

TM

R clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the R clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31516, 31606, 31616). Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure









20-520 (10)

HD465-7, HD605-7

[15SCL1]

TROUBLESHOOTING

[15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble

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


Cause

1

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN19. 3) Connect T-adapter. Hi clutch fill switch defective When disResistance Min. 1 Mz Between CN19 (male) (1) – chas- engaged sis ground When enResistance Max. 1 z gaged


3


1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN19. 3) Connect T-adapter. Resistance between ATC5A (female) (12), Wiring harness between ATC5A (female) (12) – CN19 (female) (1) CN19 (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. When disResistance Min. 1 Mz Between ATC5A (female) (12) – engaged chassis ground When enResistance Max. 1 z gaged


HD465-7, HD605-7

20-521 (10)

[15SCMA]

TROUBLESHOOTING

[15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA) Hi clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is E03 15SCMA TM sensed) • When a signal is output to the Hi clutch ECMV, the signal from the fill switch is kept OFF and the value Contents of trouble calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal. Action of controller • The controller sets the gear in Neutral. Action code


Problem that • The gear is set in Neutral suddenly during travel. appears on machine

• This failure can be checked in the monitoring function (Code: 31511, 31600, 31610). Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure


1

Possible causes and standard value 2 in normal state

3

4

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN18. 3) Connect T-adapter. Hi clutch ECMV defective Resistance 5 – 15 z Between CN18 (male) (1) – (2) Between CN18 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN18. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC2 (female) (9) – Resistance Max. 1 z (Disconnection or defective CN18 (female) (1) contact) Wiring harness between ATC2 (female) (19) – Resistance Max. 1 z CN18 (female) (2) Defective sensing by speed • Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. fective Wiring harness between ATC2 (female) (9) – Resistance 5 – 15 z ATC2 (female) (19)


20-522 (10)

HD465-7, HD605-7

[15SDL1]

TROUBLESHOOTING

[15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble

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


Cause


1 Lo clutch fill switch defective Between CN17 (male) (1) – chassis ground


3



1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN17. 3) Connect T-adapter. Resistance between Wiring harness between ATC5A ATC5A (female) (10), (female) (10) – CN17 (female) (1) CN17 (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. When disResistance Min. 1 Mz Between ATC5A (female) (10) – engaged chassis ground When enResistance Max. 1 z gaged


HD465-7, HD605-7

20-523 (10)

[15SDMA]

TROUBLESHOOTING

[15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA) Lo clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is E03 15SDMA TM sensed) • When a signal is output to the Lo clutch ECMV, the signal from the fill switch is kept OFF and the value Contents of trouble calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal. Action of controller • The controller sets the gear in Neutral. Action code


Problem that • The gear is set in Neutral suddenly during travel. appears on machine

• This failure can be checked in the monitoring function (Code: 31510, 31601, 31611). Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure


1

Possible causes and standard value 2 in normal state

3

4

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN16. 3) Connect T-adapter. Lo clutch ECMV defective Resistance 5 – 15 z Between CN16 (male) (1) – (2) Between CN16 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN16. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC2 (female) (7) – Resistance Max. 1 z (Disconnection or defective CN16 (female) (1) contact) Wiring harness between ATC2 (female) (17) – Resistance Max. 1 z CN16 (female) (2) Defective sensing by speed • Troubleshooting by the failure codes of DL**KA, and DL**LC. sensor 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. fective Wiring harness between ATC2 (female) (7) – Resistance 5 – 15 z ATC2 (female) (17)


20-524 (10)

HD465-7, HD605-7

[15SEL1]

TROUBLESHOOTING

[15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code



15SEL1

TM

Trouble

1st clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)

• When the output to the 1st clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.


Cause


1 1st clutch fill switch defective


When disResistance Min. 1 Mz Between CN7 (male) (1) – chassis engaged ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN7. 3) Connect T-adapter. Wiring harness between ATC5A (female) (13) – CN7 (female) (1)


Min. 1 Mz





HD465-7, HD605-7

20-525 (10)

[15SEMA]

TROUBLESHOOTING

[15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA) Action code



15SEMA

TM

1st clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 1st clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31512, 31602, 31612). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure





Between CN6 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 – CN6. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (2) – Resistance Max. 1 z CN6 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) – Resistance Max. 1 z CN6 (female) (2) 3




20-526 (10)

HD465-7, HD605-7

[15SFL1]

TROUBLESHOOTING

[15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code



15SFL1

TM

Trouble

2nd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)

• When the output to the 2nd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.


Cause


1

2nd clutch fill switch defective


When disResistance Min. 1 Mz Between CN9 (male) (1) – chassis engaged ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN9. 3) Connect T-adapter. Wiring harness between ATC5A (female) (14) – CN9 (female) (1)


Min. 1 Mz





HD465-7, HD605-7

20-527 (10)

[15SFMA]

TROUBLESHOOTING

[15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA) Action code



15SFMA

TM

2nd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 2nd clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31513, 31603, 31613). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure





Between CN8 (male)(1) , (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2 and CN8. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (4) – Resistance Max. 1 z CN8 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) – Resistance Max. 1 z CN8 (female) (2) 3




20-528 (10)

HD465-7, HD605-7

[15SGL1]

TROUBLESHOOTING

[15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code



15SGL1

TM

Trouble

3rd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)

• When the output to the 3rd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.


Cause


1

3rd clutch fill switch defective


Between CN13 (male) (1) – chassis ground



Min. 1 Mz





HD465-7, HD605-7

20-529 (10)

[15SGMA]

TROUBLESHOOTING

[15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble

Failure code Controller code 15SGMA

TM

3rd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 3rd clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31514, 31604, 31614). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure









20-530 (10)

HD465-7, HD605-7

[15SHL1]

TROUBLESHOOTING

[15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code



15SHL1

TM

Trouble

4th clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON)

• When the output to the 4th clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.


Cause


1

4th clutch fill switch defective






Min. 1 Mz





HD465-7, HD605-7

20-531 (10)

[15SHMA]

TROUBLESHOOTING

[15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA) Action code



15SHMA

TM

4th clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure, fill switch is ON, and slip is sensed)

• When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• This failure can be checked in the monitoring function (Code: 31515, 31605, 31615). Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure









20-532 (10)

HD465-7, HD605-7

[15SJL1]

TROUBLESHOOTING

[15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1) Action code


E03

15SJL1

TM

Trouble

Lockup clutch solenoid: 15SJ (L1) (Command is OFF and fill switch is ON)

Contents of trouble

• When the output to the lockup clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the clutch is not disengaged.


• The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

• The lockup operation is reset and the gear cannot be shifted. Problem that appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).

Cause


1

Lockup clutch fill switch defective





Min. 1 Mz





HD465-7, HD605-7

20-533 (10)

[15SJMA]

TROUBLESHOOTING

[15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA) Action code


E03

15SJMA

TM

Trouble

Lockup clutch solenoid: 15SJ (MA) (Command is OFF, fill switch is ON, and slip is sensed)

Contents of trouble

• When a signal is output to the lockup clutch ECMV, the signal from the fill switch is kept OFF and the value calculated from the signals of the engine speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.


• The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.

• The lockup operation is reset and the gear cannot be shifted. Problem that appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619). Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-

sure control valve for a defect. Cause

1

Lockup clutch ECMV defective



Between CN20 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A and CN20. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) – Resistance Max. 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) – Resistance Max. 1 z CN20 (female) (2) 3




20-534 (10)

HD465-7, HD605-7

[2F00KM]

TROUBLESHOOTING

[2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM) Action code



2F00KM

TM

Trouble

Parking brake: Mistake in operation or setting (KM) (Parking brake drags)

• When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency brake is operated.

Action of controller • None in particular. Problem that • If the machine is used without repairing, it may be broken. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31400).

Cause


• Set the parking brake switch in the FREE position and then start the Mistake in operation of park- machine. 1 ing brake switch • Stop the machine perfectly, and then set the emergency brake switch in the FREE position and start the machine. 1) Turn the starting switch OFF. 2) Replace R03 with normal one. When the parking brake relay (R03) is replaced, is failure repaired?

2

Parking brake relay (R03) defective

Yes

Relay (R03)

No

Relay (R03)

1) Turn the starting switch OFF. 2) Disconnect connector R03. 3) Check the relay. Between R03 (male) (1) – (2)




Apply 24 V between Resistance Min. 1 Mz Between R03 (male) (1) – (2). (3) – (6) Do not apply 24 V beResistance Max. 1 z tween (1) – (2). 1) Turn the starting switch OFF. 2) Disconnect connector PSW. 3) Connect T-adapter. 4) Start the engine. 3

Parking brake oil pressure switch defective

Mistake in operation of emergency brake 4 (Operation of emergency brake during travel)

HD465-7, HD605-7

Set parking brake switch in FREE posiBetween PSW (male) position. (1) – (2) Set parking brake switch in PARK position.


Resistance Max. 1 z

• Operate the emergency brake only when necessary.

20-535 (10)

[2F00KM]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R03. 3) Connect T-adapter.

Wiring harness between R03 (female) (2), (6) – Resistance Max. 1 z Disconnection in wiring har- chassis ground 1) Turn the starting switch OFF. ness 5 (Disconnection or defective 2) Disconnect connectors R03, BT3, and PSW. 3) Connect T-adapter. contact) Wiring harness between fuse BT3 (16) – PSW Resistance Max. 1 z (female) (1) Wiring harness between R03 (female) (1) – Resistance Max. 1 z PSW (female) (2) Possible causes and standard value in normal state

6

Ground fault of wiring harness

1) Turn the starting switch OFF. 2) Disconnect connectors BRC5A and R03. 3) Connect T-adapter. Between BRC5A (female), R03 (female) (3) – Resistance Min. 1 Mz chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4) Connect connector BRC5A 5) Start the engine.

7 Retarder controller defective

Set parking brake switch in FREE posiBetween BRC5A (5) – tion. chassis ground Set parking brake switch in PARK position.

Voltage

Max. 1 V

Voltage

20 – 30 V


20-536 (10)

HD465-7, HD605-7

[989A00]

TROUBLESHOOTING

[989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00) Action code



989A00

TM

Trouble Engine overrun prevention command signal: Operation (00)

• When the gear speed is not in neutral, the transmission input shaft speed signal rises higher than 2,600 rpm.

Action of controller • The controller sends a command signal to the retarder controller to apply the brake. Problem that • The brake operates and the travel speed lowers. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35000).

Cause


aIf the machine is traveling under the condition where the transmission Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2,600 rpm, the engine is and standard value overrunning. in normal state • If the machine is not traveling under the condition where the transmisTransmission controller de2 sion input shaft speed signal rises higher than 2,600 rpm, the transfective mission controller is defective.

HD465-7, HD605-7

20-537 (10)

[989AKZ]

TROUBLESHOOTING

[989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code



989AKZ

TM

Trouble

Engine overrun prevention command signal: Disconnection or short circuit (KZ)

• There is disconnection, grounding fault, or short circuit with power source in the engine overrun prevention command signal circuit.

Action of controller • The controller continues the control with the S-NET signal. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • None in particular.

Cause


1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and BRC5B. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ATC1 (female) (13) – Resistance Max. 1 z (Disconnection or defective BRC5B (female) (5) contact) Wiring harness between fuse BT3 Voltage between ATC1 20 – 30 V terminal (14) – ATC1 (female) (4) (4) – chassis ground

2


1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 – BRC5B. 3) Connect T-adapter. Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (13), Min. 1 Mz male) (13) – BRC5B (female) (5) BRC5B (female) (5) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 – BRC5B. 3) Connect T-adapter.


Wiring harness between ATC1 (female) (13) – BRC5B (female) (5)

Voltage between ATC1 (female) (13), BRC5B (female) (5) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC5B. 3) Connect T-adapter. 4 Retarder controller defective 4) Connect the connector. 5) Start the engine. Between BRC5B (5) – chassis ground

Voltage

Max. 1 V

Voltage

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Connect T-adapter. 5 4) Connect the connector. fective 5) Start the engine. Between ATC1 (13) – chassis ground


20-538 (10)

HD465-7, HD605-7

[AA10NX]

TROUBLESHOOTING

[AA10NX] AIR CLEANER ELEMENT: CLOGGING (NX) Action code



AA10NX

TM

Trouble Air cleaner element: Clogging (NX)

• The air cleaner clogging signal circuit is opened (disconnected from GND).

Action of controller • None in particular. Problem that • If the machine is used without repairing, the suction performance of the engine may be lowered. appears on machine Related information • This failure can be checked in the monitoring function (Code: 33200).

Cause 1 Clogging of air cleaner

Standard value in normal state/Remarks on troubleshooting The dust indicator is not red.

Air cleaner is normal.

The dust indicator is red.

Air cleaner is clogged.

1) Turn the starting switch OFF. 2) Replace R32 with normal one. 3) Turn the starting switch ON. When the dust indicator relay (R32) is replaced, is failure repaired?

2

Dust indicator relay (R32) defective

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R32. 3) Check the relay. Resistance 200 – 400 z

Between R32 (male) (1) – (2) 1) Turn the starting switch OFF. 2) Disconnect connector R32. 3) Check the relay. 4) Apply voltage between R32 (male) (1) – (2).

Apply 24 V between Resistance Min. 1 Mz Between R32 (male) (1) – (2). (3) – (6) Do not apply 24 V beResistance Max. 1 z tween (1) – (2). 1) Turn the starting switch OFF. Possible causes 2) Disconnect connectors FR01. and standard value Air cleaner clogging sensor 3) Connect T-adapter. 3 in normal state defective Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z (1) – (2) Air cleaner is clogged. Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and R32. Disconnection in wiring har- 3) Connect T-adapter. ness 4 Wiring harness between ATC3A (female) (16) (Disconnection or defective Resistance Max. 1 z – R32 (female) (6) contact) Wiring harness between ATC3A (female) (19) Resistance Max. 1 z – R32 (female) (3)

5


1) Turn the starting switch OFF. 2) Disconnect connector R32 and FR01. 3) Connect T-adapter. Wiring harness between R32 (female) (2) – FR01 (female) (1)

Resistance between R32 (female) (2), FR01 (female) (1)– chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect connector. 6 fective 5) Turn the starting switch ON. Between ATC3A (19) Air cleaner is normal. – (16) Air cleaner is clogged.

HD465-7, HD605-7

Voltage

20 – 30 V

Voltage

Max. 1 V

20-539 (10)

TROUBLESHOOTING

[AA10NX]


20-540 (1)

HD465-7, HD605-7

[AB00MA]

TROUBLESHOOTING

[AB00MA] ALTERNATOR: MALFUNCTION (MA) Action code



AB00MA

TM

Trouble

Alternator: Malfunction (MA) (Failure in battery charging circuit)

• A generation signal is not input from the alternator while the engine is running.

Action of controller • None in particular. • If the machine is used without repairing, the source voltage may lower so much that the machine cannot Problem that appears on machine travel. Related information • This failure can be checked in the monitoring function (Code: 04301).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector alternator terminal R. 3) Start the engine.

1 Alternator defective

Between alternator R – E

Voltage

20 – 30 V

aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started. 1) Turn the starting switch OFF. 2) Disconnect connector ATC3B. 3) Connect T-adapter. Disconnection in wiring harPossible causes ness and standard value 2 (Disconnection or defective in normal state contact)

Wiring harness between ATC3B (female) (1) – alternator terminal R

Voltage between ATC3B (fe20 – 30 V male) (1) – chassis ground Max. 1 z

Resistance

aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started. Wiring harness between battery relay terminal Resistance Max. 1 z M – alternator terminal R

1) Turn the starting switch OFF. 2) Disconnect connector ATC3B. 3) Connect T-adapter. Transmission controller de- 4) Connect the connector. 3 5) Start the engine. fective Between ATC3B (1) – chassis ground

Voltage

20 – 30 V

aIf the battery is deteriorated or used in a cold district, the voltage may not rise for a while after the engine is started.

HD465-7, HD605-7

20-541 (10)

TROUBLESHOOTING

[AB00MA]


20-542 (1)

HD465-7, HD605-7

[B@BCZK]

TROUBLESHOOTING

[B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK) Action code



B@BCZK

TM

Trouble Lowering of radiator coolant: Lowering of level (ZK)

• The radiator coolant level switch signal circuit is opened (disconnected from GND).

Action of controller • None in particular. Problem that • If the machine is used without repairing, the engine may overheat. appears on machine Related information • This failure can be checked in the monitoring function (Code: 33100).

Cause 1


• The radiator coolant level is normal. Lowering of radiator coolant aIf the radiator coolant level is low, check around the engine and ralevel diator for coolant leakage before adding coolant . 1) Turn the starting switch OFF. 2) Disconnect connector FL01. 3) Connect T-adapter.

2


Radiator coolant level switch defective

Radiator coolant level Resistance Max. 1 z Between FL01 (male) is normal. (1) – (2) Radiator coolant level Resistance Min. 1 Mz is low.

1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and FL01. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC5A (female) (3) – Resistance Max. 1 z (Disconnection or defective FL01 (female) (1) contact) Wiring harness between FL01 (female) (2) – Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Insert T-adapter. 4) Connect the connector. Transmission controller de- 5) Turn the starting switch ON. 3 fective Radiator coolant level Between ATC5A (fe- is normal. male) (3) – chassis Radiator coolant level ground is low.

Voltage

Max. 1 V

Voltage

20 – 30 V


HD465-7, HD605-7

20-543 (10)

[D1B0KZ]

TROUBLESHOOTING

[D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code


E03

D1B0KZ

TM

Transmission controller cutout relay: Disconnection or short cirTrouble cuit (KZ) (Disconnection or short circuit)

Contents of trouble

• Abnormal voltage is generated in the transmission cutout relay circuit.


• The controller turns the transmission cutout relay OFF. • The controller sets the gear in Neutral.

Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. appears on machine Related information • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R15 with normal one. 3) Turn the starting switch ON. When transmission cutout relay (R15) is replaced, is failure repaired?

1) Turn the starting switch OFF. 2) Disconnect connector R15. Transmission controller cut- 3) Check the relay. 1 out relay (R15) defective Between R15 (male) (1) – (2)

No


Yes



1) Turn the starting switch OFF. 2) Disconnect connector R15. 3) Check the relay. 4) Apply voltage between R15 (male) (1) – (2). Between R15 (male) (3) – (5) Possible causes and standard value in normal state


Resistance Max. 1 z



1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and R15. 3) Connect T-adapter.

Disconnection in wiring harWiring harness between ATC1 (female) (14) – ness Resistance Max. 1 z 2 (Disconnection or defective R15 (female) (1) contact) Between R15 (female) (2) – chassis ground Resistance Max. 1 z Wiring harness between fuse BT2 Voltage between ATC1 20 – 30 V terminal (22) – ATC1 (female) (5) (5) – chassis ground

3


1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and R15. 3) Connect T-adapter. Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (14), male) (14) – R15 (female) (1) R15 (female) (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. Transmission controller de- 4) Turn the starting switch ON. 4 fective When failure code to turn transmisBetween sion cutout relay OFF is displayed ATC1 (14) (Example: 1500LO) – (8), (16) When failure code is not displayed

20-544 (10)

Min. 1 Mz

Voltage

Max. 1 V

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

[D1BOKZ]


HD465-7, HD605-7

20-545 (1)

[D5ZMKZ]

TROUBLESHOOTING

[D5ZMKZ] DISCONNECTION, GROUNDING FAULT, OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code



D5ZMKZ

TM

Trouble

Disconnection, grounding fault, or short circuit in engine output mode command line: Disconnection or short circuit (KZ)

• Disconnection, grounding fault, or short circuit occurs in engine output mode command line.

Action of controller • The controller controls in the power mode (The machine is fixed to the power mode). Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • None in particular.

Cause


1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors ATC1 – ECMB. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between ATC1 (female) (15) – contact) Resistance Max. 1 z ECMB (female) (19)

2


3 Hot short in wiring harness Possible causes and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ECMB. 3) Connect T-adapter. Wiring harness between Resistance between ATC1 ATC1 (female) (15) – ECMB (female) (15), ECMB (feMin. 1 Mz (female) (19) male) (19) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and BRC5B. 3) Connect T-adapter. Between ATC1 (female) (15), ECMB (female) (19) – chassis ground

Voltage

Max. 1 V

Voltage

9.4 – 12 V

Voltage

0 – 2.4 V

Voltage

9.4 – 12 V

Voltage

0 – 2.4 V

1) Turn the starting switch OFF. 2) Disconnect connector ECMB. 3) Connect T-adapter. 4) Connect the connector. 5) Start the engine. Between ECMB (19) – In power mode chassis ground In economy mode

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Transmission controller de- 4) Disconnect the connector. 5 fective 5) Start the engine. Between ATC1 (15) – In power mode chassis ground In economy mode


20-546 (10)

HD465-7, HD605-7

[DAQ0KK]

TROUBLESHOOTING

[DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code



DAQ0KK

TM

Trouble Transmission controller: Lowering of source/input voltage (KK)

• While the engine is running, the voltages of both main power source voltage circuit and direct power source voltage circuit lower below 18 V.

Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage Problem that appears on machine rises to the normal level. • If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first. Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), and (17) for grounding

fault. Cause

Standard value in normal state/Remarks on troubleshooting 1) Test the battery voltage and specific gravity of the battery fluid.

1 Battery defective

Battery voltage

Voltage

Min. 24 V

Specific gravity of battery fluid

Specific gravity

Min. 1.26

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Wiring harness between ATC1 (female) (8), (16) – chassis ground


Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Disconnection in wiring har- 3) Connect T-adapter. 4) Connect the connector. ness 2 (Disconnection or defective Wiring harness between battery, Voltage between ATC1 contact) battery relay terminal B, – ATC1 (7) (7) – (8), (16)

20 – 30 V

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between battery re- Voltage between ATC1 20 – 30 V lay terminal M – ATC1 (9), (17) (9), (17) – (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1 3) Insert T-adapter. 4) Connect the connector. 3

Between ATC1 (7) – (8), (16) Transmission controller de1) Turn the starting switch OFF. fective 2) Disconnect connector ATC1 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ATC1 (9), (17) – (8), (16)

HD465-7, HD605-7

Voltage

20 – 30 V

Voltage

20 – 30 V

20-547 (10)

TROUBLESHOOTING

[DAQ0KK]


20-548 (1)

HD465-7, HD605-7

[DAQ1KK]

TROUBLESHOOTING

[DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code



DAQ1KK

TM

Trouble

Main power line of transmission controller: Lowering of source/input voltage (KK)

• The main power source voltage is lower than the direct power source voltage by 5 V or more.

Action of controller • The controller prohibits updating of information about input. Problem that • The condition before the failure is kept. appears on machine Related information • If the fuse is broken, check the line between the fuse – ATC1 (female) (9) and (17) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Wiring harness between ATC1 (female) (8), (16) – chassis ground


Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness 1 (Disconnection or defective Wiring harness between battery – Voltage between battery relay terminal B – 20 – 30 V contact) battery relay terminal B chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between battery re- Voltage between ATC1 20 – 30 V lay terminal M – ATC1 (9), (17) (9), (17) – (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Insert T-adapter. 2 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC1 (9), (17) – (8), (16)

HD465-7, HD605-7

Voltage

20 – 30 V

20-549 (10)

TROUBLESHOOTING

[DAQ1KK]


20-550 (1)

HD465-7, HD605-7

[DAQ2KK]

TROUBLESHOOTING

[DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code


E03

DAQ2KK

TM

Trouble

Transmission controller load power line: Lowering of source/input voltage (KK)

Contents of trouble

• While the transmission controller source voltage is normal, the solenoid source voltage is below 18 V.


• The controller turns the transmission cutout relay OFF. • The controller sets the gear in Neutral.

Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. appears on machine Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) (9) and (17) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R15 with normal one. 3) Turn the starting switch ON When transmission cutout relay (R15) is replaced, is failure repaired?

1) Turn the starting switch OFF. 2) Disconnect connector R15. Transmission controller cut- 3) Check the relay. 1 out relay (R15) defective Between R15 (male) (1) – (2)

No


Yes



1) Turn the starting switch OFF. 2) Disconnect connector R15. 3) Check the relay. 4) Apply voltage between R15 (male) (1) – (2). Between R15 (male) (3) – (5)



Resistance Max. 1 z



1) Turn the starting switch OFF. 2) Disconnect connectors R15. 3) Insert T-adapter. 4) Connect the connector. Disconnection in wiring har- Wiring harness between fuse BT3 Voltage between R15 (female) (3) – chassis ness to 14 – R15 (female) (3) 2 ground (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and R15. 3) Connect T-adapter.

20 – 30 V

Wiring harness between ATC2 (1), (12) – R15 Resistance Max. 1 z (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Insert T-adapter. 3 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC2 (1), (12) – chassis ground

HD465-7, HD605-7

Voltage

20 – 30 V

20-551 (10)

TROUBLESHOOTING

[DAQ2KK]


20-552 (1)

HD465-7, HD605-7

[DAQ3KK]

TROUBLESHOOTING

[DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code



DAQ3KK

TM

Trouble

Direct line of transmission controller battery: Lowering of source/ input voltage (KK)

• The direct power source voltage is below 5 V.

Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • If the fuse is broken, check the line between the fuse and ATC1 (female) (7) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. 3) Connect T-adapter.

Wiring harness between ATC1 (female) (8), Resistance Max. 1 z Disconnection in wiring har- (16) – chassis ground ness 1 (Disconnection or defective 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. contact) Possible causes 3) Insert T-adapter. and standard value 4) Connect the connector. in normal state Wiring harness between battery, Voltage between ATC1 20 – 30 V battery relay terminal B, – ATC1 (7) (7) – (8), (16) 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. Transmission controller de- 3) Insert T-adapter. 2 4) Connect the connector. fective 5) Turn the starting switch ON. Between ATC1 (7) – (8), (16)

Voltage

20 – 30 V


HD465-7, HD605-7

20-553 (10)

[DAQ9KM]

TROUBLESHOOTING

[DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM) Action code E03

Failure code Controller code DAQ9KM

TM

Trouble

Transmission controller wiring harness: Mistake in operation or setting (KM)

• The connector check signal, that is input when the starting switch is turned to the ON position, does not Contents of trouble agree with setting in the controller. • The controller turns the transmission cutout relay OFF. Action of controller • The controller keeps the gear speed in neutral. • This failure is not recorded in the fault history. Problem that • When the starting operation is performed, the machine does not start. appears on machine Related information • None in particular.

Cause 1

Wrong connection of connector

Standard value in normal state/Remarks on troubleshooting The connector of the connector check signal is connected normally. aConnector check signal connector: ATC3A (1) (OPEN), ATC5A (1) (CLOSE)

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector ATC5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between ATC5A (female) (1) – contact) Resistance Max. 1 z chassis ground Possible causes and standard value in normal state

3


1) Turn the starting switch OFF. 2) Disconnect connector ATC3A. 3) Connect T-adapter. Wiring harness between ATC3A (female) (1) – chassis ground

Resistance between ATC3A (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. Transmission controller de- 3) Connect T-adapter. 4 fective Wiring harness between ATC5A (female) (1) – Resistance Max. 1 z chassis ground Between ATC3A (female) (1) – chassis ground Resistance Min. 1 Mz


20-554 (10)

HD465-7, HD605-7

[DAQ9KQ]

TROUBLESHOOTING

[DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code



DAQ9KQ

TM

Trouble

Transmission controller wiring harness: Disagreement of model selection signals (KQ)

• The model selection signal input when the starting switch is turned ON is different from the setting of the controller.

• The controller turns the transmission cutout relay OFF. Action of controller • The controller sets the gear speed in neutral. • This failure is not recorded in the fault history. Problem that • When the starting operation is performed, the machine does not start. appears on machine Related information • This failure can be checked in the monitoring function (Code: 02701, 02702, 02703).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ATC5A (female) (14) – Resistance Max. 1 z (Disconnection or defective chassis ground contact) Wiring harness between ATC5A (female) (16) – Resistance Max. 1 z chassis ground

Possible causes Ground fault in wiring harand standard value 2 ness in normal state

3

4

Wrong setting of rotary switch

Wrong setting of rotary switch

1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Connect T-adapter. Wiring harness between ATC5A (female) (15) – MS21 (female)

Resistance between ATC5A (female) (15), Min. 1 Mz MS21 (female) – chassis ground

• For setting of the rotary switch, see ADJUSTING TRANSMISSION CONTROLLER. 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Connect T-adapter. Between ATC5A (female) (14) – chassis ground Resistance Max. 1 z Between ATC5A (female) (15) – chassis ground Resistance Min. 1 Mz Between ATC5A (female) (16) – chassis ground Resistance Max. 1 z


HD465-7, HD605-7

20-555 (10)

[DAQAKQ], [DAQSMA]

TROUBLESHOOTING

[DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code E03 Contents of trouble

Failure code Controller code DAQAKQ

TM

Trouble

Transmission controller wiring harness: Disagreement of model selection signals (KQ)

• Setting of the model by the rotary switch does not agree with setting in the controller.

• The controller turns the transmission cutout relay OFF. Action of controller • The controller sets the gear speed in neutral. • This failure is not recorded in the fault history. Problem that • When the starting operation is performed, the machine does not start. appears on machine Related information • This failure can be checked in the monitoring function (Code: 30801).

Cause


Wrong setting of rotary • For setting of the rotary switch, see ADJUSTING TRANSMISSION Possible causes 1 switch CONTROLLER. and standard value • For setting of the rotary switch, see ADJUSTING TRANSMISSION in normal state Transmission controller de2 CONTROLLER. fective aIf setting is normal, the transmission controller is defective.

[DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA) Action code E03 Contents of trouble

Failure code Controller code DAQSMA

TM

Trouble Transmission controller: Malfunction (MA)

• Communication with the machine monitor (S-NET) is defective and the optional items cannot be set.

Action of controller • The controller sets the gear speed in Neutral. Problem that • When the starting operation is performed, the machine does not start. appears on machine

• If failure code "DAQSKR" of the machine monitor system is indicated, perform troubleshooting for it first. Related information • Do not turn the starting switch to the left before starting the engine (Since the engine preheating system is automatic, the starting switch does not need to be turned to the left). Cause


Possible causes aIf the failure is not repaired by replacing the transmission controller, 1 Machine monitor defective and standard value the machine monitor is defective. in normal state Transmission controller de- aIf the failure is repaired by replacing the transmission controller, the 2 fective transmission controller is defective.

20-556 (10)

HD465-7, HD605-7

[DDTGKA]

TROUBLESHOOTING

[DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code


E03

DDTGKA

TM

Lockup clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the lockup clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.


• The controller keeps the current gear speed. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral. • The gear cannot be shifted.

Problem that • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. appears on machine

• The lockup pilot lamp does not light up.

Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).

Cause


1

Lockup clutch fill switch defective



1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN21. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (17) contact) Resistance Max. 1 z – CN21 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3




HD465-7, HD605-7

20-557 (10)

[DDTHKA]

TROUBLESHOOTING

[DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03

Failure code Controller code DDTHKA

TM

Hi clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the Hi clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.


• The controller keeps the current gear speed. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.

Problem that • The gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31511, 31600, 31610).

Cause


1 Hi clutch fill switch defective Between CN19 (male) (1) – chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact)


1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN19. 3) Connect T-adapter. Wiring harness between ATC5A (female) (12) – Resistance Max. 1 z CN19 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter.

3




20-558 (10)

HD465-7, HD605-7

[DDTJKA]

TROUBLESHOOTING

[DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code


E03

DDTJKA

TM

Lo clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the Lo clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.



Problem that • The gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31510, 31601, 31611).

Cause


1 Lo clutch fill switch defective Between CN17 (male) (1) – chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact)


1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN17. 3) Connect T-adapter. Wiring harness between ATC5A (female) (10) Resistance Max. 1 z – CN17 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter.

3




HD465-7, HD605-7

20-559 (10)

[DDTKKA]

TROUBLESHOOTING

[DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03

Failure code Controller code DDTKKA

TM

1st clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the 1st clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.


• The controller keeps the current gear speed. • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

• The gear cannot be shifted. Problem that appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31512, 31602, 31612).

Cause


1 1st clutch fill switch defective

When disResistance Min. 1 Mz Between CN7 (male) (1) – chassis engaged ground When enResistance Max. 1 z gaged

1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN7. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (13) contact) Resistance Max. 1 z – CN7 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3




20-560 (10)

HD465-7, HD605-7

[DDTLKA]

TROUBLESHOOTING

[DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code


E03

DDTLKA

TM

2nd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the 2nd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.




Cause


1

2nd clutch fill switch defective

When disResistance Min. 1 Mz Between CN9 (male) (1) – chassis engaged ground When enResistance Max. 1 z gaged

1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN9. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (14) – contact) Resistance Max. 1 z CN9 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3




HD465-7, HD605-7

20-561 (10)

[DDTMKA]

TROUBLESHOOTING

[DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03

Failure code Controller code DDTMKA

TM

3rd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the 3rd clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.




Cause


1

3rd clutch fill switch defective







20-562 (10)

HD465-7, HD605-7

[DDTNKA]

TROUBLESHOOTING

[DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code


E03

DDTNKA

TM

R clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the R clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.




Cause


1 R clutch fill switch defective Between CN11 (male) (1) – chassis ground






HD465-7, HD605-7

20-563 (10)

[DDTPKA]

TROUBLESHOOTING

[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA) Action code E03

Failure code Controller code DDTPKA

TM

4th clutch fill switch : Disconnection (KA) Trouble (Command is Holding pressure, fill switch is OFF, and slip is not sensed)

Contents of trouble

• When the output to the 4th clutch ECMV is turned ON, the clutch is engaged but the signal from the fill switch is not turned ON.




Cause


1

4th clutch fill switch defective







20-564 (10)

HD465-7, HD605-7

[DF10KA]

TROUBLESHOOTING

[DF10KA] SHIFT LEVER: DISCONNECTION (KA) Action code



DF10KA

TM

Trouble Shift lever: Disconnection (KA)

• The shift lever signal is not input at all.

Action of controller • The controller keeps the condition before occurrence of the failure.. • The gear may be shifted up above the gear speed set with the shift lever. Problem that • The gear is kept in neutral and the machine cannot start. appears on machine • The travel direction cannot be changed.

• All the shift lever position lamps go off. Related information • None in particular.

Cause 1 Wrong operation

Standard value in normal state/Remarks on troubleshooting • The shift lever is pressed by some force while it is not operated. • The shift lever is stopped between 2 positions. 1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Connect T-adapter. Wiring harness between BT3 (10) – SF1 (female) (1)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Insert T-adapter. Wiring harness between ATC5B (female) (2) – Resistance Max. 1 z SF1 (female) (3) Wiring harness between ATC5B (female) (3) – Resistance Max. 1 z Disconnection in wiring har- SF1 (female) (4) ness Wiring harness between ATC5B (female) (4) – Resistance Max. 1 z 2 (Disconnection or defective SF1 (female) (5) contact of connector) Wiring harness between ATC5B (female) (5) – Resistance Max. 1 z SF1 (female) (6) Wiring harness between ATC5B (female) (6) – Resistance Max. 1 z SF1 (female) (7)


Wiring harness between ATC5B (female) (7) – Resistance Max. 1 z SF1 (female) (8) Wiring harness between ATC5B (female) (8) – Resistance Max. 1 z SF1 (female) (9) Wiring harness between ATC5B (female) (9) – Resistance Max. 1 z SF1 (female) (10) Wiring harness between ATC5B (female) (10) – Resistance Max. 1 z SF1 (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Connect T-adapter. Wiring harness between ATC5B (female) (2) – SF1 (female) (3)

Resistance between ATC5B (female) (2), SF1 (female) (3) – chassis ground

Min. 1 Mz

Wiring harness between ATC5B (female) (3) – SF1 (female) (4)


Min. 1 Mz



Min. 1 Mz


HD465-7, HD605-7

20-565 (10)

[DF10KA]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting Wiring harness between ATC5B (female) (5) – SF1 (female) (6)


Min. 1 Mz



Min. 1 Mz



Min. 1 Mz



Min. 1 Mz



Min. 1 Mz



Min. 1 Mz


1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.


Between SF1 (3) – chassis ground Between SF1 (4) – chassis ground Between SF1 (5) – chassis ground

4 Gearshift lever defective

Between SF1 (6) – chassis ground Between SF1 (7) – chassis ground Between SF1 (8) – chassis ground Between SF1 (9) – chassis ground Between SF1 (10) – chassis ground Between SF1 (11) – chassis ground

20-566 (10)

When shift range is "R"

Voltage

20 – 30 V

When shift range is not "R"

Voltage

Max. 1 V

When shift range is "N"

Voltage

20 – 30 V

When shift range is not "N"

Voltage

Max. 1 V

When shift range is "D"

Voltage

20 – 30 V

When shift range is not "D"

Voltage

Max. 1 V

When shift range is "6"

Voltage

20 – 30 V

When shift range is not "6"

Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V

HD465-7, HD605-7

[DF10KA]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When shift range is "R" Between ATC5B (2) – When shift range is not chassis ground "R"

Voltage

20 – 30 V

Voltage

Max. 1 V

When shift range is "N" Between ATC5B (3) – When shift range is not chassis ground "N"

Voltage

20 – 30 V

Voltage

Max. 1 V

When shift range is "D" Between ATC5B (4) – When shift range is not chassis ground "D"

Voltage

20 – 30 V

Voltage

Max. 1 z

When shift range is "6" Possible causes Between ATC5B (5) – When shift range is not and standard value Transmission controller de- chassis ground 5 "6" in normal state fective When shift range is "5" Between ATC5B (6) – When shift range is not chassis ground "5"

Voltage

20 – 30 V

Voltage

Max. 1 V

Voltage

20 – 30 V

Voltage

Max. 1 V

When shift range is "4" Between ATC5B (7) – When shift range is not chassis ground "4"

Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

20 – 30 V

Voltage

Max. 1 V

HD465-7, HD605-7

20-567 (10)

TROUBLESHOOTING

[DF10KA]


20-568 (1)

HD465-7, HD605-7

[DF10KB]

TROUBLESHOOTING

[DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB) Action code



DF10KB

TM

Trouble Shift lever: Short circuit (KB)

• The shift lever signals are input from 2 or more systems.

• The controller controls with the signal having higher priority. (1): N > D > 6 > 5 > 4 > 3 > 2 > 1. Action of controller (2): N > R • If the signals of systems (1) and (2) are input simultaneously, the controller sets the gear in neutral. • The gear may be shifted up above the gear speed set with the shift lever.

Problem that • The gear is kept in neutral and the machine cannot start. appears on machine

• The shift lever position lamp is different from the shift lever position.

Related information • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B and SF1. 3) Insert T-adapter. Wiring harness between ATC5B (female) (2) – SF1 (female) (3)

Voltage between ATC5B (female) (2), SF1 (female) (3) – chassis ground

Max. 1 V



Max. 1 V



Max. 1 V



Max. 1 V


Max. 1 V



Max. 1 V



Max. 1 V



Max. 1 V



Max. 1 V

Possible causes Short circuit in wiring harand standard value 1 ness in normal state (Hot short in wiring harness) Wiring harness between ATC5B (female) (6) – SF1 (female) (7)

HD465-7, HD605-7

20-569 (10)

[DF10KB]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SF1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between SF1 (3) – chassis ground Between SF1 (4) – chassis ground Between SF1 (5) – chassis ground

2 Gearshift lever defective




When shift range is "R"

Voltage

20 – 30 V

When shift range is not "R"

Voltage

Max. 1 V

When shift range is "N"

Voltage

20 – 30 V

When shift range is not "N"

Voltage

Max. 1 V

When shift range is "D"

Voltage

20 – 30 V

When shift range is not "D"

Voltage

Max. 1 z


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When the right FNR switch is installed (Turn the right FNR switch ON)

20-570 (10)

When shift range is "R" Between ATC5B (2) – When shift range is not chassis ground "R"

Voltage

20 – 30 V

Voltage

Max. 1 V

When shift range is "N" Transmission controller de- Between ATC5B (3) – When shift range is not 3 chassis ground fective "N"

Voltage

20 – 30 V

Voltage

Max. 1 V

When shift range is "D" Between ATC5B (4) – When shift range is not chassis ground "D"

Voltage

20 – 30 V

Voltage

Max. 1 V

Between ATC5B (5) – When shift range is "6" chassis ground When shift range is not "6"

Voltage

20 – 30 V

Voltage

Max. 1 z


Voltage

20 – 30 V

Voltage

Max. 1 V

HD465-7, HD605-7

[DF10KB]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting When shift range is "4" Between ATC5B (7) – When shift range is not chassis ground "4"

Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V


Voltage

20 – 30 V


Voltage

Max. 1 V

Voltage

20 – 30 V

Voltage

Max. 1 V

Between ATC5B (8) – chassis ground Possible causes Transmission controller deand standard value 3 fective in normal state Between ATC5B (9) – chassis ground



-

HD465-7, HD605-7

20-571 (10)

[DGF1KX]

TROUBLESHOOTING

[DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

DGF1KX

TM

Trouble

Transmission valve oil temperature sensor: Out of input signal range (KX)

• The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0.97 V (above Contents of trouble 150°C) or very different from the torque converter oil temperature signal. Action of controller • The controller controls the clutch oil pressure, fixing the sensed oil temperature high. Problem that • Gear shift shocks become large. appears on machine

• This failure can be checked in the monitoring function (Code: 32500). Related information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the

transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor". Cause

1

Transmission oil temperature sensor defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN24. 3) Connect T-adapter. Between CN24 (male) Oil temperature: 25°C Resistance 37 – 50 kz (1) – (2) Oil temperature: 100°C Resistance 3.5 – 4.0 kz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and CN24. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between ATC3B (female) (9) – Resistance Max. 1 z (Disconnection or defective CN24 (female) (2) contact) Wiring harness between ATC3A (female) (16) – Resistance Max. 1 z CN24 (female) (1)

Ground fault in wiring har3 Possible causes ness and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN24. 3) Connect T-adapter. Wiring harness between ATC3B (female) (9) – CN24 (female) (2)

Resistance between ATC3B (female) (9), CN24 (female) (2) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN24. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (9) – CN24 (female) (2)

Voltage between ATC3B (female) (9), CN24 (female) (2) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and ATC3B. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 5) Turn the starting switch ON. fective Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kz male) (9) – ATC3A (feOil temperature: 100°C Resistance 3.5 – 4.0 kz male) (16)

20-572 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[GDF1KX]


HD465-7, HD605-7

20-573 (1)

[DGT1KX]

TROUBLESHOOTING

[DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUTSIGNAL RANGE (KX) Action code E01 Contents of trouble

Failure code Controller code DGT1KX

TM

Trouble

Torque converter oil temperature sensor: Out of input signal range (KX)

• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V (above 150°C) or very different from the transmission valve oil temperature signal.

Action of controller • None in particular. Problem that • The torque converter oil temperature gauge does not indicate normally. appears on machine Related information • This failure can be checked in the monitoring function (Code: 30100).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector CN23. Torque converter oil temper- 3) Connect T-adapter. 1 ature sensor defective Between CN23 (T/C-T) Oil temperature: 25°C Resistance 37 – 50 kz (male) (1) – (2) Oil temperature: 100°C Resistance 3.5 – 4.0 kz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and CN23. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ATC3B (female) (7) – 2 (Disconnection or defective Resistance Max. 1 z TC-SE (female) (2) contact) Wiring harness between ATC3A (female) (16) – Resistance Max. 1 z CN23 (female) (1)

Ground fault in wiring harPossible causes 3 ness and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN23. 3) Connect T-adapter. Wiring harness between ATC3B (female) (7) – CN23 (female) (2)

Resistance between ATC3B (female) (7), CN23 (female) (2) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN23. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (7) – CN23 (female) (2)

Voltage between ATC3B (female) (7), CN23 (female) (2) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and ATC3B. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 5) Turn the starting switch ON. fective Between ATC3B (fe- Oil temperature: 25°C Resistance 37 – 50 kz male) (7) – ATC3A (feOil temperature: 100°C Resistance 3.5 – 4.0 kz male) (16)


20-574 (10)

HD465-7, HD605-7

[DHT5KX]

TROUBLESHOOTING

[DHT5KX] TORQUE CONVERTER OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code


E01

DHT5KX

TM

Trouble

Torque converter oil pressure sensor: Out of input signal range (KX)

• The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above 4.5 Contents of trouble V. Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself. Problem that • Large shocks are made when the lockup system is operated. appears on machine Related information • This failure can be checked in the monitoring function (Code: 32600).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1, ATC3A and CN22. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between ATC3A (female) (7) – Resistance Max. 1 z ness CN22 (female) (C) 1 (Disconnection or defective Wiring harness between ATC3A (female) (17) – contact) Resistance Max. 1 z CN22 (female) (A) Wiring harness between ATC1 (female) (3) – CN22 (female) (B)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN22. 3) Connect T-adapter.

2




Resistance between ATC3A (female) (7), CN22 (female) (C) – chassis ground

Min. 1 Mz

Resistance between Wiring harness between ATC1 (fe- ATC1 (female) (3), CN22 (female) (B) – male) (3) – CN22 (female) (B) chassis ground

Min. 1 Mz

Wiring harness between ATC3A (female) (7) – CN22 (female) (C)

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN22. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (7) – CN22 (female) (C)

4

Torque converter oil pressure sensor defective

Voltage between ATC3A (female) (7), CN22 (female) (C) – chassis ground

0.8 – 2.0 V

1) Turn the starting switch OFF. 2) Disconnect connector CN22. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between CN22 (B) – (A)

Voltage

20 – 30 V

Between CN22 (C) – (A)

Voltage

0.8 – 2.0 V

1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. Transmission controller de- 4) Connect the connector. 5 fective 5) Turn the starting switch ON.

HD465-7, HD605-7

Between ATC1 (3) – ATC3A (17)

Voltage

20 – 30 V

Between ATC3A (7) – (17)

Voltage

0.8 – 2.0 V

20-575 (10)

TROUBLESHOOTING

[DHT5KX]


20-576 (1)

HD465-7, HD605-7

[DHT5L6]

TROUBLESHOOTING

[DHT5L6] TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE SEPARATE LIST (L6) Action code



DHT5L6

TM

Trouble Torque converter oil pressure sensor: *See separate list (L6)

• While the engine is stopped, an oil pressure signal is input to the signal circuit of the torque converter oil pressure sensor.

Action of controller • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in itself. Problem that • Large shocks are made when the lockup system is operated. appears on machine Related information • This failure can be checked in the monitoring function (Code: 32600).

Cause


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and CN22. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (7) – CN22 (female) (C)

Possible causes and standard value Torque converter oil presin normal state 2 sure sensor defective

Voltage between ATC3A (female) (7), CN22 (female) (C) – chassis ground

Max. 1.2 V

1) Turn the starting switch OFF. 2) Disconnect connector CN22. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between CN22 (B) – (A)

Voltage

20 – 30 V

Between CN22 (C) – (A)

Voltage

0.8 – 2.0 V

Between ATC1 (3) – ATC3A (17)

Voltage

20 – 30 V


Voltage

0.8 – 2.0 V



HD465-7, HD605-7

20-577 (10)

[DJF1KA]

TROUBLESHOOTING

[DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION (KA) Action code E01 Contents of trouble

Failure code Controller code DJF1KA

TM

Trouble Fuel level sensor: Disconnection (KA)

• The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.

Action of controller • None in particular. Problem that • The fuel level gauge does not indicate normally. appears on machine Related information • This failure can be checked in the monitoring function (Code: 04201).

Cause

1 Fuel level sensor defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T01. 3) Connect T-adapter. Fuel level: When FULL Between T01 (female) (1) – (2) Fuel level: When EMPTY

Disconnection in wiring harness 2 (Disconnection or defective contact)

Resistance Max. 12 z Resistance 74 – 100 z

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and T01. 3) Connect T-adapter. Wiring harness between ATC3B (female) (4) – Resistance Max. 1 z T01 (female) (1) Wiring harness between ATC3A (female) (16) – Resistance Max. 1 z T01 (female) (2)


1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and T01. 3) Insert T-adapter. 4) Turn the starting switch ON.. Wiring harness between ATC3B (female) (4) – T01 (female) (1)

Voltage between ATC3B (female) (4), T01 (female) (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 4) Connect the connector. Transmission controller de- 5) Turn the starting switch ON. 4 fective Between ATC3B Fuel level: When FULL (female) (3) – ATC3A (female) Fuel level: When EMPTY (16)

Max. 1 V



20-578 (10)

HD465-7, HD605-7

[DK11KX]

TROUBLESHOOTING

[DK11KX] THROTTLE ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code




DK11KX

TM

Trouble Throttle angle sensor: Out of input signal range (KX)

• The voltage of the signal circuit of the acceleration sensor for transmission control is below 0.6 V or above 4.7 V. • The controller controls the machine, assuming that the engine is at full throttle. (This is not related to the engine control, however.)

Problem that • Gear shift shocks become large. appears on machine • The gear is shifted up soon when the machine travels down a slope with the brake OFF. Related information • This failure can be checked in the monitoring function (Code: 31701).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and AS2. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between ATC3B (female) (11) – Resistance Max. 1 z ness AS2 (female) (2) 1 (Disconnection or defective Wiring harness between ATC3A (female) (16) – contact) Resistance Max. 1 z AS2 (female) (3) Wiring harness between ATC3A (female) (6) – Resistance Max. 1 z AS2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, ATC3B, and AS2. 3) Connect T-adapter.

2




Wiring harness between ATC3A (female) (6) – AS2 (female) (1)

Resistance between ATC3A (female) (6), AS2 (female) (1) – chassis ground

Min. 1 Mz

Wiring harness between ATC3B (female) (11) – AS2 (female) (2)

Resistance between ATC3B (female) (11), AS2 (female) (2) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and AS2. 3) Insert T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3B (female) (11) – AS2 (female) (2)

4

Acceleration sensor defective

Voltage between ATC3B (female) (11), AS2 (female) (2) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector AS2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between AS2 (1) – (3)

Voltage

4.6 – 5.4 V

Between AS2 (2) – (3)

Voltage

1.0 – 4.0 V


Voltage

4.6 – 5.4 V

Between ATC3B (11) – ATC3A (16)

Voltage

1.0 – 4.0 V


HD465-7, HD605-7

20-579 (10)

TROUBLESHOOTING

[DK11KX]


20-580 (1)

HD465-7, HD605-7

[DLE2KA]

TROUBLESHOOTING

[DLE2KA] ENGINE SPEED SENSOR: DISCONNECTION (KA) Action code




DLE2KA

TM

Trouble Engine speed sensor: Disconnection (KA)

• The signal circuit of the engine speed sensor is disconnected and signals are not input. • The controller keeps the current gear speed. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral. • The gear cannot be shifted.

Problem that • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. appears on machine

• The tachometer does not operate (but indicates 0 rpm).

Related information • This failure can be checked in the monitoring function (Code: 01001).

Cause


Wrong adjustment of engine 1 speed sensor

• Press the sensor lightly against the flywheel ring gear, and then return it by 1/2 – 3/4 turns. aFor details, see TESTING AND ADJUSTING, "Adjustment of engine speed sensor".

1) Turn the starting switch OFF. 2) Disconnect connector E03. Engine speed sensor defec- 3) Connect T-adapter. 2 tive Between E03 (male) (1) – (2) Possible causes and standard value in normal state

Resistance 500 – 1,000 z

Between E03 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A – E03. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (13) – Resistance Max. 1 z (Disconnection or defective E03 (female) (1) contact) Wiring harness between ATC3A (female) (14) – Resistance Max. 1 z E03 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (13) – (14)



HD465-7, HD605-7

20-581 (10)

[DLE2LC]

TROUBLESHOOTING

[DLE2LC] ENGINE SPEED SENSOR: *SEE SEPARATE LIST (LC) Action code




DLE2LC

TM

Trouble Engine speed sensor: *See separate list (LC)

• When the engine speed sensor signal is below 350 rpm, the input transmission input shaft speed sensor signal is above 500 rpm. • The controller keeps the current gear speed. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.

Problem that • The gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 01001).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector E03. Engine speed sensor defec- 3) Connect T-adapter. 1 tive Between E03 (male) (1) – (2)


Between E03 (male) (1), (2) – chassis ground Resistance Min. 1 Mz

2




1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and E03. 3) Connect T-adapter. Wiring harness between ATC3A (female) (13) – E03 (female) (1)

Resistance between ATC3A (female) (13), E03 (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and E03. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (13) – E03 (female) (1)

Voltage between ATC3A (female) (13), E03 (female) (1) – chassis ground

1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (13) – (14)

Max. 1 V



20-582 (10)

HD465-7, HD605-7

[DLF1KA]

TROUBLESHOOTING

[DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) Action code




DLF1KA

TM

Trouble Transmission input shaft speed sensor: Disconnection (KA)

• The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not input. • The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Problem that • The lockup system is reset and the gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31200).

Cause


Wrong adjustment of trans1 mission input shaft speed sensor

• Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 – 1 turn. aFor details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor".


Transmission input shaft speed sensor defective

1) Turn the starting switch OFF. 2) Disconnect connector CN3. 3) Connect T-adapter. Between CN3 (male) (1) – (2)


Between CN3 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN3. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (2) – Resistance Max. 1 z (Disconnection or defective CN3 (female) (1) contact) Wiring harness between ATC3A (female) (14) – Resistance Max. 1 z CN3 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (2) – (14)



HD465-7, HD605-7

20-583 (10)

[DLF1LC]

TROUBLESHOOTING

[DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) Action code




DLF1LC

TM

Trouble Transmission input shaft speed sensor: *See separate list (LC)

• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed sensor signal, and transmission output shaft speed sensor signal is different from the signal speed of the transmission input shaft speed sensor. • The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.


Cause

1

Transmission input shaft speed sensor defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN3. 3) Connect T-adapter. Resistance 500 – 1,000 z

Between CN3 (male) (1) – (2)

Between CN3 (male) (1), (2) – chassis ground Resistance Min. 1 Mz

2






Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN3. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (2) – CN3 (female) (1)


Voltage between ATC3A (female) (2), CN3 (female) (1) – chassis ground

Max. 1 V



20-584 (10)

HD465-7, HD605-7

[DLF2KA]

TROUBLESHOOTING

[DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA) Action code


E03

DLF2KA

TM

Trouble

Transmission intermediate shaft speed sensor: Disconnection (KA)

• The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals are Contents of trouble not input. Action of controller



Cause


• Press the sensor lightly against the revolution pickup gear, and then Wrong adjustment of transreturn it by 1/2 – 1 turn. 1 mission intermediate shaft aFor details, see TESTING AND ADJUSTING, "Adjustment of transspeed sensor mission speed sensor". 1) Turn the starting switch OFF. Transmission intermediate 2) Disconnect connector CN4. 2 shaft speed sensor defective 3) Connect T-adapter. Between CN4 (male) (1) – (2) Possible causes and standard value in normal state


Between CN4 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A – CN4. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (12) – (Disconnection or defective Resistance Max. 1 z CN4 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z – CN4 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (12) – (14)



HD465-7, HD605-7

20-585 (10)

[DLF2LC]

TROUBLESHOOTING

[DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) Action code


E03

DLF2LC

TM

Trouble

Transmission intermediate shaft speed sensor: *See separate list (LC)

• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor sigContents of trouble nal, and transmission output shaft speed sensor signal is different from the signal speed of the transmission intermediate shaft speed sensor. Action of controller


Problem that • The gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31300).

Cause

1

Transmission intermediate shaft speed sensor defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN4. 3) Connect T-adapter. Resistance 500 – 1,000 z



2




1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A – CN4. 3) Connect T-adapter. Wiring harness between ATC3A (female) (12) – CN4 (female) (1)


Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and CN4. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between ATC3A (female) (12) – CN4 (female) (1)

Voltage between ATC3A (female) (12), CN4 (female) (1) – chassis ground


Max. 1 V



20-586 (10)

HD465-7, HD605-7

[DLT3KA]

TROUBLESHOOTING

[DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) Action code




DLT3KA

TM

Trouble Transmission output shaft speed sensor: Disconnection (KA)

• The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input. • The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Problem that • The lockup system is reset and the gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral Related information • This failure can be checked in the monitoring function (Code: 31400).

Cause


Wrong adjustment of trans1 mission output shaft speed sensor

• Press the sensor lightly against the revolution pickup gear, and then return it by 1/2 - 1 turn. aFor details, see TESTING AND ADJUSTING, "Adjustment of transmission speed sensor".


Transmission output shaft speed sensor defective



Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A – CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ATC3A (female) (3) – Resistance Max. 1 z (Disconnection or defective CN5 (female) (1) contact) Wiring harness between ATC3A (female) (14) Resistance Max. 1 z – CN5 (female) (2) 1) Turn the starting switch OFF. Transmission controller de- 2) Disconnect connector ATC3A. 4 3) Connect T-adapter. fective Between ATC3A (female) (3) – (14)



HD465-7, HD605-7

20-587 (10)

[DLT3LC]

TROUBLESHOOTING

[DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) Action code




DLT3LC

TM

Trouble Transmission output shaft speed sensor: *See separate list (LC)

• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of the transmission output shaft speed sensor. • The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Problem that • The gear cannot be shifted. appears on machine • If the shift lever is set in the "N" position, the gear is set in neutral. Related information • This failure can be checked in the monitoring function (Code: 31400).

Cause

1





2



1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, and CN5. 3) Connect T-adapter. ATC3A (female) (3), Wiring harness between ATC3A BRC3A (female) (13), (female) (3) – BRC3A (female) (13) Min. 1 Mz CN5 (female) (1) – – CN5 (female) (1) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, – CN5. 3) Connect T-adapter. 4) Turn the starting switch ON.


Voltage between ATC3A (female) (3), Wiring harness between ATC3A (female) (3) – BRC3A (female) (13) BRC3A (female) (13), CN5 (female) (1) – – CN5 (female) (female) (1) chassis ground


20-588 (10)

Max. 1 V


HD465-7, HD605-7

TROUBLESHOOTING

[DLT3KA]


HD465-7, HD605-7

20-589 (1)

[DXH1KA]

TROUBLESHOOTING

[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble

Failure code Controller code DXH1KA

TM

Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA)

Trouble

• When a signal is output to the lockup clutch ECMV, any current does not flow.

Action of controller • The controller turns the lockup operation OFF. Problem that • The lockup system does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)

Cause




Between CN20 (male) (1), (2) – chassis Resistance Min. 1 Mz ground Possible causes Disconnection in wiring harand standard value ness in normal state 2 (Disconnection or defective contact)

1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN20. 3) Connect T-adapter. Wiring harness between ATC2 (female) (10) – Resistance Max. 1 z CN20 (female) (1) Wiring harness between ATC2 (female) (20) – Resistance Max. 1 z CN20 (female) (2)



20-590 (10)

HD465-7, HD605-7

[DXH1KB]

TROUBLESHOOTING

[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH1KB

TM

Trouble

Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB)

• When a signal is output to the lockup clutch ECMV, an abnormally large current flows, or some current Contents of trouble is flowing while the signal is OFF. Action of controller

• The controller keeps the current gear speed and turns the lockup operation OFF. • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral. • The lockup system is reset and the gear cannot be shifted.

Problem that • If the shift lever is set in the "N" position, the machine cannot start until it is stopped. (The machine appears on machine

cannot start again, depending on the failure condition.)

Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)

Cause




Between CN20 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN10. 3) Connect T-adapter. Possible causes and standard value Short circuit in wiring har2 in normal state ness

Resistance between Wiring harness between ATC2 (fe- ATC2 (female) (10), male) (10) – CN20 (female) (1) CN20 (female) (1) – chassis ground

Min. 1 Mz

Wiring harness between ATC2 (female) (10) – CN20 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (20) – CN20 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (10) – Resistance 5 – 15 z ATC2 (female) (20)


HD465-7, HD605-7

20-591 (10)

[DXH2KA]

TROUBLESHOOTING

[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble


TM

Trouble

Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA)

• When a signal is output to the Hi clutch ECMV, any current does not flow.

Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in neutral during travel. appears on machine • The machine cannot start again until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31511, 31600, 31610)

Cause





Between CN18 (male) (1), (2) – chassis Resistance Min. 1 Mz ground Possible causes Disconnection in wiring harand standard value ness in normal state 2 (Disconnection or defective contact)

1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN18. 3) Connect T-adapter. Wiring harness between ATC2 (female) (9) – Resistance Max. 1 z CN18 (female) (1) Wiring harness between ATC2 (female) (19) – Resistance Max. 1 z CN18 (female) (2)



20-592 (10)

HD465-7, HD605-7

[DXH2KB]

TROUBLESHOOTING

[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH2KB

TM

Trouble

Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB)

• When a signal is output to the Hi clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.

Problem that • The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure appears on machine

condition.)


Cause






Min. 1 Mz

Wiring harness between ATC2 (female) (9) – CN18 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (19) – CN18 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (9) – ATC2 (female) (19)

HD465-7, HD605-7


20-593 (10)

TROUBLESHOOTING

[DXH2KB]


20-594 (7)

HD465-7, HD605-7

[DXH3KA]

TROUBLESHOOTING

[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: DISCONNECTION (KA) Action code



DXH3KA

TM

Trouble

Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA)

• When a signal is output to the Lo clutch ECMV, any current does not flow.

Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in Neutral during travel. appears on machine • The machine cannot start again until it is stopped. Related information • This failure can be checked in the monitoring function (Code: 31510, 31601, 31611)

Cause




Between CN16 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 and CN16. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (7) – in normal state (Disconnection or defective Resistance Max. 1 z CN16 (female) (1) contact) Wiring harness between ATC2 (female) (17) – Resistance Max. 1 z CN16 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (7) – ATC2 (female) (17)



HD465-7, HD605-7

20-595 (10)

[DXH3KB]

TROUBLESHOOTING

[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code E03

Failure code Controller code DXH3KB

TM

Trouble

Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB)

• When a signal is output to the Lo clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.

Problem that • The machine cannot start until it is stopped. appears on machine

(The machine cannot start again, depending on the failure condition.)


Cause






Min. 1 Mz


20-596 (10)


HD465-7, HD605-7

TROUBLESHOOTING

[DXH3KB]


HD465-7, HD605-7

20-597 (7)

[DXH4KA]

TROUBLESHOOTING

[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble


TM

Trouble

Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA)

• When a signal is output to the 1st clutch ECMV, any current does not flow.


Cause







20-598 (10)

HD465-7, HD605-7

[DXH4KB]

TROUBLESHOOTING

[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH4KB

TM

Trouble

Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB)

• When a signal is output to the 1st clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.




Cause






Min. 1 Mz




HD465-7, HD605-7

20-599 (10)

[DXH5KA]

TROUBLESHOOTING

[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble


TM

Trouble

Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA)

• When a signal is output to the 2nd clutch ECMV, any current does not flow.


Cause




Between CN8 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 – CN8. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (4) – in normal state (Disconnection or defective Resistance Max. 1 z CN8 (female) (1) contact) Wiring harness between ATC2 (female) (15) – Resistance Max. 1 z CN8 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (4) – ATC2 (female) (15)



20-600 (10)

HD465-7, HD605-7

[DXH5KB]

TROUBLESHOOTING

[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH5KB

TM

Trouble

Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB)

• When a signal is output to the 2nd clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.




Cause






Min. 1 Mz




HD465-7, HD605-7

20-601 (10)

[DXH6KA]

TROUBLESHOOTING

[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble


TM

Trouble

Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA)

• When a signal is output to the 3rd clutch ECMV, any current does not flow.


Cause




Between CN12 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connectors ATC2 – CN12. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 2 Wiring harness between ATC2 (female) (8) – in normal state (Disconnection or defective Resistance Max. 1 z CN12 (female) (1) contact) Wiring harness between ATC2 (female) (18) – Resistance Max. 1 z CN12 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (8) – ATC2 (female) (18)



20-602 (10)

HD465-7, HD605-7

[DXH6KB]

TROUBLESHOOTING

[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH6KB

TM

Trouble

Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB)

• When a signal is output to the 3rd clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.

Problem that • The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure appears on machine

condition.)


Cause






Min. 1 Mz




HD465-7, HD605-7

20-603 (10)

[DXH7KA]

TROUBLESHOOTING

[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble


TM

Trouble

Disconnection in output circuit of R clutch solenoid: Disconnection (KA)

• When a signal is output to the R clutch ECMV, any current does not flow.


Cause







20-604 (10)

HD465-7, HD605-7

[DXH7KB]

TROUBLESHOOTING

[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXH7KB

TM

Trouble

Short circuit in output circuit of R clutch solenoid: Short circuit (KB)

• When a signal is output to the R clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.




Cause






Min. 1 Mz




HD465-7, HD605-7

20-605 (10)

[DXHHKA]

TROUBLESHOOTING

[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: DISCONNECTION (KA) Action code E03 Contents of trouble

Failure code Controller code DXHHKA

TM

Trouble

Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA)

• When a signal is output to the 4th clutch ECMV, any current does not flow.


Cause







20-606 (10)

HD465-7, HD605-7

[DXHHKB]

TROUBLESHOOTING

[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT CIRCUIT (KB) Action code


E03

DXHHKB

TM

Trouble

Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB)

• When a signal is output to the 4th clutch ECMV, an abnormally large current flows, or some current is Contents of trouble flowing while the signal is OFF. Action of controller • The controller sets the gear in Neutral. • The gear is set in Neutral during travel.




Cause






Min. 1 Mz

Wiring harness between ATC2 (female) (3) – CN14 (female) (1) and between ATC2 (female) Resistance Min. 1 Mz (13) – CN14 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. Transmission controller de- 3) Connect T-adapter. 3 fective Wiring harness between ATC2 (female) (3) – ATC2 (female) (13).



HD465-7, HD605-7

20-607 (10)

TM-1

TROUBLESHOOTING

TM-1 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY (IT ALWAYS INDICATES "FULL") Action code


Not set

Not set

Not set

Trouble

Fuel level gauge does not operate normally (It always indicates "FULL")

• The fuel level gauge does not operate normally because of grounding fault (short circuit with GND) in Contents of trouble the signal circuit of the fuel level sensor. Action of controller • None in particular. Problem that • The fuel level gauge always indicates "FULL". appears on machine Related information • If failure code "DJF1KA" is indicated, perform troubleshooting for it first.

Cause

1 Fuel level sensor defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T01. 3) Connect T-adapter. Fuel level: When FULL Between T01 (female) (1) – (2) Fuel level: When EMPTY

Possible causes and standard value in normal state 2



1) Turn the starting switch OFF. 2) Disconnect connectors ATC3B and T01. 3) Connect T-adapter. Wiring harness between ATC3B (female) (4) – T01 (female) (1)

Resistance between ATC3B (female) (4), T01 (female) (1) – chassis ground

Min. 1 Mz


20-608 (10)

HD465-7, HD605-7

TM-2

TROUBLESHOOTING

TM-2 ABNORMALITY IN BACKUP LAMP AND BACKUP BUZZER a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON Action code



Not set

Not set

Abnormality in backup lamp and backup buzzer Trouble a) When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON

• When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON

Action of controller • None in particular. Problem that • When the shift lever is set in the "R" position, the backup lamp and backup buzzer are not turned ON appears on machine Related information

• Before starting troubleshooting, check that fuse (BT-1) (16) is normal. • Failure code is not displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R05 with normal one. 3) Turn the starting switch ON. When the backup lamp and buzzer relay (R05) is replaced, is failure repaired?

1) Turn the starting switch OFF. 2) Disconnect connector R05. Backup lamp and buzzer re- 3) Check the relay. 1 lay (R05) defective Between R05 (male) (1) – (2)

No


Yes



1) Turn the starting switch OFF. 2) Disconnect connector R05. 3) Check the relay. 4) Apply voltage between R05 (male) (1) – (2). Apply 24 V between Resistance Max. 1 z Between R05 (male) (5) – (6). (4) – (3) Do not apply 24 V beResistance Min. 1 Mz tween (5) – (6). Possible causes and standard value 2 Diode (D05) defective in normal state

When diode (D05) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and fuse (16) terminal. 3) Connect T-adapter. Wiring harness between fuse BT1 terminal Resistance Max. 1 z (16) – R05 (female) (4) Disconnection in wiring har- Wiring harness between R05 (female) (5) – Resistance Max. 1 z ness D05 (female) (1) 3 (Disconnection or defective Wiring harness between D05 (female) (2) – contact) ATC5B (female) (2), and branch point of CNS Resistance Max. 1 z (female) (3) Wiring harness between R05 (female) (6) – Resistance Max. 1 z chassis ground Wiring harness between R05 (female) (3) – Resistance Max. 1 z CJT (female) (8)

4

HD465-7, HD605-7

No

Joint connector (CJT) is normal

Yes

Joint connector (CJT) is defective

Joint connector (CJT) defec- When joint connector (CJT) is replaced, if failtive ure repaired?

20-609 (10)

TROUBLESHOOTING

TM-2

b) Backup lamp is not turned ON (Backup buzzer is normal) Action code



Not set

Not set

Trouble

Abnormality in backup lamp and backup buzzer b) Abnormality in backup lamp and backup buzzer

• When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is normal).

Action of controller • None in particular. Problem that • When the shift lever is set in the "R" position, the backup lamp is not turned ON (The backup buzzer is appears on machine normal). Related information • Failure code is not displayed.

Cause


1 Backup lamp defective

Backup lamp bulb is not broken.

Backup lamp is normal

Backup lamp bulb is broken.

Backup lamp is defective

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors B04 and CJT. ness 3) Connect T-adapter. 2 Possible causes (Disconnection or defective and standard value Wiring harness between CJT (female) (2) – contact) in normal state B04 terminal

3

Resistance Max. 1 z No


Yes


Joint connector (CJT) defec- When joint connector (CJT) is replaced, is failtive ure repaired?

c) Backup buzzer is not turned ON (Backup lamp is normal) Action code



Not set

Not set

Trouble

Abnormality in backup lamp and backup buzzer c) Backup buzzer is not turned ON (Backup lamp is normal)

• When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is normal).

Action of controller • None in particular. Problem that • When the shift lever is set in the "R" position, the backup buzzer is not turned ON (The backup lamp is appears on machine normal). Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks ON troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors B05, B06, and CJT. 3) Connect T-adapter.


Disconnection in wiring har- Wiring harness between CJT (female) (6) – ness chassis ground 1 (Disconnection or defective Wiring harness between B06 terminal – CJT contact) (female) (7) terminal Wiring harness between B05 terminal – CJT (female) (1) terminal 2 Backup buzzer defective

3

20-610 (10)

Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z

When results of Item a) and Cause 1 above are Backup buzzer is normal defective No


Yes


Joint connector (CJT) defec- When joint connector (CJT) is replaced, is failtive ure repaired?

HD465-7, HD605-7

TM-2

TROUBLESHOOTING

d) While shift lever is not operated, backup lamp and backup buzzer are turned ON Action code



Not set

Not set

Abnormality in backup lamp and backup buzzer Trouble d) While shift lever is not operated, backup lamp and backup buzzer are turned ON

• While shift lever is not operated, backup lamp and backup buzzer are turned ON.

Action of controller • None in particular. Problem that • While shift lever is not operated, backup lamp and backup buzzer are turned ON. appears on machine Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R05 with normal one. 3) Turn the starting switch ON. When the backup lamp and buzzer relay (R05) is replaced, is failure repaired?

1) Turn the starting switch OFF. 2) Disconnect connector R05. Backup lamp and buzzer re- 3) Check the relay. 1 lay (R05) defective Between R05 (male) (1) – (2)

No


Yes



1) Turn the starting switch OFF. 2) Disconnect connector R05. 3) Check the relay. 4) Apply voltage between R05 (male) (1) – (2). Apply 24 V between Resistance Max. 1 z Between R05 (male) (5) – (6). (4) – (3) Do not apply 24 V beResistance Min. 1 Mz tween (5) – (6).


1) Turn the starting switch OFF. 2) Disconnect connectors ATC5B, CNS2, R05, CJT, diode (D05), and fuse (16) terminal. 3) Connect T-adapter. Voltage between R05 Wiring harness between R05 (fe- (female) (5), D05 (female) (1) – chassis male) (5) – D05 (female) (1) ground


Wiring harness between D05 (feVoltage between D05 male) (2) – ATC5B (female) (2), (female) (2) – chassis and branch point of CNS (female) ground (3) Voltage between R05 Wiring harness between R05 (fe- (female) (3), CJT (female) (3) – CJT (female) (8) male) (8) – chassis ground

Max. 1 V

Max. 1 V

Max. 1 V

Voltage between CJT Wiring harness between CJT (feMax. 1 V (female) (1), B05 termimale) (1) – B05 terminal nal – chassis ground Voltage between CJT Wiring harness between CJT (fe(female) (2), B04 termi- Max. 1 V male) (2) – B04 terminal nal – chassis ground

HD465-7, HD605-7

20-611 (10)

TROUBLESHOOTING

TM-2


20-612 (1)

HD465-7, HD605-7

TROUBLESHOOTING FOR RETARDER CONTROLLER SYSTEM (BK MODE)

Electrical system diagram related to retarder control .................................................................................. 20-704 Information in troubleshooting table ....................................................................................................... 20-706 Phenomenon code table ........................................................................................................................ 20-707 [2G42ZG] Accumulator (front): lowering of oil pressure (ZG).............................................................. 20-708 [2G43ZG] Accumulator (rear): lowering of oil pressure (ZG) .............................................................. 20-708 [D1C0KZ] Brake cutout relay: disconnection or short circuit (KZ) ....................................................... 20-709 [D5ZNKZ] Failure of front brake cutout output system (disconnection, grounding fault, short circuit) (if equipped): disconnection or short circuit (KZ) ................................................................ 20-711 [DB10KK] Retarder controller: lowering of source/input voltage (KK) ................................................. 20-713 [DB11KK] Main power line of retarder controller: lowering of source/input voltage (KK) .................... 20-715 [DB12KK] Retarder controller load power line: lowering of source/input voltage (KK) ........................ 20-717 [DB13KK] Direct power source line of retarder controller battery: lowering of source/input voltage (KK)................................................................................. 20-719 [DB19KM] Retarder controller wiring harness: mistake in operation or setting (KM) ........................... 20-720 [DB1SKQ] Wrong information on model selection: disagreement of model selection signals (KQ)..... 20-721 [DDD7KX] Failure in travel speed set switch system (if equipped): out of input signal range (KX) ..... 20-722 [DDD8KA] ARSC system switch system: disconnection (KA).............................................................. 20-724 [DDD8KB] ARSC system switch system: short circuit (KB) ................................................................. 20-725 [dGR2L8] Failure In retarder oil temperature sensor system: *see separate list (L8) ......................... 20-726 [DGR2L8] Brake oil temperature sensor (rear): *see separate list (L8)............................................... 20-727 [dHP4KX] Failure in suspension pressure sensor (FR) system (if equipped): out of input signal range (KX) .............................................................................................. 20-728 [DHP4KX] Failure in suspension pressure sensor (FR) system (if equipped): out of input signal range (KX) .............................................................................................. 20-730 [dHP5KX] Failure in suspension pressure sensor (FL) system (if equipped): out of input signal range (KX) .............................................................................................. 20-732 [DHP5KX] Failure in suspension pressure sensor (FL) system (if equipped): out of input signal range (KX) .............................................................................................. 20-734 [DHU2KX] Accumulator oil pressure sensor (front): out of input signal range (KX) ............................. 20-736 [DHU3KX] Accumulator oil pressure sensor (rear): out of input signal range (KX).............................. 20-738 [dK11KX] Failure in acceleration sensor system (if equipped): out of input signal range (KX)........... 20-740 [DK11KX] Failure in acceleration sensor system (if equipped): out of input signal range (KX)........... 20-741 [DK51L5] Retarder lever potentiometer: *see separate list (L5) ......................................................... 20-742 [DK52KX] Dump lever potentiometer 1: out of input signal range (KX)............................................... 20-745 [DK53L8] Dump lever potentiometer 2: *see separate list (L8) .......................................................... 20-747 [DK54KX] Body positioner sensor: out of input signal range (KX) ...................................................... 20-748 [DKD0L6] Failure in steering speed sensor (if equipped): *see separate list (L6) .............................. 20-750 [dLt3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-752 [dLT3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-753 [DW35KZ] Failure in output system of auto suspension solenoid 1 (if equipped) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754 [DW36KZ] Failure in output system of auto suspension solenoid 2 (if equipped) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-755 [DW72KZ] Failure in kick-out solenoid output system (D_OUT3) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ) ................................................................ 20-756 [DW73KZ] Failure in hoist select valve output system (D_OUT5) (disconnection, grounding fault, short circuit): disconnection or short circuit (KZ) ................................................................ 20-758 [DK11K4] Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4) ......... 20-759-1 [DX11KA] Disconnection in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760 HD465-7, HD605-7

20-701 (10)

[DX11KB] [DX11KY] [DX11MA] [DX13KA] [DX13KB] [DX13KY] BK-1

BK-2 BK-3 BK-4

20-702 (10)

Short circuit in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761 Grounding fault in output circuit of proportional solenoid pressure reducing valve of rear wheel (A_OUT2): short circuit with power source line (KY) .................................... 20-762 Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)............. 20-762-1 Disconnection in output circuit of hoist EPC valve (A_OUT3): disconnection (KA)............ 20-763 Grounding fault in output circuit of hoist EPC valve (A_OUT3): short circuit (KB) ............. 20-764 Short circuit in output circuit of hoist EPC valve (A_OUT3): short circuit with power source line (KY) ......................................................................................................... 20-765 Parking brake does not operate normally........................................................................... 20-767 a) When the parking brake switch is set in the OFF position, the parking brake is not released............................................................................................................... 20-767 b) When the parking brake switch is set in the PARK position, the parking brake does not work................................................................................................................ 20-769 Retarder brake oil temperature gauge does not operate normally ..................................... 20-771 Inclination alarm is turned ON when dump body is raised (when machine is not inclined more than 15°).................................................................................................................... 20-772 Touch up/down and cancellation cannot be performed ...................................................... 20-773

HD465-7, HD605-7

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL


20-704 (2)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-705 (5)


TROUBLESHOOTING



Display on panel




Cause

1

2



20-706 (10)

HD465-7, HD605-7


TROUBLESHOOTING



PHENOMENON CODE TABLE ★ Regarding phenomenon code provided with instruction "Refer to table", check it against table below. Phenomenon code

Contents

Phenomenon code

Contents

KA


L0


KB

Short circuit

L1


KK


L2


KQ


L3


KR


L4


KT


L6


KX


L8


KY


LC


KZ


LD


MA

Malfunction

LH


MB


MW

Sliding

NS

Overheat

ZG


ZK


HD465-7, HD605-7

20-707 (10)

[2G42ZG], [2G43ZG]

TROUBLESHOOTING

[2G42ZG] ACCUMULATOR (FRONT): LOWERING OF OIL PRESSURE (ZG) Action code E03 Contents of trouble

Failure code Controller code 2G42ZG

BK

Trouble Accumulator (Front): Lowering of oil pressure (ZG)

• The signal of the front accumulator oil pressure sensor lowers below 13.2 MPa {135 kg/cm2} while the engine is running (continuously for more than 30 seconds).

Action of controller • None in particular. Problem that • If the machine is used without repairing, the front brake may not work. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35500)

Cause


Possible causes Lowering of front accumula1 and standard value tor (brake) oil pressure in normal state 2 Retarder controller defective

• The front accumulator (brake) oil pressure is normal. aIf the oil pressure is not normal, perform troubleshooting for hydraulic/mechanical system. • If the front accumulator (brake) oil pressure is normal, the retarder controller is defective.

[2G43ZG] ACCUMULATOR (REAR): LOWERING OF OIL PRESSURE (ZG) Action code E03 Contents of trouble

Failure code Controller code 2G43ZG

BK

Trouble Accumulator (Rear): Lowering of oil pressure (ZG)

• The signal of the rear accumulator oil pressure sensor lowers below 8.83 MPa {90 kg/cm2} while the engine is running (continuously for more than 30 seconds).

Action of controller • None in particular. Problem that • If the machine is used without repairing, the rear brake may not work. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35501)

Cause


• The rear accumulator (brake) oil pressure is normal. Possible causes Lowering of rear accumula1 aIf the oil pressure is not normal, perform troubleshooting for hyand standard value tor (brake) oil pressure draulic/mechanical system. in normal state • If the rear accumulator (brake) oil pressure is normal, the retarder 2 Retarder controller defective controller is defective.

20-708 (10)

HD465-7, HD605-7

[D1C0KZ]

TROUBLESHOOTING

[D1C0KZ] BRAKE CUTOUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E03

Failure code Controller code Brake cutout relay: Disconnection or short circuit (KZ) Trouble (Disconnection, grounding fault, or short circuit) D1C0KZ BK

Contents of trouble

• When the output to the brake cutout relay circuit is turned ON, an abnormally large current flows or any current does not flow. Or, some current is flowing while the output is OFF.


• The controller turns the output to the brake cutout relay OFF. • When ARSC operates, the controller releases the brake gradually.

Problem that appears on machine

• The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC, ASR) • Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.


Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R14 with normal one. 3) Turn the starting switch ON. When the brake cutout relay (R14) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. 1

Brake cutout relay (R14) deResistance 200 – 400 z Between R14 (male) (1) – (2) fective 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. 4) Apply voltage between R14 (male) (1) – (2). Between R14 (male) (3) – (5)


Apply 24 V between (1) – (2)

Resistance Max. 1 z

Do not apply 24 V beResistance Min. 1 M z tween (1) – (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between fuse BR- Voltage between BRC1 20 – 30 V (4) – chassis ground 3-(12) – BRC1 (female) (4) Disconnection in wiring har- Wiring harness between fuse BT- Voltage between R14 20 – 30 V 3-(12) – R14 (female) (5) (5) – chassis ground ness (Disconnection or defective 1) Turn the starting switch OFF. 2) Disconnect connectors BRC1, BRC2, and R14. contact) 3) Connect T-adapter. Wiring harness between BRC2 (female) (1), Resistance Max. 1 z (12) – R14 (female) (3) Wiring harness between R14 (female) (2) – chassis ground

Resistance Max. 1 z

Wiring harness between BRC1 (female) (13) – Resistance Max. 1 z R14 (female) (1)

3



HD465-7, HD605-7

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Connect T-adapter. Wiring harness between BRC1 (female) (13) – R14 (female) (1)

Resistance between BRC1 (female) (13), R14 (female) Min. 1 M z (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and R14. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC1 (feBRC1 (female) (13) – R14 male) (13), R14 (female) (1) (female) (1) – chassis ground

Max. 1 V

20-709 (10)

TROUBLESHOOTING

[D1C0KZ]


20-710 (1)

HD465-7, HD605-7

[D5ZNKZ]

TROUBLESHOOTING

[D5ZNKZ] FAILURE OF FRONT BRAKE CUTOUT OUTPUT SYSTEM (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT) (IF EQUIPPED): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code



D5ZNKZ

BK

Failure of front brake cutout output system (Disconnection, grounding Trouble fault, short circuit) (if equipped): Disconnection or short circuit (KZ) (Disconnection, grounding fault, or short circuit)

• When the output to the front brake cutout switch circuit is turned ON, an abnormally large current flows or any current does not flow. Or, some current is flowing while the output is OFF.

Action of controller • The controller turns the output to the brake cutout switch circuit OFF. • When the front brake cutout switch is turned ON, the front brake cutout system does not work. Or, the Problem that appears on machine front brake cutout system works while the switch is OFF. Related information • This failure can be checked in the monitoring function (Code: 37600, 39100)

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector FBC. 3) Check the switch.

1

Front brake cutout switch defective

Between FBC (male) (1) – (3)

Turn the front brake cutout switch OFF (Press it up).

Resistance Min. 1 M z

Turn the front brake cutout switch ON (Press it down).

Resistance Max. 1 z

aWhen the front brake cutout switch is turned ON (pressed down), the front brake is cut out (the front brake does not operate). 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter. 2

Disconnection in wiring har- Wiring harness between DPC2B (female) (4) – Resistance Max. 1 z ness FBC (female) (3) (Disconnection or defective Wiring harness between fuse BTC-4 (8) – FBC contact) Resistance Max. 1 z (female) (1) Wiring harness between FBC (female) (1) – chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter.

Possible causes and standard value in normal state Ground fault in wiring har3 ness


Resistance between DPC2B (female) (4), FBC (female) (3) – chassis ground

Min. 1 M z

Wiring harness between fuse Resistance between BTC-4 (8) – FBC (female) (1) FBC (female) (1) – ★ In this case, the fuse is broken. chassis ground

Min. 1 M z

Wiring harness between DPC2B (female) (4) – FBC (female) (3)

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B and FBC. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between DPC2B (female) (4) – FBC (female) (3)

5 Machine monitor defective

1) Turn the starting switch OFF. 2) Disconnect connector DPC2B 3) Connect T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (4) – chassis ground

HD465-7, HD605-7

Voltage between DPC2B (female) (4), FBC (female) (3) – Max. 1 V chassis ground

Turn the cutout switch OFF (Press it up).

Voltage

20 – 30 V

Turn the cutout switch ON (Press it down).

Voltage

Max. 1 V

20-711 (10)

TROUBLESHOOTING

[D5ZNKZ]


20-712 (1)

HD465-7, HD605-7

[DB10KK]

TROUBLESHOOTING

[DB10KK] RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code



DB10KK

BK

Trouble Retarder controller: Lowering of source/input voltage (KK)

• The voltages of both main power source voltage circuit and direct power source voltage circuit are below 17 V.

Action of controller • None in particular. (The controller works as long as possible.) Problem that • This failure does not have a serious effect on the machine. appears on machine

• If failure code "ABOOMA" (Malfunction of alternator) is indicated, perform troubleshooting for it first. Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (7), (9), – (17) for grounding

fault. Cause

Standard value in normal state/Remarks on troubleshooting 1) Test the battery voltage and specific gravity of the battery fluid.

1 Battery defective

Battery voltage

Voltage

Min. 24 V

Specific gravity of battery fluid

Specific gravity

Min. 1.26

1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Wiring harness between BRC1 (female) (8), (16) – chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness Voltage between 2 (Disconnection or defective Wiring harness between battery, battery BRC1 (7) – (8), relay terminal B, – BRC1 (7) contact) (16) Possible causes and standard value in normal state

20 – 30 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Wiring harness between battery relay terminal M – BRC1 (9), (17)

Voltage between BRC1 (9), (17) – 20 – 30 V (8), (16)

1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 4) Connect the connector. Between BRC1 (7) – (8), (16)

Voltage

20 – 30 V

Voltage

20 – 30 V

3 Retarder controller defective 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (9), (17) – (8), (16)

HD465-7, HD605-7

20-713 (10)

TROUBLESHOOTING

[DB10KK]


20-714 (1)

HD465-7, HD605-7

[DB11KK]

TROUBLESHOOTING

[DB11KK] MAIN POWER LINE OF RETARDER CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code


E03

DB11KK

BK

Trouble

Main power line of retarder controller: Lowering of source/input voltage (KK)

Contents of trouble • The difference between the main power source voltage and direct power source voltage is 5 V or more.

Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • If the fuse is broken, check the line between the fuse and BRC1 (female) (9) – (17) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Wiring harness between BRC1 (female) (8), (16) – chassis ground


Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter. Disconnection in wiring har- 4) Connect the connector. ness Voltage between bat1 (Disconnection or defective Wiring harness between battery – tery relay terminal B – 20 – 30 V battery relay terminal B contact) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Voltage between Wiring harness between battery BRC1 (9), (17) – (8), relay terminal M – BRC1 (9), (17) (16)

20 – 30 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 2 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (9), (17) – (8), (16)

HD465-7, HD605-7

Voltage

20 – 30 V

20-715 (10)

TROUBLESHOOTING

[DB11KK]


20-716 (1)

HD465-7, HD605-7

[DB12KK]

TROUBLESHOOTING

[DB12KK] RETARDER CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/ INPUT VOLTAGE (KK) Action code


E03

DB12KK

BK

Trouble

Retarder controller load power line: Lowering of source/input voltage (KK)

Contents of trouble • While the controller source voltage is normal, the solenoid source voltage is below 17 V.

Action of controller Problem that appears on machine

• The controller turns the all output circuits OFF.. • The controller turns the 24 V sensor power source OFF. • The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC, ASR) • Failure codes (DHU2KX, DHU3KX) are displayed, too.

Related information • If the fuse is broken, check the line between the fuse – BRC1 (female) (4) – (17) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R14 with normal one. 3) Turn the starting switch ON. When brake cutout relay (R14) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay.

1

Brake cutout relay (R14) deResistance 200 – 400 z Between R14 (male) (1) – (2) fective 1) Turn the starting switch OFF. 2) Disconnect connector R14. 3) Check the relay. 4) Apply voltage between R14 (male) (1) – (2). Between R14 (male) (3) – (5)


Apply 24 V between (1) – (2)

Resistance Max. 1 z

Do not apply voltage between (1) – (2)


1) Turn the starting switch OFF. 2) Disconnect connectors R14. 3) Insert T-adapter. 4) Connect the connector. Disconnection in wiring har- Wiring harness between fuse BT-3 Voltage between R14 (female) (5) – chassis ness (12) – R14 (female) (5) 2 ground (Disconnection or defective contact) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and R14. 3) Connect T-adapter.

20 – 30 V

Wiring harness between BRC2 (1), (12) – R14 Resistance Max. 1 z (female) (5) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC2 (1), (12) – chassis ground

HD465-7, HD605-7

Voltage

20 – 30 V

20-717 (10)

TROUBLESHOOTING

[DB12KK]


20-718 (1)

HD465-7, HD605-7

[DB13KK]

TROUBLESHOOTING

[DB13KK] DIRECT POWER SOURCE LINE OF RETARDER CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code


E03

DB13KK

BK

Trouble

Direct power source line of retarder controller battery: Lowering of source/input voltage (KK)

Contents of trouble • The direct power source voltage is below 5 V.

Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • If the fuse is broken, check the line between the fuse – BRC1 (female) (7) for grounding fault.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Connect T-adapter.

Wiring harness between BRC1 (female) (8), Resistance Max. 1 z Disconnection in wiring har- (16) – chassis ground ness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connector BRC1. contact) Possible causes 3) Insert T-adapter. and standard value 4) Connect the connector. in normal state Wiring harness between battery, Voltage between battery relay terminal B, – BRC1 (7)

BRC1 (9), (17) – (8), (16)

20 – 30 V

Voltage

20 – 30 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC1 3) Insert T-adapter. 2 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (7) – (8), (16)


HD465-7, HD605-7

20-719 (10)

[DB19KM]

TROUBLESHOOTING

[DB19KM] RETARDER CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM) Action code


E03

DB19KM

BK

Retarder controller wiring harness: Mistake in operation or setting Trouble (KM) (Mistake in connection or defect in wiring harness)

Contents of trouble

• The connector check signal, that is input when the starting switch is turned to the ON position, does not agree with setting in the controller.


• The controller turns the all output circuits OFF. • This failure is not recorded in the fault history.

Problem that appears on machine

• The retarder controller system does not operate at all. (Retarder, dump, auto suspension, ARSC, ASR) • Failure codes (DB12KK, DHU2KX, DHU3KX) are displayed, too.


1

Cause



The connector of the connector check signal is connected normally. aConnector check signal connector: BRC3A (1) (OPEN), BRC5A (1) (CLOSE)

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector BRC5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between BRC5A (female) (1) – contact) Resistance Max. 1 z chassis ground Possible causes and standard value in normal state

3


1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Connect T-adapter. Wiring harness between BRC3A (female) (1) – chassis ground

Resistance between BRC3A (female) (1) – Min. 1 M z chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4 Retarder controller

Wiring harness between BRC5A (female) (1) – Resistance Max. 1 z chassis ground Between BRC3A (female) (1) – chassis ground Resistance Min. 1 M z


20-720 (10)

HD465-7, HD605-7

[DB1SKQ]

TROUBLESHOOTING

[DB1SKQ] WRONG INFORMATION ON MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code


E03

DB1SKQ

BK

Trouble

Wrong information on model selection: Disagreement of model selection signals (KQ)

• Since communication with the transmission controller (S-NET) is defective, model selection informaContents of trouble tion cannot be received or received model selection information is out of setting. Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • Other failures are detected, too. (Failure codes [DAFSKQ], [DAQAKR], [DAQSKQ] are displayed.)

Cause


Possible causes Transmission controller de- aIf the failure is not repaired by replacing the retarder controller, the 1 and standard value transmission controller is defective. fective in normal state aIf the failure is repaired by replacing the transmission controller, the 2 Retarder controller defective retarder controller is defective.

HD465-7, HD605-7

20-721 (10)

[DDD7KX]

TROUBLESHOOTING

[DDD7KX] FAILURE IN TRAVEL SPEED SET SWITCH SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code E03

Failure code Controller code DDD7KX

BK

Failure in travel speed set switch system (if equipped): Out of inTrouble put signal range (KX) (When ARSC is set and ARSC system switch is ON)

Contents of trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.

Action of controller • When ARSC operates, the controller releases the brake gradually. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • None in particular.

Cause


1) Turn the starting switch OFF. 2) Replace the travel speed set switch (ARSC SET switch). Travel speed set switch (AR1 Replace the travel Failure is not repaired. Switch is normal SC SET switch) defective speed set switch (ARFailure is repaired. Switch is defective SC SET switch). 1) Turn the starting switch OFF. 2) Disconnect connector RE3. 2 Register (250 z) defective 3) Connect T-adapter. Between RE3 (female) (1) – (2) 1) Turn the starting switch OFF. 2) Disconnect connector RE4. 3 Resistor (1,020 z) defective 3) Connect T-adapter. Between RE4 (female) (1) – (2)

Resistance 250 ± 25 z

Resistance 1,020 ± 102 z

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, ARC, RE3, and RE4. 3) Connect T-adapter. Wiring harness between BRC3A (female) (6) – Resistance Disconnection in wiring har- RE3 (male) (1) ness 4 Possible causes Wiring harness between BRC3B (female) (15) Resistance (Disconnection or defective and standard value – RE3 (male) (2) – ARC (female) (1) contact) in normal state Wiring harness between RE4 (male) (1) – ARC Resistance (female) (3) Wiring harness between RE4 (male) (2) – ARC Resistance (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (6) – (16) Voltage

Max. 1 z Max. 1 z Max. 1 z Max. 1 z

Approx. 5 V

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 5 Retarder controller defective 3) Insert T-adapter.

Between BRC3B (female) (15) – BRC3A (female) (16)

When set switch is ON Resistance 1,020 ± 102 z When set switch is Resistance 68 ± 6.8 z TOUCH UP When set switch is Resistance 198 ± 19.8 z TOUCH DOWN When set switch is CANCEL

20-722 (10)

Resistance 418 ± 41.8 z

HD465-7, HD605-7

TROUBLESHOOTING

[DDD7KX]


HD465-7, HD605-7

20-723 (1)

[DDD8KA]

TROUBLESHOOTING

[DDD8KA] ARSC SYSTEM SWITCH SYSTEM: DISCONNECTION (KA) Action code E03

Failure code Controller code ARSC system switch system: Disconnection (KA) Trouble (When ARSC is set and ARSC system switch is ON) DDD8KA BK

Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.

Action of controller • When ARSC operates, the controller releases the brake gradually. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information

Cause


1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between DPC2B (female) (1) – contact) Resistance Max. 1 z ARSC (female) (3) 1) Turn the starting switch OFF. 2) Replace the ARSC system switch with normal one. ARSC system switch defec- 3) Turn the starting switch ON. 2 Possible causes tive When the ARSC system No System switch is normal and standard value switch is replaced with norYes System switch is defective in normal state mal one, is failure repaired?


1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (1) – chassis ground

Turn the ARSC system switch ON (Press it up). Turn the ARSC system switch OFF (Press it down).

Voltage

20 – 30 V

Voltage

Max. 1 V


20-724 (10)

HD465-7, HD605-7

[DDD8KB]

TROUBLESHOOTING

[DDD8KB] ARSC SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB) Action code E03

Failure code Controller code ARSC system switch system: Short circuit (KB) Trouble (When ARSC is set and ARSC system switch is ON) DDD8KB BK

Contents of trouble • The ON input of the ARSC system switch is OFF and the OFF input of the system switch is OFF.


Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors ARSC and DPC2B. 3) Connect T-adapter.


Wiring harness beVoltage between tween DPC2B (feDPC2B (female) (1), Voltage Max. 1 V male) (1) – ARSC ARSC (female) (3) – (female) (3) chassis ground 1) Turn the starting switch OFF. 2) Replace the ARSC system switch with normal one. Possible causes ARSC system switch defec- 3) Turn the starting switch ON. 2 and standard value tive When the ARSC system No System switch is normal in normal state switch is replaced with norYes System switch is defective mal one, is failure repaired?


1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Turn the ARSC system Between switch ON (Press it up). DPC2B (1) – chassis ground Turn the ARSC system switch OFF (Press it down).

Voltage

20 – 30 V

Voltage

Max. 1 V


HD465-7, HD605-7

20-725 (10)

[dGR2L8]

TROUBLESHOOTING

[dGR2L8] FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM: *SEE SEPARATE LIST (L8) Action code


E03

dGR2L8

BK

Failure in retarder oil temperature sensor system: *See separate Trouble list (L8) (When ARSC is set and the ARSC system switch is ON)

Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.


• This failure can be checked in the monitoring function (Code: 30200). • When ARSC is not set or the ARSC system switch is OFF, failure code "DGR2L8" is displayed. Cause

1

Retarder brake oil temperature sensor defective


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter. Between T02 (male) (1) – (2)

Brake oil temperature: Resistance 37 – 50 k z 25°C Brake oil temperature: Resistance 3.5 – 4.0 k z 100°C

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter. Wiring harness between BRC3B (female) (3) – T02 (female) (1)

Resistance between BRC3B (female) (3), T02 (female) Min. 1 M z (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective Brake oil temperature: Resistance 37 – 50 k z Between BRC3B (fe25°C male) (3) – BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 – 4.0 k z 100°C


20-726 (10)

HD465-7, HD605-7

[DGR2L8]

TROUBLESHOOTING

[DGR2L8] BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE SEPARATE LIST (L8) Action code E01

Failure code Controller code Brake oil temperature sensor (Rear): *See separate list (L8) Trouble (When ARSC is set and the ARSC system switch is OFF) DGR2L8 BK

Contents of trouble • The signal circuit voltage of the retarder brake oil temperature sensor is below 0.75 V.


• This failure can be checked in the monitoring function (Code: 30200). • When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter. Retarder brake oil temperaBrake oil temperature: 1 Resistance 37 – 50 k z ture sensor defective 25°C Between T02 (male) (1) – (2) Brake oil temperature: Resistance 3.5 – 4.0 k z 100°C Possible causes and standard value Ground fault in wiring har2 in normal state ness

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter.

Wiring harness between Resistance between BRC3B BRC3B (female) (3) – T02 (female) (3), T02 (female) Min. 1 M z (female) (1) (1) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. Brake oil temperature: 3 Retarder controller defective Resistance 37 – 50 k z Between BRC3B (fe25°C male) (3) – BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 – 4.0 k z 100°C


HD465-7, HD605-7

20-727 (10)

[dHP4KX]

TROUBLESHOOTING

[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

dHP4KX

BK

Failure in suspension pressure sensor (FR) system (if equipped): Trouble Out of input signal range (KX) (When ARSC is set and the ARSC system switch is ON)

Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.


• This failure can be checked in the monitoring function (Code: 32802, 32803) • When ARSC is not set or the ARSC system switch is OFF, failure code "DHP4KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFR and PM6. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female) (20) Resistance Max. 1 z ness – SUFR (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z – SUFR (female) (A) Wiring harness between PM6 (female) (2) – Resistance Max. 1 z SUFR (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A SUFR and PM6. 3) Connect T-adapter. 2


Wiring harness between BRC3A (female) (20) – SUFR (female) (C)

Resistance between BRC3A (female) (20), SUFR (female) Min. 1 M z (C) – chassis ground

Wiring harness between Resistance between PM6 PM6 (female) (2)– SUFR (fe- (female) (2), SUFR (female) Min. 1 M z male) (B) (B) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) – male) (9), SUFR (female) Max. 1 V SUFR (female) (C) (C) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector SUFR. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFR (B) – (A) Between SUFR (C) – (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (20) – (16)

20-728 (10)

Voltage

20 – 30 V

Voltage

1.0 – 4.6 V

Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[dHP4KX]


HD465-7, HD605-7

20-729 (5)

[DHP4KX]

TROUBLESHOOTING

[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

DHP4KX

BK

Failure in suspension pressure sensor (FR) system (if equipped): Trouble Out of input signal range (KX) (When ARSC is not set or the ARSC system switch is OFF)

Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.

Action of controller • Auto suspension system does not operate. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information

• This failure can be checked in the monitoring function (Code: 32802, 32803) • When ARSC is set and the ARSC system switch is ON, failure code "dHP4KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFR and PM6. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female) (20) Resistance Max. 1 z ness – SUFR (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z – SUFR (female) (A) Wiring harness between PM6 (female) (14) – Resistance Max. 1 z SUFR (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, SUFR and PM6. 3) Connect T-adapter. 2



Wiring harness between BRC3A (female) (20) – SUFR (female) (C)

Resistance between BRC3A (female) (20), SUFR (female) Min. 1 M z (C) – chassis ground

Wiring harness between PM6 (female) (2) – SUFR (female) (B)

Resistance between PM6 (female) (2), SUFR (female) Min. 1 M z (B) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) – male) (9), SUFR (female) Max. 1 V SUFR (female) (C) (C) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector SUFR. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFR (B) – (A) Between SUFR (C) – (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (20) – (16)

20-730 (10)

Voltage

18 ± 3 V

Voltage

1.0 – 4.6 V

Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHP4KX]


HD465-7, HD605-7

20-731 (5)

[dHP5KX]

TROUBLESHOOTING

[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

dHP5KX

BK

Failure in suspension pressure sensor (FL) system (if equipped): Trouble Out of input signal range (KX) (When ARSC is set and the ARSC system switch is ON)

Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.


• This failure can be checked in the monitoring function (Code: 32802, 32803) • When ARSC is not set or the ARSC system switch is OFF, failure code "DHP5KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFL and PM6. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female) (19) Resistance Max. 1 z ness – SUFL (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z – SUFL (female) (A) Wiring harness between PM6 (female) (2) – Resistance Max. 1 z SUFL (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A SUFL and PM6. 3) Connect T-adapter. 2



Wiring harness between BRC3A (female) (19) – SUFL (female) (C)

Resistance between BRC3A (female) (19), SUFL (female) Min. 1 M z (C) – chassis ground

Wiring harness between PM6 (female) (2) – SUFL (female) (B)

Resistance between PM6 (female) (2), SUFL (female) Min. 1 M z (B) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) – male) (9), SUFL (female) (C) Max. 1 V SUFL (female) (C) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector SUFL. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FR) defective 5) Turn the starting switch ON. Between SUFL (B) – (A) Between SUFL (C) – (A) 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (19) – (16)

20-732 (10)

Voltage

18 ± 3 V

Voltage

1.0 – 4.6 V

Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[dHP5KX]


HD465-7, HD605-7

20-733 (5)

[DHP5KX]

TROUBLESHOOTING

[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

DHP5KX

BK

Failure in suspension pressure sensor (FL) system (if equipped): Trouble Out of input signal range (KX) (When ARSC is not set or the ARSC system switch is OFF)

Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.

Action of controller • ARSC does not operate. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information

• This failure can be checked in the monitoring function (Code: 32802, 32803) • When ARSC is set and the ARSC system switch is ON, failure code "dHP5KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors, BRC3A, SUFL and PM6. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female) (19) Resistance Max. 1 z ness – SUFL (female) (C) 1 (Disconnection or defective Wiring harness between BRC3A (female) (16) contact) Resistance Max. 1 z – SUFL (female) (A) Wiring harness between PM6 (female) (2) – Resistance Max. 1 z SUFL (female) (B) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, SUFL and PM6. 3) Connect T-adapter. 2



Wiring harness between BRC3A (female) (19) – SUFL (female) (C)

Resistance between BRC3A (female) (19), SUFL (female) Min. 1 M z (C) – chassis ground

Wiring harness between PM6 (female) (2) – SUFL (female) (B)

Resistance between PM6 (female) (2), SUFL (female) Min. 1 M z (B) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and SUFL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (20) – male) (9), SUFL (female) (B) Max. 1 V SUFL (female) (C) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector SUFL. 3) Insert T-adapter. Suspension pressure sensor 4) Connect the connector. 4 (FL) defective 5) Turn the starting switch ON. Between SUFL (B) – (A) Between SUFL (C) – (A) 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. BRC3A (19) – (16)

20-734 (10)

Voltage

18 ± 3 V

Voltage

1.0 – 4.6 V

Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHP5KX]


HD465-7, HD605-7

20-735 (5)

[DHU2KX]

TROUBLESHOOTING

[DHU2KX] ACCUMULATOR OIL PRESSURE SENSOR (FRONT): OUT OF INPUT SIGNAL RANGE (KX) Action code


Accumulator oil pressure sensor (Front): Out of input signal Trouble range (KX) DHU2KX BK Contents of trouble • The signal circuit voltage of the front accumulator oil pressure sensor is below 0.5 V or above 4.5 V. E01

Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35500)

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC1 and fuse BT3 terminal (12). 3) Insert T-adapter. 4) Connect the connector and fuse BT3 terminal (12). 5) Turn the starting switch ON. Voltage between Wiring harness between fuse BT3 BRC1 (5) – chassis 20 – 30 V terminal(12) – BRC1 (female) (5) ground Disconnection in wiring harness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCF. contact) 3) Connect T-adapter. Wiring harness between BRC3A (female) (9) – Resistance Max. 1 z ACCF (female) (C) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z – ACCF (female) (A) Wiring harness between BRC1 (female) (14) – Resistance Max. 1 z ACCF (female) (B)


2



4

Front accumulator oil pressure sensor defective

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ACCF. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (9) – ACCF (female) (9), ACCF (female) Min. 1 M z (female) (C) (C) – chassis ground Resistance between BRC1 Wiring harness between BRC1 (female) (14) – ACCF (female) (3), ACCF (female) Min. 1 M z (female) (B) (B) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ACCF. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (9) – ACCF male) (9), ACCF (female) Max. 1 V (female) (C) (C) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ACCF. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ACCF (B) – (A) Between ACCF (C) – (A)

Voltage Voltage

20 – 30 V 0.5 – 4.5 V

Voltage Voltage

20 – 30 V 0.5 – 4.5 V

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (14) – BRC3A (16) BRC3A (9) – (16)

20-736 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DHU2KX]


HD465-7, HD605-7

20-737 (1)

[DHU3KX]

TROUBLESHOOTING

[DHU3KX] ACCUMULATOR OIL PRESSURE SENSOR (REAR): OUT OF INPUT SIGNAL RANGE (KX) Action code


Accumulator oil pressure sensor (Rear): Out of input signal Trouble range (KX) DHU3KX BK Contents of trouble • The signal circuit voltage of the rear accumulator oil pressure sensor is below 0.5 V or above 4.5 V. E01

Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35501)

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BTC1 and fuse BT3 terminal (12). 3) Insert T-adapter. 4) Connect the connector and fuse BT3 terminal (12). 5) Turn the starting switch ON. Voltage between Wiring harness between fuse BT3 BRC1 (5) – chassis 20 – 30 V Disconnection in wiring har- terminal (12) – BRC1 (female) (5) ground ness 1) Turn the starting switch OFF. 1 (Disconnection or defective 2) Disconnect connectors BRC1, BRC3A, and ACCR. contact) 3) Connect T-adapter. Wiring harness between BRC3A (female) (10) Resistance Max. 1 z – ACCR (female) (C) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z – ACCR (female) (A) Wiring harness between BRC1 (female) (14) – Resistance Max. 1 z ACCR (female) (B)


2



4

Rear accumulator oil pressure sensor defective

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ACCR. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (10) – (female) (10), ACCR (feMin. 1 M z ACCR (female) (C) male) (C) – chassis ground Wiring harness between Resistance between BRC1 BRC1 (female) (14) – ACCR (female) (3), ACCR (female) Min. 1 M z (female) (B) (B) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ACCR. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (10) – male) (10), ACCR (female) Max. 1 V ACCR (female) (C) (C) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ACCR. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between ACCR (B) – (A) Between ACCR (C) – (A)

Voltage Voltage

20 – 30 V 0.5 – 4.5 V

Voltage Voltage

20 – 30 V 0.5 – 4.5 V

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and BRC3A. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC1 (14) – BRC3A (16) BRC3A (10) – (16)

20-738 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DHU3KX]


HD465-7, HD605-7

20-739 (1)

[dK11KX]

TROUBLESHOOTING

[dK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code E03

Failure code Controller code dK11KX

BK

Failure in acceleration sensor system (if equipped): Out of input Trouble signal range (KX) (When ARSC is set and the ARSC system switch is ON)

Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.


• If the failure code "DK11KX" related to the transmission controller is displayed, perform troubleshooting for it first. • When ARSC is not set or the ARSC system switch is OFF, failure code "DK11KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between BRC3B (female) (11) contact) Resistance Max. 1 z – ATC3B (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ATC3B. 3) Connect T-adapter. Possible causes Ground fault in wiring har2 Resistance between and standard value ness Wiring harness between BRC3B BRC3B (female) (11), in normal state (female) (11) – ATC3B (female) Min. 1 M z ATC3B (female) (11) – (11) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3B (female) (11) – chassis ground

Voltage

0.6 – 4.75 V


20-740 (10)

HD465-7, HD605-7

[DK11KX]

TROUBLESHOOTING

[DK11KX] FAILURE IN ACCELERATION SENSOR SYSTEM (IF EQUIPPED): OUT OF INPUT SIGNAL RANGE (KX) Action code


E03

DK11KX

BK

Failure in acceleration sensor system (if equipped): Out of input Trouble signal range (KX) (When ARSC is not set or the ARSC system switch is OFF)

Contents of trouble • The signal circuit voltage of the acceleration sensor is below 0.6 V or above 4.7 V.

Action of controller • ARSC does not operate. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information

• If the failure code "dK11KX" related to the transmission controller is displayed, perform troubleshooting for it first. • When ARSC is set and the ARSC system switch is ON, failure code "dK11KX" is displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3B and ATC3B. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between BRC3B (female) (11) contact) Resistance Max. 1 z – ATC3B (female) (11) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and ATC3B. 3) Connect T-adapter. Possible causes Ground fault in wiring har2 Resistance between and standard value ness Wiring harness between BRC3B BRC3B (female) (11), in normal state (female) (11) – ATC3B (female) Min. 1 M z ATC3B (female) (11) – (11) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors ATC1 and ATC3A. 3) Insert T-adapter. 3 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3B (female) (11) – chassis ground

Voltage

0.6 – 4.75 V


HD465-7, HD605-7

20-741 (10)

[DK51L5]

TROUBLESHOOTING

[DK51L5] RETARDER LEVER POTENTIOMETER: *SEE SEPARATE LIST (L5) Action code E03 Contents of trouble

Failure code Controller code Trouble Retarder lever potentiometer: *See separate list (L5) DK51L5 BK • The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or, the potentiometer signal does not agree with the switch signal.

The controller acts as follows, depending on the condition of the failure. • Controls with the potentiometer signal. Action of controller • Limits the output for the solenoid to 70%. • Turns the output for the solenoid OFF. The following appear, depending on the action of the controller. • This failure does not have a serious effect on the machine. Problem that appears on machine • The retarder cannot control finely. • The retarder does not operate (The foot brake operates, however). Related information • This failure can be checked in the monitoring function (Code: 33900, 34000, 34100). Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, BRC3B, BRC5A, RE1, and RTL. 3) Connect T-adapter.

Wiring harness between BRC2 (female) (16) – RE1 (female) (1) Wiring harness between RE1 (female) (2) – RTL (female) (1) Disconnection in wiring har- Wiring harness between BRC3A (female) (16) ness – RTL (female) (3) 1 (Disconnection or defective Wiring harness between BRC3B (female) (16) contact) – RTL (female) (2)

Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z

Wiring harness between BRC5A (female) (6) – Resistance Max. 1 z RTL (female) (4) Wiring harness between BRC5A (female) (7) – Resistance Max. 1 z RTL (female) (5) Wiring harness between RTL (female) (6) – Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B, and RE1, and RTL. 3) Connect T-adapter.




20-742 (10)

Wiring harness between Resistance between BRC2 BRC2 (female) (16) – RE1 (female) (16), RE1 (female) Min. 1 M z (female) (1) (1) – chassis ground Wiring harness between Resistance between RE1 RE1 (female) (2) – RTL (fe- (female) (2), RTL (female) Min. 1 M z male) (1) (1) – chassis ground Wiring harness between Resistance between BRC3B BRC3B (female) (16) – RTL (female) (16), RTL (female) Min. 1 M z (female) (2) (2) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and RTL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC2 (female) (16) – RE1 (female) (1) Wiring harness between RE1 (female) (2) – RTL (female) (1) Wiring harness between BRC3B (female) (16) – RTL (female) (2)

Voltage between BRC2 (female) (16), RE1 (female) (1) Max. 1 V – chassis ground Voltage between RE1 (female) (2), RTL (female) (1) – Max. 1 V chassis ground Voltage between BRC3B (female) (16), RTL (female) (2) Max. 1 V – chassis ground

HD465-7, HD605-7

[DK51L5]

TROUBLESHOOTING

Cause 4 Resistor (RE1) defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector RE1. 3) Connect T-adapter. Between RE1 (male) (1) – (2)

Resistance

250 z

Voltage Voltage

4.1 – 4.8 V 0.3 – 4.7 V

1) Turn the starting switch OFF. 2) Disconnect connector RTL 3) Connect T-adapter. 4) Insert the connector. 5) Turn the starting switch ON. 6) Check the potentiometer. Between RTL (1) – (3) Between RTL (2) – (3) 5 Retarder lever defective

1) Turn the starting switch OFF. 2) Disconnect connector RTL 3) Connect T-adapter. 4) Check the switch. Between RTL (male) (4) – (6)


Between RTL (male) (5) – (6)

Lever at OFF position Resistance Max. 1 z Lever at ON position


Lever at OFF position Resistance Min. 1 M z Lever at ON position

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and BRC3B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between BRC2 (16) – BRC3A (16) Voltage Between BRC3B (16) – BRC3A (16) 1) Turn the starting switch OFF. 6 Retarder controller defective 2) Disconnect connector RTL. 3) Connect T-adapter. 4) Check the switch.

HD465-7, HD605-7

Voltage

4.1 – 4.8 V 0.3 – 4.7 V

Between BRC5A (female) (6) – chassis ground

Lever at OFF position Resistance Max. 1 z


Lever at OFF position Resistance Min. 1 M z

Lever at ON position

Lever at ON position


Resistance Max. 1 z

20-743 (10)

TROUBLESHOOTING

[DK51L5]


20-744 (1)

HD465-7, HD605-7

[DK52KX]

TROUBLESHOOTING

[DK52KX] DUMP LEVER POTENTIOMETER 1: OUT OF INPUT SIGNAL RANGE (KX) Action code E03

Failure code Controller code Dump lever potentiometer 1: Out of input signal range (KX) Trouble (Out of input signal range of lever potentiometer 1 or 2) DK52KX BK

Contents of trouble • The signal voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V.

Action of controller • The controller recognizes the dump lever position as "HOLD". Problem that • The dump body does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34400).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter.

Wiring harness between BRC3A (female) (6) – Resistance Disconnection in wiring har- HSL (female) (4) ness 1 Wiring harness between BRC3B (female) (14) Resistance (Disconnection or defective – HSL (female) (2) contact) Wiring harness between BRC3B (female) (12) Resistance – HSL (female) (3) Wiring harness between BRC3A (female) (16) Resistance – HSL (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A BRC3A (female) (6) – HSL (female) (6), HSL (female) (4) – chassis ground Ground fault in wiring har- (female) (4) 2 ness Wiring harness between Resistance between BRC3B BRC3B (female) (14) – HSL (female) (14), HSL (female) (female) (2) (2) – chassis ground Possible causes and standard value in normal state

Max. 1 z Max. 1 z Max. 1 z Max. 1 z

Min. 1 M z

Min. 1 M z

Wiring harness between Resistance between BRC3B BRC3B (female) (12) – HSL (female) (12), HSL (female) Min. 1 M z (female) (3) (3) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (6) – HSL male) (6), HSL (female) (4) – Max. 1 V (female) (4) chassis ground Wiring harness between Voltage between BRC3B (feBRC3B (female) (14) – HSL male) (14), HSL (female) (2) Max. 1 V (female) (2) – chassis ground Voltage between BRC3B (feWiring harness between BRC3B (female) (12) – HSL male) (12), HSL (female) (3) Max. 1 V (female) (3) – chassis ground

4 Dump lever defective

HD465-7, HD605-7

1) Turn the starting switch OFF. 2) Disconnect connector HSL. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between HSL (4) – (1) Between HSL (2) – (1)

Voltage Voltage

4.6 – 5.4 V 0.3 – 4.7 V

Between HSL (3) – (1)

Voltage

0.3 – 4.7 V

20-745 (10)

[DK52KX]

TROUBLESHOOTING

Cause


1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and HSL. 3) Insert T-adapter. Possible causes 4) Connect the connector. and standard value 5 Retarder controller defective 5) Turn the starting switch ON. in normal state Between BRC3A (6) – (16) Voltage Between BRC3B (14) – BRC3A (16) Between BRC3B (12) – BRC3A (16)

Voltage Voltage

4.1 – 4.8 V 0.3 – 4.7 V 0.3 – 4.7 V


20-746 (10)

HD465-7, HD605-7

[DK53L8]

TROUBLESHOOTING

[DK53L8] DUMP LEVER POTENTIOMETER 2: *SEE SEPARATE LIST (L8) Action code


E03

DK53L8

BK

Dump lever potentiometer 2: *See separate list (L8) Trouble (Out of total range of input signal voltage of lever potentiometer 1 or 2)

Contents of trouble • The total voltage of the signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.

Action of controller • The controller recognizes the dump lever position as "NEUTRAL". Problem that • The dump body does not operate. appears on machine Related information

• This failure can be checked in the monitoring function (Code: 34300, 34301). • If the failure code "DK52KX" is displayed, perform troubleshooting for it. Cause

Possible causes 1 Dump lever defective and standard value in normal state

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HSL. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between HSL (4) – (1)

Voltage

4.6 – 5.4 V

Between HSL (2) – (1)

Voltage

0.3 – 4.7 V

Between HSL (3) –(1)

Voltage

0.3 – 4.7 V

• If the failure is not repaired by performing the troubleshooting in 1 2 Retarder controller defective above, the retarder controller is defective.


HD465-7, HD605-7

20-747 (10)

[DK54KX]

TROUBLESHOOTING

[DK54KX] BODY POSITIONER SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code E03

Failure code Controller code Body positioner sensor: Out of input signal range (KX) Trouble (Out of input signal range of lever potentiometer 1 or 2) DK54KX BK

Contents of trouble • The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.


• The controller controls dumping according to the dump level signal. • The controller controls, assuming that the body is not seated. • Body seating shocks become large.

Problem that • The dump lever positioner does not function. appears on machine • The maximum gear speed is limited.

• The machine cannot travel in reverse if the dump lever is not at FLOAT. Related information • This failure can be checked in the monitoring function (Code: 34300, 34301, 34400, 34600).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female)(6) – Resistance ness B07 (female) (C) 1 (Disconnection or defective Wiring harness between BRC3B (female) (13) contact) Resistance – B07 (female) (B) Wiring harness between BRC3A (female) (16) Resistance – B07 (female) (A) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter. Wiring harness between Resistance between BRC3A Ground fault in wiring har2 BRC3A (female) (6) – B07 (female) (6), B07 (female) ness (female) (C) (C) – chassis ground Wiring harness between Resistance between BRC3B BRC3B (female) (13) – B07 (female) (13), B07 (female) (female) (B) (B) – chassis ground Possible causes and standard value in normal state 3 Hot short in wiring harness

4 Body positioner defective

Between BRC3B (13) – BRC3A (16)

(10)

Max. 1 z Max. 1 z

Min. 1 M z

Min. 1 M z

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between Voltage between BRC3A (feBRC3A (female) (6) – B07 male) (6), B07 (female) (C) – Max. 1 V (female) (C) chassis ground Wiring harness between Voltage between BRC3B (feBRC3B (female) (13) – B07 male) (13), B07 (female) (B) Max. 1 V (female) (B) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector B07. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between B07 (C) – (A) Voltage 4.6 – 5.4 V

Between B07 (B) – (A) Voltage 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A, BRC3B, and B07. 3) Insert T-adapter. 5 Retarder controller defective 4) Connect the connector. 5) Turn the starting switch ON. Between BRC3A (6) – (16) Voltage

20-748

Max. 1 z

Voltage

0.3 – 4.7 V

4.1 – 4.8 V 0.3 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DK54KX]


HD465-7, HD605-7

20-749 (1)

[DKD0L6]

TROUBLESHOOTING

[DKD0L6] FAILURE IN STEERING SPEED SENSOR (IF EQUIPPED): *SEE SEPARATE LIST (L6) Action code


E01

DKD0L6

BK

Trouble

Failure in steering speed sensor (if equipped): *See separate list (L6)

• Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sensor Contents of trouble and no signals are input. Action of controller • None in particular. Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35401).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and SR2. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between BRC3A (female) (12) Resistance Max. 1 z ness – SR2 (female) (2) 1 (Disconnection or defective Wiring harness between BRC3A (female) (14) contact) Resistance Max. 1 z – SR2 (female) (3) Wiring harness between BRC2 (female) (14) – Resistance Max. 1 z SR2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and SR2. 3) Connect T-adapter. 2


Wiring harness between Resistance between BRC3A BRC3A (female) (14) – SR2 (female) (14), SR2 (female) Min. 1 M z (female) (3) (3) – chassis ground Wiring harness between BRC2 (female) (14) – SR2 (female) (1)

Resistance between BRC3B (female) (14), SR2 (female) Min. 1 M z (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector SR2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Turn the steering wheel slowly.


Steering speed sensor defective

Between SR2 (1) – (3)

Voltage

10 – 13 V

Voltage

See FIG-1.

Voltage

10 – 13 V

Voltage

See FIG-1.

1) Turn the starting switch OFF. 2) Disconnect connector SR2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between SR2 (2) – (3) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.

Between BRC2 (14) – (21) 4 Retarder controller defective 1) Turn the starting switch OFF. 2) Disconnect connector BRC3A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Turn the steering wheel slowly. Between BRC3A (12) – (14)

20-750 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DKD0L6]


HD465-7, HD605-7

20-751 (1)

[dLt3KA]

TROUBLESHOOTING

[dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) Action code



dLt3KA

BK

Trouble

Transmission output shaft speed sensor: Disconnection (KA) (When ARSC is set and ARSC system switch is ON)

• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are input.


• This failure can be checked in the monitoring function (Code: 31400). • When ARSC is not set or the ARSC system switch is OFF, failure code "dLT3KA" is displayed. Cause








Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between BRC3A (female) (13) Resistance Max. 1 z (Disconnection or defective – CN5 (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z – CN5 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ATC3A. 4 Retarder controller defective 3) Connect T-adapter. Between BRC3A (female) (13) – (14)



20-752 (10)

HD465-7, HD605-7

[dLT3KA]

TROUBLESHOOTING

[dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA) Action code



dLT3KA

BK

Trouble

Transmission output shaft speed sensor: Disconnection (KA) (When ARSC is not set or ARSC system switch is OFF)

• The signal circuit of the transmission output shaft speed sensor is disconnected and no signals are input.


• This failure can be checked in the monitoring function (Code: 31400). • When ARSC is set and the ARSC system switch is ON, failure code "dLT3KA" is displayed. Cause








Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and CN5. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between BRC3A (female) (13) Resistance Max. 1 z (Disconnection or defective – CN5 (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z – CN5 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and ATC3A. 4 Retarder controller defective 3) Connect T-adapter. Between BRC3A (female) (13) – (14)



HD465-7, HD605-7

20-753 (10)

[DW35KZ]

TROUBLESHOOTING

[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E01 Contents of trouble

Failure code Controller code DW35KZ

BK

Failure in output system of auto suspension solenoid 1 (if Trouble equipped) (Disconnection, grounding fault, short circuit): Disconnection or short circuit (KZ)

• When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any current does not flow. Or, some current is flowing while the output is OFF.

Action of controller • The controller turns the output to auto suspension solenoid 1 OFF. Problem that • The auto suspension system does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 39300).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector S04. Auto suspension solenoid 1 3) Insert T-adapter. 1 defective Between S04 (female) (1) – (2) Between S04 (female) (1), (2) – chassis ground Possible causes and standard value in normal state

Resistance 15 – 35 z Resistance Min. 1 M z

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and S04. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC1 (female) (1) – Resistance Max. 1 z (Disconnection or defective S04 (female) (1) contact) Wiring harness between S04 (female) (2) – Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3 Retarder controller defective 3) Insert T-adapter. Between BRC1 (female) (1) – chassis ground Resistance 15 – 20 z


20-754 (10)

HD465-7, HD605-7

[DW36KZ]

TROUBLESHOOTING

[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (IF EQUIPPED) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code



DW36KZ

BK

Failure in output system of auto suspension solenoid 2 (if Trouble equipped) (Disconnection, grounding fault, short circuit): Disconnection or short circuit (KZ)

• When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any current does not flow. Or, some current is flowing while the output is OFF.

Action of controller • The controller turns the output to auto suspension solenoid 2 OFF. Problem that • The auto suspension system does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 39301).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector S05. Auto suspension solenoid 2 3) Insert T-adapter. 1 defective Between S05 (female) (1) – (2) Between S05 (female) (1), (2) – chassis ground Possible causes and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and S05. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC1 (female) (2) – (Disconnection or defective Resistance Max. 1 z S05 (female) (1) contact) Wiring harness between S05 (female) (2) – Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3 Retarder controller defective 3) Insert T-adapter. Between BRC1 (female) (2) – chassis ground Resistance 15 – 20 z


HD465-7, HD605-7

20-755 (10)

[DW72KZ]

TROUBLESHOOTING

[DW72KZ] FAILURE IN KICK-OUT SOLENOID OUTPUT SYSTEM (D_OUT3) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E01 Contents of trouble


BK

Failure in kick-out solenoid output system (D_OUT3) (DisconTrouble nection, grounding fault, short circuit): Disconnection or short circuit (KZ)

• When the output to the dump lever kick-out solenoid circuit is ON, a too large current flows or any current does not flow. Or, some current is flowing while the output is OFF.

Action of controller • The controller turns the output to the dump lever kick-out solenoid OFF. Problem that • Detent lock is not applied to the dump lever. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34700).

Cause


1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and LK0. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between LK0 (female) (2) – (Disconnection or defective Resistance Max. 1 z chassis ground contact) Wiring harness between BRC1 (female) (11) – Resistance Max. 1 z LK0 (female) (1)

Possible causes 2 Hot short in wiring harness and standard value in normal state

3

Dump lever kick-out solenoid defective

1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and LK0. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC1 (female) (11) – LK0 (female) (1)

Voltage between BRC1 (female) (11), LK0 (female) (1) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector LK0. 3) Connect T-adapter. Between LK0 (male) (1) – (2)

Resistance 39 z ± 5%

Between LK0 (male) (1), (2) – chassis ground Resistance Min. 1 M z 1) Turn the starting switch OFF. 2) Disconnect connector LK0. 4 Retarder controller defective 3) Connect T-adapter. Between BRC1 (female) (11) – chassis ground Resistance 39 z ± 5%

20-756 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DW72KZ]


HD465-7, HD605-7

20-757 (1)

[DW73KZ]

TROUBLESHOOTING

[DW73KZ] FAILURE IN HOIST SELECT VALVE OUTPUT SYSTEM (D_OUT5) (DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E03


BK

Failure in hoist select valve output system (D_OUT5) (DisconTrouble nection, grounding fault, short circuit): Disconnection or short circuit (KZ)

Contents of trouble

• When the output to the dump lever select valve solenoid circuit is ON, a too large current flows or any current does not flow. Or, some current is flowing while the output is OFF.


• The controller turns the output to the dump lever select valve solenoid OFF. • The controller turns the output to the dump lever EPC valve solenoid OFF.

Problem that • The dump body does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34800).

Cause


1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and HSOL. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between HSOL (female) (B) – 1 Resistance Max. 1 z (Disconnection or defective chassis ground contact) Wiring harness between BRC1 (female) (12) – Resistance Max. 1 z HSOL (female) (A)


1) Turn the starting switch OFF. 2) Disconnect connectors BRC1 and HSOL. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between Wiring harness between BRC1 BRC1 (female) (12), (female) (12) – HSOL (female) (A) HSOL (female) (A) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector HSOL. Dump lever select valve so- 3) Connect T-adapter. 3 lenoid defective Between HSOL (male) (A) – (B) Between HSOL (male) (A), (B) – chassis ground

Max. 1 V


1) Turn the starting switch OFF. 2) Disconnect connector HSOL. 4 Retarder controller defective 3) Connect T-adapter. Between BRC1 (female) (12) – chassis ground Resistance 15 – 35 z

20-758 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DW73KZ]


HD465-7, HD605-7

20-759 (1)

[DK11K4]

TROUBLESHOOTING

[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: UNCONTROLLABLE (K4) Action code


E03

DK11K4

BK

Trouble

Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4)

Contents of trouble • The proportional solenoid pressure reducing valve does not return (does not move).

Action of controller • Resets the retarder solenoid output. Problem that • The retarder (rear brake), ARSC, and overrun prevention system do not operate. appears on machine Related information

• The state of the retarder oil pressure switch can be checked with the monitoring function (Code: 34100). Cause


Defective proportional • Check proportional solenoid pressure reducing valve of rear wheel 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve of rear wheel

2

Defective retarder oil pressure switch

1) Turn starting switch OFF. 2) Disconnect connector RESW. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between RESW (female) (1) – (2)



Oil pressure ON

Resistance Max. 1 z

Oil pressure OFF


1) Turn starting switch OFF. 2) Disconnect connector BRC5A and RESW. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC5A (female) (4) – RESW (female) (1)


Resistance between BRC5A (female) (4), RESW (female) Max. 1 z (1) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC5A (female) (4) – RESW (female) (1)

Voltage between BRC5A (female) (4), RESW (female) Max. 1 V (1) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 5 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5A (4) – Oil pressure ON shassis ground Oil pressure OFF

20-759-1 (10)

Voltage

Max. 1 V

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

[DK11K4]


HD465-7, HD605-7

20-759-2 (5)

[DX11KA]

TROUBLESHOOTING

[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): DISCONNECTION (KA) Action code E03 Contents of trouble

Failure code Controller code DX11KA

BK

Disconnection in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Disconnection (KA)

• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, any current does not flow.

Action of controller • The controller turns the output to the rear brake pressure reducing valve solenoid OFF. Problem that • The retarder (rear brake) does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 33800, 33801).

Cause


1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) – (2) Between RETV (female) (1), (2) – chassis ground Possible causes and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC2 (female) (7) – (Disconnection or defective Resistance Max. 1 z RETV (female) (1). contact) Wiring harness between BRC2 (female) (17) – Resistance Max. 1 z RETV (female) (2). 1) Turn the starting switch OFF. 2) Disconnect connector BRC. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) – (17)



20-760 (10)

HD465-7, HD605-7

[DX11KB]

TROUBLESHOOTING

[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT (KB) Action code



DX11KB

BK

Short circuit in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit (KB)

• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, a too large current flows.


Cause


1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) – (2) Between RETV (female) (1), (2) – chassis ground



1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. 3) Connect T-adapter. Resistance between Grounding fault or short cir- Wiring harness between BRC2 BRC2 (female) (9), 2 cuit in wiring harness (female) (7) – RETV (female) (1). RETV (female) (1) – chassis ground.

Min. 1 M z

Wiring harness between BRC2 (female) (7) – RETV (female) (1) and between BRC (female) (17) – RETV (female) Min. 1 M z (2) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) – (17)



HD465-7, HD605-7

20-761 (10)

[DX11KY]

TROUBLESHOOTING

[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL (A_OUT2): SHORT CIRCUIT WITH POWER SOURCE LINE (KY) Action code E03 Contents of trouble

Failure code Controller code DX11KY

BK

Grounding fault in output circuit of electromagnetic proportional Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit with power source line (KY)

• While the output to the rear wheel pressure reducing valve solenoid circuit is OFF, some current is flowing.


Cause


1) Turn the starting switch OFF. 2) Disconnect connector RETV. Rear brake pressure reduc- 3) Insert T-adapter. 1 ing valve solenoid defective Between RETV (female) (1) – (2) Between RETV (female) (1), (2) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and RETV. 3) Connect T-adapter.


Voltage between Wiring harness between BRC2 BRC2 (female) (7), (female) (7) – RETV (female) (1). RETV (female) (1) – chassis ground.

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (7) – (17)



20-762 (10)

HD465-7, HD605-7

[DX11MA]

TROUBLESHOOTING

[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR WHEEL: MALFUNCTION (MA) Action code


E03

DX11MA

BK

Trouble

Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)

Contents of trouble • The proportional solenoid pressure reducing valve does not operate (does not move).

Action of controller • Resets the retarder solenoid output. Problem that • The retarder (rear brake), ARSC, and overrun prevention system do not operate. appears on machine Related information

• The state of the retarder oil pressure switch can be checked with the monitoring function (Code: 34100). Cause


Defective proportional sole- • Check the proportional solenoid pressure reducing valve of rear 1 noid pressure reducing wheel and repair or replace it, if it has abnormality (mechanical failvalve of rear wheel ure).

2

Defective retarder oil pressure switch

1) Turn starting switch OFF. 2) Disconnect connector RESW. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between RESW (female) (1) – (2)


Oil pressure ON

Resistance Max. 1 z

Oil pressure OFF


1) Turn starting switch OFF. 2) Disconnect connector BRC5A – RESW. Disconnection in wiring har- 3) Connect T-adapter. 3 ness Wiring harness between Resistance between BRC5A BRC5A (female) (4) – (female) (4), RESW (female) Max. 1 z RESW (female) (1) (1) – chassis ground 1) Turn starting switch OFF. 2) Disconnect connector BRC5A. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5A (4) – Oil pressure ON chassis ground (16) Oil pressure OFF

Voltage

Max. 1 V

Voltage

20 – 30 V


HD465-7, HD605-7

20-762-1 (10)

[DX13KA]

TROUBLESHOOTING

[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): DISCONNECTION (KA) Action code


E03

DX13KA

BK

Trouble

Disconnection in output circuit of hoist EPC valve (A_OUT3): Disconnection (KA)

Contents of trouble • When the output to the dump EPC solenoid circuit is ON, any current does not flow.


• The controller turns the output to the dump select valve solenoid OFF. • The controller turns the output to the dump EPC valve solenoid OFF.

Problem that • The dump body does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34900, 34901).

Cause

1


Dump EPC valve solenoid defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HEPC. 3) Insert T-adapter. Between HEPC (female) (1) – (2)


Between HEPC (female) (1), (2) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. Disconnection in wiring har- 3) Connect T-adapter. ness 2 Wiring harness between BRC2 (female) (10) – Resistance Max. 1 z (Disconnection or defective HEPC (female) (1). contact) Wiring harness between BRC2 (female) (20) – Resistance Max. 1 z HEPC (female) (1). 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. 19. Between BRC2 (female) (10) – (20)



HD465-7, HD605-7

20-763 (10)

[DX13KB]

TROUBLESHOOTING

[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT (KB) Action code


E03

DX13KB

BK

Grounding fault in output circuit of hoist EPC valve (A_OUT3): Trouble Short circuit (KB)

Contents of trouble • When the output to the dump EPC valve solenoid circuit is ON, a too large current flows.

• The controller turns the output to the dump select valve solenoid OFF. Action of controller • The controller turns the output to the dump EPC valve solenoid OFF. Problem that • The dump body does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34900, 34901).

Cause

1







1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. 3) Connect T-adapter. Resistance between BRC2 (female) (10), Grounding fault or short cir- Wiring harness between BRC2 2 (female) (10) – HEPC (female) (1). HEPC (female) (1) – cuit in wiring harness chassis ground.

Min. 1 M z

Wiring harness between BRC2 (female) (10) – HEPC (female) (1) and between BRC2 (female) (20) – HEPC (fe- Min. 1 M z male) (2) 1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (10) – (20)



20-764 (10)

HD465-7, HD605-7

[DX13KY]

TROUBLESHOOTING

[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3): SHORT CIRCUIT WITH POWER SOURCE LINE (KY) Action code


E03

DX13KY

BK

Trouble

Short circuit in output circuit of hoist EPC valve (A_OUT3): Short circuit with power source line (KY)

Contents of trouble • While the output to the dump EPC valve solenoid circuit is OFF, some large current is flowing.


• The controller turns the output to the dump select valve solenoid OFF. • The controller turns the output to the dump EPC valve solenoid OFF.

Problem that • The dump body does not operate. appears on machine Related information • This failure can be checked in the monitoring function (Code: 34900, 34901).

Cause

1







1) Turn the starting switch OFF. 2) Disconnect connectors BRC2 and HEPC. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between Hot short in wiring harness Wiring harness between BRC2 BRC2 (female) (10), 2 (Contact with power source (female) (10) – HEPC (female) (1). HEPC (female) (1) – wiring harness) chassis ground.

Max. 1 V

Voltage between Wiring harness between BRC2 BRC2 (female) (20), (female) (20) – HEPC (female) (2). HEPC (female) (2) – chassis ground.

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector BRC2. 3 Retarder controller defective 3) Insert T-adapter. Between BRC2 (female) (10) – (20)

HD465-7, HD605-7


20-765 (10)

TROUBLESHOOTING

[DX13KY]


20-766 (1)

HD465-7, HD605-7

BK-1

TROUBLESHOOTING

BK-1 PARKING BRAKE DOES NOT OPERATE NORMALLY a) When the parking brake switch is set in the OFF position, the parking brake is not released Action code


Not set

Not set

BK

Parking brake does not operate normally Trouble a) When the parking brake switch is set in the OFF position, the parking brake is not released

Contents of trouble • When the parking brake switch is set in the OFF position, the parking brake is not released.

Action of controller • None in particular. Problem that • When the parking brake switch is set in the OFF position, the parking brake is not released. appears on machine Related information

• Before performing the troubleshooting, check that fuse (BT4) (4) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) • Failure code is not displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. When parking brake switch (R33) is disconnected, does parking brake operate?

No

Parking brake switch (R33) is normal

Yes

Parking brake switch (R33) is defective

1) Turn the starting switch OFF. 2) Disconnect connector R33. Parking brake switch defec- 3) Connect T-adapter. 1 tive Set the parking brake switch in PARK. Between R33 (male) (1) – (2) Set the parking brake switch in OFF. Set the parking brake switch in PARK. Between R33 (male) (1) – (3) Set the parking brake switch in OFF. 1) Turn the starting switch OFF. 2) Disconnect connector PSOL Parking brake solenoid de- 3) Connect T-adapter. 2 fective Between PSOL (male) (1) – (2) Between PSOL (male) (1), (2) – chassis ground


Resistance Min. 1 M z Resistance Max. 1 z Resistance Max. 1 z Resistance Min. 1 M z


1) Turn the starting switch OFF. 2) Replace R19 with normal one. 3) Turn the starting switch ON. When parking brake safety relay (R19) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. 3

Parking brake safety relay (R19) defective

Resistance 200 – 400 z Between R19 (male) (1) – (2) 1) Turn the starting switch OFF. 2) Disconnect connector R19. 3) Check the relay. 4) Apply voltage between R19 (male) (1) – (2). Between R19 (male) (3) – (5)


HD465-7, HD605-7

Apply 24 V between (1) – (2). Do not apply 24 V between (1) – (2). Apply 24 V between (1) – (2). Do not apply 24 V between (1) – (2).

Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z

20-767 (10)

BK-1

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R19, R33, PSOL, fuse BT4 (4). 3) Connect T-adapter.

Wiring harness between fuse BT4 (4) – R19 Possible causes Disconnection in wiring har- (female) (5), R33 (female) (3) and standard value ness 4 Wiring harness between R19 (female) (1), (3) in normal state (Disconnection or defective – R33 (female) (1) contact) Wiring harness between R33 (female) (2) – PSOL (female) (1) Wiring harness between PSOL (female) (2) – chassis ground

20-768 (10)


HD465-7, HD605-7

BK-1

TROUBLESHOOTING

b) When the parking brake switch is set in the PARK position, the parking brake does not work Action code


Not set

Not set

Not set

Parking brake does not operate normally Trouble b) When the parking brake switch is set in the PARK position, the parking brake does not work

Contents of trouble • When the parking brake switch is set in the PARK position, the parking brake does not work.

Action of controller • None in particular. Problem that • When the parking brake switch is set in the PARK position, the parking brake does not work. appears on machine Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R33. 3) Connect T-adapter.

Between R33 Parking brake switch defec- (male) (1) – (2) 1 tive


Set the parking brake switch Resistance Min. 1 M z in PARK. Set the parking brake switch Resistance Max. 1 z in OFF. Set the parking brake switch Resistance Max. 1 z in PARK. Set the parking brake switch Resistance Min. 1 M z in OFF.

1) Turn the starting switch OFF. 2) Replace R19 with normal one. 3) Turn the starting switch ON. When parking brake safety relay (R19) is replaced, is failure repaired?

No


Yes



Possible causes and standard value in normal state Parking brake safety relay 2 (R19) defective






Resistance Max. 1 z

Do not apply 24 V beResistance Min. 1 M z tween (1) – (2). Apply 24 V between (1) – (2).


Do not apply 24 V beResistance Max. 1 z tween (1) – (2).

1) Turn the starting switch OFF. 2) Disconnect connectors R33 and PSOL. 3) Connect T-adapter. 3 Hot short in wiring harness

HD465-7, HD605-7

Voltage between R33 Wiring harness between R33 (fe- (female) (2), PSOL (feMax. 1 z male) (2) – PSOL (female) (1) male) (1) – chassis ground

20-769 (10)

TROUBLESHOOTING

BK-1


20-770 (1)

HD465-7, HD605-7

BK-2

TROUBLESHOOTING

BK-2 RETARDER BRAKE OIL TEMPERATURE GAUGE DOES NOT OPERATE NORMALLY Action code


Not set

Not set

Not set

Trouble

Retarder brake oil temperature gauge does not operate normally (When ARSC is not set or ARSC system switch is OFF)

Contents of trouble • The signal circuit voltage of the retarder brake oil temperature gauge is below 0.75 V.

Action of controller • When ARSC operates, the controller releases the brake gradually. Problem that • This failure does not have a serious effect on the machine. appears on machine • When ARSC is set or the ARSC system switch is ON, failure code "dGR2L8" is displayed. Related information • This failure can be checked in the monitoring function (Code: 30200).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector T02. 3) Connect T-adapter.

1

Retarder brake oil temperature gauge defective

Possible causes and standard value 2 Hot short in wiring harness in normal state

Between T02 (male) (1) – (2)

Brake oil temperature: Resistance 37 – 50 kz 25°C Brake oil temperature: Resistance 3.5 – 4.0 kz 100°C

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and T02. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between BRC3B (female) (3) – T02 (female) (1)

Voltage between BRC3B (female) (3), T02 (female) (1) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective

Brake oil temperature: Resistance 37 – 50 kz Between BRC3B (fe25°C male) (3) – BRC3A (feBrake oil temperature: male) (16) Resistance 3.5 – 4.0 kz 100°C


HD465-7, HD605-7

20-771 (10)

BK-3

TROUBLESHOOTING

BK-3 INCLINATION ALARM IS TURNED ON WHEN DUMP BODY IS RAISED (WHEN MACHINE IS NOT INCLINED MORE THAN 15°) Action code Not set


Not set

Trouble

Inclination alarm is turned ON when dump body is raised (When machine is not inclined more than 15°)

• The inclination alarm is turned ON when the dump body is raised while the machine is not inclined Contents of trouble more than 15°) Action of controller • None in particular. Problem that • The inclination alarm is turned ON when the dump body is raised while the machine is not inclined appears on machine more than 15°) Related information

• If the inclination alarm is turned ON while the machine is incline more than 15°, it is not defective (it is normal). • This failure can be checked in the monitoring function (Code: 30200). Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SR3. 3) Connect T-adapter.

1 Inclination sensor defective Between SR3 (male) (1) – (2)

Inclination is below 15° Resistance Max. 1 z Inclination is 15° or more


1) Turn the starting switch OFF. Possible causes Disconnection in wiring har- 2) Disconnect connectors BRC5A and SR3. and standard value ness 3) Connect T-adapter. 2 in normal state (Disconnection or defective Wiring harness between BRC5A (female) (12) contact) Resistance Max. 1 z – SR3 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Connect T-adapter. 3 Retarder controller defective


Inclination is below 15° Resistance Max. 1 z Inclination is 15° or more



20-772 (10)

HD465-7, HD605-7

BK-4

TROUBLESHOOTING

BK-4 TOUCH UP/DOWN AND CANCELLATION CANNOT BE PERFORMED Action code


Not set

Not set

Not set

Trouble

Touch up/down and cancellation cannot be performed. (When ARSC is set and ARSC system switch is ON)

Contents of trouble • Touch up/down and cancellation cannot be performed.

Action of controller • When ARSC operates, the controller releases the brake gradually. Problem that • Touch up/down and cancellation cannot be performed. appears on machine Related information • If failure code "DDD7KX" is displayed, perform troubleshooting for it.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the travel speed set switch (ARSC SET switch).

1

Travel speed set switch (ARFailure is not repaired. Switch is normal Replace the travel SC SET switch) defective speed set switch (ARFailure is repaired. Switch is defective SC SET switch).

2 Register (250 z) defective

1) Turn the starting switch OFF. 2) Disconnect connector RE3. 3) Connect T-adapter. Between RE3 (female) (1) – (2)

Resistance 250 ± 25 z

1) Turn the starting switch OFF. 2) Disconnect connector RE4. 3 Resistor (1,020 z) defective 3) Connect T-adapter. Between RE4 (female) (1) – (2)


1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors BRC3A, ARC, and RE4. ness Possible causes 3) Connect T-adapter. 4 (Disconnection or defective and standard value Wiring harness between BRC3A (female) (16) contact) in normal state Resistance Max. 1 z – ARC (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between BRC3A (6) – (16)

Voltage

Approx. 5 V

1) Turn the starting switch OFF. 5 Retarder controller defective 2) Disconnect connectors BRC3A and BRC3B. 3) Insert T-adapter. Between BRC3B (female) (15) – BRC3A (female) (16)

When set switch is ON


When set switch is TOUCH UP


When set switch is TOUCH DOWN


When set switch is CANCEL Resistance 418 ± 41.8 z

HD465-7, HD605-7

20-773 (10)

TROUBLESHOOTING

BK-4


20-774 (1)

HD465-7, HD605-7

TROUBLESHOOTING FOR PAYLOAD METER SYSTEM (CARD TYPE) (LC MODE)

Electrical system diagram related to payload meter.................................................................................... 20-802 Service codes of payload meter (card type) and contents of self-diagnosis ....................................... 20-804 Information in troubleshooting table........................................................................................................ 20-807 Phenomenon code table ......................................................................................................................... 20-808 LC- 1 When starting switch is turned ON, any item is not displayed .................................................... 20-809 LC- 2 After starting switch is turned ON, all external pilot lamps do not light up .................................. 20-811 LC- 3 External lamps light up while condition for lighting is not set...................................................... 20-814 LC- 4 Lighting level of external pilot lamps is abnormal ....................................................................... 20-816 LC- 5 Cycle data and engine ON/OFF data not recorded (charge level signal system: judges that engine is stopped) ...................................................... 20-818 LC- 6 Calibration cannot be performed and displayed clock does not conform to condition (shift lever "N" position signal system)........................................................................................ 20-819 LC- 7 Displayed logic is abnormal........................................................................................................ 20-821 a) When loaded dump truck starts traveling, "0" is kept displayed............................................ 20-821 b) After loaded dump truck start traveling, display of odometer does not increase................... 20-821 c) When travel speed exceeds limit speed, "SP:SP" does not go off........................................ 20-821 d) Integrated pay load is not displayed ..................................................................................... 20-822 e) Displayed and saved pay load is not correct ........................................................................ 20-823 LC- 8 Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in "FLOAT" position while truck is not dumping)............................................................................. 20-824 LC- 9 Payload meter displays "F:09" (lowering of internal backup battery voltage) ............................. 20-826 LC-10 Payload meter displays " :FULL" (data saving memory is full) ................................................ 20-826 LC-11 Payload meter displays "F-20" : failure in power source of suspension pressure sensor and clinometer system....................................................................................................................... 20-827 LC-12 Payload meter displays "F-21" – "F-24" : disconnection or grounding fault in suspension sensor signal system .................................................................................................................. 20-829 LC-13 Payload meter displays "F-25" – "F-28" : short circuit with power source (Hot short) in suspension sensor signal system ........................................................................................... 20-832 LC-14 Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) ... 20-834 LC-15 Payload meter displays "F:43" – "F:45" (short circuit with power source (Hot short) in external pilot lamp relay system) ............................................................................................ 20-835 LC-16 Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) ........... 20-837 LC-17 External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck travels for 160 m after it is loaded ............................................................................ 20-839 LC-18 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal system ........................................................................................................................................ 20-840 LC-19 Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal system ........................................................................................................................................ 20-842 LC-20 Payload meter displays "F:18" (disconnection in charge level signal system) ........................... 20-844

HD465-7, HD605-7

20-801 (10)

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER


20-802 (2)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-803 (2)

SERVICE CODES OF PAYLOAD METER (CARD TYPE) AND CONTENTS OF SELF-DIAGNOSIS

TROUBLESHOOTING

SERVICE CODES OF PAYLOAD METER DIAGNOSIS

(CARD TYPE) AND CONTENTS OF SELF-

The following are displayed on the display unit of Payload Meter monitor panel.) Priority of display 1

Contents Dump lever is not in FLOAT position (Truck is not dumping)

2

Memory card is not inserted

3

Backup battery voltage is lowered

(Card type). (They are not displayed on the

Service code

External pilot lamps

b-FL lighting up

All lighting up

b-FL lighting up

—

Cd flashing

—

F-09 flashing

—

See (*1) on next page.

—

Cycle data memory is FULL Engine ON/OFF data is FULL 4 Abnormality warning data memory is FULL Data memory of integrated pay load and total number of cycle is FULL 5

Disconnection of terminal R

F-18 flashin

All flashing

6

Abnormality in sensor power source (18 V)

F-20 flashin

All flashing

F-21 flashin

All flashing

F-22 flashin

All flashing

F-23 flashin

All flashing

F-24 flashin

All flashing

F-25 flashin

All flashing

F-26 flashin

All flashing

F-27 flashin

All flashing

F-28 flashin

All flashing

F-31 flashin

All flashing

7 8 9 10 11 12 13 14 15

Short circuit with chassis ground or disconnection in front left suspension pressure sensor system Short circuit with chassis ground or disconnection in front right suspension pressure sensor system Short circuit with chassis ground or disconnection in rear left suspension pressure sensor system Short circuit with chassis ground or disconnection in rear right suspension pressure sensor system Short circuit with power source in front left suspension pressure sensor system Short circuit with power source in front right suspension pressure sensor system Short circuit with power source in rear left suspension pressure sensor system Short circuit with power source in rear right suspension pressure sensor system Short circuit with chassis ground or disconnection in clinometer system

16

Short circuit with power source of clinometer system

F-32 flashin

All flashing

17

Calibration has not been performed or RAM is abnormal

F • CAL flashin

All flashing

18

Short circuit in external pilot lamp G relay

F-43 flashin

19

Short circuit in external pilot lamp Y relay

F-44 flashin

20

Short circuit in external pilot lamp R relay

F-45 flashin

21

Pay load in cycle data is inaccurate [See (*2) in page 20-806]

22

Higher than limit speed

23

20-804 (1)

Communication defective or wrong option code setting

Related lamps While stopped: Kept lighted up While traveling: Turned OFF Other lamps While loading: Normal operation While stopped without loading: Flashing While traveling: Turned OFF

L. bad flashin

—

SP : SP flashin

—

F-71 flashin F-73 flashin F-80 flashin F-81 flashin F-91 flashin F-92 flashin F-93 flashin F-94 flashin F-95 flashin F-96 flashin F-97 flashin F-98 flashin

—

HD465-7, HD605-7

TROUBLESHOOTING


(*1) Alarm displayed when memory is FULL 1. Cycle data 1) If the number of saved cycles reaches 2600 (the remaining capacity is 300 cycles or less), the following is repeated. L : FUL flashes 7 times. : flashes 1 time. 2) If the number of saved cycles reaches 2900 (the remaining capacity is 0 cycle), the following is repeated. L : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the number of saved cycles exceeds 2900, the new cycles are saved as 2901st cycle, 2902nd cycle ---. Each time the new cycle is saved, however, the cycle data are deleted from the oldest one. (The alarm of "2)" above is maintained.) 2. Engine ON/OFF data 1) If the number of saved ON/OFF times reaches 105 (the remaining capacity is 10 times or less), the following is repeated 2 times and then goes off. E : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the number of saved ON/OFF times reaches 115 (the remaining capacity is 0 time), the following is repeated 2 times and then goes off. E : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the number of saved ON/OFF times exceeds 115, the new ON/OFF times are saved as 116th time, 117th time ---. Each time the new ON/OFF time is saved, however, the engine ON/OFF data are deleted from the oldest one. 3. Abnormality/Warning data 1) If the number of saved abnormalities/ warnings reaches 220 (the remaining capacity is 10 abnormalities/warnings or less), the following is repeated. E : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the number of saved abnormalities/ warnings reaches 230 (the remaining capacity is 0 abnormality/warning), the following is repeated. E : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the number of saved abnormalities/ warnings exceeds 230, the new abnormalities/warnings are saved as 231st abnormality/warning, 232nd abnormality/ warning ---. Each time the new abnormality/warning is saved, however, the HD465-7, HD605-7

abnormality/warning data are deleted from the oldest one. (The alarm of "2)" above is maintained.) 4. Integrated pay load/Total number of cycles data 1) If the total number of cycles reaches 9994 (the remaining capacity is 5 cycles or less) or the difference between the saved integrated pay load and 999900 tons (upper limit) becomes 5 times the rated hauling capacity, the following is repeated. H : FUL flashes 7 times (for 3 seconds). : flashes 1 time. 2) If the total number of cycles reaches 9997 (the remaining capacity is 2 cycles or less) or the difference between the saved integrated pay load and 999900 tons (upper limit) becomes 5 times the rated hauling capacity, the following is repeated. H : FUL lights up (for 3 seconds). : flashes 1 time. 3) If the total number of cycles reaches 9999 or the saved integrated pay load exceeds 999900 tons, both of the integrated pay load and total number of cycles are cleared to 0, and then they are integrated again. (The display unit displays the operating time normally again.) 5. For the method of resetting the data in 1 – 3 above when they become FULL, see "8.3 Operator check mode" in the instruction manual for Payload Meter (Card type). Once the data in 4 becomes FULL, it is not reset until it is cleared to 0 automatically. For the method of clearing this data to 0 forcibly before it becomes FULL, see "8.2 Forcible display of integrated pay load/total number of cycles" in the instruction manual for Payload Meter . 6. As for the order of display, any priority is not given to the items in 1 – 4 above. If multiple data become FULL simultaneously, they are displayed while the dump truck is not being loaded.

20-805 (1)

TROUBLESHOOTING


(*2) Inaccurate pay load in cycle data 1. The payload meter constantly senses the pay load by the signals from the suspension pressure sensor. The sensed pay load becomes a little inaccurate during and just after loading because of the dynamic friction of the suspension. To save the pay load more accurately, the payload meter senses and saves the pay load just before dumping after the dynamic friction of the suspension during loading is canceled by loaded travel. (The payload meter saves the payload meter as a part of the cycle data.) 2. Accordingly, if the load is dumped (if the dump lever is operated) before pitching of the machine body stops, the payload meter may save the pay load inaccurately. 3. When the dump truck is braked sharply or stopped by chocks in the dumping place, the pay load may be saved inaccurately. 4. If the load is dumped before the dump truck stops pitching for the above reasons, the payload meter displays "Inaccurate pay load in cycle data" in the abnormality/warning items list to call the operator's attention. The pay load sensed in this case is saved, however.

20-806 (1)

HD465-7, HD605-7


TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Action code


Display on panel

Display on panel

Display on panel




Cause

1

2



HD465-7, HD605-7

20-807 (10)


TROUBLESHOOTING




Contents

Phenomenon code

Contents

KA


L0


KB

Short circuit

L1


KK


L2


KQ


L3


KR


L4


KT


L6


KX


L8


KY


LC


KZ


LD


MA

Malfunction

LH


MB


MW

Sliding

NS

Overheat

ZG


ZK


20-808 (10)

HD465-7, HD605-7

LC-1

TROUBLESHOOTING

LC-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM IS NOT DISPLAYED Action code


Not set

Not set

Not set

Trouble When starting switch is turned ON, any item is not displayed

Contents of trouble • When the starting switch is turned ON, any item is not displayed.

Action of controller • None in particular. Problem that • When the starting switch is turned ON, any item is not displayed. appears on machine Related information

• Before performing the troubleshooting, check that fuse BT2 (12) circuit breaker (80 A) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R10 with normal one. 3) Turn the starting switch ON. When LC GDL relay (R10) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R10. 3) Check the relay. 1 LC GDL relay (R10) defective Between R10 (male) (5) – (6)


1) Turn the starting switch OFF. 2) Disconnect connector R10. 3) Check the relay. 4) Apply voltage between R10 (male) (1) – (2) Between R10 (male) (3) – (5)



Resistance Max. 1 z

Do not apply 24 V beResistance Min. 1 M z tween (1) – (2).

1) Turn the starting switch OFF. 2) Disconnect connector connectors R10 and fuse BT2 (12). 3) Connect T-adapter. Wiring harness between battery relay terminal Resistance Max. 1 z Disconnection in wiring har- M, fuse BT2 (12) – R10 (female) (1), (5) ness Wiring harness between R10 (female) (2) – 2 (Disconnection or defective Resistance Max. 1 z chassis ground contact) Wiring harness between PM5 (female) (1) – Resistance Max. 1 z R10 (female) (3) Wiring harness between R10 (female) (13) – chassis ground

3 Payload meter defective

1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM5 (1) – (13)

HD465-7, HD605-7

Resistance Max. 1 z

Voltage

20 – 30 V

20-809 (10)

TROUBLESHOOTING

LC-1


20-810 (1)

HD465-7, HD605-7

LC-2

TROUBLESHOOTING

LC-2 AFTER STARTING SWITCH IS TURNED ON, ALL EXTERNAL PILOT LAMPS DO NOT LIGHT UP Action code



Not set

Not set

After starting switch is turned ON, all external pilot lamps do not light up Trouble (Perform troubleshooting with shift lever in N and starting switch in ON)

• After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with shift lever in N and starting switch in ON.)

Action of controller • None in particular. • After starting switch is turned ON, all external pilot lamps do not light up. (Perform troubleshooting with Problem that appears on machine shift lever in N and starting switch in ON.) • Check that any bulb is not broken. • If there is grounding fault between the fuse and shift lever switch terminal N (on the power supply side), failure code "DF10KA" related to the transmission controller is displayed. Related information • Before performing the troubleshooting, check that fuse BT2 (14) is not broken. (If the fuse is broken, check its wiring harness for grounding fault.) Cause 1 Breakage of bulb

Standard value in normal state/Remarks on troubleshooting Any bulb must not be broken. 1) Turn the starting switch OFF. 2) Replace R40 with normal one. 3) Turn the starting switch ON. When payload meter relay (R40) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R40. 3) Check the relay. Between R40 (male) (5) – (6) 2

Payload meter relay (R40) defective

Between R40 (male) (1) – (2) Possible causes and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connector R40. 3) Check the relay. 4) Apply voltage between R40 (male) (5) – (6)



Resistance Max. 1 z


Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, PM5, R43, R44, R45, B1, B2, and B3. 3) Connect T-adapter. 1) Any lamp does not light up. Wiring harness between SF1 (female) (4) – R40 (female) (5)

Disconnection in wiring harWiring harness between R40 (female) (6) – ness 3 (Disconnection or defective chassis ground contact) 2) Specific lamps do not light up.

Resistance Max. 1 z Resistance Max. 1 z

Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z – R43 (female) (3) Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z – R44 (female) (3) Wiring harness between R40 (female) (2), (4) Resistance Max. 1 z – R45 (female) (3)

HD465-7, HD605-7

20-811 (10)

LC-2

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting Wiring harness between R43 (female) (6) – G Resistance Max. 1 z (female) (1) Wiring harness between R44 (female) (6) – A Resistance Max. 1 z (female) (1)


Wiring harness between R45 (female) (6) – R Resistance Max. 1 z (female) (1) Wiring harness between B1 (female) (1) – chassis ground

Resistance Max. 1 z

Wiring harness between B2 (female) (1) – chassis ground

Resistance Max. 1 z

Wiring harness between B3 (female) (1) – chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, PM5, R43, R44, and R45. 3) Connect T-adapter. 1) Any lamp does not light up. aIn this case, fuse BT3 (10) (for supplying power to shift switch N) is broken. Wiring harness between SF1 (female) (4) – R40 (female) (5)




20-812 (10)

Resistance between SF1 (female) (4), R40 Min. 1 M z (female) (5) – chassis ground

2) Specific lamps do not light up. Resistance between Wiring harness between PM5 (fe- PM5 (female) (4), R43 male) (4) – R43 (female) (2) (female) (2) – chassis ground

Max. 1 z

Resistance between Wiring harness between PM5 (fe- PM5 (female) (5), R44 male) (5) – R44 (female) (2) (female) (2)– chassis ground

Max. 1 z

Resistance between Wiring harness between PM5 (fe- PM5 (female) (6), R45 male) (6) – R45 (female) (2) (female) (2) – chassis ground

Max. 1 z


Voltage

20 – 30 V

Between PM5 (5) – (13)

Voltage

20 – 30 V


Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

LC-2


HD465-7, HD605-7

20-813 (1)

LC-3

TROUBLESHOOTING

LC-3 EXTERNAL LAMPS LIGHT UP WHILE CONDITION FOR LIGHTING IS NOT SET Action code Not set


Not set

Trouble External lamps light up while condition for lighting is not set

Contents of trouble • External lamps light up while condition for lighting is not set.

Action of controller • None in particular. Problem that • External lamps light up while condition for lighting is not set. appears on machine Related information • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON. When payload meter lamp relays (R43), (R44), and (R45) is replaced with normal ones respectively, is failure repaired?

No

Relays (R43), (R44), and (R45) are normal

Yes

Relays (R43), (R44), and (R45) are defective

1) Turn the starting switch OFF. Payload meter lamp relays 2) Disconnect connectors R43, R44, and R45. 1 (R43), (R44), and (R45) de- 3) Check the relays. fective Between R43, R44, and R45 (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) – (2). Between R43, R44, and R45 (3) – (6).



Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors SF1, R40, R43, R44, and R45. 3) Insert T-adapter. 4) Turn the starting switch ON. Voltage between SF1 (female) (4), R40 (female) (5) – chassis ground

Max. 1 V

Voltage between PM5 Wiring harness between R40 (fe- (female) (4), R43 (female) (2), (4) – R43 (female) (3) male) (2) – chassis ground

Max. 1 V


Max. 1 V


Max. 1 V

Wiring harness between SF1 (female) (4) – R40 (female) (5)


20-814 (10)

HD465-7, HD605-7

TROUBLESHOOTING

LC-3


HD465-7, HD605-7

20-815 (1)

LC-4

TROUBLESHOOTING

LC-4 LIGHTING LEVEL OF EXTERNAL PILOT LAMPS IS ABNORMAL Action code Not set


Not set

Trouble Lighting level of external pilot lamps is abnormal

Contents of trouble • Lighting level of external pilot lamps is abnormal.

Action of controller • None in particular. Problem that • Lighting level of external pilot lamps is abnormal. appears on machine Related information • If this phenomenon is stopped by performing calibration again, it is not a failure.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON. 4) Set the shift lever in N. When payload meter lamp relays (R43), (R44), and (R45) is replaced with normal ones respectively, is failure repaired?

No

Relays (R43), (R44), and (R45) are normal

Yes

Relays (R43), (R44), and (R45) are defective

Payload meter lamp relays 1) Turn the starting switch OFF. 1 (R43), (R44), and (R45) de- 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. fective Between R43, R44, and R45 (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) – (2). Between R43, R44, and R45 (3) – (6). Possible causes and standard value in normal state


Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors PM5, R43, R44, and R45. 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between PM5 (female) (4) – ness R43 (female) (2) 2 (Disconnection or defective Wiring harness between PM5 (female) (5) – contact) R44 (female) (2) Wiring harness between PM5 (female) (6) – R45 (female) (2)


1) Turn the starting switch OFF. 2) Disconnect connectors R40, R43, R44, R45, G, A, and R. 3) Connect T-adapter.


20-816 (10)

Voltage between R43 Wiring harness between R43 (fe- (female) (6), G (female) (6) – G (female) (1) male) (1) – chassis ground

Max. 1 V

Voltage between R44 Wiring harness between R44 (fe- (female) (6), A (female) (6) – A (female) (1) male) (1) – chassis ground

Max. 1 V

Voltage between R45 Wiring harness between R45 (fe- (female) (6), R (female) (6) – R (female) (1) male) (1) – chassis ground

Max. 1 V

HD465-7, HD605-7

LC-4

TROUBLESHOOTING

Cause

Possible causes and standard value 5 Payload meter defective in normal state

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM5 (4) – (13)

Voltage

20 – 30 V


Voltage

20 – 30 V


Voltage

20 – 30 V


HD465-7, HD605-7

20-817 (10)

LC-5

TROUBLESHOOTING

LC-5 CYCLE DATA AND ENGINE ON/OFF DATA NOT RECORDED (CHARGE LEVEL SIGNAL SYSTEM: JUDGES THAT ENGINE IS STOPPED) Action code Not set


Not set

Trouble

Cycle data and engine ON/OFF data not recorded (Charge level signal system: Judges that engine is stopped)

• Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine Contents of trouble is stopped.) Action of controller • None in particular. • Cycle data and engine ON/OFF data not recorded. (Charge level signal system: Judges that engine Problem that appears on machine is stopped.) Related information • If the engine ON/OFF data are recorded, perform troubleshooting of LC-7.

Cause



1) Turn the starting switch OFF. 2) Disconnect connector PM5. Disconnection in wiring har- 3) Insert T-adapter. 4) Connect the connector. ness 1 (Disconnection or defective 5) Start the engine. 6) Depress the accelerator pedal more than "half". contact) Wiring harness between PM5 (fe- Voltage between PM5 male) (9) – alternator terminal R (9) – chassis ground


Min. 5 V

1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Start the engine. 6) Depress the accelerator pedal more than "half". Between PM5 (9) – chassis ground

Voltage

Min. 5 V


20-818 (10)

HD465-7, HD605-7

LC-6

TROUBLESHOOTING

LC-6 CALIBRATION CANNOT BE PERFORMED AND DISPLAYED CLOCK DOES NOT CONFORM TO CONDITION (SHIFT LEVER "N" POSITION SIGNAL SYSTEM) Action code



Not set

Not set

Calibration cannot be performed and displayed clock does not Trouble conform to condition (Shift lever "N" position signal system)

• Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N" position signal system)

Action of controller • None in particular. Problem that • Calibration cannot be performed and displayed clock does not conform to condition. (Shift lever "N" appears on machine position signal system) Related information • Check that the external pilot lamp operates as described in the operation manual.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R02 with normal one. 3) Turn the starting switch ON. When transmission neutral relay (R02) is replaced with normal one, is failure repaired?

1

Transmission neutral relay (R02) defective

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. Between R02 (male) (1) – (2)


1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. 3) Check the relays. 4) Apply voltage between R02 (male) (1) – (2). Between R02 (male) (3) – (6)


Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and R02. 3) Connect T-adapter.

Possible causes Disconnection in wiring har- Wiring harness between PM6 (female) (10) – and standard value Resistance Max. 1 z ness R02 (female) (6) 2 in normal state (Disconnection or defective Wiring harness between SF1 (female) (4) – contact) Resistance Max. 1 z R02 (female) (1) Wiring harness between R02 (female) (2), (3) Resistance Max. 1 z – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter.

3


Resistance between Wiring harness between PM6 (fe- PM6 (female) (10), male) (10) – R02 (female) (6) R02 (female) (6) – chassis ground

Min. 1 M z

Resistance between Wiring harness between SF1 (fe- SF1 (female) (4), R02 Min. 1 M z male) (4) – R02 (female) (1) (female) (1) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. When shift lever is N Between PM6 (10) – PM5 (13) When shift lever is not N

HD465-7, HD605-7

Voltage

20 – 30 V

Voltage

Max. 1.5 V

20-819 (10)

TROUBLESHOOTING

LC-6


20-820 (1)

HD465-7, HD605-7

LC-7

TROUBLESHOOTING

LC-7 DISPLAYED LOGIC IS ABNORMAL a) When loaded dump truck starts traveling, "0" is kept displayed. b) After loaded dump truck start traveling, display of odometer does not increase. c) When travel speed exceeds limit speed, "SP:SP" does not go off. Action code


Not set

Not set

Not set

Displayed logic is abnormal a) When loaded dump truck starts traveling, "0" is kept displayed. b) After loaded dump truck start traveling, display of odometer Trouble does not increase. c) When travel speed exceeds limit speed, "SP:SP" does not go off.

• When loaded dump truck starts traveling, "0" is kept displayed. Contents of trouble • After loaded dump truck start traveling, display of odometer does not increase.

• When travel speed exceeds limit speed, "SP:SP" does not go off. Action of controller • None in particular. • When loaded dump truck starts traveling, "0" is kept displayed.

Problem that • After loaded dump truck start traveling, display of odometer does not increase. appears on machine

• When travel speed exceeds limit speed, "SP:SP" does not go off.

• If the pay load is displayed during loading but "0" is displayed after the dump truck starts traveling until it dumps the load, the travel speed signal is not sensed. Related information • If failure codes "DLT3KA" and "DLT3LC" related to transmission controller or failure codes "DLT3KA" and "dLT3LC" related to retarder controller are displayed, perform troubleshooting for them first. Cause


1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and R02. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between PM5 (female) (7) – (Disconnection or defective Possible causes CN5 (female) (1) contact) and standard value Wiring harness between PM5 (female) (8) – in normal state CN5 (female) (2)



1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Connect T-adapter. Wiring harness between PM5 (female) (7) – (8) Resistance Max. 1 z


HD465-7, HD605-7

20-821 (10)

LC-7

TROUBLESHOOTING

d) Integrated pay load is not displayed. Action code Not set


Not set

Trouble

Displayed logic is abnormal d) Integrated pay load is not displayed.

Contents of trouble • Integrated pay load is not displayed.

Action of controller • None in particular. Problem that • Integrated pay load is not displayed. appears on machine

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

20-822 (10)

HD465-7, HD605-7

LC-7

TROUBLESHOOTING

e) Displayed and saved pay load is not correct. Action code


Not set

Not set

Not set

Trouble

Displayed logic is abnormal e) Displayed and saved pay load is not correct.

Contents of trouble • Displayed and saved pay load is not correct.

Action of controller • None in particular. Problem that • Displayed and saved pay load is not correct. appears on machine

• The error of the payload meter is ± 5%. • The possible causes of display of wrong displayed and saved values are as follows (1) Defective setting of model selection switch of payload meter (2) Defective adjustment of suspension (3) Negligence of calibration of payload meter Related information i) If the load is dumped while the displayed pay load is changing because of pitching of the truck body, the saved value may become inaccurate. Accordingly, dump after the displayed value is fixed. ii) The pay load displayed in the loading place (just after loading) may be a little (1 - 5 t) less than that displayed in the dumping place. aFor details, see Operation Manual, 3. For higher accuracy. Cause

Standard value in normal state/Remarks on troubleshooting LC display: "CO: X. X"

1 Wrong model setting X. X display

HD465-7

HD605-7

0. 7

0. A

i) When truck is empty (1) Empty, (2) Flat place aSee STRUCTURE AND OPERATION, Service Check Mode, (b) Display of data for calculation of pay load. Pressure difference between both sides (Front)


0.98 MPa {10 kg/cm2}

Pressure difference between both sides (Rear) 1.47 MPa {15 kg/cm2} 2

Improper suspension gas pressure

• If the pressure difference exceeds the above range, adjust the suspension gas, referring to "Testing and adjusting suspension cylinder". ii) When truck is loaded Contact (Interference) of frame stopper and rear axle housing

There must not be contact (Interference)

iii)When truck turns on slope Contact (Interference) of frame stopper and rear axle housing 3 Improper calibration

HD465-7, HD605-7

There must not be contact (Interference)

• Perform calibration according to the operation manual.

20-823 (10)

LC-8

TROUBLESHOOTING

LC-8 PAYLOAD METER KEEPS DISPLAYING "b:FL" (BODY "FLOAT" SIGNAL SYSTEM: DUMP LEVER IS NOT IN "FLOAT" POSITION WHILE TRUCK IS NOT DUMPING) Action code



Not set

Not set

Payload meter keeps displaying "b:FL" Trouble (Body "FLOAT" signal system: Dump lever is not in "FLOAT" position while truck is not dumping)

• Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT" position while truck is not dumping)

Action of controller • None in particular. • Payload meter keeps displaying "b:FL" (Body "FLOAT" signal system: Dump lever is not in "FLOAT" Problem that appears on machine position while truck is not dumping) Related information

• Check that failure codes "DK52KX", "DK53L8", and "DK24KX" (failure in dump lever system) related to retarder controller are not displayed. If any of them is displayed, perform troubleshooting for it. Cause


1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors PM6 and BRC1. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between PM6 (female) (9) – contact) BRC1 (female) (15)

2



1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and BRC1. 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (9), Min. 1 M z male) (9) – BRC1 (female) (15) BRC1 (female) (15) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector BRC1. 3) Insert T-adapter. 4) Connect the connector. 3 Retarder controller defective 5) Turn the starting switch ON. Between BRC1 Dump lever is in "FLOAT". (15) – chassis Dump lever is out of ground "FLOAT".


(10)

Voltage

20 – 30 V

Voltage

Max. 1 V

Dump lever is in "FLOAT".

Voltage

20 – 30 V

Dump lever is out of "FLOAT".

Voltage

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector PM6. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM6 (9) – chassis ground

20-824

Resistance Max. 1 z

HD465-7, HD605-7

TROUBLESHOOTING

LC-8


HD465-7, HD605-7

20-825 (1)

LC-9, LC-10

TROUBLESHOOTING

LC-9 PAYLOAD METER DISPLAYS "F:09" (LOWERING OF INTERNAL BACKUP BATTERY VOLTAGE) Action code Not set

Failure code Controller code Payload meter displays "F:09"

Not set

Trouble

Payload meter displays "F:09" (Lowering of internal backup battery voltage)

Contents of trouble • Payload meter displays "F:09" (Lowering of internal backup battery voltage)

Action of controller • None in particular. Problem that • Payload meter displays "F:09" (Lowering of internal backup battery voltage) appears on machine Related information • None in particular.

Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard value Lowering of internal backup 1 Replace the internal backup battery according to the operation manual. in normal state battery voltage

LC-10 PAYLOAD METER DISPLAYS " :FULL" (DATA SAVING MEMORY IS FULL) Action code Not set

Failure code Controller code Payload meter displays " :FULL"

Not set

Contents of trouble • Payload meter displays "

Trouble

Payload meter displays " :FULL" (Data saving memory is full)

:FULL". (Data saving memory is full.)

Action of controller • None in particular. Problem that • Payload meter displays " appears on machine

:FULL". (Data saving memory is full.)



Cause


Cycle data saving memory 1 full a"L. FULL" is displayed

• Download the data to a personal computer and clear the memory to "0" (zero ) according to the operation manual.

Engine ON/OFF data saving • Download the data to a personal computer and clear the memory to 2 memory full "0" (zero ) according to the operation manual. a"E. FULL" is displayed Failure and warning data 3 saving memory full a"F. FULL" is displayed

• Download the data to a personal computer and clear the memory to "0" (zero ) according to the operation manual.

Integrated pay load and total number of cycles data sav- • Download the data to a personal computer and clear the memory to 4 ing memory full "0" (zero ) according to the operation manual. a"F. FULL" is displayed

20-826 (10)

HD465-7, HD605-7

LC-11

TROUBLESHOOTING

LC-11 PAYLOAD METER DISPLAYS "F-20" : FAILURE IN POWER SOURCE OF SUSPENSION PRESSURE SENSOR AND CLINOMETER SYSTEM Action code Not set

Failure code Controller code Payload meter displays "F-20"

Not set

LC-11 Payload meter displays "F-20" Trouble : Failure in power source of suspension pressure sensor and clinometer system

Contents of trouble • The sensor power source output is below 15 V while the source voltage is above 20 V.

Action of controller • All the external pilot lamps flash. • Pay load is not displayed correctly. Problem that appears on machine • Operation data is not saved correctly. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, SURR, and PM3. 3) Connect T-adapter.

1


Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) – SUFL (female) (B) SUFL (female) (B) – chassis ground

Min. 1 M z

Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) – SUFR (female) (B) SUFR (female) (B) – chassis ground

Min. 1 M z

Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) – SURL (female) (B) SURL (female) (B) – chassis ground

Min. 1 M z

Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), male) (2) – SURR (female) (B) SURR (female) (B) – chassis ground

Min. 1 M z

Resistance between Wiring harness between PM6 (fe- PM6 (female) (2), PM3 Min. 1 M z male) (2) – PM3 (female) (C) (female) (C) – chassis ground


1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, the error is corrected. fective. When front left suspension pressure sensor is Front left sensor is replaced, the error is not corrected. normal. When front right suspension pressure sensor Front right sensor is is replaced, the error is corrected. defective. 2

Suspension pressure sensor When front right suspension pressure sensor Front right sensor is defective is replaced, the error is not corrected. normal. When rear left suspension pressure sensor is Rear left sensor is dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, the error is not corrected. mal. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is corrected. defective. When Rear right suspension pressure sensor Rear right sensor is is replaced, the error is not corrected. normal.

HD465-7, HD605-7

20-827 (10)

LC-11

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON.


3 Clinometer sensor defective When the clinometer is replaced, the error is corrected. When the clinometer is replaced, the error is not corrected.


Clinometer is defective. Clinometer is normal.

1) Turn the starting switch OFF. 2) Disconnect connector PM6. 3) Connect T-adapter (only payload meter side). 4) Turn the starting switch ON. Between PM6 (male) (2) – (3)

Voltage

18 ± 3 V


20-828 (10)

HD465-7, HD605-7

LC-12

TROUBLESHOOTING

LC-12 PAYLOAD METER DISPLAYS "F-21" – "F-24" : DISCONNECTION OR GROUNDING FAULT IN SUSPENSION SENSOR SIGNAL SYSTEM Action code Not set

Failure code Controller code Payload meter displays "F-21" – "F-24"

Not set

Payload meter displays "F-21" – "F-24" Trouble : Disconnection or grounding fault in suspension sensor signal system

Contents of trouble • Input signal of suspension pressure sensor is below 1 V.

Action of controller • All the external pilot lamps flash. Problem that • Pay load is not displayed correctly. appears on machine • Operation data is not saved correctly. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR. 3) Connect T-adapter. Wiring harness between PM6 (female) (2) – SUFL (female) (B)

Resistance Max. 1 z

Wiring harness between PM6 (female) (2) – SUFR (female) (B)

Resistance Max. 1 z

Wiring harness between PM6 (female) (2) – SURL (female) (B) Wiring harness between PM6 (female) (2) – SURR (female) (B) Wiring harness between PM6 (female) (4) – Disconnection in wiring har- SUFL (female) (C) ness Wiring harness between PM6 (female) (5) – 1 (Disconnection or defective SUFR (female) (C) contact) Wiring harness between PM6 (female) (6) – SURL (female) (C)

Resistance Max. 1 z

Wiring harness between PM6 (female) (7) – SURR (female) (C)

Resistance Max. 1 z

Wiring harness between PM6 (female) (3) – SUFL (female) (A) Wiring harness between PM6 (female) (3) – SUFR (female) (A) Wiring harness between PM6 (female) (3) – SURL (female) (A) Wiring harness between PM6 (female) (3) – SURR (female) (A)

Resistance Max. 1 z




1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (4), Min. 1 M z male) (4) – SUFL (female) (C) SUFL (female) (C) – chassis ground Ground fault in wiring har2 ness

Resistance between Wiring harness between PM6 (fe- PM6 (female) (5), male) (5) – SUFR (female) (C) SUFR (female) (C) – chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (6), male) (6) – SURL (female) (C) SURL (female) (C) – chassis ground Resistance between Wiring harness between PM6 (fe- PM6 (female) (7), male) (7) – SURR (female) (C) SURR (female) (C) – chassis ground

HD465-7, HD605-7

Min. 1 M z

Min. 1 M z

Min. 1 M z

20-829 (10)

LC-12

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, the error is corrected. fective. When front left suspension pressure sensor is Front left sensor is replaced, the error is not corrected. normal. When front right suspension pressure sensor Front right sensor is is replaced, the error is corrected. defective.

3

Suspension pressure sensor When front right suspension pressure sensor Front right sensor is defective is replaced, the error is not corrected. normal. When rear left suspension pressure sensor is Rear left sensor is dereplaced, the error is corrected. fective.


When rear left suspension pressure sensor is Rear left sensor is norreplaced, the error is not corrected. mal. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is corrected. defective. When Rear right suspension pressure sensor Rear right sensor is is replaced, the error is not corrected. normal. 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. 4 Payload meter defective

20-830 (10)


Voltage

18 ± 3 V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V

HD465-7, HD605-7

TROUBLESHOOTING

LC-12


HD465-7, HD605-7

20-831 (1)

LC-13

TROUBLESHOOTING

LC-13 PAYLOAD METER DISPLAYS "F-25" – "F-28" : SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN SUSPENSION SENSOR SIGNAL SYSTEM Action code Not set

Failure code Controller code Payload meter displays "F-25" – "F-28"

Not set

Payload meter displays "F-25" – "F-28" Trouble : Short circuit with power source (Hot short) in suspension sensor signal system

Contents of trouble • The suspension pressure input signal is above 5 V.


Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6, SUFL, SUFR, SURL, and SURR 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between PM6 Wiring harness between PM6 (fe- (female) (4), SUFL (feMax. 1 V male) (4) – SUFL (female) (C) male) (C) and chassis ground


Voltage between PM6 Wiring harness between PM6 (fe- (female) (5), SUFR Max. 1 V male) (5) – SUFR (female) (C) (female) (C) and chassis ground Voltage between PM6 Wiring harness between PM6 (fe- (female) (6), SURL (feMax. 1 V male) (6) – SURL (female) (C) male) (C) and chassis ground Voltage between PM6 Wiring harness between PM6 (fe- (female) (7), SURR Max. 1 V male) (7) – SURR (female) (C) (female) (C) and chassis ground


1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON. When front left suspension pressure sensor is Front left sensor is dereplaced, the error is corrected. fective. When front left suspension pressure sensor is Front left sensor is replaced, the error is not corrected. normal. When front right suspension pressure sensor Front right sensor is is replaced, the error is corrected. defective. 2

Suspension pressure sensor When front right suspension pressure sensor Front right sensor is defective is replaced, the error is not corrected. normal. When rear left suspension pressure sensor is Rear left sensor is dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, the error is not corrected. mal. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is corrected. defective. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is not corrected. normal.

20-832 (10)

HD465-7, HD605-7

LC-13

TROUBLESHOOTING

Cause


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between PM6 (2) – (3)

Voltage

18 ± 3 V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V


HD465-7, HD605-7

20-833 (10)

LC-14

TROUBLESHOOTING

LC-14 PAYLOAD METER DISPLAYS "F-CAL" (NEGLIGENCE OF CALIBRATION OR INTERNAL DAMAGE OF PAYLOAD METER) Action code Not set

Failure code Controller code Payload meter displays "F-CAL"

Not set

Trouble

Payload meter displays "F-CAL" (Negligence of calibration or internal damage of payload meter)

Contents of trouble • Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter)

Action of controller • All the external pilot lamps flash. Problem that • Payload meter displays "F-CAL". (Negligence of calibration or internal damage of payload meter) appears on machine Related information • None in particular.

Cause


Possible causes Negligence of calibration or and standard value internal damage of payload 1 • Repair according to the operation manual. in normal state meter a"F-CAL" is displayed.

20-834 (10)

HD465-7, HD605-7

LC-15

TROUBLESHOOTING

LC-15 PAYLOAD METER DISPLAYS "F:43" – "F:45" (SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN EXTERNAL PILOT LAMP RELAY SYSTEM) Action code


Not set

Not set

Not set

Trouble

Payload meter displays "F:43" – "F:45" (Short circuit with power source in external pilot lamp relay system)

Contents of trouble • There is short circuit with power source (Hot short) in external pilot lamp relay system.

Action of controller • None in particular. • There is short circuit with power source (Hot short) in external pilot lamp relay system. Problem that appears on machine • Payload meter displays "F:43" – "F:45". Related information • None in particular.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R43, R44, and R45 with normal ones. (Replace only the defective relays with normal ones.) 3) Turn the starting switch ON.


Relays (R43), (R44), When payload meter lamp relays No and (R45) are normal (R43), (R44), and (R45) is rePayload meter lamp relays placed with normal ones respecRelays (R43), (R44), Yes (R43), (R44), and (R45) de- tively, is failure repaired? and (R45) are defective fective 1) Turn the starting switch OFF. aWhen "F:43" is displayed, 2) Disconnect connectors R43, R44, and R45. 1 R43 is defective. 3) Check the relays. aWhen "F:44" is displayed, Resistance 200 – 400 z Between R43, R44, and R45 (1) – (2) R44 is defective. aWhen "F:45" is displayed, 1) Turn the starting switch OFF. 2) Disconnect connectors R43, R44, and R45. R45 is defective. 3) Check the relays. 4) Apply voltage between R43, R44, and R45 (1) – (2). Between R43, R44, and R45 (3) – (6).


Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors PM5, R40, R43, R44, and R45. 3) Connect T-adapter. Hot short in wiring harness aWhen "F:43" is displayed, R43 system is short-circuited. aWhen "F:44" is displayed, 2 R44 system is short-circuited. aWhen "F:45" is displayed, R45 system is short-circuited.

HD465-7, HD605-7

Voltage between PM5 Wiring harness between PM5 (fe- (female) (4), R43 (female) (4) – R43 (female) (2) male) (2) – chassis ground

Max. 1 V


Max. 1 V


Max. 1 V

20-835 (10)

LC-15

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R40, R43, R44, and R45. 3) Connect T-adapter.



Payload meter defective aWhen "F:43" is displayed, PM5 (4) system is defective. aWhen "F:44" is displayed, 4 PM5 (5) system is defective. aWhen "F:45" is displayed, PM5 (6) system is defective.


Max. 1 V


Max. 1 V


Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between PM 5 (4) – (13)

Voltage

20 – 30 V

Between PM 5 (5) – (13)

Voltage

20 – 30 V

Between PM 5 (6) – (13)

Voltage

20 – 30 V


20-836 (10)

HD465-7, HD605-7

LC-16

TROUBLESHOOTING

LC-16 PAYLOAD METER DISPLAYS "L-bad" (CYCLE DATA WERE SAVED WHILE TRUCK BODY WAS PITCHING) Action code


Not set

Not set

Not set

Trouble

Payload meter displays "L-bad" (Cycle data were saved while truck body was pitching)

Contents of trouble • Since truck pitches during dumping, the pay load in the cycle data is not correct.

Action of controller • None in particular. Problem that • Since truck pitches during dumping, the pay load in the cycle data is not correct. appears on machine

• The pay load must be calculated accurately and saved as a cycle data when the truck dumps. If the truck pitches when it dumps, the calculation accuracy is lowered. Pitching of the truck during dumping is notified to the operator by "L-bad". Accordingly, wait for 5 seconds after the truck stops, and then Related information start dumping. • If "L-bad" is displayed during dumping, it is maintained until the empty truck starts traveling. • If "L-bad" is always displayed and the pay load in the cycle data is abnormal, perform the following troubleshooting. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5, PM6, SUFL, SUFR, SURL, and SURR. 3) Connect T-adapter. Wiring harness between PM5 (female) (13) – Resistance Max. 1 z SUFR (female) (A)

Disconnection in wiring har- Wiring harness between PM6 (female) (4) – ness SUFL (female) (C) 1 (Disconnection or defective Wiring harness between PM6 (female) (5) – contact) SUFR (female) (C)


Wiring harness between PM6 (female) (6) – SURL (female) (C)

Resistance Max. 1 z

Wiring harness between PM6 (female) (7) – SURR (female) (C)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON.


When front left suspension pressure sensor is Front left sensor is dereplaced, the error is corrected. fective. When front left suspension pressure sensor is Front left sensor is replaced, the error is not corrected. normal. When front right suspension pressure sensor Front right sensor is is replaced, the error is corrected. defective. 2

Suspension pressure sensor When front right suspension pressure sensor Front right sensor is defective is replaced, the error is not corrected. normal. When rear left suspension pressure sensor is Rear left sensor is dereplaced, the error is corrected. fective. When rear left suspension pressure sensor is Rear left sensor is norreplaced, the error is not corrected. mal. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is corrected. defective. When rear right suspension pressure sensor is Rear right sensor is replaced, the error is not corrected. normal.

HD465-7, HD605-7

20-837 (10)

LC-16

TROUBLESHOOTING

Cause


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON. Between PM6 (2) – (3)

Voltage

18 ± 3 V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V


Voltage

1–5V


20-838 (10)

HD465-7, HD605-7

LC-17

TROUBLESHOOTING

LC-17 EXTERNAL PILOT LAMP INDICATES FORECAST WHILE TRUCK IS NOT BEING LOADED OR CLOCK IS DISPLAYED WHILE TRUCK TRAVELS FOR 160 M AFTER IT IS LOADED Action code



Not set

Not set

External pilot lamp indicates forecast while truck is not being Trouble loaded or clock is displayed while truck travels for 160 m after it is loaded

• External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck travels for 160 m after it is loaded

Action of controller • None in particular. • External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck Problem that appears on machine travels for 160 m after it is loaded Related information • None in particular.

Possible causes Cause and standard value 1 Improper calibration in normal state

HD465-7, HD605-7

Standard value in normal state/Remarks on troubleshooting • Perform calibration according to the operation manual.

20-839 (10)

LC-18

TROUBLESHOOTING

LC-18 PAYLOAD METER DISPLAYS "F-31" : GROUNDING FAULT OR DISCONNECTION IN CLINOMETER SENSOR SIGNAL SYSTEM Action code Not set


Not set

Payload meter displays "F-31" Trouble : Grounding fault or disconnection in clinometer sensor signal system

Contents of trouble • The signal circuit voltage of the clinometer sensor is below 1.6 V.


• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phenomenon does not indicate a failure) and the clinometer is installed normally. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between PM6 (female) (8) – ness PM3 (female) (B) 1 (Disconnection or defective Wiring harness between PM6 (female) (2) – contact) PM3 (female) (C) Wiring harness between PM6 (female) (3) – PM3 (female) (A)




1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter. Resistance between Wiring harness between PM6 (fe- PM6 (female) (8), PM3 Min. 1 M z male) (8) – PM3 (female) (B) (female) (B) – chassis ground 1) Turn the starting switch OFF. 2) Replace the sensor. 3) Turn the starting switch ON.

3 Clinometer sensor defective When the clinometer is replaced, error is cor- Clinometer is defecrected. tive. When the clinometer is replaced, error is not corrected.


20-840 (10)

Clinometer is normal.


Voltage

18 ± 3 V


Voltage

1.6 – 3.6 V

HD465-7, HD605-7

TROUBLESHOOTING

LC-18


HD465-7, HD605-7

20-841 (1)

LC-19

TROUBLESHOOTING

LC-19 PAYLOAD METER DISPLAYS "F-32" : SHORT CIRCUIT WITH POWER SOURCE IN CLINOMETER SENSOR SIGNAL SYSTEM Action code Not set


Not set

Trouble Payload meter displays "F-32"

Contents of trouble • The signal circuit voltage of the clinometer sensor is above 3.6 V.


• Before performing troubleshooting, check that the slope angle is 10° or less (if it exceeds 10°, this phenomenon does not indicate a failure) and the clinometer is installed normally. Cause


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors PM6 and PM3. 3) Connect T-adapter. 4) Turn the starting switch ON. Voltage between PM6 Wiring harness between PM6 (fe- (female) (8), PM3 (female) (8) – PM3 (female) (B) male) (B) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector PM3. Possible causes 3) Insert T-adapter. and standard value in normal state 2 Clinometer sensor defective 4) Connect the connector. 5) Turn the starting switch ON.


20-842 (10)

Between PM3 (C) – (A)

Voltage

18 ± 3 V

Between PM3 (B) – (A)

Voltage

1.6 – 3.6 V

Between PM6 (2) – PM5 (13)

Voltage

18 ± 3 V

Between PM6 (8) – PM5 (13)

Voltage

1.6 – 3.6 V

1) Turn the starting switch OFF. 2) Disconnect connectors PM5 and PM6. 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON.

HD465-7, HD605-7

TROUBLESHOOTING

LC-19


HD465-7, HD605-7

20-843 (1)

LC-20

TROUBLESHOOTING

LC-20 PAYLOAD METER DISPLAYS "F:18" (DISCONNECTION IN CHARGE LEVEL SIGNAL SYSTEM) Action code Not set


Not set

Trouble

Payload meter displays "F:18" (Disconnection in charge level signal system)

Contents of trouble • There is disconnection in the charge level signal system.

Action of controller • None in particular. • There is disconnection in the charge level signal system. Problem that appears on machine • Payload meter displays "F:18". Related information

• If failure code "AB00MA" (Malfunction of alternator) related to transmission controller is displayed, perform troubleshooting for it first. Cause



1) Turn the starting switch OFF. 2) Disconnect connector PM5. Disconnection in wiring har- 3) Insert T-adapter. 4) Connect the connector. ness 1 (Disconnection or defective 5) Start the engine. 6) Depress the accelerator pedal more than "half". contact) Wiring harness between PM5 (fe- Voltage between PM5 male) (9) – alternator terminal R (9) – chassis ground


Min. 5 V

1) Turn the starting switch OFF. 2) Disconnect connector PM5. 3) Insert T-adapter. 4) Connect the connector. 5) Start the engine. 6) Depress the accelerator pedal more than "half". Between PM5 (9) – chassis ground

Voltage

Min. 5 V


20-844 (10)

HD465-7, HD605-7

TROUBLESHOOTING FOR MONITOR SYSTEM (MON MODE)

Electrical system diagram related to monitor .............................................................................................. 20-904 Information in troubleshooting table........................................................................................................ 20-905 Phenomenon code table ......................................................................................................................... 20-906 [B@C7NS] Rear brake oil: overheating (NS) ........................................................................................ 20-907 [B@CENS] Torque converter: overheating (NS) ................................................................................... 20-907 [DAF0KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-908 [DAF9KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-911 [DAFSKQ] Monitor panel: disagreement of model selection signals (KQ) ........................................... 20-912 [DAQSKR] S-NET communication defective (between transmission controller and machine monitor) (KR)............................................ 20-913 [DASRKR] CAN communication/Communication defective: abnormality in objective component (KR) .... 20-916 [DB1SKR] S-NET communication defective (between retarder controller and machine monitor) (KR)..... 20-918 [DV00KB] Short circuit in alarm buzzer output: short circuit (KB) ....................................................... 20-921 MON- 1 When starting switch is turned ON, machine monitor does not display any item ............... 20-922 MON- 2 When starting switch is turned OFF and machine monitor does not operate normally ...... 20-923 MON- 3 Alarm buzzer defective ....................................................................................................... 20-925 a) Alarm buzzer does not sound ....................................................................................... 20-925 b) Alarm buzzer does not stop sounding........................................................................... 20-926 MON- 4 Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal ...................................................................................................................... 20-927 a) Items displayed by gauges are different from machine condition ................................. 20-927 b) Items displayed by warning lamps are different from machine condition ...................... 20-928 c) Character display does not display any item or it displays abnormally ......................... 20-928 MON- 5 Operation of machine monitor cannot be checked normally .............................................. 20-929 MON- 6 Display of character display cannot be selected normally.................................................. 20-930 a) Machine monitor mode select switch 1 system is abnormal ......................................... 20-930 b) Machine monitor mode select switch 2 system is abnormal ......................................... 20-932 MON- 7 Power mode select function does not work normally ......................................................... 20-934 MON- 8 Seat belt warning lamp does not operate normally ............................................................ 20-935 a) Lamp lights up while seat belt is fastened..................................................................... 20-935 b) Lamp does not light up while seat belt is unfastened.................................................... 20-936 MON- 9 Turn signals and hazard lamp do not operate normally...................................................... 20-937 a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash................................................................................................................ 20-937 b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up ................................................................................................. 20-938 c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash (When hazard lamp switch is operated, however, turn signal lamps flash normally) ......... 20-939 d) When hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-940 e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally).......... 20-942 f) Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however) ................................................................. 20-943

HD465-7, HD605-7

20-901 (10)

MON-10

MON-11

MON-12

Night lighting is abnormal ................................................................................................... 20-945 a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up. .................................................................................. 20-945 b) When lamp switch is set in 1st position, small lamp and night lamp do not light up ..... 20-946 c) When lamp switch is OFF, small lamp and night lamp light up ..................................... 20-947 d) When dimmer switch is operated, brightness of night lighting does not change........... 20-948 e) Head lamp "Hi" beam does not light up ........................................................................ 20-949 f) Head lamp "Lo" beam does not light up........................................................................ 20-950 g) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-951 h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-952 Power window does not operate normally.......................................................................... 20-954 a) Operating left side does not .......................................................................................... 20-954 b) Operating right side does not ........................................................................................ 20-955 Defective air conditioner ..................................................................................................... 20-957 a) Air conditioner does not operate ................................................................................... 20-957 b) Air does not come out or air flow cannot be adjusted ................................................... 20-958 c) Air is not cooled or temperature cannot be adjusted (Electric system) ......................... 20-960 d) Recirculated air and fresh air cannot be selected ......................................................... 20-962 e) Air outlets cannot be selected ....................................................................................... 20-963 f) Air is not cooled (Mechanical system)........................................................................... 20-965 g) Air is not heated (Defective hot water circuit)................................................................ 20-966 h) Abnormal sound comes out .......................................................................................... 20-966 i) Water leaks ................................................................................................................... 20-967

a For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM Mode).

20-902 (5)

HD465-7, HD605-7

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR a For details of this page, see page 90-21.

20-904 (2)

HD465-7, HD605-7


TROUBLESHOOTING



Display on panel

Display on panel

Display on panel




Cause

1

2



HD465-7, HD605-7

20-905 (10)


TROUBLESHOOTING




Contents

Phenomenon code

Contents

KA


L0


KB

Short circuit

L1


KK


L2


KQ


L3


KR


L4


KT


L6


KX


L8


KY


LC


KZ


LD


MA

Malfunction

LH


MB


MW

Sliding

NS

Overheat

ZG


ZK


20-906 (10)

HD465-7, HD605-7

[B@C7NS], [B@CENS]

TROUBLESHOOTING

[B@C7NS] REAR BRAKE OIL: OVERHEATING (NS) Action code


E02

B@C7NS

MON

Trouble

Rear brake oil: Overheating (NS) (Brake cooling oil overheating)

Contents of trouble • Brake cooling oil is overheating.

Action of controller • None in particular. Problem that • If the machine is used without repairing, the rear brake may be broken. appears on machine Related information • This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Cause


Possible causes Overheating of brake cool1 and standard value ing oil in normal state 2 Machine monitor defective

• If the brake cooling oil is not overheating, the machine monitor is defective.

[B@CENS] TORQUE CONVERTER: OVERHEATING (NS) Action code


E02

B@CENS

MON

Trouble Torque converter: Overheating (NS)

Contents of trouble • Torque converter is overheating

Action of controller • None in particular. Problem that • If the machine is used without repairing, the torque may be broken. appears on machine Related information • This failure code is displayed when possibility of occurrence of a failure in the electric system is low.

Cause Possible causes Overheating of torque con1 and standard value verter in normal state 2 Machine monitor defective

HD465-7, HD605-7


• If the torque converter is not overheating, the machine monitor is defective.

20-907 (10)

[DAF0KM]

TROUBLESHOOTING

[DAF0KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM) Action code E03 Contents of trouble

Failure code Controller code Monitor panel: Mistake in operation or setting (KM) Trouble (Disagreement of optional settings) DAF0KM MON • The optional settings of the rotary switch and dip switch on the rear side of the machine monitor do not agree with the signals of the optional setting connector.

• The controller maintains the abnormal state until the starting switch is turned OFF. • The controller does not recognize the functions (If equipped), the settings of which do not agree the Action of controller signals. • The controller does not record this failure in the fault history. Problem that • Some functions (If equipped) do not work. appears on machine

• Connections of wiring harnesses OP1–OP7 depend on the specification. For details, see "Adjustment of machine monitor". • This failure can be checked with SW1–3 (monitor code: 30800), SW5–1, 5–2 (monitor code: 30900), Related information SW5–3, 5–4 (monitor code: 30901), SW6–1, 6–2 (monitor code: 30902), SW6–3, and 6–4 (monitor code: 30903) on the rear side of the machine monitor. • This failure can be checked with optional selection connectors OP1, 2 (monitor code: 31000), OP3, 4 (monitor code: 31001), and OP5, 6 (monitor code: 31002). Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter. Resistance between DPC3A (female) (4) – Max. 1 z chassis ground Resistance between DPC3A (female) (4) – Min. 1 M z chassis ground Resistance between When connected DPC3A (female) (6) – Max. 1 z Wiring harness (CLOSED) chassis ground between DPC3A (female) (6) – Resistance between When disconOP2 (female) (1) nected DPC3A (female) (6) – Min. 1 M z (OPENED) chassis ground

When connected Wiring harness (CLOSED) between DPC3A (female) (4) – When disconOP1 (female) (1) nected (OPENED)


When connected Wiring harness (CLOSED) between DPC3A (female) (7) – When disconOP3 (female) (1) nected (OPENED)

Resistance between DPC3A (female) (7) – chassis ground

Resistance between DPC3A (female) (7) – chassis ground Resistance between When connected DPC3A (female) (13) – Wiring harness (CLOSED) chassis ground between DPC3A (female) (13) – When disconResistance between OP4 (female) (1) nected DPC3A (female) ((13) (OPENED) – chassis ground Resistance between When connected DPC3A (female) (14) – Wiring harness (CLOSED) chassis ground between DPC3A (female) (14) – When disconResistance between OP5 (female) (1) nected DPC3A (female) (14) – (OPENED) chassis ground

20-908 (10)

Max. 1 z

Min. 1 M z

Max. 1 z

Min. 1 M z

Max. 1 z

Min. 1 M z

HD465-7, HD605-7

[DAF0KM]

TROUBLESHOOTING

Cause

1




HD465-7, HD605-7

Standard value in normal state/Remarks on troubleshooting When connected Wiring harness (CLOSED) between DPC3A (female) (15) – When disconOP6 (female) (1) nected (OPENED)

Resistance between DPC3A (female) (15) – Max. 1 z chassis ground Resistance between DPC3A (female) (15) – Min. 1 M z chassis ground

Resistance between When connected DPC3A (female) (16) – Wiring harness (CLOSED) chassis ground between DPC3A (female) (16) – When disconResistance between OP7 (female) (1) nected DPC3A (female) (16) – (OPENED) chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter. When connected Resistance Resistance between (CLOSED) DPC3A (female) (4) – When disconnected chassis ground Resistance (OPENED)

Max. 1 z

Min. 1 M z

Max. 1 z Min. 1 M z

When connected Resistance between (CLOSED) DPC3A (female) (6) – When disconnected chassis ground (OPENED)

Resistance Max. 1 z

When connected Resistance between (CLOSED) DPC3A (female) (7) – When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (13) – When disconnected chassis ground (OPENED)

Resistance Max. 1 z

When connected Resistance between (CLOSED) DPC3A (female) (14) – When disconnected chassis ground (OPENED)

Resistance Max. 1 z

When connected Resistance between (CLOSED) DPC3A (female) (15) – When disconnected chassis ground (OPENED) When connected Resistance between (CLOSED) DPC3A (female) (16) – When disconnected chassis ground (OPENED)

Resistance Max. 1 z


Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z


Resistance Min. 1 M z Resistance Max. 1 z Resistance Min. 1 M z

20-909 (10)

TROUBLESHOOTING

[DAF0KM]


20-910 (1)

HD465-7, HD605-7

[DAF9KM]

TROUBLESHOOTING

[DAF9KM] MONITOR PANEL: MISTAKE IN OPERATION OR SETTING (KM) Action code


E03

DAF9KM

MON

Trouble

Monitor panel: Mistake in operation or setting (KM) (Wrong connection of connector)

Contents of trouble • The check signal of the connector does not agree with the internal setting of the machine monitor.


• The controller maintains the abnormal state until the starting switch is turned OFF. • The controller does not record this failure in the fault history. • The machine monitor mode select switch does not work.

Problem that • The optional functions do not work. appears on machine

• The head lamp HIGH pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.


1

Cause



The connector check signal connectors are connected normally. aConnector check signal connectors: DPC3A (5) (OPEN), DPC2A (5) (CLOSE)

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connector DPC2A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between fuse terminal BT4 (2) contact) Resistance Max. 1 z – DPC2A (female) (5) Possible causes and standard value in normal state

1) Turn the starting switch OFF. 2) Disconnect connector DPC3A. 3) Connect T-adapter.

Ground fault in wiring har3 ness Wiring harness between DPC3A (female) (5) – Resistance Min. 1 M z (Grounding fault of terminal) chassis ground aThis must not occur basically, since the wiring harness is not connected.


1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Connect T-adapter. Resistance between DPC2A (female) (5) – chassis ground



HD465-7, HD605-7

20-911 (10)

[DAFSKQ]

TROUBLESHOOTING

[DAFSKQ] MONITOR PANEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code E03

Failure code Controller code DAFSKQ

MON

Trouble Monitor panel: Disagreement of model selection signals (KQ)

Contents of trouble

• Since communication with the transmission controller (S-NET) is defective, model selection information cannot be received or the rotary switch of the transmission controller is not set normally.


• The controller maintains the abnormal state until the starting switch is turned OFF. • The controller controls the truck as HD465-7.

• None of the meters and gauges display. Problem that appears on machine • Some panel switches and lamps do not work. Related information • If another failure code "DAQAKQ" is displayed, perform troubleshooting for it.

Cause 1

Communication circuit defective

Possible causes and standard value 2 Machine monitor defective in normal state

3

20-912 (10)

Standard value in normal state/Remarks on troubleshooting Perform troubleshooting for "DAQSKR". aIf the failure is not repaired by replacing the machine monitor, the machine monitor is defective. aWhen replacing the machine monitor, see TESTING AND ADJUSTING, Adjustment of machine monitor.

Transmission controller de- aIf the failure is not repaired by replacing the machine monitor, the fective transmission controller is defective.

HD465-7, HD605-7

[DAQSKR]

TROUBLESHOOTING

[DAQSKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN TRANSMISSION CONTROLLER AND MACHINE MONITOR) (KR) Action code


E03

DAQSKR

MON

Trouble

S-NET communication defective (KR) (Between transmission controller and machine monitor)

Contents of trouble • Communication (S-NET) information cannot be obtained from the transmission controller.

Action of controller • The controller maintains the condition at the time when the failure occurs. • The meters, gauges, warning lamps, and special functions that obtain information from the transmisProblem that appears on machine sion controller do not operate or display. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG. 3) Connect T-adapter. Between each couple of JCB (male) terminals Resistance Max. 1 z

1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z Between each couple of JCD (male) terminals Resistance Max. 1 z Between each couple of JCE (male) terminals Resistance Max. 1 z Between each couple of JCF (male) terminals Resistance Max. 1 z Between each couple of JCG (male) terminals Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. Wiring harness between DPC4 (female) (1) – Resistance Max. 1 z ATC4 (female) (12)


Wiring harness between DPC4 (female) (2) – Resistance Max. 1 z Disconnection in wiring har- ATC4 (female) (6) ness 2 (Disconnection or defective Wiring harness between DPC4 (female) (4) – Resistance Max. 1 z ATC4 (female) (10) contact) Wiring harness between DPC4 (female) (5) – Resistance Max. 1 z ATC4 (female) (10) aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 3


Between DPC4 (female) (1), (2) – chassis ground


aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 4) Turn the starting switch ON.



Voltage

Max. 1 V

aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted.

HD465-7, HD605-7

20-913 (10)

[DAQSKR]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC4. 3) Connect T-adapter. 4) Turn the starting switch ON.

Possible causes and standard value Transmission controller de- Between ATC4 (6) – (10) 5 in normal state fective Between ATC4 (12) – (10)

Voltage

6–9V

Voltage

6–9V

aIf any other controller does not have an error in S-NET communication, disconnect only the S-NET signal output of the transmission controller and check that the transmission controller is outputting the normal voltage.

20-914 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DAQSKR]


HD465-7, HD605-7

20-915 (2)

[DASRKR]

TROUBLESHOOTING

[DASRKR] CAN COMMUNICATION/COMMUNICATION DEFECTIVE: ABNORMALITY IN OBJECTIVE COMPONENT (KR) Action code E03

Failure code Controller code DASRKR

MON

CAN communication/Communication defective: Abnormality in Trouble objective component (KR) (Between engine controller and machine monitor)

Contents of trouble • Communication (CAN) information cannot be obtained from the engine controller.

Action of controller • The controller maintains the condition at the time when the failure occurs. Problem that • The meters, gauges, warning lamps, and special functions that obtain information from the engine conappears on machine troller do not operate or display. Related information

Cause


1) Turn the starting switch OFF. 2) Disconnect connector JC14. 1 Junction connector defective 3) Connect T-adapter. Between JC14 (male) (2) – (8)


Between JC14 (male) (4) – (6) 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4 and ECMB. 3) Connect T-adapter.

2 Wiring harness defective


Wiring harness between DPC4 (female) (3) – Resistance 40 – 80 z DPC4 (female) (8) aCheck that terminal resistors CAN and CAN2 are connected. The resistance of each terminal resistor is 120 z. aCheck that a personal computer or a controller is not connected to CAN1. aIf VHMS is connected, disconnect it. 1) Turn the starting switch OFF. 2) Replace the engine controller. 3) Turn the starting switch ON.


When the engine controller is replaced, does communication become normal?

No

Engine controller is normal.

Yes

Engine controller is defective.

No

Machine monitor is normal.

Yes

Machine monitor is defective

1) Turn the starting switch OFF. 2) Replace the machine monitor. 3) Turn the starting switch ON. 4 Machine monitor defective

When the machine monitor is replaced, does communication become normal?

aWhen replacing the machine monitor, see TESTING AND ADJUSTING, Adjustment of machine monitor.

20-916 (10)

HD465-7, HD605-7

TROUBLESHOOTING

[DASRKR]


HD465-7, HD605-7

20-917 (1)

[DB1SKR]

TROUBLESHOOTING

[DB1SKR] S-NET COMMUNICATION DEFECTIVE (BETWEEN RETARDER CONTROLLER AND MACHINE MONITOR) (KR) Action code


E03

DB1SKR

MON

Trouble

S-NET communication defective (KR) (Between retarder controller and machine monitor)

Contents of trouble • Communication (S-NET) information cannot be obtained from the retarder controller.

Action of controller • The controller maintains the condition at the time when the failure occurs. • The meters, gauges, warning lamps, and special functions that obtain information from the retarder Problem that appears on machine controller do not operate or display. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors JCB, JCC, JCD, JCE, JCF, and JCG. 3) Connect T-adapter. Between each couple of JCB (male) terminals Resistance Max. 1 z

1 Junction connector defective Between each couple of JCC (male) terminals Resistance Max. 1 z Between each couple of JCD (male) terminals Resistance Max. 1 z Between each couple of JCE (male) terminals Resistance Max. 1 z Between each couple of JCF (male) terminals Resistance Max. 1 z Between each couple of JCG (male) terminals Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. Wiring harness between DPC4 (female) (1) – Resistance Max. 1 z BRC4 (female) (12)


Wiring harness between DPC4 (female) (2) – Resistance Max. 1 z Disconnection in wiring har- BRC4 (female) (6) ness 2 (Disconnection or defective Wiring harness between DPC4 (female) (4) – Resistance Max. 1 z BRC4 (female) (10) contact) Wiring harness between DPC4 (female) (5) – Resistance Max. 1 z BRC4 (female) (10) aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 3




aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC4, ATC4, and BRC4. 3) Connect T-adapter. 4) Turn the starting switch ON.



Voltage

Max. 1 V

aIf another controller also has an error in S-NET communication, perform troubleshooting from the wiring harness. aDisconnect the connectors to which the S-NET signals of all the controllers connected to S-NET are allotted.

20-918 (10)

HD465-7, HD605-7

[DB1SKR]

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector BRC4. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.

Possible causes and standard value 5 Retarder controller defective Between BRC4 (6) – (10) in normal state Between BRC4 (12) – (10)

Voltage

6–9V

Voltage

6–9V

aIf any other controller does not have an error in S-NET communication, disconnect only the S-NET signal output of the retarder controller and check that the retarder controller is outputting the normal voltage.

HD465-7, HD605-7

20-919 (10)

TROUBLESHOOTING

[DB1SKR]


20-920 (2)

HD465-7, HD605-7

[DV00KB]

TROUBLESHOOTING

[DV00KB] SHORT CIRCUIT IN ALARM BUZZER OUTPUT: SHORT CIRCUIT (KB) Action code


E01

DV00KB

MON

Trouble Short circuit in alarm buzzer output: Short circuit (KB)

Contents of trouble • There is short circuit with the power source in the output circuit of the alarm buzzer.


• The controller maintains the abnormal state until the starting switch is turned OFF. • The controller turns the output circuit of the alarm buzzer OFF.

Problem that • The alarm buzzer does not sound. appears on machine Related information • None in particular.

Cause


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors DPC1 and BZ2. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between DPC1 (female) (13) – BZ2 (female) (2)


Voltage between DPC1 (female) (13), BZ2 (female) (2) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector BZ2 (2) and remove the buzzer. 3) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2 (male) (2). 2 Alarm buzzer defective

The alarm buzzer sounds.

Alarm buzzer is normal.

The alarm buzzer does not sound.

Alarm buzzer is defective.

aCheck the alarm buzzer unit. 3 Machine monitor defective

• If the results of 1) and 2) above are normal, the machine monitor is defective.


HD465-7, HD605-7

20-921 (10)

MON-1

TROUBLESHOOTING

MON-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT DISPLAY ANY ITEM Action code Not set


MON

Trouble

When starting switch is turned ON, machine monitor does not display any item

Contents of trouble • When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges.

Action of controller • None in particular. Problem that • When the starting switch is turned ON, machine monitor does not display any of the lamps and gauges. appears on machine

• Failure code is not displayed. Related information • Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not

broken. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON.

Disconnection in wiring har- Wiring harness between battery ness relay B – fuse BT2 (1) 1 (Disconnection or defective Wiring harness between fuse BT2 contact) (2) – DPC1 (female) (6), (7) Possible causes and standard value in normal state

Voltage between BT2 20 – 30 V (1) and chassis ground Voltage between DPC1 (6), (7) and chassis ground

20 – 30 V

1) Turn the starting switch OFF. 2) Disconnect connectors DPC4 and BRC4. 3) Connect T-adapter.


Wiring harness between DPC1 (9), (10) – chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON. Between DPC1(6), (7) – (9), (10)

Voltage

20 – 30 V


20-922 (10)

HD465-7, HD605-7

MON-2

TROUBLESHOOTING

MON-2 WHEN STARTING SWITCH IS TURNED OFF AND MACHINE MONITOR DOES NOT OPERATE NORMALLY Action code


Not set

Not set

MON

Trouble

When starting switch is turned OFF and machine monitor does not operate normally

• When the starting switch is turned OFF and the machine monitor mode select switch is operated, the service meter and odometer are not displayed. Contents of trouble • When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not turned on. Action of controller • None in particular. • When the starting switch is turned OFF and the machine monitor mode select switch is operated, the service meter and odometer are not displayed. Problem that appears on machine • When the starting switch is turned OFF and the hazard lamp switch is operated, the hazard lamp is not turned on. • Failure code is not displayed. • Before performing troubleshooting, check that fuses BT2 (2) and BT2 (22) and fusible link FUA are not Related information broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) Cause

Standard value in normal state/Remarks on troubleshooting When the starting switch is turned Main power source (SW power ON, the machine monitor operates source) is normal. normally.

1

Main power source (SW power source) defective

Even if the starting switch is turned Main power source (SW power ON, the machine monitor does not source) is defective. operate normally. aIf the main power source (SW power source) is defective, perform troubleshooting of MON-1. 1) Turn the starting switch OFF.

Disconnection in wiring har- Wiring harness between J01 (feness male) (Y) – fuse BT2 (21) Possible causes 2 (Disconnection or defective and standard value Wiring harness between fuse BT2 contact) in normal state (22) – DPC1 (female) (4), (5)

Voltage between BT2 (21) – chassis ground

20 – 30 V

Voltage between DPC1 (4), (5) – chassis ground

20 – 30 V

Hazard lamp switch, related 3 wiring harness, or related re- aReferring to MON-9 d), perform troubleshooting. lay defective Machine monitor mode se4 lect switch 1 or related wiring aReferring to MON-6, perform troubleshooting. harness defective


1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. aKeep the starting switch OFF. Between DPC1 (4), (5) – (9), (10)

HD465-7, HD605-7

Voltage

20 – 30 V

20-923 (10)

TROUBLESHOOTING

MON-2


20-924 (1)

HD465-7, HD605-7

MON-3

TROUBLESHOOTING

MON-3 ALARM BUZZER DEFECTIVE a) Alarm buzzer does not sound Action code


Alarm buzzer defective Trouble a) Alarm buzzer does not sound Not set MON • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps Contents of trouble light up, the alarm buzzer does not sound. Action of controller • None in particular. Not set

Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps appears on machine light up, the alarm buzzer does not sound.

• Failure code is not displayed. • If failure code "DV00KB" is displayed, perform troubleshooting for it. Related information • Before performing troubleshooting, check that the fuse is not broken and the voltage between BZ2 and chassis ground is 20 – 30 V when the starting switch is ON. Cause


1) Turn the starting switch OFF. 2) Disconnect connectors BZ2 and battery BT4 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between fuse BT4 (2) – BZ2 Resistance Max. 1 z (Disconnection or defective (female) (1) contact) Wiring harness between BZ2 (female) (2) – Resistance Max. 1 z DPC (female) (13)


2 Alarm buzzer defective

1) Turn the starting switch ON. 2) Connect BZ2 (2) to the chassis ground. The alarm buzzer sounds. Alarm buzzer is normal. The alarm buzzer does not sound. 1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON.


Alarm buzzer is defective.

Under the condition for turning the Voltage between alarm buzzer ON DPC1 (13) – (9), (10)

Max. 1 V

Under the condition for turning the Voltage between alarm buzzer OFF DPC1 (13) – (9), (10)

20 – 30 V

aThe condition for turning the alarm buzzer ON is that the starting switch is ON, an emergency stop item lights up, the centralized warning lamps light up, etc.


HD465-7, HD605-7

20-925 (10)

MON-3

TROUBLESHOOTING

b) Alarm buzzer does not stop sounding Action code



Not set

MON

Trouble

Alarm buzzer defective b) Alarm buzzer does not stop sounding

• When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps light up, the alarm buzzer does not sound.

Action of controller • None in particular. Problem that • When the starting switch is ON or an emergency stop item lights up or the centralized warning lamps appears on machine light up, the alarm buzzer does not sound. Related information

• Failure code is not displayed. • If failure code "DV00KB" is displayed, perform troubleshooting for it. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors BZ2 and battery BT4 terminal (2). 3) Connect T-adapter.

1

Short circuit in wiring harness

Resistance between wiring harness between fuse BT4 (2) – BZ2 (female) (1) and wiring harness between DPC1 (fe- Min. 1 M z male) (13) – BZ2 (female) (2) Wiring harness between BZ2 (female) (2) – DPC (female) (13)


Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Turn the starting switch ON. 2 Machine monitor defective

Under the condition for turning the Voltage between alarm buzzer ON DPC1 (13) – (9), (10)

Max. 1 V

Under the condition for turning the Voltage between alarm buzzer OFF DPC1 (13) – (9), (10)

20 – 30 V

aThe condition for turning the alarm buzzer ON is that the starting switch is ON, an emergency stop item lights up, the centralized warning lamps light up, etc.


20-926 (10)

HD465-7, HD605-7

MON-4

TROUBLESHOOTING

MON-4 ITEMS DISPLAYED BY GAUGES, WARNING LAMPS, AND CHARACTER DISPLAY OF MACHINE MONITOR ARE ABNORMAL a) Items displayed by gauges are different from machine condition Action code



Not set

MON

Items displayed by gauges, warning lamps, and character disTrouble play of machine monitor are abnormal a) Items displayed by gauges are different from machine condition

• The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The items displayed by the gauges are different from the machine condition.)

Action of controller • None in particular. Problem that • The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The items displayed by the gauges are different from the machine condition.) Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. 2) Operate the machine monitor.

If the inputting condition of the related sensor Sensor signal system signal is monitored, the gauges display noris normal. Sensor signal system defec- mally. 1 tive If the inputting condition of the related sensor Sensor signal system Possible causes signal is monitored, the gauges do not display is defective. and standard value normally. in normal state aIf the sensor signal system is defective, perform troubleshooting for each related signal system. 1) Turn the starting switch ON. 2 Machine monitor defective

If the machine monitor check switch is operat- Machine monitor is ed, the gauges display normally. normal. If the machine monitor check switch is operat- Machine monitor is deed, the gauges do not display normally. fective.

HD465-7, HD605-7

20-927 (10)

MON-4

TROUBLESHOOTING

b) Items displayed by warning lamps are different from machine condition Action code



Not set

MON

Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal Trouble b) Items displayed by warning lamps are different from machine condition

• The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The items displayed by the warning lamps are different from the machine condition.)

Action of controller • None in particular. Problem that • The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The items displayed by the warning lamps are different from the machine condition.) Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. 2) Operate the machine monitor. If the inputting condition of the related sensor Switch or sensor sigsignal is monitored, the gauges display nornal system is normal. mally.


Switch or sensor signal sys- If the inputting condition of the related sensor Switch or sensor sigtem defective signal is monitored, the gauges do not display nal system is defecnormally. tive. aIf the switch or sensor signal system is defective, perform troubleshooting for each related signal system. (See troubleshooting for the controllers to which the related sensor signals are input.) 1) Turn the starting switch ON.


If the machine monitor check switch is operat- Machine monitor is ed, the lamps display normally. normal. If the machine monitor check switch is operat- Machine monitor is deed, the lamps do not display normally. fective.

c) Character display does not display any item or it displays abnormally Action code Not set Contents of trouble


MON

Items displayed by gauges, warning lamps, and character display of machine monitor are abnormal Trouble c) Character display does not display any item or it displays abnormally

• The items displayed by the gauges, warning lamps, and character display of the machine monitor are abnormal. (The character display does not display any item or it displays abnormally.)

Action of controller • None in particular. Problem that • The items displayed by the gauges, warning lamps, and character display of the machine monitor are appears on machine abnormal. (The character display does not display any item or it displays abnormally.) Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON.

Possible causes and standard value 1 Machine monitor defective in normal state

20-928 (10)

If the machine monitor check switch is operat- Machine monitor is ed, the character display displays normally. normal. If the machine monitor check switch is operatMachine monitor is deed, the character display does not display norfective. mally.

HD465-7, HD605-7

MON-5

TROUBLESHOOTING

MON-5 OPERATION OF MACHINE MONITOR CANNOT BE CHECKED NORMALLY Action code



Not set

MON

Trouble Operation of machine monitor cannot be checked normally

• When the machine monitor check switch is operated, any of the lamps and gauges does not display. Or, the lamps continue the operation while the machine monitor check switch is not operated.

Action of controller • None in particular. Problem that • When the machine monitor check switch is operated, any of the lamps and gauges does not display. appears on machine Or, the lamps continue the operation while the machine monitor check switch is not operated. Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CK1. 3) Check the switch

1

Machine monitor check switch defective

Between CK1 (male) (3) – (6)

Operate (Press) the machine monResistance Max. 1 z itor check switch. Do not operate (Release) the maResistance Min. 1 M z chine monitor check switch.

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CK1, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. ness Possible causes 2 Wiring harness between fuse BT2 (2) – CK1 Resistance Max. 1 z (Disconnection or defective and standard value (female) (3) contact) in normal state Wiring harness between DPC2A (female) (10) Resistance Max. 1 z – CK1 (female) (6)


1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2A (10) – chassis ground

Operate (Press) the machine monitor check switch.

Voltage

20 – 30 V

Do not operate (Release) the machine monitor check switch.

Voltage

Max. 1 V


HD465-7, HD605-7

20-929 (10)

MON-6

TROUBLESHOOTING

MON-6 DISPLAY OF CHARACTER DISPLAY CANNOT BE SELECTED NORMALLY a) Machine monitor mode select switch 1 system is abnormal Action code Not set

Failure code Controller code Display of character display cannot be selected normally Trouble a) Machine monitor mode select switch 1 system is abnormal Not set MON

• Display of the character display cannot be selected normally. (Machine monitor mode select switch 1 system is abnormal.) Action of controller • None in particular.

Contents of trouble

Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 1 appears on machine system is abnormal.) Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CH1. 3) Check the switch.

Machine monitor mode se1 lect switch 1 system defective

Between CH1 (male) (2) – (3)

Press [ ] of the machine monitor Resistance Max. 1 z select switch 1. Set the machine monitor select switch in NEUTRAL.


Set the machine monitor select Resistance Min. 1 M z switch in NEUTRAL. Press [ ] of the machine monitor Resistance Max. 1 z select switch 1. 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CH1, and fuse BT2 terminal (22). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (22) – CH1 Resistance Max. 1 z ness (female) (3) 2 (Disconnection or defective Wiring harness between DPC2A (female) (8) – contact) Resistance Max. 1 z CH1 (female) (2) Wiring harness between DPC2A (female) (14) Resistance Max. 1 z – CH1 (female) (1) Between CH1 (male) (1) – (3)



1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A and CH1. 3) Connect T-adapter. Voltage between Wiring harness between DPC2A DPC2A (female) (8), (female) (8) – CH1 (female) (2) CH1 (female) (2) – chassis ground Wiring harness between DPC2A (female) (14) – CH1 (female) (1)

Voltage between DPC2A (female) (14), CH1 (female) (1) – chassis ground

Max. 1 V

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.


20-930 (10)

Between DPC2A (8) – chassis ground

Press [ ] of the machine monitor select switch 1.

Voltage

20 – 30 V

Set the machine monitor select switch in NEUTRAL.

Voltage

Max. 1 V


Set the machine monitor select switch in NEUTRAL.

Voltage

Max. 1 V

Press [ ] of the machine monitor select switch 1.

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

MON-6


HD465-7, HD605-7

20-931 (1)

MON-6

TROUBLESHOOTING

b) Machine monitor mode select switch 2 system is abnormal Action code


Display of character display cannot be selected normally Trouble a) Machine monitor mode select switch 2 system is abnormal Not set MON • Display of the character display cannot be selected normally. (Machine monitor mode select switch 2 Contents of trouble system is abnormal.) Action of controller • None in particular. Not set

Problem that • Display of the character display cannot be selected normally. (Machine monitor mode select switch 2 appears on machine system is abnormal.) Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CH2. 3) Check the switch.

Machine monitor mode se1 lect switch 2 system defective

Press [>] of the machine monitor select switch 2. Set the machine monitor select switch in NEUTRAL. Between Set the machine monitor select switch in NEUTRAL. CH2 (male) (1) Press [<] of the machine monitor – (3) select switch 2.

Between CH2 (male) (2) – (3)

Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, CH2, and fuse BT2 terminal (2). 3) Connect T-adapter. Disconnection in wiring har- Wiring harness between fuse BT2 (2) – CH2 Resistance Max. 1 z ness (female) (3) 2 (Disconnection or defective Wiring harness between DPC2A (female) (6) – contact) Resistance Max. 1 z CH2 (female) (2) Wiring harness between DPC2A (female) (15) Resistance Max. 1 z – CH2 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A and CH2. 3) Connect T-adapter.



Wiring harness between DPC2A (female) (6) – CH2 (female) (2)

Wiring harness between DPC2A (female) (15) – CH2 (female) (1)

Voltage between DPC2A (female) (6), CH2 (female) (2) – chassis ground Voltage between DPC2A (female) (15), CH2 (female) (1) – chassis ground

Max. 1 V

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector DPC1. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.


Between DPC2A (6) – chassis ground Between DPC2A (15) – chassis ground

20-932 (10)

Press [>] of the machine monitor select switch 2. Set the machine monitor select switch in NEUTRAL. Set the machine monitor select switch in NEUTRAL. Press [<] of the machine monitor select switch 2.

Voltage

20 – 30 V

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

MON-6


HD465-7, HD605-7

20-933 (1)

MON-7

TROUBLESHOOTING

MON-7 POWER MODE SELECT FUNCTION DOES NOT WORK NORMALLY Action code



Not set

MON

Trouble Power mode select function does not work normally

• When the power mode select switch is operated, the power mode select function does not work normally.

Action of controller • None in particular. Problem that • When the power mode select switch is operated, the power mode select function does not work norappears on machine mally. Related information • Failure code is not displayed.

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector PWM. 3) Check the switch.

1

Power mode select switch defective

Set the power mode select switch Resistance Min. 1 M z in ECONOMY MODE (Press its upper part).

Between PWM (male) (1) Set the power mode select switch – (3) in HIGH POWER MODE (Press its Resistance Max. 1 z lower part: Normal work).

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PWM, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) – PWM Resistance Max. 1 z (female) (1) in normal state contact) Wiring harness between DPC2A (female) (13) Resistance Max. 1 z – PWM (female) (3) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 3 Machine monitor defective


Set the power mode select switch in ECONOMY MODE (Press its upper part).

Voltage

20 – 30 V

Set the power mode select switch in HIGH POWER MODE (Press its lower part: Normal work).

Voltage

Max. 1 V


20-934 (10)

HD465-7, HD605-7

MON-8

TROUBLESHOOTING

MON-8 SEAT BELT WARNING LAMP DOES NOT OPERATE NORMALLY a) Lamp lights up while seat belt is fastened Action code


Not set

Not set

Not set

Trouble

Seat belt warning lamp does not operate normally a) Lamp lights up while seat belt is fastened

Contents of trouble • The lamp lights up while the seat belt is fastened.

Action of controller • None in particular. Problem that • The lamp lights up while the seat belt is fastened. appears on machine Related information • Failure code is not displayed.

Cause

1 Seat belt switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SBS. 3) Check the switch. Between SBS (male) (1) – (2)

Seat belt "Fastened"

Resistance Max. 1 z

Seat belt "Unfastened" Resistance Min. 1 M z

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between fuse BT2 (2) – SBS Resistance Max. 1 z (female) (1) in normal state contact) Wiring harness between DPC2B (female) (11) Resistance Max. 1 z – SBS (female) (2)


1) Turn the starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Between DPC2B (11) Seat belt "Fastened" – chassis ground Seat belt "Unfastened"

HD465-7, HD605-7

Voltage

20 – 30 V

Voltage

Max. 1 V

20-935 (10)

MON-8

TROUBLESHOOTING

b) Lamp does not light up while seat belt is unfastened Action code Not set


MON

Trouble

Seat belt warning lamp does not operate normally b) Lamp does not light up while seat belt is unfastened

Contents of trouble • The lamp does not light up while the seat belt is unfastened.

Action of controller • None in particular. Problem that • The lamp does not light up while the seat belt is unfastened. appears on machine Related information • Failure code is not displayed.

Cause

1 Seat belt switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector SBS. 3) Check the switch. Between SBS (male) (1) – (2)

Seat belt "Fastened"

Resistance Max. 1 z

Seat belt "Unfastened" Resistance Min. 1 M z

1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, SBS, and fuse BT2 terminal (2). Disconnection in wiring har- 3) Connect T-adapter. Possible causes and standard value 2 ness Voltage between (Disconnection or defective in normal state Wiring harness between DPC2B DPC2B (female) (11), contact) Max. 1 V (female) (11) – SBS (female) (2) SBS (female) (2) – chassis ground


1) Turn the starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert T-adapter. 4) Turn the starting switch ON. Between DPC2B (11) Seat belt "Fastened" – chassis ground Seat belt "Unfastened"

Voltage

20 – 30 V

Voltage

Max. 1 V


20-936 (10)

HD465-7, HD605-7

MON-9

TROUBLESHOOTING

MON-9 TURN SIGNALS AND HAZARD LAMP DO NOT OPERATE NORMALLY a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash Action code


Not set

Not set

Not set

Turn signals and hazard lamp do not operate normally Trouble a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash

Contents of trouble • When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash

Action of controller • None in particular. Problem that • When the turn signal lever and hazard lamp switch are operated, any turn signal lamp does not flash appears on machine

• Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) • The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly, Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. • Failure code is not displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. Between R17 (male) (1) – (2) 1 Possible causes and standard value in normal state

Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF. 2) Disconnect connector R17. tive 3) Check the relay. 4) Apply voltage between R17 (male) (1) – (2). Between R17 (male) (5) – (3)


2

HD465-7, HD605-7



Resistance Max. 1 z




1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors R17, FLB, FLL, CM, and R16. 3) Connect T-adapter. ness (Disconnection or defective Between R17 (female) (3) – FLB Resistance Max. 1 z contact) Wiring harness between FLL – CM (female) (6) Resistance Max. 1 z and branching point of R16 (female) (1), (3)

20-937 (10)

MON-9

TROUBLESHOOTING

b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up Action code Not set Contents of trouble


MON

Turn signals and hazard lamp do not operate normally Trouble b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but light up

• When the turn signal lever and lamp hazard switch are operated, the turn signal lamps do not flash but light up

Action of controller • None in particular. Problem that • When the turn signal lever and hazard lamp switch are operated, the turn signal lamps do not flash but appears on machine light up Related information

• Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) • Failure code is not displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, and R16. 3) Connect T-adapter.


Resistance between Wiring harness between FLL, CM FLL, CM (female) (6), (female) (6), – R16 (female) (1) R16 (female) (1), (3) – and (3) chassis ground

Max. 1 z

1) Turn the starting switch OFF. 2) Replace the flasher. 2 Flasher defective

If the flasher is replaced, the failure is not repaired.

Flasher is normal

If the flasher is replaced, the failure is repaired. Flasher is defective

20-938 (10)

HD465-7, HD605-7

MON-9

TROUBLESHOOTING

c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash (When hazard lamp switch is operated, however, turn signal lamps flash normally) Action code



Not set

MON

Turn signals and hazard lamp do not operate normally c) When turn signal lever is operated, turn signal lamps on either Trouble or both sides do not flash (When hazard lamp switch is operated, however, turn signal lamps flash normally)

• When the turn signal lever is operated, the turn signal lamps on either or both sides do not flash (When the hazard lamp switch is operated, however, the turn signal lamps flash normally)

Action of controller • None in particular. Problem that • When the turn signal lever is operated, however, the turn signal lamps on either or both sides do not appears on machine flash (When the hazard lamp switch is operated, the turn signal lamps flash normally) Related information


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the lever.

1 Turn signal lever defective

Between CM (male) (6) – (7)

Between CM (male) (6) – (8)

Set the turn signal leResistance Max. 1 z ver in LEFT. Set the turn signal leResistance Min. 1 M z ver in RIGHT. Set the turn signal leResistance Min. 1 M z ver in LEFT. Set the turn signal leResistance Max. 1 z ver in RIGHT.

1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is replaced, is failure repaired?

No


Yes




Between R17 (male) (1) – (2) 2

Hazard relay 2 (R17) defec- 1) Turn the starting switch OFF. 2) Disconnect connector R17. tive 3) Check the relay. 4) Apply voltage between R17 (male) (1) – (2). Between R17 (male) (5) – (3)


3



Resistance Max. 1 z




1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 terminal (4). Disconnection in wiring har3) Connect T-adapter. ness (Disconnection or defective Wiring harness between fuse BT1 (4), – R17 contact) (female) (6), – FLB

Resistance Max. 1 z

Wiring harness between CM (female) (6), FLL, Resistance Max. 1 z – branching point of R16 (female) (1), (3)

HD465-7, HD605-7

20-939 (10)

MON-9

TROUBLESHOOTING

d) When hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally) Action code



Not set

MON

Turn signals and hazard lamp do not operate normally d) When hazard lamp switch is turned ON, any turn signal lamp Trouble does not flash (When turn signal lever is operated, however, turn signal lamps flash normally)

• When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever is operated, however, turn signal lamps flash normally).

Action of controller • None in particular. Problem that • When the hazard lamp switch is turned ON, any turn signal lamp does not flash (When turn signal lever appears on machine is operated, however, turn signal lamps flash normally). Related information


1

Hazard lamp switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Turn the hazard lamp switch ON. Resistance Max. 1 z HAZ (male) (1) Turn the hazard lamp switch OFF. Resistance Min. 1 M z – (3) 1) Turn the starting switch OFF. 2) Replace R16 with normal one. 3) Turn the starting switch ON. When hazard relay 1 (R16) is replaced, is failure repaired?

No


Yes


1) Turn the starting switch OFF. 2) Disconnect connector R16. 3) Check the relay. Resistance 200 – 400 z

Between R16 (male) (5) – (6) Hazard relay 1 (R16) defecPossible causes 2 tive and standard value in normal state




Resistance Max. 1 z




1) Turn the starting switch OFF. 2) Replace R17 with normal one. 3) Turn the starting switch ON. When hazard relay 2 (R17) is reHazard relay 2 (R17) defec- placed, is failure repaired? 3 tive 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. Between R17 (male) (1) – (2)

20-940 (10)

No


Yes



HD465-7, HD605-7

MON-9

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R17. 3) Check the relay. 4) Apply voltage between R17 (male) (1) – (2).

Hazard relay 2 (R17) defec- Between R17 (male) 3 (5) – (3) tive



Resistance Max. 1 z




1) Turn the starting switch OFF. 2) Disconnect connectors R17, FLB, FLL, CM, R16, and fuse BT1 terminal (4). 3) Connect T-adapter.


Wiring harness between fuse BT1 (24) – R17 Resistance Max. 1 z (female) (5) Wiring harness between FLL and R16 (female) Resistance Max. 1 z (1) – (3)

Disconnection in wiring harWiring harness between R16 (female) (6) – ness 4 (Disconnection or defective chassis ground contact) Wiring harness between R17 (female) (2) – chassis ground


Wiring harness between fuse BT2 (24) – HAZ Resistance Max. 1 z (female) (1)

HD465-7, HD605-7

Wiring harness between HAZ (female) (3) – R16 (female) (5)

Resistance Max. 1 z

Wiring harness between HAZ (female) (3) – R17 (female) (1)

Resistance Max. 1 z

20-941 (10)

MON-9

TROUBLESHOOTING

e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally) Action code



Not set

MON

Turn signals and hazard lamp do not operate normally e) When hazard lamp switch is turned OFF, turn signal lamps Trouble continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally)

• When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal lever is operated, however, turn signal lamps flash normally).

Action of controller • None in particular. Problem that • When the hazard lamp switch is turned OFF, the turn signal lamps continue flashing (When turn signal appears on machine lever is operated, however, turn signal lamps flash normally). Related information • Failure code is not displayed.

Cause

1

Hazard lamp switch defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Between Turn the hazard lamp switch ON. Resistance Max. 1 z HAZ (male) (1) Turn the hazard lamp switch OFF. Resistance Min. 1 M z – (3) 1) Turn the starting switch OFF. 2) Replace R16 with normal one. 3) Turn the starting switch ON. When hazard relay 1 (R16) is replaced, is failure repaired?

No


Yes




Hazard relay 1 (R16) defec- 1) Turn the starting switch OFF. 2 2) Disconnect connector R16. tive Possible causes 3) Check the relay. and standard value 4) Apply voltage between R16 (male) (5) – (6). in normal state Apply 24 V between Resistance Max. 1 z Between R16 (male) (5) – (6). (1) – (2) Do not apply 24 V beResistance Min. 1 M z tween (5) – (6). Between R16 (male) (3) – (4)




1) Turn the starting switch OFF. 2) Disconnect connectors HAZ, R17, and R16. 3) Connect T-adapter. 4) Turn the starting switch ON.


20-942 (10)

Voltage between HAZ Wiring harness between HAZ (fe- (female) (3), R16 (female) (3) – R16 (female) (5) male) (5) – chassis ground

Max. 1 V

Voltage between HAZ Wiring harness between HAZ (fe- (female) (3), R17 (female) (3) – R17 (female) (1) male) (1) – chassis ground

Max. 1 V

HD465-7, HD605-7

MON-9

TROUBLESHOOTING

f)

Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however) Action code


Not set

Not set

MON

Turn signals and hazard lamp do not operate normally Trouble f) Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally, however)

Contents of trouble • The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however).

Action of controller • None in particular. Problem that • The turn signal pilot lamps do not flash normally (The turn signal lamps flash normally, however). appears on machine

• Before performing troubleshooting, check that fuse BT2 (24) and BT3 (4) are not broken. (If either or both of them are broken, there is a grounding fault. Accordingly, check the related wiring harness.) • The turn signal lamps are branched at the switch and relay to the front, rear, right, and left. Accordingly, Related information if only 1 lamp is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. • Failure code is not displayed. Cause


1) Turn the starting switch OFF. 2) Disconnect connectors BTC2A and R16. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between DPC2A (female) (7) – Resistance Max. 1 z (Disconnection or defective R16 (female) (4) contact) Wiring harness between DPC2A (female) (16) Resistance Max. 1 z – R16 (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn the starting switch ON.



Between Set the turn signal lever in RIGHT. DPC2A (7) – chas- Set the turn signal lever in NEUsis ground TRAL. Between Set the turn signal lever in NEUTRAL. DPC2A (7) – chassis ground Set the turn signal lever in LEFT.

Voltage

Max. 1 V / 20 – 30 V (*)

Voltage

Max. 1 V

Voltage

Max. 1 V

Voltage

Max. 1 V / 20 – 30 V (*)

(*) Voltage changes alternately.

HD465-7, HD605-7

20-943 (10)

TROUBLESHOOTING

MON-9


20-944 (1)

HD465-7, HD605-7

MON-10

TROUBLESHOOTING

MON-10 NIGHT LIGHTING IS ABNORMAL a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up. Action code



Not set

Not set

Night lighting is abnormal Trouble a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp, and head lamp does not light up.

• When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head lamp does not light up.

Action of controller • None in particular. Problem that • When the lamp switch is set in the 1st or 2nd position, any of the small lamp, night lamp, and head appears on machine lamp does not light up.

• Before performing troubleshooting, check that fuses BT1 (2), BT1 (6), BT1 (8), BT1 (10), and BT1 (12) are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related wiring harness.) • The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly, Related information if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the wiring harness on the signal side (between the branching point and lamp), and defect of the wiring harness on the GND side. • Failure code is not displayed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch.

1 Lamp switch defective Possible causes and standard value in normal state

Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) – (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) – (3) Set the lamp switch in 2nd position. Resistance Max. 1 z

1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors CM – fuse BT1 (2) 3) Insert T-adapter. ness 2 (Disconnection or defective 4) Turn the starting switch ON. contact) Wiring harness between BT1 (2) – Voltage between CM CM (female) (1) (1) – chassis ground

HD465-7, HD605-7

20 – 30 V

20-945 (10)

MON-10

TROUBLESHOOTING

b) When lamp switch is set in 1st position, small lamp and night lamp do not light up Action code Not set


Not set

Night lighting is abnormal Trouble b) When lamp switch is set in 1st position, small lamp and night lamp do not light up

Contents of trouble • When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up.

Action of controller • None in particular. Problem that • When the lamp switch is set in the 1st position, the small lamp and night lamp do not light up. appears on machine



1 Lamp switch defective Possible causes and standard value in normal state


1) Turn the starting switch OFF. 2) Disconnect connectors CM and fuse BT1 (2) Disconnection in wiring har- 3) Insert T-adapter. ness 4) Turn the starting switch ON. 2 (Disconnection or defective Wiring harness between CM (fecontact) Voltage between CM male) (2), DPC2B (female), – (2) – chassis ground branching point of BT1 (1), (11)

20-946 (10)

20 – 30 V

HD465-7, HD605-7

MON-10

TROUBLESHOOTING

c) When lamp switch is OFF, small lamp and night lamp light up Action code


Not set

Not set

MON

Trouble

Night lighting is abnormal c) When lamp switch is OFF, small lamp and night lamp light up

Contents of trouble • When the lamp switch is OFF, the small lamp and night lamp light up.

Action of controller • None in particular. Problem that • When the lamp switch is OFF, the small lamp and night lamp light up. appears on machine Related information • Failure code is not displayed.

Cause


1 Lamp switch defective




1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, LS, fuse BT1 (2), and tachograph. 3) Connect T-adapter. 4) Turn the starting switch ON. Wiring harness between CM (female) (2), DPC2B (female), – branching point of BT1 (1), (11)

HD465-7, HD605-7

Voltage between CM (female) (2) – chassis ground

Max. 1 V

20-947 (10)

MON-10

TROUBLESHOOTING

d) When dimmer switch is operated, brightness of night lighting does not change Action code Not set


Not set

Night lighting is abnormal Trouble d) When dimmer switch is operated, brightness of night lighting does not change

Contents of trouble • When the dimmer switch is operated, the brightness of the night lighting does not change.

Action of controller • None in particular. Problem that • When the dimmer switch is operated, the brightness of the night lighting does not change. appears on machine


Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, fuse BT1 (9), (11), Switch, and Tachograph. 3) Insert T-adapter. 4) Turn the starting switch ON.


Disconnection in wiring harWiring harness between LS (female) (3) – ness chassis ground 1 (Disconnection or defective Wiring harness between LS (female) (2) – contact) DPC2B (female) (12) (branching point of Switch)

(10)

Resistance Max. 1 z

Wiring harness between LS (female) (1), DPC2B (female) (5) – branching point of BT1 Resistance Max. 1 z (9), (11) Tachograph

2 Dimmer switch defective

20-948

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. 6) Set the lamp switch in 1st position. Between LS (1) – (3)

Voltage

20 – 30 V

Between LS (2) – (3)

Voltage

6 – 27 V

HD465-7, HD605-7

MON-10

TROUBLESHOOTING

e) Head lamp "Hi" beam does not light up Action code


Not set

Not set

Not set

Trouble

Night lighting is abnormal e) Head lamp "Hi" beam does not light up

Contents of trouble • The head lamp cannot be set to "Hi" or "Lo".

Action of controller • None in particular. Problem that • The head lamp cannot be set to "Hi" or "Lo". appears on machine




Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Max. 1 z (1) – (2) Set the lamp switch in 2nd position. Resistance Max. 1 z Between Set the lamp switch in OFF position. Resistance Min. 1 M z CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M z (1) – (3) Set the lamp switch in 2nd position. Resistance Max. 1 z 1) Turn the starting switch OFF. 2) Replace R30 with normal one. 3) Turn the starting switch ON. When head lamp "Lo" relay (R30) is replaced, is failure repaired?

Possible causes Head lamp "Hi" relay (R30) and standard value 2 defective in normal state

No

Relay R30

Yes

Relay R30





Resistance Max. 1 z


1) Turn the starting switch OFF. 2) Disconnect connectors DPC2B, CM, fuse BT1 (9) – (11), Switch, and Tachograph 3) Insert T-adapter. 4) Connect the connectors. Disconnection in wiring har5) Turn the starting switch ON. ness 3 (Disconnection or defective Wiring harness between R30 (female) (1), (3) Resistance Max. 1 z – branching point of wiring harness contact)

HD465-7, HD605-7

Wiring harness between R30 (female) (2) – DCP1 (female) (14)

Resistance Max. 1 z

Wiring harness between R30 (female) (5) – branching point of wiring harness

Resistance Max. 1 z

20-949 (10)

MON-10

TROUBLESHOOTING

f)

Head lamp "Lo" beam does not light up Action code Not set


Not set

Trouble

Night lighting is abnormal f) Head lamp "Lo" beam does not light up

Contents of trouble • The head lamp "Lo" beam does not light up.

Action of controller • None in particular. Problem that • The head lamp "Lo" beam does not light up. appears on machine






1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1 terminals (5) and (6) 3) Connect T-adapter. Wiring harness between PL1 (female) (1) – chassis ground

Resistance Max. 1 z

Disconnection in wiring har- Wiring harness between PR1 (female) (1) – Resistance Max. 1 z ness chassis ground 2 (Disconnection or defective Wiring harness between battery relay terminal contact) M (CN-02), fuse BT1 terminals (1), (2), – CM Resistance Max. 1 z (female) (1)

20-950 (10)

Wiring harness between CM (female) (3) – fuse BT1 terminal (7)

Resistance Max. 1 z

Wiring harness fuse BT1 terminal (8) – PL1 (female) (1), PR1 (female) (1)

Resistance Max. 1 z

HD465-7, HD605-7

MON-10

TROUBLESHOOTING

g) Head lamp cannot be set to "Hi" or "Lo" Action code


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

Action of controller • None in particular. Problem that • The head lamp "Hi" beam does not light up. appears on machine


1 Passing switch defective

2

Head lamp "Passing" relay (R29) defective

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CM. 3) Check the switch. Set the passing switch in RAISE Resistance Max. 1 z Between (PASS) position. CM (male) Set the passing switch in RETURN (4) – (5) Resistance Min. 1 M z (OFF) position. 1) Turn the starting switch OFF. 2) Replace R29 with normal one. 3) Turn the starting switch ON. Relay R29 No When head lamp "Hi" relay (R29) is replaced, is failure repaired? Yes Relay R29 1) Turn the starting switch OFF. 2) Disconnect connector R29. 3) Check the relay. Between R29 (male) (1) – (2)


1) Turn the starting switch OFF. 2) Disconnect connector R29. 3) Check the relay. 4) Apply voltage between R29 (male) (1) – (2). Apply 24 V between Resistance Max. 1 z Between R29 (male) (1) – (2). (3) – (5) Do not apply 24 V beResistance Min. 1 M z tween (1) – (2). 1) Turn the starting switch OFF. 2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1 terminals (5) and (6) 3) Connect T-adapter.


Wiring harness between PL2 (female) (1) – chassis ground Wiring harness between PR2 (female) (1) – chassis ground Disconnection in wiring harWiring harness between fuse BT1 terminal (6) ness 3 (Disconnection or defective – PL2 (female) (1), PR2 (female) (1) contact) Wiring harness between R29 (female) (2) – chassis ground

HD465-7, HD605-7


Wiring harness between R29 (female) (3) – branching point of wiring harness

Resistance Max. 1 z

Wiring harness between CM (female) (5) – R29 (female) (1)

Resistance Max. 1 z

Wiring harness between CM (female) (4) – branching point of wiring harness

Resistance Max. 1 z

20-951 (10)

MON-10

TROUBLESHOOTING

h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up Action code Not set


Not set

Night lighting is abnormal Trouble h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up

Contents of trouble • When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.

Action of controller • None in particular. Problem that • When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up. appears on machine



1) Turn the starting switch OFF. Disconnection in wiring har- 2) Disconnect connectors DPC2A, CM, and R29. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between DPC2A (female) (4) – contact) Resistance Max. 1 z CM (female) (5) – R29 (female) (1) Possible causes and standard value in normal state 2 Machine monitor defective

1) Turn the starting switch OFF. 2) Disconnect connector DPC2A. 3) Insert T-adapter. 4) Connect the connector. 5) Turn the starting switch ON. Set the passing switch Between DPC2A (5) – in "Lo". chassis ground Set the passing switch in "Hi".

20-952 (10)

Voltage

Max. 1 V

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

MON-10


HD465-7, HD605-7

20-953 (2)

MON-10

TROUBLESHOOTING

MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY a) Operating left side does not Action code Not set

Failure code Controller code Power window does not operate normally Trouble a) Operating left side does not Not set Not set

Contents of trouble • The power window does not operate normally. (Operating left side does not)

Action of controller • None in particular. Problem that • The power window does not operate normally. (Operating left side does not) appears on machine Related information

• Before performing troubleshooting, check that fuses BT2 (8) are not broken. (If any of them is broken, there is a ground fault. Accordingly, check the related wiring harness.) Cause


1) Turn the starting switch OFF. 2) Disconnect connector R34. 3) Check the switch. Power window switch (L.H.) "Left Between up" R34 Power window switch (L.H.) "OFF" Power window switch (L.H.) (male) (1) Power window switch (L.H.) "Left 1 – (2) defective down" Power window switch (L.H.) "Left Between up" R34 Power window switch (L.H.) "OFF" (male) (1) Power window switch (L.H.) "Left – (3) down" 1) Turn the starting switch OFF. 2) Replace R25 with normal one. Power window relay (R25) 3) Turn the starting switch ON. 2 defective No When power window relay (R25) is replaced, is failure repaired? Yes

Resistance Min. 1 M z Resistance Min. 1 M z Resistance Max. 1 z Resistance Max. 1 z Resistance Min. 1 M z Resistance Min. 1 M z

Relay R25 is normal Relay R25 is defective

1) Turn the starting switch OFF. 2) Disconnect connectors R25, R34, PWL, and fuse BT2 terminal (8). Possible causes 3) Insert T-adapter. and standard value 4) Connect the connectors. in normal state 5) Turn the starting switch ON. Wiring harness between fuse BT2 terminal (8) Resistance Max. 1 z – R34 (female) (1) Wiring harness between fuse BT2 terminal (8) Resistance Max. 1 z Disconnection in wiring har- – R25 (female) (8) ness Wiring harness between R25 (female) (2) – 3 Resistance Max. 1 z (Disconnection or defective R34 (female) (3) contact) Wiring harness between R25 (female) (1) – Resistance Max. 1 z CAB1 (5) – PWL (female) (1) Wiring harness between R25 (female) (5) – CAB1 (6) – PWL (male) (1)

Resistance Max. 1 z

Wiring harness between R25 (female) (4) – Resistance Max. 1 z R34 (female) (2) Wiring harness between R25 (female) (3) – Resistance Max. 1 z chassis ground 1) Turn the starting switch OFF. 2) Replace power window motor (L.H.) with motor normal one. 3) Turn the starting switch ON. Power window motor (L.H.) aIf the results of 1 – 3 above are normal, perform the following test. 4 defective Motor is normal When power window motor (L.H.) No is motor replaced, is failure reYes Motor is defective placed ?

20-954 (10)

HD465-7, HD605-7

MON-11

TROUBLESHOOTING

b) Operating right side does not Action code


Power window does not operate normally Trouble b) Operating right side does not Not set Not set Contents of trouble • The power window does not operate normally. (Operating right side does not) Not set

Action of controller • None in particular. Problem that • The power window does not operate normally. (Operating right side does not) appears on machine Related information

• Before performing troubleshooting, check that fuses BT2 (10) are not broken. (If any of them is broken, there is a ground fault. Accordingly, check the related wiring harness.) Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector R35. 3) Check the switch. Power window switch (R.H.) "Right Resistance Min. 1 M z Between up" R35 Power window switch (R.H.) "OFF" Resistance Min. 1 M z Power window switch (R.H.) (male) (1) 1 Power window switch (R.H.) "Right – (2) Resistance Max. 1 z defective down" Power window switch (R.H.) "Right Resistance Max. 1 z Between up" R35 Power window switch (R.H.) "OFF" Resistance Min. 1 M z (male) (1) Power window switch (R.H.) "Right – (3) Resistance Min. 1 M z down"

2

Power window relay (R25) defective

1) Turn the starting switch OFF. 2) Replace R25 with normal one. 3) Turn the starting switch ON. When power window relay (R25) is replaced, is failure repaired?

No Yes

Relay R25 is normal Relay R25 is defective

1) Turn the starting switch OFF. 2) Disconnect connectors R25, R35, PWR, and fuse BT2 terminal (10). 3) Insert T-adapter. 4) Connect the connectors. 5) Turn the starting switch ON.


Wiring harness between fuse BT2 terminal (10) – R35 (female) (1) Wiring harness between fuse BT2 terminal Disconnection in wiring har- (10) – R25 (female) (11) ness Wiring harness between R25 (female) (7) – 3 (Disconnection or defective R35 (female) (3) contact) Wiring harness between R25 (female) (6) – CAB1 (7) – PWR (female) (1) Wiring harness between R25 (female) (10) – CAB1 (8) – PWR (male) (1)

Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z

Wiring harness between R25 (female) (9) – R35 (female) (2)

Resistance Max. 1 z

Wiring harness between R25 (female) (3) – chassis ground

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Replace power window motor (R.H.) with motor normal one. 3) Turn the starting switch ON. Power window motor (R.H.) a If the results of 1 – 3 above are normal, perform the following test. 4 defective Motor is normal When power window motor (R.H.) No is motor replaced, is failure reMotor is defective Yes placed ?

HD465-7, HD605-7

20-955 (10)

TROUBLESHOOTING

MON-11


20-956 (2)

HD465-7, HD605-7

MON-12

TROUBLESHOOTING

MON-12 DEFECTIVE AIR CONDITIONER a) Air conditioner does not operate Action code Not set

Failure code Controller code Defective air conditioner Trouble a) Air conditioner does not operate Not set Not set

Contents of trouble • The air conditioner does not operate.

Action of controller • None in particular. Problem that • The air conditioner does not operate. appears on machine Related information

• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for ground fault. Cause


1) Turn starting switch OFF. 2) Disconnect connector ACP1 and fuse BT3 (4) terminal. Disconnection in wiring har- 3) Connect T-adapter. Possible causes ness 1 Wiring harness between fuse BT3 (4) – ACP1 and standard value Resistance Max. 1 z (Disconnection or defective (female) (1) in normal state contact) Wiring harness between ACP1 (female) (14) – Resistance Max. 1 z chassis ground 2

HD465-7, HD605-7

Defective air conditioner control panel

a Check the control panel and repair or replace it, if it has abnormality.

20-957 (10)

MON-12

TROUBLESHOOTING

b) Air does not come out or air flow cannot be adjusted Action code


Defective air conditioner Trouble b) Air does not come out or air flow cannot be adjusted Not set Not set Contents of trouble • Air does not come out or air flow cannot be adjusted Not set

Action of controller • None in particular. Problem that • Air does not come out or air flow cannot be adjusted appears on machine Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACR1, ACR2, ACR3, and ACR4 and fuse terminals BT1 (18) and BT3 (4). 3) Connect T-adapter. Wiring harness between fuse BT3 (4) – ACR1 Resistance Max. 1 z (female) (1)

1

Disconnection in power Wiring harness between fuse BT3 (4) – ACR2 supply wiring harness (Disconnection or defective (female) (1) contact) Wiring harness between fuse BT3 (4) – ACR3 (female) (1) Wiring harness between fuse BT3 (4) – ACR4 (female) (1) Wiring harness between fuse BT1 (18) – ACR1 (female) (3)


1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5, ACBM, and ACRE. 3) Connect T-adapter. Wiring harness between ACP1 (female) (2) – Resistance Max. 1 z ACR1 (female) (2) Wiring harness between ACP1 (female) (5) – Resistance Max. 1 z ACR2 (female) (2) Wiring harness between ACP1 (female) (4) – Resistance Max. 1 z ACR3 (female) (2)


Wiring harness between ACP1 (female) (3) – Resistance Max. 1 z ACR4 (female) (2) Disconnection in wiring harness 2 (Disconnection or defective contact)

20-958 (10)

Wiring harness between ACR1 (female) (4) – Resistance Max. 1 z ACBM (female) (1) Wiring harness between ACR2 (female) (3) – ACBM (female) (2), ACRE (female) (1) Wiring harness between ACR3 (female) (3) – ACRE (female) (2) Wiring harness between ACR4 (female) (3) – ACRE (female) (3) wiring harness between ACR2 (female) (4) – chassis ground

Resistance Max. 1 z

wiring harness between ACR3 (female) (4) – chassis ground

Resistance Max. 1 z

wiring harness between ACR4 (female) (4) – chassis ground

Resistance Max. 1 z

wiring harness between ACRE (female) (4) – chassis ground

Resistance Max. 1 z


HD465-7, HD605-7

MON-12

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5, ACBM, and ACRE. 3) Connect T-adapter. Wiring harness between Resistance between ACR1 ACR1 (female) (4) – ACBM (female) (4), ACBM (female) Min. 1 M z (female) (1) (1) – chassis ground

3


Wiring harness between ACR2 (female) (3) – ACBM (female) (2), ACRE (female) (1)

Resistance between ACR2 (female) (3), ACBM (female) Min. 1 M z (2), ACRE (female) (1) – chassis ground

Wiring harness between Resistance between ACR3 ACR3 (female) (3) – ACRE (female) (3), ACRE (female) Min. 1 M z (female) (2) (2) – chassis ground Wiring harness between Resistance between ACR4 ACR4 (female) (3) – ACRE (female) (3), ACRE (female) Min. 1 M z (female) (3) (3) – chassis ground 1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4 Defective blower main relay 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal.

5 Defective blower Hi relay Possible causes and standard value in normal state

1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Condition becomes normal. Replace relay with normal one. Condition does not become normal. Relay is normal.

6 Defective blower M2 relay


7 Defective blower M1 relay


8 Defective blower motor

1) Turn starting switch OFF. 2) Replace motor. 3) Turn starting switch ON. 4) Start air conditioner. Relay is defective. Replace motor Condition becomes normal. with normal one. Condition does not become normal. Relay is normal. 1) Turn starting switch OFF. 2) Disconnect connector ACRE. 3) Check resistor unit.

9 Defective blower resistor

10

HD465-7, HD605-7


Between ACRE (female) (1) – (2)

Resistance

2.8 z


Resistance

4.8 z


Resistance

4.0 z


20-959 (10)

MON-12

TROUBLESHOOTING

c) Air is not cooled or temperature cannot be adjusted (Electric system) Defective air conditioner Trouble c) Air is not cooled or temperature cannot be adjusted (Electric Not set Not set Not set system) Contents of trouble • Air is not cooled or temperature cannot be adjusted Action code


Action of controller • None in particular. Problem that • Air is not cooled or temperature cannot be adjusted appears on machine Related information

• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for ground fault. If fuse BT1 (18) is broken, check the wiring harness between fuse BT1 (18) and ACR5 (female) (3) for grounding fault. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACR5 and fuse terminals BT1 (18) and BT3 (4). 3) Connect T-adapter.

Disconnection in power supply wiring harness 1 Wiring harness between fuse BT3 (4) – ACR5 Resistance Max. 5 z (Disconnection or defective (female) (1) contact) Wiring harness between fuse BT1 (18) – ACR5 Resistance Max. 1 z (female) (3) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH, ACPS, and E07. 3) Connect T-adapter. Wiring harness between ACP1 (female) (6) – Resistance Max. 1 z ACPS (female) (2) Wiring harness between ACP1 (female) (9) – Resistance Max. 1 z ACTH (female) (1) Wiring harness between ACP1 (female) (10) – Resistance Max. 1 z ACM1(female) (4) Wiring harness between ACP1 (female) (13) – Disconnection in wiring har- ACTH (female) (2) 2 ness (Disconnection or deWiring harness between ACP1 (female) (13) – fective contact) ACM1 (female) (3) Possible causes and standard value Wiring harness between ACP1 (female) (16) – in normal state ACM1 (female) (1) Wiring harness between ACP2 (female) (3) – ACM1 (female) (2)


Wiring harness between ACP2 (female) (4) – Resistance Max. 1 z ACM1 (female) (5) Wiring harness between ACR5 (female) (2) – Resistance Max. 1 z ACPS (female) (1) Wiring harness between ACR5 (female) (4) – Resistance Max. 1 z E07 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH, ACPS, and E07. 3) Connect T-adapter.

3


Wiring harness between ACP1 (female) (6) – ACPS (female) (2)

Resistance between ACP1 (female) (6), ACPS (female) Min. 1 M z (2) – chassis ground

Wiring harness between ACP1 (female) (9) – ACTH (female) (1)

Resistance between ACP1 (female) (9), ACTH (female) Min. 1 M z (1) – chassis ground

Resistance between ACP1 Wiring harness between ACP1 (female) (10) – ACM1 (female) (10), ACM1 (female) Min. 1 M z (female) (4) (4) – chassis ground

20-960 (10)

HD465-7, HD605-7

MON-12

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting Wiring harness between Resistance between ACP1 ACP1 (female) (13) – ACTH (female) (13), ACTH (female) Min. 1 M z (female) (2) (2) – chassis ground Wiring harness between Resistance between ACP1 ACP1 (female) (13) – ACM1 (female) (13), ACM1(female) Min. 1 M z (female) (3) (3) – chassis ground Wiring harness between Resistance between ACP1 ACP1 (female) (16) – ACM1 (female) (16), ACM1 (female) Min. 1 M z (female) (1) (1) – chassis ground

3


Wiring harness between ACP2 (female) (3) – ACM1 (female) (2)

Resistance between ACP2 (female) (3), ACM1 (female) (2) – chassis ground

Min. 1 M z



Min. 1 M z



Min. 1 M z

Wiring harness between ACR5 (female) (2) – ACPS (female) (1)

Resistance between ACR5 (female) (2), ACPS (female) (1) – chassis ground

Min. 1 M z

Wiring harness between Resistance between ACR5 ACR5 (female) (4) – E07 (fe- (female) (4), E07 (female) male) (1) (1) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Replace relay. 3) Turn starting switch ON. Defective compressor clutch 4) Start air conditioner. 4 relay Possible causes Relay is defective. Condition becomes normal. and standard value Replace relay in normal state with normal one. Condition does not become normal. Relay is normal.

5 Defective pressure switch

1) Turn starting switch OFF. 2) Disconnect connector ACPS. 3) Connect T-adapter. 4) Turn starting switch ON. Air conditioner switch OFF Between ACPS (male) (1) – (2) Air conditioner switch ON in cooling mode

6 Defective thermistor

Defective temperature adjustment servomotor

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch ON. 4) Start air conditioner. Between ACTH (male) Temperature: 25°C (1) – (2) Temperature: 100°C

7


Resistance 37 – 50 k z Resistance 3.5 – 4.0 k z

1) Turn starting switch OFF. 2) Replace motor. 3) Turn starting switch ON. 4) Start air conditioner. Motor is defective. Replace motor Condition becomes normal. with normal one. Condition does not become normal. Motor is normal.

8

HD465-7, HD605-7

Defective air conditioner compressor

1) Turn starting switch OFF. 2) Replace air conditioner compressor. 3) Turn starting switch ON. 4) Start air conditioner. Replace air Condition becomes normal. Compressor is defective. conditioner compressor with Condition does not become Compressor is normal. normal. normal one.

20-961 (10)

MON-12

TROUBLESHOOTING

Cause

Possible causes 9 Defective diode (E08) and standard value in normal state 10


Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace diode (E08). Replace diode (E08) with normal one.

Condition becomes normal. Diode (E08) is defective. Condition does not become normal.

Diode (E08) is normal.


d) Recirculated air and fresh air cannot be selected Action code


Defective air conditioner Trouble d) Recirculated air and fresh air cannot be selected Not set Not set Contents of trouble • Recirculated air and fresh air cannot be selected because of a defect in the air conditioner system. Not set

Action of controller • None in particular. Problem that • Recirculated air and fresh air cannot be selected. appears on machine Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP2 and ACM3. Disconnection in wiring 3) Connect T-adapter. harness 1 Wiring harness between ACP2 (female) (5) – (Disconnection or defective Resistance Max. 1 z ACM3 (female) (2) contact) Wiring harness between ACP2 (female) (6) – Resistance Max. 1 z ACM3 (female) (5) Possible causes and standard value in normal state

20-962 (10)

2


1) Turn starting switch OFF. 2) Disconnect connectors ACP2 and ACM3. 3) Connect T-adapter. Wiring harness between Resistance between ACP2 ACP2 (female) (5) – ACM3 (female) (5), ACM3 (female) Min. 1 M z (female) (2) (2) – chassis ground Wiring harness between Resistance between ACP2 ACP2 (female) (6) – ACM3 (female) (6), ACM3 (female) Min. 1 M z (female) (5) (5) – chassis ground

3



HD465-7, HD605-7

MON-12

TROUBLESHOOTING

e) Air outlets cannot be selected Action code


Defective air conditioner Trouble e) Air outlets cannot be selected Not set Not set Contents of trouble • Air outlets cannot be selected Not set

Action of controller • None in particular. Problem that • Air outlets cannot be selected appears on machine Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, and ACM2. 3) Connect T-adapter. Wiring harness between ACP1 (female) (11) – Resistance Max. 1 z ACM2 (female) (4) Disconnection in wiring Wiring harness between ACP1 (female) (13) – Resistance Max. 1 z harness ACM2 (female) (3) 1 (Disconnection or defective Wiring harness between ACP2 (female) (1) – contact) Resistance Max. 1 z ACM2 (female) (2) Wiring harness between ACP2 (female) (2) – Resistance Max. 1 z ACM2 (female) (5) Wiring harness between ACP2 (female) (7) – Resistance Max. 1 z ACM2 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors ACP1, ACP2, and ACM2. 3) Connect T-adapter.


Resistance between ACP1 Wiring harness between ACP1 (female) (11) – ACM2 (female) (11), ACM2 (female) Min. 1 M z (female) (4) (4) – chassis ground

Ground fault in wiring har2 ness

3

HD465-7, HD605-7


Resistance between ACP1 Wiring harness between ACP1 (female) (13) – ACM2 (female) (13), ACM2 (female) (female) (3) (3) – chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (1) – ACM2 (female) (1), ACM2 (female) (female) (2) (2) – chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (2) – ACM2 (female) (2), ACM2 (female) (female) (5) (5) – chassis ground Resistance between ACP2 Wiring harness between ACP2 (female) (7) – ACM2 (female) (7), ACM2 (female) (female) (1) (1) – chassis ground

Min. 1 M z

Min. 1 M z

Min. 1 M z

Min. 1 M z


20-963 (10)

TROUBLESHOOTING

MON-12


20-964 (5)

HD465-7, HD605-7

MON-12

TROUBLESHOOTING

f)

Air is not cooled (Mechanical system) Action code


Defective air conditioner Trouble f) Air is not cooled (Mechanical system) Not set Not set Contents of trouble • Air is not cooled because of abnormality in mechanical system. Not set

Action of controller • None in particular. Problem that • Air is not cooled because of abnormality in mechanical system. appears on machine Related information

Cause Gas leakage through pipe 1 joints or parts 2

Natural leakage through hose, etc. (Refrigerant has not been added for long time)

3 Insufficient refrigerant level 4 Defective expansion valve 5

Clogging of low-pressure circuit and evaporator

6 Clogging of evaporator fins Possible causes and standard value 7 Clogging of filter in normal state Defective installation of ther8 mistor Air leakage through air con9 ditioner unit and duct 10 Insufficient set air flow 11 Excessive refrigerant 12 Entry of air 13 Clogging of condenser fins Insufficient compression by 14 compressor Entry of water in refrigerant 15 circuit

HD465-7, HD605-7

Standard value in normal state/Remarks on troubleshooting • Check and repair or replace, if abnormal. • Check refrigerant level and add new refrigerant to proper level, if nec essary. • Add new refrigerant to proper level. • Check and repair or replace, if abnormal. a Check the valve for excessive opening and defective contact of heat-sensor tube, too. • Check and remove clogging material, if there is any, or replace. • Check and remove clogging material, if there is any, and clean evaporator. • Check and clean, or replace. • Check and repair or replace, if abnormal. • Check and repair or replace leaking part. • Increase set air flow. • Check refrigerant level and reduce it to proper level, if necessary. • Evacuate system and fill it with refrigerant to proper level and replace receiver drier. • Check fins for clogging and clean them, if necessary. • Check and repair or replace, if necessary. • Evacuate system and fill it with refrigerant to proper level and replace receiver drier.

20-965 (10)

MON-12

TROUBLESHOOTING

g) Air is not heated (Defective hot water circuit) Action code


Defective air conditioner Trouble g) Air is not heated (Defective hot water circuit) Not set Not set Contents of trouble • Air is not heated (Defective hot water circuit). Not set

Action of controller • None in particular. Problem that • Air is not heated (Defective hot water circuit). appears on machine Related information

• Check that water is not leaking through the hot water circuit. • Check that air is flowing out of the air outlets. Cause

Standard value in normal state/Remarks on troubleshooting • Check heater core fins for clogging and clean them, if necessary. 1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet of the heater core becomes high. • Check and repair or replace leaking part. Air leakage through air con2 a If this is the cause, the temperature at the hot water inlet and outlet ditioner unit of the heater core becomes high. Possible causes • Check and remove clogging material, or replace valve. and standard value 3 Defective water valve a If this is the cause, the temperature at the hot water inlet of the heat(Clogging or defective valve) in normal state er core becomes high but that at the hot water outlet becomes low. 4 Clogging of heater core

5

Clogging up to hot water inlet of heater core

• Check and repair or replace leaking part. a If this is the cause, the temperature at the hot water inlet of the heater core becomes high but that at the hot water outlet becomes low. • Check and repair or replace leaking part. a If this is the cause, the temperature at the hot water inlet of the heater core becomes low.

h) Abnormal sound comes out Action code


Defective air conditioner Trouble h) Abnormal sound comes out Not set Not set Contents of trouble • Abnormal sound comes out. Not set

Action of controller • None in particular. Problem that • Abnormal sound comes out. appears on machine Related information

Cause Standard value in normal state/Remarks on troubleshooting Defective installation of bolts 1 • Check and repair, if abnormal. (screws) related to case 2

Interference of fan case, etc. • Check and repair or replace, if abnormal. or breakage of fan

Entry of foreign matter in 3 blower motor or defective Possible causes blower motor and standard value in normal state 4 Defective expansion valve 5

Loosened or worn compressor V-belt

Insufficient or excessive refrigerant 7 Defective compressor 6

20-966 (10)

• Check and remove foreign matter, if there is any, and repair or replace • Check and replace, if abnormal sound (peep or gas leakage sound) comes out. • Check and repair or replace, if loosened or worn. • Check refrigerant level and reduce or increase it to proper level, if necessary. • Check and repair or replace, if abnormal.

HD465-7, HD605-7

MON-12

TROUBLESHOOTING

i)

Water leaks Action code


Not set

Not set Contents of trouble • Water leaks.

Not set

Trouble

Defective air conditioner i) Water leaks

Action of controller • None in particular. Problem that • Water leaks. appears on machine Related information

Cause Standard value in normal state/Remarks on troubleshooting Clogging of water drain hole • Check and repair, if abnormal. 1 in air conditioner unit 2

Clogging, bend, defective installation, or breakage of • Check and repair or replace, if abnormal. drain hose of air conditioner unit

Possible causes Breakage (Cracking) of air • Check and repair or replace, if broken (cracked). and standard value 3 conditioner unit case in normal state Defective installation of bolts 4 (screws) related to air • Check and repair or replace, if abnormal. conditioner unit case Defective joints of hot water • Check and repair or replace, if abnormal. circuit piping 6 Defective heater core • Check and repair or replace, if abnormal. 5

7 Defective water valve

HD465-7, HD605-7

• Check and repair or replace, if abnormal.

20-967 (10)

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

HD465-7, HD605-7

20-1001 (10)

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER


20-1002 (5)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-1003 (5)

TROUBLESHOOTING

20-1003-1 (5)


HD465-7, HD605-7

INFORMATION GIVEN IN TROUBLESHOOTING CHART

TROUBLESHOOTING

INFORMATION GIVEN IN TROUBLESHOOTING CHART a The following type of information is given in the troubleshooting charts and related circuit diagrams, so make sure that you understand the content fully before starting troubleshooting. Action code Shown on panel display

Failure code Controller code Trouble Problem that appeared on machine Shown on Shown on panel display panel display

Contents of trouble Condition when monitor panel or controller detected failure.

Action of controller Action taken to protect system or equipment when monitor panel or controller detected failure. Problem that Problem that appeared on machine when monitor panel or controller took above action. appears on machine Related information Information related to troubleshooting or failure that occurred.

Cause

1

2

Standard value in normal state/Remarks on troubleshooting • Standard value when condition is normal (used to judge status of probable failure). • Remarks used to judge status of probable failure. • Disconnection Defective connection of connector or disconnection in wiring harness. • Ground fault Wiring harness not connected to GND (ground) circuit is in contact with GND circuit. • Short circuit with power source (Hot short) Wiring harness not connected to power source (24V) circuit is in contact with power source circuit. • Short circuit Wiring harnesses of independent circuits are in abnormal contact.

Probable cause Probable cause of existing and standard value 3 failure (the numbers are when normal index numbers and do not indicate the order of priority) 1) Method of displaying connector No. and method of handling Tadapter If there are no special instructions, insert or connect the T-adapter as follows. 4 • If there is no indication of (male) or (female) with the connector No., disconnect the connector and insert the T-adapter into both the male and female sides. • If (male) or (female) is indicated with the connector No., disconnect the connector and insert the T-adapter into only the side indicated (either male or female). 2) Order of listing pin No. and method of handling test lead 5 If there are no special instructions, connect the (+) lead and (–) lead of the tester as follows. • Connect the (+) lead to the pin No. or wiring harness given first. • Connect the (–) lead to the pin No. or wiring harness given last.

20-1004 (10)

HD465-7, HD605-7

PHENOMENON TYPE CODE LIST

TROUBLESHOOTING


This is the section of the circuit diagram that shows the parts related to the failure. • Connector No.: (type – No. of pins) (color). • Arrows ( ): Shows approximate mounting position on machine.

PHENOMENON TYPE CODE LIST a For phenomenon type codes marked "See list", refer to this list. Phenomenon code

Contents

Phenomenon code

Contents

KA

Disconnection

L0

Fill signal for non-existent combination of clutches ON simultaneously for 2 or more channels.

KB

Short circuit

L1

Fill signal ON when command current to ECMV is OFF.

KK

Drop in power source voltage, input

L2

Fuel pressure is higher than max. specified value.

KQ

Mismatch in model selection signal

L3

Target components cannot be controlled.

KR

Defective communications

L4

ON/OFF signals from 2 systems do not match.

KT

Abnormality inside controller

L6

Engine speed signal, C terminal signal, oil pressure switch, coolant temperature sensor signals do not match operating condition or stopped condition.

KX

Input signal outside range

L8

Analog signals of 2 systems do not match.

KY


LC

Speed signals of 2 systems do not match.

KZ


LD

Switch remains pressed for length of time unthinkable for normal operations .

MA

Defective function

LH

Fill signal is turned OFF when command current to ECMV is ON.

MB

Drop in function

MW

Slippage

NS

Overheat

ZG

Drop in oil pressure

ZK

Drop in level

HD465-7, HD605-7

20-1005 (10)

[A000N1]

TROUBLESHOOTING

[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN Action code Not set

Failure code Controller code A000N1

Not set

Trouble Engine overrun

Contents of trouble • Engine speed of more than 2,625 rpm is detected when engine is running.

Action of controller • Carries out control for default mode. Problem that • If machine continues to be used as it is, engine may be damaged. appears on machine

• Engine speed can be checked with monitoring function (code: 01001) • LED display is [n201] Related information • If failure codes [C115KZ] or [C121LC] related to engine controller are displayed, carry out troubleshooting first for the applicable code. Cause 1 Engine overrun Defective engine speed Probable cause 2 sensor and standard value when normal 3 Defective VHMS controller

20-1006 (10)

Standard value in normal state/Remarks on troubleshooting Inspect engine and repair if any abnormality is found. Carry out troubleshooting for failure code [C115KZ] or [C121LC]. 1) Start engine. 2) Check with monitoring function (code: 01001). Monitoring code: High idle speed 01001

Power mode

2,270 ± 50 rpm

HD465-7, HD605-7

[DBB0KK]

TROUBLESHOOTING

[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE VOLTAGE Action code


Not set

DBB0KK

Not set

Trouble Abnormality source voltage

Contents of trouble • The switch source voltage is below 9.5(± 2.5)V or above 42.4(± 6)V.

Action of controller • None in particular. Problem that • The system may not operate normally. appears on machine Related information • VHMS controller LED indicates "n901".

Cause 1 Defective circuit breaker

Standard value in normal state/Remarks on troubleshooting • If the circuit breaker is turned OFF, the circuit probably has grounding fault (See cause 3). 1) Turn starting switch OFF. 2) Disconnect connector HM-CN1 and battery relay terminal CN-02 (Terminal M). 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN1 (female) (8), Resistance Max. 1 z 2 ness (Disconnection or de- (9) – battery relay CN-02 (Terminal M) fective contact) Wiring harness between HM-CN1 (female) Resistance Max. 1 z (11), (12) – ER Wiring harness between HM-CN1 (female) (19), (20) – ER

Probable cause and standard value when normal

3


4 Defective VHMS controller

1) Turn starting switch OFF. 2) Disconnect connector HM-CN1, battery relay terminal CN-02 (Terminal M), and connectors related to them. 3) Connect T-adapter. Wiring harness between Resistance between HMHM-CN1 (female) (8), (9) – CN1 (female) (8), (9) – chasbattery relay CN-02 (Termi- sis ground Min. 1 M z nal M) and wiring harnesses related to it 1) Turn starting switch OFF. 2) Disconnect HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (8), (9) – chassis ground

HD465-7, HD605-7

Resistance Max. 1 z

Voltage

20 – 30 V

20-1006-1 (10)

TROUBLESHOOTING

[DBB0KK]


20-1006-2 (5)

HD465-7, HD605-7

[DBB5KP]

TROUBLESHOOTING

[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER SOURCE (5 V) SYSTEM Action code


Not set

DBB5KP

Not set

Trouble Abnormality in sensor power source (5 V) system

Contents of trouble • Sensor power source (5 V) voltage is out of the normal range (4.5 – 5.5 V).


Cause

1




Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-12. 3) Connect T-adapter. Wiring harness between HM-CN1 (female) (4), (5) – HM-12 (female) (B)

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-12. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN1 (female) (4), (5) – HM-12 (female) (B)


Resistance between HMCN1 (female) (4), (5), HMMin. 1 M z CN12 (female) (B) – chassis ground

Voltage between HM-CN1 (female) (4), (5), HM-12 (female) (B) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connector HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (4), (5) – (11), (12)

HD465-7, HD605-7

Max. 1 V

Voltage

4.5 – 5.5 V

20-1006-3 (10)

TROUBLESHOOTING

[DBB5KP]


20-1006-4 (5)

HD465-7, HD605-7

[DBB6KP]

TROUBLESHOOTING



Not set

DBB6KP

Not set


Contents of trouble • Sensor power source (24 V) voltage is out of the normal range (20 - 30V).


Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-23A, HM-23B, SUFR, SUFL, SURR, and SURL. 3) Connect T-adapter.

1


Wiring harness between HM-CN1 (female) (2) – HM23A (female) (A), HM-23B (female) (A)

Resistance between HMCN1 (female) (2), HM-23A (female) (A), HM-23B (female) – chassis ground

Wiring harness between HM-CN1 (female) (2) – HMSUFL (female) (B), HMSUFR (female) (B)

Resistance between HMCN1 (female) (2), HM-SUFL Min. 1 M z (female) (B), HM-SUFR (female) (B) – chassis ground

Wiring harness between HMCN1 (female) (2) – HMSURL (female) (B), HMSURR (female) (B)

Resistance between HMCN1 (female) (2), HM-SURL Min. 1 M z (female) (B), HM-SURR (female) (B) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, GR-2, HM-23A, HM-23B, SUFR, SUFL, SURR, and SURL. 3) Connect T-adapter. 4) Turn starting switch ON.




Wiring harness between HM-CN1 (female) (2) – HM23A (female) (A), HM-23B (female) (A)

Voltage between HM-CN1 (female) (2), HM-23A (female) (A), HM-23B (female) (A) – chassis ground

Max. 1 V

Wiring harness between HM-CN1 (female) (2) – HMSUFL (female) (B), HMSUFR (female) (B)

Voltage between HM-CN1 (female) (2), HM-SUFL (female) (B), HM-SUFR (female) (B) – chassis ground

Max. 1 V

Wiring harness between HM-CN1 (female) (2) – HMSURL (female) (B), HMSURR (female) (B)

Voltage between HM-CN1 (female) (2), HM-SURL (female) (B), HM-SURR (female) (B) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector HM-CN1. 3) Connect T-adapter. 4) Turn starting switch ON. Between HM-CN1 (2) – (11), (12)

HD465-7, HD605-7

Voltage

20 – 30 V

20-1006-5 (10)

TROUBLESHOOTING

[DBB6KP]


20-1006-6 (5)

HD465-7, HD605-7

[DBB7KP]

TROUBLESHOOTING



Not set

DBB7KP

Not set


Contents of trouble • Sensor power source (12 V) voltage is out of the normal range (10 – 15 V).


Cause

1


Probable cause and standard value when normal 2 Hot short in wiring harness

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and GDL. 3) Connect T-adapter. Wiring harness between Resistance between HMHM-CN1 (female) (3) – GDL CN1 (female) (3), GDL Min. 1 M z (male) (1) (male) (1) – chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and GDL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between Voltage between HM-CN1 HM-CN1 (female) (3) – GDL (female) (3), GDL (male) (1) (male) (1) and chassis ground


1) Turn starting switch OFF. 2) Disconnect HM-CN1. 3) Insert T-adapter. 4) Turn starting switch ON. Between HM-CN1 (3) – (11), (12)

HD465-7, HD605-7

Max. 1 V

Voltage

10 – 15V

20-1006-7 (10)

TROUBLESHOOTING

[DBB7KP]


20-1006-8 (5)

HD465-7, HD605-7

[DBBRKR]

TROUBLESHOOTING

[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS: DEFECTIVE COMMUNICATIONS (KR) (BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER) Action code


E03

DBBRKR

Not set

Trouble

Defective CAN communications: Defective communications (KR) (between engine controller and VHMS controller)

Contents of trouble • Communications (CAN) data from engine controller cannot be obtained.

Action of controller • Maintains condition existing when abnormality occurred. Problem that • VHMS function for obtaining data from engine controller not working. appears on machine

• LED display is [n801] Related information • If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first

for the applicable code. Cause

Disconnection in wiring harness 1 (disconnection, defective contact)

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN4A and CAN1. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (4) – CAN1 (female) (A)

Resistance Max. 1 z

Wiring harness between HM-CN4A (female) (12) – CAN1 (female) (B)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN4A and CAN1. 3) Connect T-adapter.

2



Wiring harness between HM-CN4A (female) (4) – CAN1 (female) (A)

Resistance between HMCN4A (female) (4), CAN1 (female) (A) – chassis ground

Max. 1 z


Resistance between HMCN4A (female) (12), CAN1 (female) (B) – chassis ground

Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN4A. 3) Connect T-adapter. 4) Turn starting switch ON. 3 Hot short in wiring harness

Wiring harness between HM-CN4A (female) (4) – CAN1 (female) (A)

Voltage between HM-CN4A (female) (4), CAN1 (female) (A) – chassis ground

Max. 1 V


Voltage between HM-CN4A (female) (12), CAN1 (female) (B) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Replace VHMS controller. 3) Turn starting switch ON. 4 Defective VHMS controller

HD465-7, HD605-7

Does not communicate Is communication normally normal when VHMS controller is replaced? Communicates normally

VHMS controller normal VHMS controller defective

20-1007 (10)

TROUBLESHOOTING

[DBBRKR]


20-1008 (2)

HD465-7, HD605-7

[DBBSKR]

TROUBLESHOOTING

[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS: (KR) Action code


E03

DBBSKR

Not set

Trouble Defective S-NET communications: (KR)

Contents of trouble • Communications data from controller cannot be obtained.

Action of controller • Machine monitor shows abnormal display screen (red) to warn operator of abnormality. Problem that • In some cases, system does not work normally. appears on machine Related information

• If failure code [DAQSKR], [DBISKR] related to S-NET of other controllers is displayed, carry out troubleshooting first for the applicable code. • LED display is [n803] Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN3A, JCB, JCC, and JCD. 3) Connect T-adapter.


Wiring harness between HM-CN3A (female) (8) – JCB (female) (8)

Resistance Max. 1 z

Wiring harness between HM-CN3A (female) (18) – JCD (female) (4)

Resistance Max. 1 z

Wiring harness between HM-CN3A (female) (9) ,(17) – JCC (female) (4), JCE (female) (4)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN3A, JCB, and JCD. 3) Connect T-adapter. Ground fault in wiring har2 ness Probable cause and standard value when normal


Resistance between HMCN3A (female) (8), JCB (fe- Min. 1 Mz male) (8) – chassis ground


Resistance between HMCN3A (female) (18), JCD (female) (4) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN3A, JCB, and JCD. 3) Connect T-adapter. 3 Hot short in wiring harness


HD465-7, HD605-7


Voltage between HM-CN3A (female) (18), JCB (female) (8) – chassis ground

Max. 1 V


Voltage between HM-CN3A (female) (18), JCD (female) (4) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN3A. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN3A (8) – (17)

Voltage

Max. 6 – 9 V

Between HM-CN3A (18) – (17)

Voltage

Max. 6 – 9 V

20-1009 (10)

TROUBLESHOOTING

[DBBSKR]


20-1010 (2)

HD465-7, HD605-7

[DGE1KB]

TROUBLESHOOTING

[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE OIL TEMPERUTURE SENSOR SYSTEM (KB) {30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE} Action code


Not set

DGE1KB

Not set

Disconnection, short circuit with chassis ground in engine oil Trouble temperature sensor system (KB) {30 min (at 500 rpm or above) after starting engine}

Contents of trouble • Signal voltage of engine oil temperature sensor has dropped below 0.3V.

Action of controller • None in particular. Problem that • Engine oil temperature cannot be monitored with monitoring function. appears on machine Related information

• Engine oil temperature can be checked with monitoring function (code: 42700). • LED display is [n242] Cause

1

Defective engine oil temperature sensor

Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector HM-31. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-31 (male) (1) – (2)



3



25 °C

Resistance Approx. 35 – 50 kz

100 °C

Resistance Approx. 3.3 – 4.3 kz

1) Turn the starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) – HM-31 (female) (1)

Resistance Max. 1 z

Wiring harness between HM-CN2A (female) (12) – HM-31 (female) (2)

Resistance Max. 1 z

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) – HM-31 (female) (1)

Resistance between HMCN2A (female) (3), HM-31 (female) (1) – chassis ground

Min. 1 Mz

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. Between HM-CN2A (female) (3) – (12)

25 °C


100 °C



HD465-7, HD605-7

20-1011 (10)

[DGE1KY]

TROUBLESHOOTING

[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY) Action code Not set

Failure code Controller code DGE1KY

Not set

Trouble

Short circuit with power source (Hot short) in engine oil temperature sensor system (KY)

Contents of trouble • Signal voltage of engine oil temperature sensor has risen above 4.9V.

Action of controller • None in particular. Problem that • Engine oil temperature cannot be monitored with monitoring function. appears on machine Related information

• Engine oil temperature can be checked with monitoring function (code: 42700). • LED display is [n241] Cause

1

Defective engine oil temperature sensor

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-31. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-31 (male) (1) – (2)




25 °C


100 °C


1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-31. 3) Connect T-adapter. Wiring harness between HM-CN2A (female) (3) – HM-31 (female) (1)

Voltage between HM-CN2A (female) (3), HM-31 (female) (1) – chassis ground

Max. 1 V

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. Between HM-CN2A (female) (3) – (12)

25 °C


100 °C



20-1012 (10)

HD465-7, HD605-7

[DGE5KX]

TROUBLESHOOTING

[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX) Action code


Not set

DGE5KX

Not set

Trouble

Failure in ambient temperature sensor system: Input signal outside range (KX)

Contents of trouble • Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.

Action of controller • None in particular. Problem that • Ambient temperature cannot be monitored with monitoring function. appears on machine Related information

• Ambient temperature can be checked with monitoring function (code: 37501). • LED display is [n401] Cause

1

Defective ambient temperature sensor

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-35. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-35 (male) (1) – (2)



3


0 °C


20 °C


50 °C



Resistance Max. 1 z

Wiring harness between HM-CN2A (female) (12) – HM-35 (female) (2)

Resistance Max. 1 z


Resistance between HMCN2A (female) (10), HM-35 Min. 1 Mz (female) (1) – chassis ground

1) Turn the starting switch OFF. 2) Disconnect connector HM-CN2A. 3) Connect T-adapter. 4 Defective VHMS controller Between HM-CN2A (female) (10) – (12)

0 °C


20 °C


50 °C



HD465-7, HD605-7

20-1013 (10)

[DGT4KA]

TROUBLESHOOTING

[DGT4KA] (OR VHMS_LED DISPLAYS [n312]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) Action code


Not set

DGT4KA

Not set

Trouble

Disconnection, short circuit with chassis ground in No. 1, 2, 3 (front) exhaust temperature sensor system (KA)

Contents of trouble • Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.

Action of controller • None in particular. Problem that • No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function. appears on machine Related information

• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). • LED display is [n312]. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 1, 2, 3 (front) exhaust temperature sensor.

1

Exhaust temperature sensor Defective No. 1, 2, 3 (front) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced

1) Turn starting switch OFF. 2) Disconnect connector HM-23A. 3) Insert T-adapter. Defective No. 1, 2, 3 (front) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) – (C) HM-23A


Between (B) – (C)

Exhaust temperature sensor defective

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and HM-23A. 3) Connect T-adapter. Disconnection in wiring harness 3 (disconnection, defective contact)

Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – HM-23A (female) (A) Wiring harness between HM-CN2A (female) (7) – HM-23A (female) (B)

Resistance Max. 1 z

Wiring harness between HM-22A (female) (1) Resistance Max. 1 z – HM-21A (female) (1) Wiring harness between HM-22A (female) (2) Resistance Max. 1 z – HM-21A (female) (2) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and HM-23A. 3) Connect T-adapter. Ground fault in wiring har4 ness

Resistance between HMWiring harness between CN1 (female) (2), HM-23A HM-CN1 (female) (2) – HM(female) (A) – chassis 23A (female) (A) ground Wiring harness between HM-CN2A (female) (7) – HM-23A (female) (B)

20-1014 (10)

Min. 1 Mz

Resistance between HMCN2A (female) (7), HM-23A Min. 1 Mz (female) (B) – chassis ground

HD465-7, HD605-7

[DGT4KA]

TROUBLESHOOTING

Cause

Probable cause and standard value 5 Defective VHMS controller when normal

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) – HM-CN2A (12) Between HM-CN2A (7) – (12)

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2V

500 °C

Voltage

Approx. 2.6 – 3.5 V


HD465-7, HD605-7

20-1015 (10)

[DGT4KB]

TROUBLESHOOTING

[DGT4KB] (OR VHMS_LED DISPLAYS [n311]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KB) Action code


Not set

DGT4KB

Not set

Trouble

Short circuit with power source (Hot short) in No. 1, 2, 3 (front) exhaust temperature sensor system (KB)

Contents of trouble • Signal voltage of more than 4.9V detected from No. 1, 2, 3 (front) exhaust temperature sensor.

Action of controller • None in particular. Problem that • No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function appears on machine Related information

• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). • LED display is [n311] Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 1, 2, 3 (front) exhaust temperature sensor

1

Exhaust temperature sensor Defective No. 1, 2, 3 (front) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced

1) Turn starting switch OFF. 2) Disconnect connector HM-23A. 3) Insert T-adapter. Defective No. 1, 2, 3 (front) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) – (C) HM-23A

Probable cause Ground fault in wiring harand standard value 3 ness when normal


Between (B) – (C)

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-21A and HM-22A. 3) Connect T-adapter. Resistance between HMWiring harness between 22A (female) (1), HM-22A (female) (1) – HMMin. 1 Mz HM-21A (female) (1) – chas21A (female) (1) sis ground 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-23A. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (7) – HM-23A (female) (B)

5

Resistance between HMCN2 (female) (7), Min. 1 Mz HM-23A (female) (B) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. Defective VHMS controller 5) Start engine. Between HM-CN1 (2) – HM-CN2A (12) Between HM-CN2A (7) – (12)

20-1016 (10)


Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

HD465-7, HD605-7

TROUBLESHOOTING

[DGT4KB]


HD465-7, HD605-7

20-1017 (2)

[DGT5KA]

TROUBLESHOOTING

[DGT5KA] (OR VHMS_LED DISPLAYS [n322]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA) Action code


Not set

DGT5KA

Not set

Trouble

Disconnection, short circuit with chassis ground in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA)

Contents of trouble • Signal voltage of less than 0.3V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.

Action of controller • None in particular. Problem that • No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function appears on machine Related information

• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). • LED display is [n322] Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor

1

Exhaust temperature sensor Defective No. 4, 5, 6 (rear) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced

1) Turn starting switch OFF. 2) Disconnect connector HM-23B. 3) Insert T-adapter. Defective No. 4, 5, 6 (rear) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) – (C) HM-23B


Between (B) – (C)


Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and HM-23B. 3) Connect T-adapter. Disconnection in wiring harness 3 (disconnection, defective contact)

Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – HM-23B (female) (A) Wiring harness between HM-CN2A (female) (5) – HM-23B (female) (B)

Resistance Max. 1 z

Wiring harness between HM-22B (female) (1) Resistance Max. 1 z – HM-21B (female) (1) Wiring harness between HM-22B (female) (2) Resistance Max. 1 z – HM-21B (female) (2) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and HM-23B. 3) Connect T-adapter. Ground fault in wiring har4 ness

20-1018 (10)

Wiring harness between HM-CN1 (female) (2) – HM-23B (female) (A)

Resistance between HMCN1 (female) (2), HM-23B (female) (A) – chassis ground

Wiring harness between HM-CN2A (female) (5) – HM-23B (female) (B)

Resistance between HMCN2A (female) (5), HM-23B Min. 1 Mz (female) (B) – chassis ground

Min. 1 Mz

HD465-7, HD605-7

[DGT5KA]

TROUBLESHOOTING

Cause

Probable cause and standard value 5 Defective VHMS controller when normal

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) – HM-CN2A (12) Between HM-CN2A (5) – (12)

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V


HD465-7, HD605-7

20-1019 (10)

[DGT5KB]

TROUBLESHOOTING

[DGT5KB] (OR VHMS_LED DISPLAYS [n321]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KB) Action code


Not set

DGT5KB

Not set

Trouble

Short circuit with power source (Hot short) in No. 4, 5, 6 (rear) exhaust temperature sensor system (KB)

Contents of trouble • Signal voltage of more than 4.9V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.

Action of controller • None in particular. Problem that • No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function. appears on machine Related information

• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). • LED display is [n321] Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor

1

Exhaust temperature sensor Defective No. 4, 5, 6 (rear) Does not become normal when replaced exhaust temperature sensor normal Becomes normal when replaced

1) Turn starting switch OFF. 2) Disconnect connector HM-23B. 3) Insert T-adapter. Defective No. 4, 5, 6 (rear) 4) Connect connector. 2 exhaust temperature sensor 5) Start engine. amp Between (A) – (C) HM-23B

Probable cause Ground fault in wiring harand standard value 3 ness when normal


Between (B) – (C)

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-21B and HM-22B. 3) Connect T-adapter. Resistance between Wiring harness between HM-22B (female) (1), HM-22B (female) (1) – HMHM-21B (female) (1) – 21B (female) (1) chassis ground

Resistance between HM-CN2 (female) (5), HM-23B (female) (B) – chassis ground


(10)

Min. 1 Mz

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. Defective VHMS controller 5) Start engine. Between HM-CN1 (2) – HM-CN2A (12)

20-1020

Min. 1 Mz

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-23B. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (5) – HM-23B (female) (B)

5


Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V

HD465-7, HD605-7

TROUBLESHOOTING

[DGT5KB]


HD465-7, HD605-7

20-1021 (2)

[DHE5KB]

TROUBLESHOOTING

[DHE5KB] (OR VHMS_LED DISPLAYS [n332]) DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KA) Action code


Not set

DHE5KB

Not set

Trouble

Disconnection, short circuit with chassis ground in engine blowby pressure sensor system (KA)

Contents of trouble • Signal voltage of blow-by pressure sensor has dropped below 0.1V.

Action of controller • None in particular. Problem that • Blow-by pressure cannot be monitored with monitoring function. appears on machine Related information

• Blow-by pressure can be checked with monitoring function (code: 42800). • LED display is [n332] Cause

1

Defective engine blow-by pressure sensor

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-12. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-12 (B) – (A)

Voltage

4.5 – 5.5V

Between HM-12 (C) – (A)

Voltage

0.3 – 0.7V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12. Disconnection in wiring har- 3) Connect T-adapter. 2 ness (disconnection, defec- Wiring harness between HM-CN1 (female) Resistance Max. 1 z tive contact) (4),(5) – HM-12 (female) (B) Wiring harness between HM-CN2A (female) (18) – HM-12 (female) (C) Probable cause and standard value when normal

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12. 3) Connect T-adapter.

3



Wiring harness between HM-CN1 (female) (4),(5) – HM-12 (female) (B)

Resistance between HMCN1 (female) (4),(5), HM-12 Min. 1 Mz (female) (B) – chassis ground

Wiring harness between HM-CN2A (female) (18) – HM-12 (female) (C)

Resistance between HMCN2A (female) (18), HM-12 Min. 1 Mz (female) (C) - chassis ground

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (5) – HM-CN2A (12)

Voltage

4.5 – 5.5V


Voltage

0.3 – 0.7V


20-1022 (10)

HD465-7, HD605-7

[DHE5KY]

TROUBLESHOOTING

[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY) Action code


Not set

DHE5KY

Not set

Trouble

Short circuit with power source (Hot short) in engine blow-by pressure sensor system (KY)

Contents of trouble • Signal voltage of blow-by pressure sensor has risen above 4.7V.

Action of controller • None in particular. Problem that • Blow-by pressure cannot be monitored with monitoring function. appears on machine Related information

• Blow-by pressure can be checked with monitoring function (code: 42800). • LED display is [n331] Cause

1


Defective engine blow-by pressure sensor


Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-12. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-12 (B) – (A)

Voltage

4.5 – 5.5 V

Between HM-12 (C) – (A)

Voltage

0.3 – 0.7 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2A and HM-12. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2A (female) (18) – HM-12 (female) (C)


Voltage between HM-CN2A (female)(18), HM-12 (female) (C) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Connect T-adapter. Between HM-CN1 (5) – HM–CN2A (12)

Voltage

4.5 – 5.5 V


Voltage

0.3 – 0.7 V


HD465-7, HD605-7

20-1023 (10)

[DhP4KX]

TROUBLESHOOTING

[DhP4KX]

SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIGNAL RANGE (KX)

Action code



DhP4KX

PLM

Trouble

Suspension pressure sensor (Front right): Out of input signal range (KX)

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

Action of controller • None in particular. Problem that • The payload is not indicated and saved correctly. appears on machine Related information

• The suspension pressure (Front right) signal can be checked with the monitoring function (Code: 32804). • This failure occurs only when the built-in PLM function is installed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (1) – SUFR (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – SUFR (female) (B) Wiring harness between HM-CN2B (female) (9) – SUFR (female) (A)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR. 3) Connect T-adapter.

2




Wiring harness between HM-CN2B (female) (1) – SUFR (female) (C)

Resistance between HMCN2B (female) (1), SUFR (female) (C) – chassis ground

Min. 1 M z

Wiring harness between HM-CN1 (female) (2) – SUFR (female) (B)

Resistance between HMCN1 (female) (2), SUFR (female) (B) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SUFR. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (1) – SUFR (female) (C)

Voltage between HM-CN2B (female) (1), SUFR (female) (C) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector SUFR. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Front right) 5) Turn starting switch ON.

5

20-1023-1 (10)

Defective VHMS & PLM controller

Between SUFR (B) – (A)

Voltage

20 – 30 V

Between SUFR (C) – (A)

Voltage

1.0 – 4.6 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2B. 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN1 (2) – HM-CN2B (9)

Voltage

20 – 30 V

Between HM-CN2B (1) – (9)

Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DhP4KX]


HD465-7, HD605-7

20-1023-2 (5)

[DhP5KX]

TROUBLESHOOTING

[DhP5KX]

SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIGNAL RANGE (KX)

Action code



DhP5KX

PLM

Trouble

Suspension pressure sensor (Front left): Out of input signal range (KX)

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


• The suspension pressure (Front left) signal can be checked with the monitoring function (Code: 32805). • This failure occurs only when the built-in PLM function is installed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (2) – SUFL (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – SUFL (female) (B) Wiring harness between HM-CN2B (female) (9) – SUFL (female) (A)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL. 3) Connect T-adapter. Ground fault in wiring har2 ness


Wiring harness between HM-CN2B (female) (2) – SUFL (female) (C)

Resistance between HMCN2B (female) (2), SUFL (female) (C) – chassis ground

Wiring harness between HM-CN1 (female) (2) – SUFL (female) (B)

Resistance between HMCN1 (female) (2), SUFL (fe- Min. 1 M z male) (B) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SUFL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (2) – SUFL (female) (C)

Voltage between HM-CN2B (female) (2), SUFL (female) (C) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector SUFL. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Front left) 5) Turn starting switch ON.

5

20-1023-3 (10)


Between SUFL (B) – (A)

Voltage

20 – 30 V

Between SUFL (C) – (A)

Voltage

1.0 – 4.6 V


Voltage

20 – 30 V


Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DhP5KX]


HD465-7, HD605-7

20-1023-4 (5)

[DhP6KX]

TROUBLESHOOTING

[DhP6KX]

SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIGNAL RANGE (KX)

Action code



DhP6KX

PLM

Trouble

Suspension pressure sensor (Rear right): Out of input signal range (KX)

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


• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32806). • This failure occurs only when the built-in PLM function is installed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURR. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (7) – SURR (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – SURR (female) (B) Wiring harness between HM-CN2B (female) (9) – SURR (female) (A)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURR. 3) Connect T-adapter.

2




Wiring harness between HM-CN2B (female) (7) – SURR (female) (C)

Resistance between HMCN2B (female) (7), SURR (female) (C) – chassis ground

Min. 1 M z

Wiring harness between HM-CN1 (female) (2) – SURR (female) (B)

Resistance between HMCN1 (female) (7), SURR (female) (B) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SURR. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (7) – SURR (female) (C)

Voltage between HM-CN2B (female) (7), SURR (female) (C) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector SURR. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Rear right) 5) Turn starting switch ON.

5

20-1023-5 (10)


Between SURR (B) – (A)

Voltage

20 – 30 V

Between SURR (C) – (A)

Voltage

1.0 – 4.6 V


Voltage

20 – 30 V


Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DhP6KX]


HD465-7, HD605-7

20-1023-6 (5)

[DhP7KX]

TROUBLESHOOTING

[DhP7KX]

SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL RANGE (KX)

Action code



DhP7KX

PLM

Trouble

Suspension pressure sensor (Rear right): Out of input signal range (KX)

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


• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32807). • This failure occurs only when the built-in PLM function is installed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURL. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (8) – SURL (female) (C) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – SURL (female) (B) Wiring harness between HM-CN2B (female) (9) – SURL (female) (A)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and SURL. 3) Connect T-adapter. Ground fault in wiring har2 ness


Wiring harness between HM-CN2B (female) (8) – SURL (female) (C)

Resistance between HMCN2B (female) (8), SURL (female) (C) – chassis ground

Wiring harness between HM-CN1 (female) (2) – SURL (female) (B)

Resistance between HMCN1 (female) (2), SURL (fe- Min. 1 M z male) (B) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN2B and SURL. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (8) – SURL (female) (C)

Voltage between HM-CN2B (female) (8), SURL (female) (C) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector SURL. 3) Insert connect T-adapter. Defective suspension pres- 4) Connect connector. 4 sure sensor (Rear left) 5) Turn starting switch ON.

5

20-1023-7 (10)


Between SURL (B) – (A)

Voltage

20 – 30 V

Between SURL (C) – (A)

Voltage

1.0 – 4.6 V


Voltage

20 – 30 V


Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DhP7KX]


HD465-7, HD605-7

20-1023-8 (5)

[DKH1KX]

TROUBLESHOOTING

[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code


E01

DKH1KX

PLM

Trouble Pitch angle sensor: Out of input signal range (KX)

Contents of trouble • The voltage of the signal circuit of the pitch angle sensor is below 0.3 V or above 4.9 V.


• The pitch angle sensor signal [Angle (rad.)] can be checked with the monitoring function (Code: 32901). • This failure occurs only when the built-in PLM function is installed. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, and PM3. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z 1 ness (Disconnection or de- (3) – PM3 (female) (B) fective contact) Wiring harness between HM-CN1 (female) (2) Resistance Max. 1 z – PM3 (female) (C) Wiring harness between HM-CN2B (female) (9) – PM3 (female) (A)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter. 2



Wiring harness between HM-CN2B (female) (3) – PM3 (female) (B)

Resistance between HMCN2B (female) (3), PM3 (fe- Min. 1 M z male) (B) – chassis ground

Wiring harness between HM-CN1 (female) (2) – PM3 (female) (C)

Resistance between HMCN1 (female) (2), PM3 (female) (C) – chassis ground

Min. 1 M z

1) Turn starting switch OFF. 2) Disconnect connectors BRC3B and PM3. 3) Connect T-adapter. 4) Turn starting switch ON. Wiring harness between HM-CN2B (female) (3) – PM3 (female) (B)

Voltage between HM-CN2B (female) (3), MP3 (female) (B) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connectors PM3. 3) Insert connect T-adapter. 4 Defective pitch angle sensor 4) Connect connector. 5) Turn starting switch ON.

5

20-1023-9 (10)


Between PM3 (C) – (A)

Voltage

20 – 30 V

Between PM3 (B) – (A)

Voltage

1.0 – 4.6 V

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2B 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between HM-CN1 (2) – HM-CN2B (9)

Voltage

20 – 30 V


Voltage

1.0 – 4.6 V

HD465-7, HD605-7

TROUBLESHOOTING

[DKH1KX]


HD465-7, HD605-7

20-1023-10 (6)

[F@BBZL]

TROUBLESHOOTING

[F@BBZL] (OR VHMS_LED DISPLAYS [n338]) ENGINE BLOW-BY PRESSURE IS HIGH: (ZL) Action code Not set

Failure code Controller code F@BBZL

Not set

Trouble Engine blow-by pressure is high: (ZL)

Contents of trouble • Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.

Action of controller • None in particular. Problem that • If machine continues to be used as it is, engine may be damaged. appears on machine

• Blow-by pressure can be checked with monitoring function (code: 42800). • LED display is [n338] Related information • If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in blow-by 1 pressure

Probable cause and standard value Defective orifice inside when normal 2 breather


20-1024 (10)

Standard value in normal state/Remarks on troubleshooting Inspect engine and repair if any abnormality is found Inspect orifice inside breather and repair if any abnormality is found If Items 1 and 2 are normal, defective VHMS controlle

HD465-7, HD605-7

[F@BYNR]

TROUBLESHOOTING

[F@BYNR] (OR VHMS_LED DISPLAYS [n362]) NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR) Action code



F@BYNR

Not set

Trouble No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)

• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust temperature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750 °C at more than rated output speed and 800 °C at less than max. torque speed)


• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600) • LED display is [n362] Related information • If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 1, 2, 3 1 (front) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller


Inspect engine and repair if any abnormality is found

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1 and HM-CN2A. 3) Insert T-adapter. 4) Connect connector. 5) Start engine. Between HM-CN1 (2) – HM-CN2A (12) Between HM-CN2A (7) – (12)

Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V


HD465-7, HD605-7

20-1025 (10)

[F@BYNS]

TROUBLESHOOTING

[F@BYNS] (OR VHMS_LED DISPLAYS [n361]) NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS) Action code Not set Contents of trouble

Failure code Controller code F@BYNS

Not set

Trouble No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)

• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust temperature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700 °C at more than rated output speed and 750 °C at less than max. torque speed)


• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). • LED display is [n361] Related information • If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 1, 2, 3 1 (front) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller




Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V


20-1026 (10)

HD465-7, HD605-7

[F@BZNR]

TROUBLESHOOTING

[F@BZNR] (OR VHMS_LED DISPLAYS [n372]) NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR) Action code



F@BZNR

Not set

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)

• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust temperature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750 °C at more than rated output speed and 800 °C at less than max. torque speed)


• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600). • LED display is [n372] Related information • If failure codes [DGT5KA] or [DGT5KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 4, 5, 6 1 (rear) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller




Voltage

20 – 30 V

20 °C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V


HD465-7, HD605-7

20-1027 (10)

[F@BZNS]

TROUBLESHOOTING

[F@BZNS] (OR VHMS_LED DISPLAYS [n371]) NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS) Action code Not set Contents of trouble

Failure code Controller code F@BZNS

Not set

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)

• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust temperature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700 °C at more than rated output speed and 750 °C at less than max. torque speed)


• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601). • LED display is [n371] Related information • If failure codes [DGT5KA] or [DGT5KB] are displayed, carry out troubleshooting first for the applicable code. Cause Abnormal rise in exhaust temperature for No. 4, 5, 6 1 (rear) (When system is normal) Probable cause and standard value when normal 2 Defective VHMS controller




Voltage

20 – 30 V

20° C

Voltage

Approx. 0.9 – 1.2 V

500 °C

Voltage

Approx. 2.6 – 3.5 V


20-1028 (10)

HD465-7, HD605-7

VHMS-1

TROUBLESHOOTING

VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION a) Satellite communication data are not transmitted Action code


Not set

Not set

Not set

Trouble

Abnormality in satellite data communication a) Satellite communication data are not transmitted

Contents of trouble • Satellite communication data are not transmitted.

Action of controller • None in particular. Problem that • Satellite communication data are not transmitted. appears on machine Related information

Cause 1


Machine is in tunnel or build- • Not defective. ing aMove the machine outdoors.

Machine is behind building • Not defective. 2 or mountain and only a part aMove the machine to a place from where you can look out over the of heaven is seen from it heavens. 3

Abnormality in communica- • Check communication antenna. If it is broken or removed, repair or tion antenna replace it.

Entry of foreign matter in 4 communication antenna connector 5

• Check inside of communication antenna and remove foreign matter.

Abnormality in communica- • Check communication antenna. If it is broken (or disconnected), retion antenna cable pair or replace it. 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Connect T-adapter. Wiring harness between ORB-B (female) (1) – Resistance Max. 1 z HM-CN4B (female) (4)

Wiring harness between ORB-B (female) (2) – Probable cause Resistance Max. 1 z Disconnection in wiring har- HM-CN4B (female) (10) and standard value 6 ness (Disconnection or deWiring harness between ORB-B (female) (3) – when normal Resistance Max. 1 z fective contact) HM-CN4B (female) (3) Wiring harness between ORB-A (female) (7), Resistance Max. 1 z (8) – HM-CN1 (female) (6), (7) Wiring harness between ORB-A (female) (10), Resistance Max. 1 z (11) – HM-CN1 (female) (19), (20) Wiring harness between ORB-A (female) (2) – Resistance Max. 1 z HM-CN2 (female) (17) 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Connect T-adapter. Wiring harness between ORB-B (female) (1) – HMGround fault or short circuit CN4B (female) (4) 7 in wiring harness Wiring harness between ORB-B (female) (2) – HMCN4B (female) (10)

Resistance between ORB-B (female) (1), HM-CN4B (fe- Min. 1M z male) (4) – chassis ground

Wiring harness between ORB-B (female) (3) – HMCN4B (female) (3)


HD465-7, HD605-7


20-1029 (10)

VHMS-1

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting Wiring harness between ORB-A (female) (7), (8) – HM-CN1 (female) (6), (7)

Resistance between ORB-A (female) (7), (8), HM-CN1 Min. 1M z (female) (6), (7) – chassis ground

Resistance between ORB-A Wiring harness between (female) (10), (11), HM-CN1 ORB-A (female) (10), (11) – Min. 1M z (female) (19), (20) – chassis HM-CN1 (female) (19), (20) ground


Wiring harness between ORB-A (female) (2) – HMCN2A (female) (17)

Resistance between ORB-A (female) (2), HM-CN2A (fe- Min. 1M z male) (17) – chassis ground

Wiring harness between ORB-B (female) (1) – HMCN4B (female) (4) and between ORB-B (female) (2) – HM-CN4B (female) (10)

Resistance between ORB-B (female) (1) – HM-CN4B (female) (4) and between ORB- Min. 1M z B (female) (2) – HM-CN4B (female) (10)

Wiring harness between ORB-B (female) (1) – HMGround fault or short circuit CN4B (female) (4) and be7 in wiring harness tween ORB-B (female) (3) – HM-CN4B (female) (3)

Resistance between ORB-B (female) (1) – HM-CN4B (female) (4) and between ORB- Min. 1M z B (female) (3) – HM-CN4B (female) (3)

Wiring harness between ORB-B (female) (2) – HMCN4B (female) (10) and between ORB-B (female) (3) – HM-CN4B (female) (3)

Resistance between ORB-B (female) (2) – HM-CN4B (female) (10) and between Min. 1M z ORB-B (female) (3) – HMCN4B (female) (3)

Wiring harness between ORB-A (female) (7), (8) – HM-CN1 (female) (6), (7) and between ORB-A (female) (10), (11) – HM-CN1 (female) (19), (20)

Resistance between ORB-A (female) (7), (8) – HM-CN1 (female) (6), (7) and beMin. 1M z tween ORB-A (female) (10), (11) – HM-CN1 (female) (19), (20)

Wiring harness between ORB-A (female) (2) – HMCN2A (female) (17) and between ORB-A (female) (10), (11) – HM-CN1 (female) (19), (20)

Resistance between ORB-A (female) (2) – HM-CN2A (female) (17) and between Min. 1M z ORB-A (female) (10), (11) – HM-CN1 (female) (19), (20)


20-1030 (10)

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A, and ORB-B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON.

HD465-7, HD605-7

VHMS-1

TROUBLESHOOTING

Cause



Standard value in normal state/Remarks on troubleshooting Wiring harness between ORB-B (female) (1) – HMCN4B (female) (4)

Voltage between ORB-B (female) (1), HM-CN4B (female) (4) – chassis ground

Max. 1 V



Max. 1 V



Max. 1 V

Wiring harness between ORB-A (female) (2) – HMCN2A (female) (17)

Voltage between ORB-A (female) (2), HM-CN2A (female) (17) – chassis ground

Max. 1 V

1) Turn starting switch ON. About 3 minutes after the VHMS controller is turned ON, judge by the state of the decimal point of the VHMS controller LED (7 segments on the right side). Decimal point goes off

9

• VHMS controller cannot communicate with ORBCOMM controller (Abnormality in ORBCOMM controller).

Defective ORBCOMM con• Communication with VHMS is normal. troller Decimal point lights up • ORBCOMM controller does not have data to transmit. • Communication with VHMS is normal. Decimal point flashes • ORBCOMM controller has data to transmit quickly and has captured satellite (is transmitting). • Communication with VHMS is normal. Decimal point flashes • ORBCOMM controller has data to transmit slowly but has not captured satellite.


HD465-7, HD605-7

20-1031 (10)

VHMS-1

TROUBLESHOOTING

b) Abnormality in downloading into PC or setting of PC Action code Not set


Not set

Trouble

Abnormality in satellite data communication b) Abnormality in downloading into PC or setting of PC

Contents of trouble • PC cannot download or cannot be set.

Action of controller • None in particular. Problem that • PC cannot download or cannot be set. appears on machine Related information

Cause

Disconnection in wiring harness (Disconnection or de1 fective contact) aWiring harness for downloading in cab

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors HM-CN4A and VHMS. 3) Connect T-adapter. Wiring harness between HM-CN4A (female) (9) – VHMS (female) (B)

Resistance Max. 1 z

Wiring harness between HM-CN4A (female) (10) – VHMS (female) (C)

Resistance Max. 1 z

Wiring harness between HM-CN4A (female) (11) – VHMS (female) (D)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors HM-CN4A and VHMS. 3) Connect T-adapter.


Wiring harness between HM-CN4A (female) (9) – VHMS (female) (B)

Resistance between HMCN4A (female) (9), VHMS (female) (B) – chassis ground

Wiring harness between HM-CN4A (female) (10) – VHMS (female) (C)

Resistance between HMCN4A (female) (10), VHMS Min. 1M z (female) (C) – chassis ground

Wiring harness between HM-CN4A (female) (11) – Ground fault or short circuit VHMS (female) (D) in wiring harness 2 aWiring harness for down- Wiring harness between loading inside cab HM-CN4A (female) (9) –

Resistance between HMCN4A (female) (11), VHMS (female) (D) – chassis ground

Min. 1M z

Min. 1M z

Resistance between HMCN4A (female) (9) – VHMS VHMS (female) (B) and be- (female) (B) and between Min. 1M z tween HM-CN4A (female) HM-CN4A (female) (10) – (10) – VHMS (female) (C) VHMS (female) (C)

20-1032 (10)

Wiring harness between HM-CN4A (female) (9) – VHMS (female) (B) and between HM-CN4A (female) (11) – VHMS (female) (D)

Resistance between HMCN4A (female) (9) – VHMS (female) (B) and between Min. 1M z HM-CN4A (female) (11) – VHMS (female) (D)

Wiring harness between HM-CN4A (female) (10) – VHMS (female) (C) and between HM-CN4A (female) (11) – VHMS (female) (D)

Resistance between HMCN4A (female) (10) – VHMS (female) (C) and between Min. 1M z HM-CN4A (female) (11) – VHMS (female) (D)

HD465-7, HD605-7

VHMS-1

TROUBLESHOOTING

Cause

Disconnection in wiring harness (Disconnection or de3 fective contact) aWiring harness for downloading inside cab

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors VHMS and VDL. 3) Connect T-adapter. Wiring harness between VHMS (male) (B) – VDL (female) (B)

Resistance Max. 1 z

Wiring harness between VHMS (male) (C) – VDL (female) (C)

Resistance Max. 1 z

Wiring harness between VHMS (male) (D) – VDL (female) (D)

Resistance Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors VHMS and VDL. 3) Connect T-adapter. Wiring harness between Resistance between VHMS VHMS (male) (B) – VDL (fe- (male) (B) – VDL (female) Min. 1M z male) (B) (B) – chassis ground Wiring harness between Resistance between VHMS VHMS (male) (C) – VDL (fe- (male) (C) – VDL (female) Min. 1M z male) (C) (C) – chassis ground


Wiring harness between Resistance between VHMS VHMS (male) (D) – VDL (fe- (male) (D) – VDL (female) Min. 1M z male) (D) (D) – chassis ground

Ground fault or short circuit Wiring harness between in wiring harness 4 aWiring harness for down- VHMS (male) (B) – VDL (female) (B) and between loading outside cab VHMS (male) (C) – VDL (female) (C)

Resistance between VHMS (male) (B) – VDL (female) (B) and between VHMS Min. 1M z (male) (C) – VDL (female) (C)

Wiring harness between VHMS (male) (B) – VDL (female) (B) and between VHMS (female) (D) – VDL (male) (D)

Resistance betweenVHMS (male) (B) – VDL (female) (B) and between VHMS (male) (D) – VDL (female) (D)

Wiring harness between VHMS (male) (C) – VDL (female) (C) and between VHMS (male) (D) – VDL (female) (D)

Resistance between VHMS (male) (C) – VDL (female) (C) and between VHMS Min. 1M z (male) (D) – VDL (female) (D)

Min. 1M z


HD465-7, HD605-7

20-1033 (10)

VHMS-2

TROUBLESHOOTING

VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER (DATA ARE NOT SAVED) Action code Not set Contents of trouble


Not set

Abnormality in saving data in VHMS controller Trouble (Data are not saved) a LED of VHMS counts up and operates normally

• Data are not saved in the VHMS controller. aPower is kept turned off.

Action of controller • None in particular. Problem that • None in particular. appears on machine Related information

• If fuse BT-2 (29) is broken, check the wiring harness between fuse and HM-CN1 (6), (7) for grounding fault. Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector HM-CN1 and fuse terminal BT-2 (29). 3) Connect T-adapter.

Wiring harness between HM-CN1 (female) (6), Resistance Max. 1 z Probable cause (7) – fuse terminal BT-2 (29) Disconnection in wiring harand standard value 1 ness (Disconnection or de- *1) After the starting switch is turned to the OFF position, the LED of when normal the VHMS displays SH (Processing time of memory), and then the fective contact) all operation is finished (the power for the VHMS is turned OFF), if the all system is normal. *2) If the power for the VHMS is turned OFF immediately after the starting switch is turned to the OFF position, the power is not applied constantly.

20-1034 (10)

HD465-7, HD605-7

TROUBLESHOOTING

VHMS-2


HD465-7, HD605-7

20-1035 (5)

VHMS-3

TROUBLESHOOTING

VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW (WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT IS NORMAL) Action code Not set


Not set

Engine blow-by pressure indicated by monitor is low Trouble (When blow-by pressure measured with measuring instrument is normal)

Contents of trouble • The engine blow-by pressure indicated by the monitor is low.

Action of controller • None in particular. • The engine blow-by pressure indicated by the monitor is low. Problem that appears on machine (The blow-by pressure measured with a measuring instrument is normal.) Related information

• The blow-by pressure can be checked with the monitoring function (Code: 42800). • If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.

Cause Standard value in normal state/Remarks on troubleshooting Probable cause and standard value 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal. when normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.

20-1036 (10)

HD465-7, HD605-7

TROUBLESHOOTING OF ASR CONTROLLER SYSTEM (ASR MODE)

Electrical system diagram related ASR control ........................................................................................ 20-1052 Information in troubleshooting table...................................................................................................... 20-1053 Phenomenon code table....................................................................................................................... 20-1054 [DDDAKA] ASR system switch system: Disconnection (KA).............................................................. 20-1055 [DDDAKB] ASR system switch system: Short circuit (KB) ................................................................. 20-1056 [DK30KX] Steering angle sensor: Out of input signal range (KX) .................................................... 20-1057 [DLF8KA] Wheel speed sensor (RR): Disconnection (KA) ............................................................... 20-1059 [DLF8LC] Wheel speed sensor (RR): *See separate list (LC) ......................................................... 20-1060 [DLF9KA] Wheel speed sensor (RL): Disconnection (KA) ................................................................ 20-1061 [DLF9LC] Wheel speed sensor (RL): *See separate list (LC)........................................................... 20-1062 [dLT3LC] Transmission output shaft speed sensor: *See separate list (LC) ................................... 20-1063 [DWNBK4] Shut-off solenoid valve: Uncontrollable (K4) .................................................................... 20-1065 [DWNBKA] Shut-off solenoid valve: Disconnection (KA) .................................................................... 20-1067 [DWNBKB] Shut-off solenoid valve: Short circuit (KB) ....................................................................... 20-1068 [DWNBKY] Shut-off solenoid valve: Short circuit with power source (Hot short) (KY) ........................ 20-1069 [DWNBMA] Shut-off solenoid valve: Malfunction (MA) ........................................................................ 20-1070 [DX17K4] ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4) ............ 20-1071 [DX17KA] ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA) ............ 20-1073 [DX17KB] ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)................ 20-1074 [DX17KY] ASR proportional solenoid pressure reducing valve (Right): Short circuit with power source (Hot short) (KY).......................................................................................... 20-1075 [DX17MA] ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)................ 20-1076 [DX18K4] ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4) .............. 20-1077 [DX18KA] ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA) .............. 20-1079 [DX18KB] ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB) .................. 20-1080 [DX18KY] ASR proportional solenoid pressure reducing valve (Left): Short circuit with power source (Hot short) (KY).......................................................................................... 20-1081 [DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082

HD465-7, HD605-7

20-1051 (10)

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL

ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL

20-1052 (5)

HD465-7, HD605-7


TROUBLESHOOTING



Display on panel

Display on panel

Display on panel


Contents of trouble Condition at the time when the monitor panel or controller detects the trouble


The action taken by the monitor panel or controller to protect the system or devices when the monitorpanel or controller detects the trouble

The problem that appears on the machine as a result of the action taken by the monitor panel or controller Problem that appears on machine (shown above) Related information Information related to the detected trouble or troubleshooting

Cause

1

2


Possible causes 3 Possible causes of trouble and standard value (Given numbers are refer- 1) Method of indicating connector No. and handling of Tin normal state ence numbers, which do not adapter indicate priority) Insert or connect T-adapter as explained below for trouble-

shooting, unless otherwise specified. 4

• If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side.

2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. 5

HD465-7, HD605-7

• Connect positive (+) lead to pin No. or harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

20-1053 (10)


TROUBLESHOOTING


This a circuit diagram of the part related to the failure. • Connector No.: Shows the "Type – Number of pin" and " Color". • Arrow ( ): Roughly shows the location on the machine.


Contents

Phenomenon code

Contents

KA


L0


KB

Short circuit

L1


KK


L2


KQ


L3


KR


L4


KT


L6


KX


L8


KY


LC


KZ


LD


MA

Malfunction

LH


MB


MW

Sliding

NS

Overheat

ZG


ZK


20-1054 (10)

HD465-7, HD605-7

[DDDAKA]

TROUBLESHOOTING

[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA) Action code


E01

DDDAKA

BK

Trouble ASR system switch system: Disconnection (KA)

Contents of trouble • The ASR system switch ON input and system switch OFF input are turned OFF.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter.


Wiring harness between DPC2B (female) (3) – Resistance Max. 1 z ASR (female) (3) 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter. Wiring harness between DPC2B (female) (9) – Resistance Max. 1 z ASR (female) (3)

Possible causes and standard value Defective ASR system 2 in normal state switch

1) Turn starting switch OFF. 2) Replace ASR system switch with normal one. 3) Turn starting switch ON. When ASR system switch is replaced with normal one, does condition become normal?

Yes

System switch is normal

No

System switch is defective

1) Turn starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. 3 Defective machine monitor

Between DPC2B (3) – ASR system switch ON chassis ground ASR system switch OFF

Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

Max. 1 V

Voltage

20 – 30 V


HD465-7, HD605-7

20-1055 (10)

[DDDAKB]

TROUBLESHOOTING

[DDDAKB] ASR SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB) Action code E01

Failure code Controller code DDDAKB

BK

Trouble ASR system switch system: Short circuit (KB)

Contents of trouble • The ASR system switch ON input and system switch OFF input are turned ON.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors ASR and DPC2B. 3) Connect T-adapter. 4) Turn starting switch ON.


Possible causes Defective ASR system and standard value 2 switch in normal state

Wiring harness between DPC2B (female) (3) – ASR (female) (3)

Voltage between DPC2B (female) (3), ASR (female) (3) – Max. 1 V chassis ground

Wiring harness between DPC2B (female) (9) – ASR (female) (2)

Voltage between DPC2B (female) (9), ASR (female) (2) – Max. 1 V chassis ground

1) Turn starting switch OFF. 2) Replace ASR system switch with normal one. 3) Turn starting switch ON. When ASR system switch is replaced with normal one, does condition become normal?

Yes

System switch is normal

No

System switch is defective

1) Turn starting switch OFF. 2) Disconnect connector DPC2B. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. 3 Defective machine monitor


Voltage

20 – 30 V

Voltage

Max. 1 V


Voltage

Max. 1 V

Voltage

20 – 30 V


20-1056 (10)

HD465-7, HD605-7

[DK30KX]

TROUBLESHOOTING

[DK30KX] STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code


E01

DK30KX

BK

Trouble Steering angle sensor: Out of input signal range (KX)

Contents of trouble • The voltage of the signal circuit of the steering angle sensor is below 0.5 V or above 4.7 V.

Action of controller • Controls the ASR by setting the steering angle (turning angle) to 20 degrees. Problem that • The machine is not affected badly. appears on machine Related information • The steering angle can be checked with the monitoring function (Code: 35400).

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter.

Disconnection in wiring Wiring harness between BRC2 (female) (16) – Resistance Max. 1 z harness ASR1 (female) (3) 1 (Disconnection or defective Wiring harness between BRC3A (female) (7) – contact) Resistance Max. 1 z ASR1 (female) (2) Wiring harness between BRC3A (female) (16) Resistance Max. 1 z – ASR1 (female) (1) 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter. 2


Resistance between BRC2 Wiring harness between BRC2 (female) (16) – ASR1 (female) (16), ASR 1 (female) Min. 1 Mz (female) (3) (3) – chassis ground Resistance between BRC3A Wiring harness between BRC3A (female) (7) – ASR1 (female) (7), ASR1 (female) Min. 1 Mz (female) (2) (2) – chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC2, BRC3A, and ASR1. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON.


4

Defective steering angle sensor

Voltage between BRC2 Wiring harness between BRC2 (female) (16) – ASR1 (female) (16), ASR1 (female) (female) (3) (3) – chassis ground

Max. 1 V

Voltage between BRC3A Wiring harness between BRC3A (female) (7) – ASR1 (female) (7), ASR1 (female) (female) (2) (2) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector RTL. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR1 (3) – (1)

Voltage

4.6 – 5.4 V

Between ASR1 (2) – (1)

Voltage

2–3V

Between BRC1 (16) – BRC3A (16)

Voltage

4.6 – 5.4 V

Between BRC3A (7) – (16)

Voltage

2–3V

1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and RTL. 3) Insert connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON.

HD465-7, HD605-7

20-1057 (10)

TROUBLESHOOTING

[DK30KX]


20-1058 (5)

HD465-7, HD605-7

[DLF8KA]

TROUBLESHOOTING

[DLF8KA] WHEEL SPEED SENSOR (RR): DISCONNECTION (KA) Action code


E01

DLF8KA

BK

Trouble Wheel speed sensor (RR): Disconnection (KA)

Contents of trouble • The signal circuit of the wheel speed sensor (RR) is disconnected and signals are not input.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

Cause

1


Defective wheel speed sensor (RR)

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRR. 3) Connect T-adapter. Between WSRR (male) (1) – (2)


Between WSRR (male) (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Connect T-adapter.

Disconnection in wiring harness 2 Wiring harness between BRC3A (female) (3) – Resistance Max. 1 z (Disconnection or defective WSRR (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z – WSRR (female) (2)

3

1) Turn starting switch OFF. 2) Disconnect connector BRC3A. Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) – (14)



HD465-7, HD605-7

20-1059 (10)

[DLF8LC]

TROUBLESHOOTING

[DLF8LC] WHEEL SPEED SENSOR (RR): *SEE SEPARATE LIST (LC) Action code



DLF8LC

BK

Trouble Wheel speed sensor (RR): *See separate list (LC)

• The wheel speed (RR) calculated from the transmission output shaft speed sensor signal and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

Cause

1


3

Defective wheel speed sensor (RR)



Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRR. 3) Connect T-adapter. Between WSRR (male) (1) – (2)


Between WSRR (male) (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Connect T-adapter. Wiring harness between BRC3A (female) (3) – WSRR (female) (1)

Resistance between BRC3A (female) (3), WSRR (female) Min. 1 Mz (1) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRR. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between BRC3A (female) (3) – WSRR (female) (1)

Voltage between BRC3A (female) (3), WSRR (female) (1) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 4 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) – (14)



20-1060 (10)

HD465-7, HD605-7

[DLF9KA]

TROUBLESHOOTING

[DLF9KA] WHEEL SPEED SENSOR (RL): DISCONNECTION (KA) Action code


E01

DLF9KA

BK

Trouble Wheel speed sensor (RL): Disconnection (KA)

Contents of trouble • The signal circuit of the wheel speed sensor (RL) is disconnected and signals are not input.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

Cause


1) Turn starting switch OFF. 2) Disconnect connector WSRL. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (RL) Between WSRL (male) (1) – (2) Between WSRL (male) (1), (2) – chassis ground Possible causes and standard value in normal state

Resistance 950 – 1,450 z Resistance Min. 1 Mz

1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Connect T-adapter.

Disconnection in wiring harness 2 Wiring harness between BRC3A (female) (2) – (Disconnection or defective Resistance Max. 1 z WSRL (female) (1) contact) Wiring harness between BRC3A (female) (14) Resistance Max. 1 z – WSRL (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 3 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (3) – (14)



HD465-7, HD605-7

20-1061 (10)

[DLF9LC]

TROUBLESHOOTING

[DLF9LC] WHEEL SPEED SENSOR (RL): *SEE SEPARATE LIST (LC) Action code



DLF9LC

BK

Trouble Wheel speed sensor (RL): *See separate list (LC)

• The wheel speed (RL) calculated from the transmission output shaft speed sensor signal and wheel (RR) speed sensor signal is different from the signal speed of the wheel (RL) speed sensor.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

Cause

1


3

Defective wheel speed sensor (RL)



Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector WSRL. 3) Connect T-adapter. Between WSRL (male) (1) – (2)


Between WSRL (male) (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Connect T-adapter. Resistance between BRC3A Wiring harness between BRC3A (female) (3) – WSRL (female) (3), WSRL (female) Min. 1 Mz (female) (1) (1) – chassis ground 1) Turn starting switch OFF. 2) Disconnect connectors BRC3A and WSRL. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Voltage between BRC3A Wiring harness between BRC3A (female) (3) – WSRL (female) (3), WSRL (female) (female) (1) (1) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connector BRC3A. 4 Defective retarder controller 3) Connect T-adapter. Between BRC3A (female) (2) – (14)



20-1062 (10)

HD465-7, HD605-7

[dLT3LC]

TROUBLESHOOTING

[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE SEPARATE LIST (LC) Action code


E01

dLT3LC

BK

Trouble

Transmission output shaft speed sensor: *See separate list (LC) (ASR is set and ASR system switch is turned ON)

• The travel speed calculated from the transmission output shaft speed sensor signal, wheel (RR) speed Contents of trouble sensor signal, and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor and wheel (RL) speed sensor. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

• The transmission output shaft speed can be checked with the monitoring function (Code: 31400). The wheel speed can be checked with the monitoring function (Code: 39700, 39701). Cause

1

Defective transmission output shaft speed sensor

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector CN5. 3) Connect T-adapter. Between CN5 (male) (1) – (2)


Between CN5 (male) (1), (2) – chassis ground Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5. 3) Connect T-adapter. 2




Wiring harness between ATC3A (female) (3) – BRC3A (female) (13) – PM5 (female) (7) – CN5 (female) (1)

Resistance between BRC3A (female) (13), ATC3A (female) Min. 1 Mz (3), PM5 (female) (7), CN5 (female) (1) – chassis ground

1) Turn starting switch OFF. 2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between ATC3A (female) (3) – BRC3A (female) (13) – PM5 (female) (7) – CN5 (female) (1)

Voltage between ATC3A (female) (3), BRC3A (female) (13), PM5 (female) (7), CN5 (female) (1) – chassis ground

1) Turn starting switch OFF. Defective transmission con- 2) Disconnect connector BRC3A. 4 3) Connect T-adapter. troller Between BRC3A (female) (13) – (14)

HD465-7, HD605-7

Max. 1 V


20-1063 (10)

TROUBLESHOOTING

[dLT3LC]


20-1064 (5)

HD465-7, HD605-7

[DWNBK4]

TROUBLESHOOTING

[DWNBK4] SHUT-OFF SOLENOID VALVE: UNCONTROLLABLE (K4) Action code


E01

DWNBK4

BK

Trouble Shut-off solenoid valve: Uncontrollable (K4)

Contents of trouble • The shut-off solenoid valve does not return (does not move) or the pressure switch system is defective.

Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause 1

2


Defective shut-off solenoid valve

• Check the shut-off solenoid valve and repair or replace it, if it has abnormality (mechanical failure).

Defective shut-off solenoid valve oil pressure switch

1) Turn starting switch OFF. 2) Disconnect connector ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz



1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Resistance between BRC5B Wiring harness between BRC5B (female) (8) – ASR7 (female) (8), ASR7 (female) (female) (1) (1) – chassis ground


Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Voltage between BRC5B BRC5B (female) (8) – ASR7 (female) (8), ASR7 (female) (female) (1) (1) – chassis ground

Max. 1 V

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4) Connect connector. 5 Defective retarder controller 5) Turn starting switch ON. Between BRC5B (8) – BRC2 Oil pressure ON (21) Oil pressure OFF

HD465-7, HD605-7

Voltage

Max. 1 V

Voltage

20 – 30 V

20-1065 (10)

TROUBLESHOOTING

[DWNBK4]


20-1066 (5)

HD465-7, HD605-7

[DWNBKA]

TROUBLESHOOTING

[DWNBKA] SHUT-OFF SOLENOID VALVE: DISCONNECTION (KA) Action code


E01

DWNBKA

BK

Trouble Shut-off solenoid valve: Disconnection (KA)

Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, any current does not flow.


Cause

1


Possible causes and standard value in normal state Disconnection in wiring 2 harness (Disconnection or defective contact)

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Disconnect connector ASR2. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR2 (female) (1) – (2)


Between ASR2 (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter. Wiring harness between BRC2 (female) (2) – Resistance Max. 1 z ASR2 (female) (1) Wiring harness between BRC2 (female) (13) – Resistance Max. 1 z ASR2 (female) (2)

1) Turn starting switch OFF. 2) Disconnect connector BRC2. 3 Defective retarder controller 3) Connect T-adapter. Between BRC2 (female) (2) – (13)



HD465-7, HD605-7

20-1067 (10)

[DWNBKB]

TROUBLESHOOTING

[DWNBKB] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT (KB) Action code E01

Failure code Controller code DWNBKB

BK

Trouble Shut-off solenoid valve: Short circuit (KB)

Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, too much current flows.


Cause

1






1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter.


Ground fault or short circuit in wiring harness

Wiring harness between BRC2 (female) (2) – ASR2 (female) (1)

Resistance between BRC2 (female) (2), ASR2 (female) (1) – chassis ground

Max. 1 z

Between wiring harness between BRC2 (female) (2) – ASR2 (female) (1) and between BRC2 (female) (13) – ASR2 (female) (2)

Resistance between BRC2 (female) (2), ASR2 (female) (1) – BRC2 (female) (13), ASR2 (female) (2)

Max. 1 z




20-1068 (10)

HD465-7, HD605-7

[DWNBKY]

TROUBLESHOOTING

[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY) Action code


E01

DWNBKY

BK

Trouble

Shut-off solenoid valve: Short circuit with power source (Hot short) (KY)

Contents of trouble • When the output to the shut-off solenoid valve circuit is turned OFF, a current flows.


Cause

1







1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR2. 3) Connect T-adapter. 4) Connect connector 5) Turn starting switch ON. Wiring harness between BRC2 (female) (2) – ASR2 (female) (1)

Voltage between BRC2 (female) (2), ASR2 (female) (1) – chassis ground

Max. 1 V




HD465-7, HD605-7

20-1069 (10)

[DWNBMA]

TROUBLESHOOTING

[DWNBMA] SHUT-OFF SOLENOID VALVE: MALFUNCTION (MA) Action code E01 Contents of trouble

Failure code Controller code DWNBMA

BK

Trouble Shut-off solenoid valve: Malfunction (MA)

• The shut-off solenoid valve does not operate (does not move) or the pressure switch system is defective.


Cause Defective shut-off solenoid 1 valve

2

Defective shut-off solenoid valve oil pressure switch

Standard value in normal state/Remarks on troubleshooting • Check the shut-off solenoid valve and repair or replace it, if it has abnormality (mechanical failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR7. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz


Disconnection in wiring harness

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR7. 3) Connect T-adapter. Wiring harness between Resistance between BRC5B BRC5B (female) (8) – ASR7 (female) (8), ASR7 (female) (female) (1) (1) – chassis ground

Max. 1 z


Voltage

Max. 1 V

Voltage

20 – 30 V


20-1070 (10)

HD465-7, HD605-7

[DX17K4]

TROUBLESHOOTING

[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): UNCONTROLLABLE (K4) Action code


E01

DX17K4

BK

Trouble

ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4)

• The ASR proportional solenoid pressure reducing valve (Right) does not return (does not move) or the Contents of trouble pressure switch system is defective. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Cause


Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve 1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical valve (Right) failure). 1) Turn starting switch OFF. 2) Disconnect connector ASR5. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Right) oil pressure 5) Turn starting switch ON. switch Between ASR5 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz


3


1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR5. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (7) – ASR5 (female) (7), ASR5 (female) (female) (1) (1) – chassis ground


Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR5. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (7) – ASR5 (female) (7), ASR5 (female) (female) (1) (1) – chassis ground

Max. 1 V


HD465-7, HD605-7

Voltage

Max. 1 V

Voltage

20 – 30 V

20-1071 (10)

TROUBLESHOOTING

[DX17K4]


20-1072 (5)

HD465-7, HD605-7

[DX17KA]

TROUBLESHOOTING

[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): DISCONNECTION (KA) Action code


E01

DX17KA

BK

Trouble

ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA)

• When the output to the ASR proportional solenoid pressure reducing valve (Right) circuit is turned ON, Contents of trouble any current does not flow. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) – (2) Between ASR3 (1), (2) – chassis ground Possible causes and standard value in normal state

Resistance 10 – 30 z Resistance Min. 1 Mz


Disconnection in wiring harness 2 Wiring harness between BRC2 (female) (9) – Resistance Max. 1 z (Disconnection or defective ASR3 (female) (1) contact) Wiring harness between BRC2 (female) (19) – Resistance Max. 1 z ASR3 (female) (2) 1) Turn starting switch OFF. 2) Disconnect connector BRC2. 3 Defective retarder controller 3) Connect T-adapter. Between BRC2 (female) (9) – (19)



HD465-7, HD605-7

20-1073 (10)

[DX17KB]

TROUBLESHOOTING

[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): SHORT CIRCUIT (KB) Action code


E01

DX17KB

BK

Trouble

ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)

• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any Contents of trouble current does not flow. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) – (2) Between ASR3 (1), (2) – chassis ground






Resistance between BRC2 (female) (9), ASR3 (female) Min. 1 Mz (1) – chassis ground

Wiring harness between BRC2 (female) (9) – ASR3 (female) (1) and between BRC2 (female) (19) – ASR3 (female) (2)

Min. 1 Mz




20-1074 (10)

HD465-7, HD605-7

[DX17KY]

TROUBLESHOOTING

[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY) Action code


E01

DX17KY

BK

Trouble

ASR proportional solenoid pressure reducing valve (Right): Short circuit with power source (Hot short) (KY)

• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a curContents of trouble rent flows. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR3. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Right) Between ASR3 (female) (1) – (2) Between ASR3 (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR3. 3) Insert connect T-adapter. 4) Connect connector 5) Turn starting switch ON.





Max. 1 V

Min. 1 Mz




HD465-7, HD605-7

20-1075 (10)

[DX17MA]

TROUBLESHOOTING

[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT): MALFUNCTION (MA) Action code


E01

DX17MA

BK

Trouble

ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)

• The ASR proportional solenoid pressure reducing valve (Right) does not operate (does not move) or Contents of trouble the pressure switch system is defective. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Cause


Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve 1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical valve (Right) failure).


1) Turn starting switch OFF. 2) Disconnect connector ASR5. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Right) oil pressure 5) Turn starting switch ON. switch Between ASR5 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz

3



Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5B (7) – BRC2 Oil pressure ON (21) Oil pressure OFF

Voltage

Max. 1 V

Voltage

20 – 30 V


20-1076 (10)

HD465-7, HD605-7

[DX18K4]

TROUBLESHOOTING

[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): UNCONTROLLABLE (K4) Action code


E01

DX18K4

BK

Trouble

ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4)

• The ASR proportional solenoid pressure reducing valve (Left) does not return (does not move) or the Contents of trouble pressure switch system is defective. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

Cause


Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve (Left) 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve (Left) 1) Turn starting switch OFF. 2) Disconnect connector ASR6. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Left) oil pressure 5) Turn starting switch ON. switch Between ASR6 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz


3


1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR6. 3) Connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Resistance between BRC5B BRC5B (female) (6) – ASR6 (female) (6), ASR6 (female) (female) (1) (1) – chassis ground


Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and ASR6. 3) Insert connect T-adapter. 4) Connect connector. 5) Turn starting switch ON. Wiring harness between Voltage between BRC5B BRC5B (female) (6) – ASR6 (female) (6), ASR6 (female) (female) (1) (1) – chassis ground

Max. 1 V


HD465-7, HD605-7

Voltage

Max. 1 V

Voltage

20 – 30 V

20-1077 (10)

TROUBLESHOOTING

[DX18K4]


20-1078 (5)

HD465-7, HD605-7

[DX18KA]

TROUBLESHOOTING

[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): DISCONNECTION (KA) Action code


E01

DX18KA

BK

Trouble

ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA)

• When the output to the ASR proportional solenoid pressure reducing valve (Left) circuit is turned ON, Contents of trouble any current does not flow. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) – (2) Between ASR4 (1), (2) – chassis ground Possible causes and standard value in normal state Disconnection in wiring 2 harness (Disconnection or defective contact)


1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR4. 3) Connect T-adapter. Wiring harness between BRC2 (female) (8) – Resistance Max. 1 z ASR4 (female) (1) Wiring harness between BRC2 (female) (18) – Resistance Max. 1 z ASR4 (female) (2)




HD465-7, HD605-7

20-1079 (10)

[DX18KB]

TROUBLESHOOTING

[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): SHORT CIRCUIT (KB) Action code


E01

DX18KB

BK

Trouble

ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB)

• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any Contents of trouble current does not flow. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) – (2) Between ASR4 (1), (2) – chassis ground






Resistance between BRC2 (female) (8), ASR4 (female) Min. 1 Mz (1) – chassis ground


Min. 1 Mz




20-1080 (10)

HD465-7, HD605-7

[DX18KY]

TROUBLESHOOTING

[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): SHORT CIRCUIT WITH POWER SOURCE (HOT SHORT) (KY) Action code


E01

DX18KY

BK

Trouble

ASR proportional solenoid pressure reducing valve (Left): Short circuit with power source (Hot short) (KY)

• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a curContents of trouble rent flows. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information

Cause


1) Turn starting switch OFF. 2) Disconnect connector ASR4. 3) Insert connect T-adapter. Defective ASR proportional 1 solenoid pressure reducing 4) Connect connector. 5) Turn starting switch ON. valve (Left) Between ASR4 (female) (1) – (2) Between ASR4 (1), (2) – chassis ground


1) Turn starting switch OFF. 2) Disconnect connectors BRC2 and ASR4. 3) Insert connect T-adapter. 4) Connect connector 5) Turn starting switch ON.





Max. 1 V

Min. 1 Mz




HD465-7, HD605-7

20-1081 (10)

[DX18MA]

TROUBLESHOOTING

[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT): MALFUNCTION (MA) Action code


E01

DX18MA

BK

Trouble

ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA)

• The ASR proportional solenoid pressure reducing valve (Left) does not operate (does not move) or the Contents of trouble pressure switch system is defective. Action of controller • Resets the ASR control. • The machine is not affected badly. Problem that appears on machine • The ASR system cannot be controlled. Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

Cause


Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve (Left) 1 solenoid pressure reducing and repair or replace it, if it has abnormality (mechanical failure). valve (Left)


1) Turn starting switch OFF. 2) Disconnect connector ASR6. Defective ASR proportional 3) Insert connect T-adapter. solenoid pressure reducing 4) Connect connector. 2 valve (Left) oil pressure 5) Turn starting switch ON. switch Between ASR6 (female) (1) Oil pressure ON Resistance Max. 1 z – (2) Oil pressure OFF Resistance Min. 1 Mz

3



Max. 1 z

1) Turn starting switch OFF. 2) Disconnect connectors BRC5B and BRC2. 3) Connect T-adapter. 4 Defective retarder controller 4) Connect connector. 5) Turn starting switch ON. Between BRC5B (6) – BRC2 Oil pressure ON (21) Oil pressure OFF

Voltage

Max. 1 V

Voltage

20 – 30 V


20-1082 (10)

HD465-7, HD605-7

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)

H-1

Machine does not start ....................................................................................................................20-1102

H-2

Machine does not travel smoothly (machine jerks) .........................................................................20-1104

H-3

Lock-up clutch cannot be disengaged (engine stalls) .....................................................................20-1104

H-4

Excessive shock when starting or shifting.......................................................................................20-1105

H-5

Transmission does not shift up........................................................................................................20-1105 a. Does not shift up ........................................................................................................................20-1105 b. Does not shift up ........................................................................................................................20-1105

H-6

Machine lacks power or speed when traveling................................................................................20-1106 a. Abnormality at all speed ranges.................................................................................................20-1106 b. Torque converter lock-up does not engage................................................................................20-1107 c. Abnormality at specific speed ranges ........................................................................................20-1108

H-7

Time lag is excessive when starting or shifting gear .......................................................................20-1110

H-8

Torque converter oil temperature is high .........................................................................................20-1112

H-9

Torque converter oil pressure is low................................................................................................20-1113

H-10 Front brake is ineffective, or effective only on one side ..................................................................20-1114 H-11 Rear brake is ineffective, or effective only on one side ...................................................................20-1115 H-12 Steering wheel is heavy ..................................................................................................................20-1116 H-13 Steering wheel does not work .........................................................................................................20-1117 H-14 Steering wheel vibrates ...................................................................................................................20-1117 H-15 Hoist cylinder lacks lifting force (lifting speed) ...............................................................................20-1118 H-16 Hoist cylinder does not work ...........................................................................................................20-1119 H-17 Excessive hydraulic drift of dump body ...........................................................................................20-1120

HD465-7, HD605-7

20-1101 (2)

TROUBLESHOOTING

H-1

H-1 Machine does not start Ask the operator the following questions • Did the problem suddenly happen? Yes = Internal seizure, damage • When this happened, was there any abnormal noise? Yes = Broken part

Air sucked in at suction side of pump

Defective pump

Pump does not drive (defective PTO)

Drop in set pressure of main relief valve (torque converter valve)

Defective operation of ECMV valve

Defective transmission clutch seal ring, groove

Seized transmission clutch

Defective speed clutch (defective oil tightness)

Defective shaft seal ring in speed clutch circuit

Damage inside transmission

Damage inside torque converter

Defective actuation of ECMV solenoid valve

Defective speed sensor function

a

b

c

d

e

f

g

h

i

j

k

l

m

n

Causes Clogged strainer

Checks before troubleshooting • Is the oil level in the transmission case correct? • Is the torque converter, transmission input shaft broken? (Check with the transmission input shaft speed sensor.) • Is the drive shaft broken? • Is there any dragging of the brakes? • Is any failure code related power trains displayed?

Remedy No.

C

Problems 1

Abnormal noise comes from between pump and filter

2

Machine does not start in any speed range (Item 1 normal)

3

Machine starts normally in certain speed range

4

Machine does not start when torque converter oil temperature rises

5 6

Low at every speed range Set pressure of transmission is low

Becomes lower at certain speed range Indicator is unstable and fluctuates excessively

7 8

When pressure pickup plug is removed and engine is cranked, no oil comes out

9

Modulation pressure is abnormal

10

Hydraulic pressure at pump outlet port is low

20-1102 (10)

HD465-7, HD605-7

TROUBLESHOOTING

H-1

Clutch combination table Clutch No. Speed range

H

L

4th

3rd

2nd

1st

R

(Rotat- (Rotating) ing)

R N F1 F2 F3 F4 F5 F6 F7

HD465-7, HD605-7

20-1103 (2)

H-2, H-3

TROUBLESHOOTING

H-2 Machine does not travel smoothly (machine jerks) • There is hunting. • Look-up lamp flashes. Checks before troubleshooting • Is the oil level in the transmission case correct? • Is any failure code related power trains displayed? Causes •

Drop in main relief pressure

•

Worn clutch seal ring

Remedy

A. See H-6

H-3 Lock-up clutch cannot be disengaged (engine stalls)

Remedy . No.

Defective actuation of lock-up ECMV solenoid valve

Defective actuation of lock-up ECMV valve

Seized lock-up clutch

Causes

Checks before troubleshooting • Is the oil level in the transmission case correct? • Is any failure code related power trains displayed?

a

b

c

C

Problems 1

Lock-up pressure does not become "0"

2

Lock-up clutch is not disengaged even when lock-up pressure is "0"

3

Operation of lock-up ECMV valve is normal

4

Operation of lock-up ECMV solenoid valve is normal

20-1104 (10)

HD465-7, HD605-7

H-4, H-5

TROUBLESHOOTING

H-4 Excessive shock when starting or shifting Judgement standard There is some shock, but it is difficult to judge if the shock is excessive or not, so judge that it is excessive in the following cases. • It is clear that the shock has suddenly become excessive. • The shock is excessive compared with other machines of the same class. Cause • Defective operation because of dirt caught in the ECMV pressure control valve spool and pressure detector valve spool, or defective operation of the ECMV proportional solenoid.

H-5 Transmission does not shift up a. Does not shift up a Shifts up on downhill slopes. Causes

Remedy

Slipping or damage of torque converter lock-up clutch

a The above is the most probable cause, but for details, see "Torque converter lock-up does not engage".

b. Does not shift up Causes

Remedy

Defective operation of ECMV for clutch which does not shift up

C

Defective piston seal ring, defective groove for clutch which does not shift up Drop in main relief pressure

A

C


H

L

4th

3rd

2nd

1st

R


R N F1 F2 F3 F4 F5 F6 F7

HD465-7, HD605-7

20-1105 (10)

TROUBLESHOOTING

H-6

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


Defective pump

Drop in performance of engine

Drop in set pressure of main relief valve (torque converter valve)

Excessive oil leakage inside torque converter (defective seal ring, loose plug)

Defective torque converter freewheel

Defective operation of torque converter relief valve, deteriorated spring

Cooler, piping beyond torque converter outlet port damaged

Damage inside torque converter (turbine rivet broken)

Torque converter lock-up does not engage

a

b

c

d

e

f

g

h

i

j

k

Causes

Checking for abnormalities • Engine high idle speed • Torque converter stall speed • Machine travel speed • Transmission clutch pressure • Torque converter lock-up pressure • Main relief pressure

Crogged strainer

Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints? • Is there any dragging of the parking brake, service brake, or retarder? • Is any failure code related power trains displayed?

Remedy No.

A C

A

1


2

Torque converter stall speed is high

3

Torque converter stall speed is low

See TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.

Low at every speed range (Item 2 abnormal)

4 5

See b. TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.

Problems

Set pressure of transmission is low

Indicator is unstable and fluctuates excessively Low after entering torque converter lock-up

6 7

Hydraulic pressure at torque converter inlet port is low (Items 4 – 6 normal)

8

Hydraulic pressure at torque converter outlet port is low (Item 7 normal)

9

Pieces of iron and aluminium stuck to strainer and drain plug of transmission case

10

Hydraulic pressure at pump outlet port is low

11

When oil temperature rises, oil pressure drops

20-1106 (10)

HD465-7, HD605-7

H-6

TROUBLESHOOTING

b. Torque converter lock-up does not engage Ask the operator the following questions • Did the problem suddenly happen? Yes = Internal seizure, damage • When this happened, was there any abnormal noise? Yes = Broken part • Is any failure code related power trains displayed? Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage ? • Is electricity flowing to the lock-up solenoid? (Use a checker)

Drop in set pressure of main relief valve

Defective lock-up ECMV solenoid

Defective operation of lock-up ECMV solenoid valve spool

Defective operation of lock-up ECMV valve spool

Worn lock-up clutch piston seal ring

Worn lock-up clutch disc

Cracked lock-up clutch case

Causes

Checking for abnormalities • Main relief pressure • Lock-up oil pressure • Main travel speed

a

b

c

d

e

f

g

Remedy No. Problems 1

Main relief pressure is low

2

With Item 1 normal, lock-up pressure is low or "0"

3

Solenoid is normal in Item 2 (proper continuity, no short circuit)

4

Solenoid is defective in Item 2 (no continuity, there is short circuit)

5

With Items 1 – 4 normal, lock-up pressure is low

6

Oil pressure is normal in Item 5

7

Lock-up pressure is low and main pressure is also low

8

Lock-up takes time to engage

HD465-7, HD605-7

20-1107 (10)

H-6

TROUBLESHOOTING

c. Abnormality at specific speed ranges Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any dragging of the parking brake, service brake, or retarder? • Is any failure code related power trains displayed?


Checking for abnormalities • Machine travel speed

H

L

4th

3rd

2nd

1st

R


R N F1 F2 F3 F4 F5 F6 F7


(1) F1 is normal, but F2 is defective (2) Returns to normal when replaced with any ECMV except 2nd.

2

(1) F2 is normal, but F1 is defective or only F1 is defective (2) Returns to normal when replaced with any ECMV except 1st.

3

(1) F1 and F2 are normal, but F3 is defective (2) Returns to normal when replaced with any ECMV except H.

4

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

5

(1) F1 – F5 are normal, but F6 is defective (2) Returns to normal when replaced with any ECMV except 4th.

6

(1) F3, F5, and F7 are normal, but others are defective (2) Returns to normal when replaced with any ECMV except L.

7

(1) Only R is defective (2) Returns to normal when replaced with any ECMV except R.

a Remove all the mud and dirt from around the ECMV, and clean it before replacing. a After replacing, tighten the ECMV mounting bolts to the specified tightening torque. ECMV mounting bolt : 8.0 – 10.0 Nm {0.8 – 1.0 kgm}

20-1108 (7)

HD465-7, HD605-7

H clutch disc worn or seized, seal ring worn L clutch disc worn or seized, seal ring worn 4th clutch disc worn or seized, seal ring worn 3rd clutch disc worn or seized, seal ring worn 2nd clutch disc worn or seized, seal ring worn 1st clutch disc worn or seized, seal ring worn R clutch disc worn or seized, seal ring worn Defective operation of H clutch ECMV Defective operation of L clutch ECMV Defective operation of 4th clutch ECMV Defective operation of 3rd clutch ECMV Defective operation of 2nd clutch ECMV Defective operation of 1st clutch ECMV Defective operation of R clutch ECMV

Causes

TROUBLESHOOTING

HD465-7, HD605-7

H-6

a b c d e f g h i j k l m n

20-1109

(7)

H-7

TROUBLESHOOTING

H-7 Time lag is excessive when starting or shifting gear Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints? • Is operation of control valve normal? • Is any failure code related power trains displayed? Clutch combination table

Checking for abnormalities • See the STANDARD VALUE TABLE to check if the time lag is actually excessive.

Clutch No. Speed range

H

L

4th

3rd

2nd

1st

R


R N F1 F2 F3 F4 F5 F6 F7


Abnormal noise comes from pump

2

There is time lag when transmission is placed in any speed range

3

F1 is normal, but there is time lag when shifting to F2

4

F2 is normal, but there is time lag when shifting to F1

5

F1 and F2 are normal, but there is time lag when shifting to F3

6

F1, F2, and F3 are normal, but there is time lag when shifting to F4

7

F1 - F5 are normal, but there is time lag when shifting to F6

8

F3, F5, and F7 are normal, but there is time lag when in other speed ranges

9

There is time lag in R

10 Transmission modulating pressure is low when placed in any speed range 11 Torque converter oil temperature goes above operating range

20-1110 (2)

HD465-7, HD605-7

Clogged strainer Air sucked in at suction side of pump Defective pump Defective oil tightness in rotating clutch Defective shaft seal ring in rotating clutch circuit Drop in set pressure of main relief valve H clutch disc worn or defective seal ring, worn groove L clutch disc worn or defective seal ring, worn groove 4th clutch disc worn or defective seal ring, worn groove 3rd clutch disc worn or defective seal ring, worn groove 2nd clutch disc worn or defective seal ring, worn groove 1st clutch disc worn or defective seal ring, worn groove R clutch disc worn or defective seal ring, worn groove Defective operation of H clutch ECMV Defective operation of L clutch ECMV Defective operation of 4th clutch ECMV Defective operation of 3rd clutch ECMV Defective operation of 2nd clutch ECMV Defective operation of 1st clutch ECMV Defective operation of R clutch ECMV

Causes

TROUBLESHOOTING

HD465-7, HD605-7

H-7

a b c d e f g h i j k l m n o p q r s t

C

20-1111

(7)

TROUBLESHOOTING

H-8

H-8 Torque converter oil temperature is high Ask the operator the following questions • Does oil temperature go up when torque converter is stalled and go down when torque converter is not stalled? Yes = Normal (If torque converter is stalled frequently, however, selection of speed range is incorrect) Checks before troubleshooting • Is oil level in transmission case correct? • Is any failure code related power trains displayed?

b

c

Oil leakage inside torque converter (defective seal ring, loose bolt, crack in pump, turbine)

Torque converter

Tank-pump a

Defective operation of torque converter relief valve

Clogged filter

Defective pump


Clogged strainer

Causes

Checking for abnormalities • Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high. a If oil temperature is normal but oil temperature gauge on machine goes above operating range. odefective oil temperature gauge

d

e

f

Remedy C

No. Problems 1

Pump makes abnormal noise when oil temperature is low

2

High idle and low idle speeds are low

3

Torque converter outlet port oil pressure is low

4

Torque converter inlet port oil pressure is low

5

Transmission modulating pressure is low

6

Excessive leakage inside torque converter If troubleshooting shows that all other items are normal, this is the cause.

20-1112 (10)

HD465-7, HD605-7

H-9

TROUBLESHOOTING

H-9 Torque converter oil pressure is low Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints? • Is any failure code related power trains displayed?

Remedy No.

Clogged hydraulic pump suction strainer or suction of air into circuit

Defective hydraulic pump

Drop in set pressure of torque converter relief valve

Excessive leakage inside torque converter

Causes

Checking for abnormalities • Pump outlet port oil pressure

a

b

c

d

C

Problems 1

Abnormal noise comes from pump

2

Oil pressure is low between pump and relief valve

3

Torque converter inlet port pressure is low

4

Transmission and lock-up pressures are normal, but torque converter inlet pressure is low

5

When set pressure of torque converter relief valve is adjusted, inlet pressure becomes high

HD465-7, HD605-7

20-1113 (2)

H-10

TROUBLESHOOTING

Air sucked in at suction side of brake operating pump

Defective brake operating pump

Defective front brake accumulator charge valve

Drop in front brake accumulator gas pressure (gas leakage, defective piston seal

Defective brake valve (front)

Defective operation of front brake cut valve

Defective wheel brake piston seal

Air in brake circuit

Causes

Checks before troubleshooting • Is the oil level in the transmission case correct? • Is the brake pedal play correct? • Is there any leakage of oil from the brake piping or deformation of the piping? • Is the tire inflation and tread condition normal? • Is any failure code related to the brakes displayed? • Is the front brake cut-off switch turned on?

Defective brake operating pump drive system (PTO)

H-10 Front brake is ineffective, or effective only on one side

a

b

c

d

e

f

g

h

i


Brake has no effect only when brake pedal is depressed

2

When brake pedal is depressed, it is light

3

When brake pedal is depressed, it is heavy

4

Extremely large operating effort is needed to obtain specified braking effect

5

Hydraulic and steering do not work

6

Abnormal noise is heard from around PTO

7

Abnormal noise is heard from around transmission oil pan or PPC pump

8

Accumulator charge pressure is low

9

Brake immediately loses power after engine is stopped

10

There is time lag before brake starts to take effect

11

Brake oil pressure is low

12

When air is bled from brake system, air comes out

13

When front brake cut-off switch is turned ON (When its lower part is pressed), front brake is not released

20-1114 (10)

HD465-7, HD605-7

H-11

TROUBLESHOOTING

H-11 Rear brake is ineffective, or effective only on one side

Defective brake operating pump drive system (PTO)

Air sucked in at suction side of brake operating pump

Defective brake operating pump

Defective rear brake accumulator charge valve

Drop in rear brake accumulator gas pressure (gas leakage, defective piston seal)

Defective brake valve (rear)

Defective slack adjuster

Defective wheel brake piston seal

Defective operation of wheel brake piston

Breakage inside wheel brake

Worn wheel brake disc

Defective retarder lever

Defective retarder solenoid valve (Proportional reducing valve)

Air in brake circuit

Improper axle oil

Causes

Checks before troubleshooting • Is the oil level in the transmission case correct? • Is the brake pedal play correct? • Is there any leakage of oil from the brake piping or deformation of the piping? • Is the tire inflation and tread condition normal? • Is any failure code related to the brakes displayed?

a

b

c

d

e

f

g

h

i

j

k

l

m

n

O


Brake has no effect only when brake pedal is depressed

2

When brake pedal is depressed, it is light

3

When brake pedal is depressed, it is heavy

4

Even when retarder lever is pulled, retarder has no effect

5

Extremely large operating effort is needed to obtain specified braking effect

6

When brakes are applied, abnormal noise is heard from brake portion of axle

7

Hydraulic and steering do not work

8

Abnormal noise is heard from around PTO

9

Abnormal noise is heard from around transmission oil pan or PPC pump

10

When oil is drained from inside axle case, large amounts of metal particles are found

11

Accumulator charge pressure is low

12

Brake immediately loses power after engine is stopped

13

There is time lag before brake starts to take effect

14

Brake oil pressure is low

15

Brake disc wear amount is high

16

When air is bled from brake system, air comes out

HD465-7, HD605-7

20-1115 (10)

H-12

TROUBLESHOOTING

H-12 Steering wheel is heavy Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is there any external oil leakage between the pump and steering valve? • Is the steering wheel play correct? • Is any failure code related steerings displayed?

Remedy No.

e

f

g

h

Defective steering valve

Defective hoist pump

d

Demand valve

Defective steering cylinder

Defective steering pump

c

Defective opening of check valve

Clogged strainer

b

Defective operation of spool or stuck spool

Air sucked in at suction end

a

Drop in relief valve set pressure or defective sealing

Crushed suction tube

Causes

Checking for abnormalities • Operating effort of steering wheel • Time taken to turn the steering wheel from lock to lock • Relief pressure of steering circuit

i

j

A C

Problems 1

Circuit pressure is too high at engine low idle or pressure rises to relief pressure

2

Relief pressure in steering circuit is too low

3

Hoist force is also low

4

Item 3 is abnormal and noise of oil blowing is heard from relief valve

5

Relief pressure is low at end of cylinder stroke (Items 1 – 4 normal)

6


7

When steering wheel is turned to right (left), oil flows out continuously when hose on opposite side is removed

8

Condition is normal at engine low idle

9

Pump discharge amount is too low

10

Item 3 is normal but speed is slow

11

Excessive play in steering wheel

20-1116 (10)

HD465-7, HD605-7

H-13, H-14

TROUBLESHOOTING

Clogged strainer


Defective hoist pump

c

d

e

f

g

h

i

Defective steering valve

Air sucked in at suction side

b

Demand valve

Defective steering cylinder


a



Causes

Checking for abnormalities • Relief pressure


Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is there any external oil leakage between pump and steering valve? • Is the steering wheel play correct? • Is any failure code related steerings displayed?


H-13 Steering wheel does not work

j

k

A

Remedy C

No. Problems 1

Hoist cylinder also does not work

2

When pressure pickup port plug is removed and engine is cranked, no oil comes out

3

Circuit pressure is too high at engine low idle, or pressure rises to relief pressure (Item 2 normal)

4

Hoist is normal

5

Relief pressure is low at end of cylinder stroke (Item 4 normal)

6


7


8

Steering wheel works when engine is at low idle

9

When steering wheel is turned to right (left) and hose on opposite side is removed, rod does not move but oil flows out

10

Pump discharge amount is too low

11

Excessive play in steering wheel

H-14 Steering wheel vibrates Checks before troubleshooting • Is any failure code related steerings displayed? Causes Air in hydraulic oil

Remedy A

Leakage of air inside steering cylinder

HD465-7, HD605-7

20-1117 (10)

H-15

TROUBLESHOOTING

H-15 Hoist cylinder lacks lifting force (lifting speed)

Remedy No.

C

A C

h

Drop in dump EPC circuit oil pressure or defective operation of EPC valve

g

Defective dump lever

f

Defective hoist cylinder

e

i

l

m

n

A

j


Drop in performance of steering pump

d

Hoist valve


Drop in performance of hydraulic pump

c

Demand valve

Drop in safety valve set pressure or defective sealing


b


Clogged strainer

a



Causes

Checking for abnormalities • Relief pressure • Body lifting speed


Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is the actuation of the control levers normal? • Is the input signal value of the dump lever in the normal range? • Is any failure code related dump bodys displayed? • Is there any external oil leakage from between pump and cylinder?

k

A

Problems

1

Steering wheel is also heavy

2

Steering wheel is normal

3

Item 1 is defective and hoist circuit relief pressure is low

4


5

Hoist circuit pressure is too high at engine high idle (Items 1 – 4 are normal)

6

Only hoist circuit relief pressure is low

7


8

Dump body rises irregularly

9

Pump discharge amount is low

10

Measured dump EPC valve oil pressure is low

11

Excessive hydraulic drift of hoist cylinde

12

Items 1 – 10 are normal but dump body lifting speed is slow

13


20-1118 (10)

HD465-7, HD605-7

H-16

TROUBLESHOOTING

H-16 Hoist cylinder does not work

h

Drop in dump EPC circuit oil pressure or defective operation of EPC valve

A

Remedy

g

Defective dump lever

f

Defective hoist cylinder

e

i

j

l

m

n

A

A


d

Hoist valve



c

Demand valve

Drop in safety valve set pressure or defective sealing

Defective hydraulic pump

b


Clogged strainer

a


Crushed pump suction tube

Causes

Checking for abnormalities • Relief pressure


Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is the input signal value of the dump lever in the normal range? • Is any failure code related dump bodys displayed?


Ask the operator the following questions • Did the problem suddenly happen? Yes = Seizure, damage to equipment • Had drop in lifting speed or other symptoms appeared before? Yes = Worn parts, deteriorated spring, etc.

k

C

No. Problems 1

When pressure pickup port plug is removed and engine is cranked, no oil comes out

2

Steering also does not work

3

Steering is normal, only hoist does not work

4

In Item 2, hoist circuit relief pressure is low

5


6

Only hoist circuit relief pressure is low at engine high idle

7


8

Hoist circuit pressure is too high at engine low idle or pressure rises to relief pressure (Items 1 - 5 normal)

9

Works when engine is at low idle

10

Pump discharge amount is low

11

When hoist lever is operated to RAISE, and hose on opposite side is removed, cylinder does not move, but oil comes out

12

Measured dump EPC valve oil pressure is low

HD465-7, HD605-7

20-1119 (10)

H-17

TROUBLESHOOTING

H-17 Excessive hydraulic drift of dump body Checks before troubleshooting • Is any failure code related dump bodys displayed?

Defective hoist cylinder piston ring

Defective sealing of valve spool

Causes

Checking for abnormalities • Hydraulic drift of cylinder

a

b

Remedy No. Problems 1 2

When engine is stopped with Oil continues to flow out body fully raised and head pipOil does not continue to flow out ing is removed

20-1120 (10)

HD465-7, HD605-7

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

HD465-7, HD605-7

20-1151 (10)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the coolant temperature to go down before removing the radiator cap. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing a plug or cap from a location which is under pressure from oil, coolant, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

20-1152 (10)

HD465-7, HD605-7

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.

[Questions] Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in (B) are items that can be obtained from the user, depending on the user's level.

[Check items] The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection.

[Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.

HD465-7, HD605-7

20-1153 (10)

TROUBLESHOOTING

•


Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • Defective condition of fuel injection • Excessive injection of fuel • Defective HPI sensor • Defective HPI actuator • Normal output is not applied a See Troubleshooting S-6

20-1154 (10)

HD465-7, HD605-7

TROUBLESHOOTING


Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.

Three symptoms

Step 2 Add up the total of and marks where the horizontal limes for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Defective contact of valve, valve seat: (3) Leakage of air between turbocharger and head: (4) Worn piston ring, cylinder liner: (5) Defective timing rail pressure sensor:

Step 3 The calculation in Step 2 shows that the closest relationship is with [Worn piston ring, cylinder liner]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

HD465-7, HD605-7

20-1155 (10)

S-1

TROUBLESHOOTING

S-1

Starting performance is poor (starting always takes time)

General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel • Defective HPI sensor • Defective HPI actuator Clogged air cleaner element

Defective contact of valve, valve seat

Worn piston ring, cylinder liner

Clogged fuel tank cap

Clogged fuel filter, strainer

Loose piping, fuel filter, entry of air

Defective fuel pump

Defective shut-off valve

Clogged timing rail actuator screen

Defective injector

Defective injector check ball

Cut, worn injector O-ring

Defective or deteriorated battery

Defective preheating circuit (when starting in low temperatures)

Defective alternator

Defective alternator regulator

Clean

Correct

Replace

Correct

Clean

Clean

Replace

Replace

Clean

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Causes

Confirm recent repair history Degree of use of machine

Operated for long period

Questions

Starting performance became worse gradually Engine starts easily when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Charge caution lamp lights up When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged

Check items

Starting motor cranks engine slowly When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting motor, Fuel pump outlet port coupler is pushed, air comes out together with fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Difficult to stop engine Inspect air cleaner element directly When compression pressure is measured, it is found to be low Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high

When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low Troubleshooting

Inspect fuel pump directly Inspect fuel shut-off valve directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect injector directly When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is turned to HEAT, heater mount does not become warm Is voltage 26 - 30V between alternator terminal B and terminal E with engine at low idle?

Yes No

Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging)

Remedy

20-1156 (10)

HD465-7, HD605-7

S-1

TROUBLESHOOTING

Defective atmospheric pressure sensor

Defective boost pressure sensor

Defective fuel rail pressure sensor

Defective timing rail pressure sensor

Defective fuel pump pressure sensor

Defective coolant temperature sensor

Defective intake manifold temperature sensor

Defective fuel rail actuator (*1)

Defective timing rail actuator (*1)

Defective fuel pump actuator (*1)

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Causes

HD465-7, HD605-7

(*1) If the following failure codes are displayed, carry out the troubleshooting in "ENG mode". (If any of the following failure codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C514LK]:Abnormality in fuel rail actuator [C112LK]:Abnormality in timing rail actuator [C318LK]:Abnormality in fuel pump actuator

20-1157 (10)

TROUBLESHOOTING

S-2

S-2

Engine does not start

a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a See Troubleshooting S-4. • Defective electrical system • Problem in power train (troubleshooting for machine) a See the manual for the machine.

Defective starting switch

Defective battery relay

Defective starting motor

Defective starting motor safety relay or safety switch

Replace

Replace

Replace

Defective battery terminal connection Correct

Defective starting circuit wiring

Defective or deteriorated battery Replace

Replace

Broken flywheel ring gear Replace

Causes

Questions



Condition of horn when starting switch is turned ON

Horn does not sound Horn volume is low

Battery electrolyte is low Battery terminal is loose When starting switch is turned to ON, there is no clicking sound from battery relay Check items

When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is turned to START, starting pinion moves out, but

Makes grating noise Soon disengages again Makes rattling noise and does not turn

When specific gravity of electrolyte and voltage of battery are measured, one of them is low When terminal B and terminal C of starting switch are connected, engine starts There is no 24V between battery relay terminal B and terminal E When terminal B and terminal C of starting motor are connected, engine starts

(*1)

Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

When terminal B and terminal C of safety relay are connected, engine starts When terminal of safety switch and terminal B of starting motor are connected, engine starts Remedy

—

Troubleshooting

Inspect flywheel ring gear directly

(*1) Carry out troubleshooting of machine

HD465-7, HD605-7

20-1159 (10)

S-2

TROUBLESHOOTING

b) Engine turns but no exhaust smoke comes out (fuel is not being injected) General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) • Defective HPI sensor • Defective HPI actuator

Insufficient fuel in tank




Broken fuel pump drive shaft

Defective fuel shut-off valve

Defective fuel shut-off valve wiring

Clogged timing actuator screen


Add

Correct

Clean

Clean

Replace

Replace

Replace

Replace

Replace

Causes

Questions



Exhaust smoke suddenly stopped coming out (when starting again) Starting performance became worse gradually Starts when engine is warm Replacement of filters has not been carried out according to Operation Manual When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained

Check items

When fuel filter is drained, fuel does not come out There is leakage from fuel piping Wiring of fuel shut-off valve is loose Cylinder block ground wiring is loose When engine is cranked with starting motor, and

Fuel pump outlet port coupler is pushed, almost no fuel comes out Fuel pump outlet port coupler is pushed, air comes out together with fuel

When negative pressure at inlet port of fuel pump is measured, it is found to be high Troubleshooting

Inspect fuel filter, strainer directly Inspect fuel pump drive shaft directly Inspect fuel shut-off valve directly When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector pins Inspect timing rail actuator screen directly Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Remedy

20-1160 (10)

HD465-7, HD605-7

S-2

TROUBLESHOOTING






Defective coolant temperature sensor

Defective intake manifold temperature sensor




Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Causes

HD465-7, HD605-7

20-1161 (10)

S-2

TROUBLESHOOTING

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel and oil • Defective HPI sensor • Defective HPI actuator


Defective fuel pump

Clogged timing actuator screen

Defective injector

Defective or deteriorated battery

Defective preheating heater circuit

Replace

Replace

Replace

Replace

Correct

Clogged fuel tank cap Clean


Worn piston ring, cylinder liner Replace

Clean

Defective dynamic valve system (valve, rocker arm, etc.) Replace

Clean

Clogged air cleaner element Clean

Causes

Confirm recent repair history

Questions

Degree of use of machine


Suddenly failed to start Starting performance became worse gradually Starts when engine is warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently When preheating, preheating indicator lamp does not light up Dust indicator is red Air breather hole in fuel tank cap is clogged

Check items

Rust and water are found when fuel tank is drained When fuel filter is drained, no fuel comes out There is leakage from fuel piping Starting motor cranks engine slowly When engine is cranked, abnormal noise is generated around cylinder head When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Inspect air cleaner element directly Inspect dynamic valve system directly When compression pressure is measured, it is found to be low Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high When fuel filter, strainer directly Inspect fuel pump directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is at HEAT, heater mount does not become warm Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator directly Remedy

20-1162 (10)

HD465-7, HD605-7

Defective atmospheric pressure sensor Defective boost pressure sensor Defective fuel rail pressure sensor Defective timing rail pressure sensor Defective fuel pump pressure sensor Defective coolant temperature sensor Defective intake manifold temperature sensor Defective fuel rail actuator (*1) Defective timing rail actuator (*1) Defective fuel pump actuator (*1) Clogged fuel rail actuator

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

TROUBLESHOOTING

HD465-7, HD605-7

S-2

Causes


20-1163

(10)

S-3

TROUBLESHOOTING

Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Defective condition of fuel spray • Improper fuel used • Abnormality in fuel control system • Defective HPI sensor • Defective HPI actuator • Normal output is not applied (See Troubleshooting S-6)

Clogged air cleaner element

Seized turbocharger

Defective contact of valve and valve seat

Improper valve clearance





Defective fuel pump

Defective injector


Correct

Replace

Correct

Replace

Correct

Clean

Clean

Replace

Replace

Replace

Causes

Clean

S-3


Questions



Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel is drained There is leakage from fuel piping When engine is cranked with starting motor, and


Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas

Blue under light load Black

Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low

Troubleshooting

Inspect valve clearance directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When intake air pressure (boost pressure) is measured, it is found to be normal Inspect actuator directly (Resistance and filter for clogging) Inspect sensor directly (Output voltage and resistance) Inspect for air leakage

Remedy

20-1164 (10)

HD465-7, HD605-7

S-3

TROUBLESHOOTING





Air leakage from piping between turbocharger and cylinder head

Replace

Replace

Replace

Replace

Replace

Causes

HD465-7, HD605-7


20-1165 (10)

S-4

TROUBLESHOOTING

Engine stops during operations

General causes why engine stops during operations • Seized parts inside engine • There is overheating a See Troubleshooting S-14. • Problem in power train (troubleshooting for machine) a See the manual for the machine. • Defective HPI sensor • Defective HPI actuator • Low power source voltage of controller

Broken, seized main bearing, connecting rod bearing

Broken, seized gear train





Broken fuel pump drive shaft

Defective injector

Broken auxiliary equipment (pump, compressor, etc.)

Replace

Add

Correct

Correct

Clean

Replace

Replace

Replace


Broken, seized piston, connecting rod

Replace

Defective in power train (troubleshooting for machine)

Broken dynamic valve system (valve, rocker arm, etc.)

Replace

Causes

Replace

S-4


Operated for long period Abnormal noise was heard and engine stopped suddenly

Questions

Condition when engine stopped

Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Fuel level warning lamp lights up When fuel tank is inspected, it is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained Metal particles are found when oil is drained

Check items

Does not turn at all When it is attempted to turn by hand using barring tool

Turns in opposite direction Moves amount of gear backlash

Fuel pump shaft does not turn When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and Engine turns, but stops when load is applied to machine Carry out troubleshooting of machine

Inspect dynamic valve system directly Inspect piston, connecting rod directly

Troubleshooting

Inspect main bearing, connecting rod directly Inspect gear train directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Inspect sensor directly (Output voltage and resistance)

20-1166 (10)

Replace

Remedy

—

Inspect actuator directly (Resistance and filter for clogging)

HD465-7, HD605-7

TROUBLESHOOTING

S-4









Defective fuel shut-off valve

Clogged fuel inlet circuit

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Causes

HD465-7, HD605-7

20-1167 (10)

S-5

TROUBLESHOOTING

S-5

Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly • Air in fuel system • Defective governor mechanism • Defective HPI sensor • Defective HPI actuator • Normal output is not applied a See Troubleshooting S-6




Defective fuel pump

Defective actuation of fuel rail actuator

Defective actuation of timing rail actuator

Defective injector

Defective injector check ball


High resistance, clogged fuel return circuit

Replace

Clean

Clean

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Causes

Confirm recent repair history Questions


Operated for long period Occurs at a certain speed range

Condition of hunting

Occurs at low idle Occurs even when speed is raised Occurs on slopes

When fuel tank is inspected, it is found to be empty Rust, water are found when fuel tank is drained

Check items

Leakage from fuel piping When engine is cranked with starting motor, and


When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine speed sometimes rises too far Engine is difficult to stop Inspect fuel filter, strainer directly

Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to vary When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low When flow of spill fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator screen directly Inspect timing rail actuator screen directly Remedy

20-1168 (10)

HD465-7, HD605-7

Clogged fuel rail actuator screen Clogged timing rail actuator screen

Replace


Replace

Defective in speed sensor


Replace

Replace


Replace

Defective in throttle sensor


Replace

Replace


Replace

—


Replace

TROUBLESHOOTING

HD465-7, HD605-7

S-5

Causes

(*1) If the following failure code is displayed, carry out the troubleshooting in "ENG mode". (If it is not displayed, it is not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C318LK]: Abnormality in fuel pump actuator

20-1169

(10)

S-6

TROUBLESHOOTING

S-6

Engine lacks output (or lacks power)

a Measure the engine speed and judge if the problem is in the engine or on the machine. General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Improper fuel used (if non-specified fuel is used, output drops) • There is overheating a See Troubleshooting S-14. • Defective HPI sensor • Defective HPI actuator • Wrong pare number of controller • High fuel temperature


Seized turbocharger, interference


Improper adjustment of valve clearance





Defective fuel pump

Defective injector



Clean

Replace

Replace

Adjust

Replace

Correct

Clean

Clean

Replace

Replace

Replace

Replace

Causes


Questions


Operated for long period Suddenly

Power was lost

Gradually

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator lamp is red When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out cranked with starting Fuel pump outlet port coupler is pushed, air comes out together with fuel motor, and When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Check items

Color of exhaust gas

Black Blue under light load

Clanging sound is heard from around cylinder head Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is irregular There is hunting from engine (rotation is irregular) High idle speed of engine is low Blow-by gas is excessive Inspect air cleaner element directly When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low Inspect valve clearance directly When pressure at outlet port of fuel pump is measured, it is found to vary Inspect fuel filter, strainer directly When negative pressure at inlet port of fuel pump is measured, it is found to be high When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low

Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Check part No. of controller calibration data Remedy

20-1170 (10)

HD465-7, HD605-7

TROUBLESHOOTING

S-6





Replace

Replace

Replace

Clean

Defective controller calibration data

Defective fuel pump pressure sensor Replace

Defective throttle sensor

Defective timing rail pressure sensor Replace

—

Defective fuel rail pressure sensor Replace

HD465-7, HD605-7

—

Defective boost pressure sensor Replace

Causes


20-1171 (10)

S-7

TROUBLESHOOTING

S-7

Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black • Insufficient intake of air • Defective condition of fuel injection • Excessive injection of fuel • Defective HPI sensor • Defective HPI actuator • Normal output is not applied a See Troubleshooting S-6


Seized turbocharger, interference


Improper adjustment of valve clearance

Leakage of air between turbocharger and cylinder head

Crushed, clogged muffler


Defective fuel pump

Defective injector


Failure timing rail pressure sensor


Clean

Replace

Replace

Adjust

Correct

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Causes


Operated for long period Suddenly became black

Questions


Gradually became black Blue under light load

Non-specified fuel is being used Engine oil must be added more frequently Power was lost

Suddenly Gradually

Dust indicator is red Muffler is crushed Leakage of air between turbocharger and head, loose clamp Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Noise of interference is heard from around turbocharger Clanging sound is heard from around cylinder head Exhaust noise is abnormal Engine pickup is poor and combustion is irregular Blow-by gas is excessive Inspect air cleaner directly When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low Inspect valve clearance directly When muffler is removed, exhaust sound improves Inspect between turbocharger and cylinder head directly When pressure at outlet port of fuel pump is measured, it is found to be low When temperature of injector of each cylinder is measured, there are some cylinders that are low Abnormality in timing rail pressure sensor system is indicated (*2) Inspect sensor directly (Output voltage) Inspect actuator directly (Resistance and filter for clogging) Remedy

20-1172 (10)

HD465-7, HD605-7

TROUBLESHOOTING

S-7

(*1) If the following failure codes are displayed, carry out the troubleshooting in "ENG mode". (If any of the following failure codes is not displayed, they are not probably the cause of the trouble. In this case, inspect the other devices for the cause.) [C112LK]: Abnormality in timing rail actuator (*2) If an failure code of the timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode".

HD465-7, HD605-7

20-1173 (10)

TROUBLESHOOTING

Oil consumption is excessive (or exhaust smoke is blue)

a To prevent the oil from leaking up or down in the turbocharger, do not run the engine at idle for more than 20 minutes continuously (both low and high idle).

Leakage from oil piping

Leakage from oil pan or cylinder head

Leakage from oil drain plug Correct

Correct

Too much engine oil added Correct

Leakage from oil filter or oil cooler

Worn, broken rear oil seal Correct

Correct

Clogged breather or breather hose Clean

Broken oil cooler

Broken piston ring Replace

Correct

Worn piston ring, cylinder liner Replace

Worn seal at blower end

Worn, damaged valve (stem, guide, seal) Correct

Turbocharger

Dust sucked in from intake system

General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of parts in lubrication system

Worn seal at turbine end

Causes

Replace

S-8

S-8

Questions



Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Oil level is above H level on gauge Outside of engine is dirty with oil There are loose piping clamps in intake system

Check items

Inside of turbocharger intake pipe is dirty with oil Inside of exhaust pipe is dirty with oil There is oil in engine coolant Oil level in clutch chamber or damper chamber rises Exhaust smoke is blue under light load Amount of blow-by gas

Excessive None

Troubleshooting

When intake manifold is removed, dust is found inside Excessive play of turbocharger shaft When intake manifold is removed, inside is found to be dirty with oil When compression pressure is measured, it is found to be low Inspect breather element directly Inspect rear oil seal directly There is external leakage of oil from engine

HD465-7, HD605-7

Replace

Replace

Remedy

Correct

Pressure-tightness test of oil cooler shows there is leakage

20-1175 (10)

S-9

TROUBLESHOOTING

Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Defective combustion • Improper fuel used • Operation under excessive load • Oil change interval is too long Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end

Worn valve (stem, guide, seal)


Clogged breather, breather tube

Too much engine oil added

Clogged oil cooler

Clogged oil filter

Defective oil filter safety valve

Clean

Replace

Replace

Replace

Clean

Correct

Clean

Replace

Replace

Causes

Exhaust smoke is black

S-9

Questions



Non-specified oil is being used Engine oil must be added more frequently Oil level is above H level on gauge When oil filter is inspected, metal particles are found

Check items

When exhaust pipe is removed, inside is found to be dirty with oil Even when engine oil temperature rises, oil filter warning lamp lights up (machines equipped with warning lamp)

Engine oil temperature rises quickly Color of exhaust gas Amount of blow-by gas

Blue under light load Black Excessive None Carry out Troubleshooting S-7

Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather element directly Inspect oil cooler directly Inspect oil filter directly Inspect safety valve directly Remedy

20-1176 (10)

—

Troubleshooting

Inspect turbocharger lubrication drain tube directly

HD465-7, HD605-7

S-10

TROUBLESHOOTING

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Defective condition of fuel injection • Excessive injection of fuel • Defective HPI sensor





Replace

Replace

Replace

Clean


Defective injector Replace


Defective fuel pump Replace

Replace

Clogged fuel filter, strainer Clean

Replace

Leakage of fuel inside head cover Correct

Causes



Operated for long period More than for other machines of same model

Condition of fuel consumption

Gradually increased Suddenly increased

There is external leakage of fuel from engine

Check items

Engine oil level rises and smells of diesel fuel When engine is cranked with starting motor, and


When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Exhaust smoke color

Black White

Inspect inside of head cover directly Troubleshooting

When negative pressure at inlet port of fuel pump is measured, it is found to be high Inspect fuel pump directly When temperature of injector of each cylinder is measured, there are some cylinders that are low When pressure at outlet port of fuel pump is measured, it is found to be low Abnormality in fuel rail pressure sensor system is indicated (*1) Abnormality in timing rail pressure sensor system is indicated (*1) When flow of return fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage)

(*1) If an failure code of the fuel rail pressure sensor system or timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode".

HD465-7, HD605-7

Remedy

20-1177 (10)

S-11

TROUBLESHOOTING

S-11 Oil is in coolant, or water spurts back, or coolant level goes down General causes why oil is in coolant • Internal leakage in lubrication system • Internal leakage in cooling system

Broken cylinder head, head gasket

Internal cracks in cylinder block

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring, holes caused by pitting

Broken oil cooler core, O-ring

Broken water pump seal

Broken power train oil cooler (troubleshooting for machine)

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Causes

Questions

Confirm recent repair history Degree of use of machine Oil level

Operated for long period Suddenly increased Gradually increased

Troubleshooting

Check items

Hard water is being used as coolant (or corrosion resistor valve is closed) Excessive air bubbles inside radiator, spurts back Engine oil level has risen, oil is cloudy white Hydraulic oil, transmission oil on machine side is cloudy white When hydraulic oil, transmission oil on machine side is drained, water is found Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect cylinder liner directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Remedy

20-1178 (10)

HD465-7, HD605-7

S-12

TROUBLESHOOTING

S-12 Oil pressure warning lamp lights up (drop in oil pressure) General causes why oil pressure warning lamp lights up • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper selection of fuel (insufficient viscosity) • Deterioration of oil due to overheating

Defective oil pump

Defective oil pump relief valve

Clogged oil cooler

Clogged oil filter

Leaking, crushed hydraulic piping

Replace

Adjust

Replace

Clean

Correct

Defective oil pressure sensor

Broken oil pump suction pipe brazing Correct

Defective oil level sensor

Clogged, broken oil pump suction pipe Clean

Replace

Clogged oil pan suction strainer Clean

Replace

Lack of oil in oil pan Add

Coolant, fuel in oil

Worn crankshaft journal Clean

Causes

Questions



Non-specified oil is being used Replacement of filters has not been carried out according to Operation Manual Engine oil pressure warning lamp lights up Lights up at low idle Condition when oil pressure warning lamp lights up.

Lights up at low, high idle Lights up on slopes

Check items

Sometimes lights up Oil level warning lamp lights up (machines equipped with warning lamp) There is crushing, external leakage from hydraulic piping Oil level in oil pan is low Oil is cloudy white or smells of diesel oil When oil is drained, metal particles are found When oil filter is inspected, metal particles are found

Oil pump rotation is heavy, there is play Inspect relief valve, regulator valve directly Inspect oil filter directly When engine oil level sensor is replaced, oil pressure warning lamp goes out (machines equipped with oil level sensor) When oil pressure is measured, it is found to be normal Remedy

HD465-7, HD605-7

—

Carry out Troubleshooting S-13

Troubleshooting

Inspect oil filter directly Inspect suction strainer, pipe directly

20-1179 (10)

S-13

TROUBLESHOOTING

S-13 Oil level rises

Broken cylinder head, head gasket

Defective cylinder head injector sleeve

Cracks inside cylinder block


Broken, broken rear oil seal face

Broken oil cooler core, O-ring

Clogged water pump drain hole (breather hole), defective seal

Defective thermostat seal

Defective fuel pump seal


Defective auxiliary equipment (pump, compressor) seal

Replace

Replace

Replace

Correct

Replace

Replace

Correct

Replace

Correct

Replace

Causes

Replace

Questions

General causes why oil level rises • Coolant in oil (milky white) • Fuel in oil (diluted, and smells of diesel fuel) • Entry of coolant or oil from other component



Fuel must be added more frequently Engine oil smells of diesel fuel There is oil in coolant (*1) When engine is first started, drops of water come from muffler

Check items

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or coolant (*1) spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level goes down in clutch or damper chamber Oil level goes down in hydraulic tank When compression pressure is measured, it is found to be low

Troubleshooting

Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect rear oil seal directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Inspect thermostat directly Inspect fuel pump directly Inspect injector directly Inspect pump auxiliary equipment (pump, compressor) directly Remedy

(*1) If there is oil in coolant, carry out Troubleshooting S-11.

20-1180 (10)

HD465-7, HD605-7

S-14

TROUBLESHOOTING

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Rise in oil temperature in power train (troubleshooting for machine) a See the manual for the machine.


Clogged, broken oil cooler

Lack of coolant

Clogged radiator core

Clogged, crushed radiator fins

Defective radiator cap (pressure valve)

Fan belt slipping, worn fan pulley

Broken water pump

Defective operation of thermostat

Replace

Replace

Add

Correct

Correct

Replace

Correct

Replace

Replace

Rise in power train oil temperature (troubleshooting for machine)

Cracks inside cylinder block Replace

Defective coolant temperature gauge

Broken cylinder head, head gasket Replace

Causes


Degree of use of machine Condition of overheating Coolant temperature gauge

Operated for long period Suddenly overheated Always tends to overheat Rises quickly Does not go down from red range

Radiator coolant level warning lamp lights up (machines equipped with warning lamp) Engine oil level has risen, oil is cloudy white Cloudy white oil is floating on coolant Excessive air bubbles inside radiator, coolant spurts back Check items

When light bulb is held behind radiator, no light passes through Radiator shroud, inside of underguard are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose Fan belt whines under sudden load Coolant flows out from overflow hose Power train oil temperature enters red range faster than engine coolant temperature Carry out troubleshooting of machine

When compression pressure is measured, it is found to be low Carry out pressure-tightness test of cylinder head

Troubleshooting

Inspect cylinder block, liner directly Inspect oil cooler directly Inspect radiator core directly When temperature difference between top and bottom radiator tanks is measured, it is found to be slight Carry out function test on radiator cap (cracking pressure) When temperature difference between top and bottom radiator tanks is measured, it is found to be excessive Carry out function test on thermostat (cracking temperature)

HD465-7, HD605-7

—

Remedy

Replace

When coolant temperature is measured, it is found to be normal

20-1181 (10)

S-15

TROUBLESHOOTING

S-15 Abnormal noise is made General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion noise • Air sucked in from intake system

Improper gear train backlash

Deformed cooling fan, fan belt interference

Defective injector

Air leakage from auxiliary equipment (pump, compressor)

Correct

Replace

Replace

Excessive wear of piston ring, cylinder liner Replace

Missing, seized gear bushing

Defect inside muffler (dividing board out of position) Replace

Correct

Defective adjustment of valve clearance Adjust

Seized crankshaft bearing

Broken dynamic valve system (valve, rocker arm, etc.) Replace

Replace

Leakage of air between turbocharger and head Correct

Replace

Seized turbocharger, internal interference (*1) Replace

Causes




Condition of abnormal noise

Gradually occurred Suddenly occurred

Non-specified fuel is being used Engine oil must be added more frequently Seal on injection pump has come off Metal particles are found in oil filter Leakage of air between turbocharger and head, loose clamp Noise of interference is heard from around turbocharger

Check items

Clanging sound is heard from around cylinder head Vibrating noise is heard from around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low


Blue under light load Black

Engine pickup is poor and combustion is abnormal Abnormal noise is loud when accelerating engine Blow-by gas is excessive When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

Inspect dynamic valve system directly Inspect valve clearance directly When muffler is removed, abnormal noise disappears When compression pressure is measured, it is found to be low Inspect crankshaft bearing directly Inspect front gear and rear gear directly Inspect cooling fan, belt directly When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly Remedy

(*1) Judge if the noise is an internal noise or an external noise.

20-1182 (10)

HD465-7, HD605-7

S-16

TROUBLESHOOTING

S-16 Vibration is excessive a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also. General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment between engine and chassis • Abnormal combustion

Replace

(troubleshooting for machine)

Clogged injector

Adjust

Internal damage in clutch chamber or damper chamber


Replace

Loose engine mounting bolts, broken cushion

Defective vibration damper

Correct

Worn front support spigot joint portion

Improper gear train backlash

Replace

Replace

Worn cam bushing

Replace

Replace

Defective dynamic valve system (valve, rocker arm, etc. stuck)

Worn main bearing, connecting rod

Replace

Causes

Questions

Confirm recent repair history Degree of use of machine Condition of vibration

Operated for long period Suddenly increased Gradually increased

Non-specified fuel is being used Metal particles are found in oil filter

Check items

Metal particles are found when oil is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Troubleshooting

Inspect main bearing, connecting rod directly Inspect cam bushing directly Inspect front gear train and rear gear train directly Inspect vibration damper directly Injection pump test shows that injection amount is incorrect Inspect front support spigot joint directly Inspect engine mounting bolts, cushions directly

Remedy

HD465-7, HD605-7

Replace

Inspect clutch chamber or damper chamber directly (troubleshooting for machine)

20-1183 (10)

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)

Electrical system diagram related to emergency steering control ............................................................. 20-1202 Information in troubleshooting table .......................................................................................................... 20-1203 E-1 Emergency steering system does not operate ................................................................................. 20-1205

HD465-7, HD605-7

20-1201 (11)

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL

ELECTRICAL SYSTEM DIAGRAM RELATED TO EMERGENCY STEERING CONTROL a For details of this page, see page 90-19.

20-1202 (11)

HD465-7, HD605-7


TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Trouble in machine Information related to detected trouble or troubleshooting Cause

1

2


3

4

5

HD465-7, HD605-7

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

• Disconnection Connector is connected imperfectly or harness is broken. • Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Possible causes of trouble Independent harnesses are in contact with each other abnormally. (Given numbers are reference numbers, which do not indicate priority) 1) Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or harness entered on front side. • Connect negative (–) lead to pin No. or harness entered on rear side.

20-1203 (11)

TROUBLESHOOTING




20-1204 (11)

HD465-7, HD605-7

E-1

TROUBLESHOOTING

E-1 EMERGENCY STEERING SYSTEM DOES NOT OPERATE Trouble Related information

1) When emergency steering switch is pressed, emergency steering system does not operate. 2) Automatic emergency steering system does not operate. aSee Operation and Maintenance Manual, Operation, Testing and adjusting before starting engine, Inspection of emergency steering and Inspection of automatic emergency steering. • When parking brake is released, voltage is generated at pin H01 (2). When flow on flow switch is lost and flow switch is turned ON, voltage is generated at pin H01 (1). Cause


Defective fuse BT2-(26) or If fuse is broken, circuit probably has ground fault. (Carry out trouble1 BT3-(16) shooting for cause 8.) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2

Defective emergency steering switch

Terminals of switch

Emergency steering switch

Resistance

Between input terminal – output terminal

ON

Max. 1 z

OFF

Min. 1 Mz

1) Turn starting switch OFF and disconnect parking brake connector PSW (or HTA). 2) Start engine and apply retarder brake, then carry out troubleshooting. 3

Defective parking brake switch

PSW (male)


Resistance

When parking brake is released

Max. 1 z

Between (1) – (2)

When parking brake is operated (applied)

Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between inlet terminal from fuse BT2 (26) – chassis ground


4

Defective emergency steering timer

Voltage

20 – 30V

aEven if starting switch is turned ON, parking brake is not released until parking brake switch is turned ON (operated) and OFF once. (While parking brake is released, contacts of parking brake should be connected to each other.) 1) Start engine, charge accumulator, apply retarder brake, and stop engine. 2) Turn starting switch ON. 3) Turn parking brake switch OFF (Release). Between inlet terminal from flow switch – chassis ground

Voltage

20 – 30V

Between emergency steering relay drive terminal – chassis ground

Voltage

20 – 30V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between switch ground terminal – chassis Resistance Max. 1 z ground (GND 2) 1) Turn starting switch ON. 2) Turn emergency steering switch ON and carry out troubleshooting. 5 Defective starting motor

Between motor (+) terminal – chassis ground

20 – 30V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between motor (-) terminal – chassis ground

HD465-7, HD605-7

Voltage

Resistance Max. 1 z

20-1205 (11)

E-1

TROUBLESHOOTING

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch ON. 2) Turn emergency steering switch ON and carry out troubleshooting.

Defective emergency 6 steering relay (Both are same)

Between emergency steering relay terminal B – chassis ground

Voltage

20 – 30V

Between emergency steering relay terminal M – chassis ground

Voltage

20 – 30V

Between emergency steering relay drive terminal – chassis ground

Voltage

20 – 30V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between emergency steering relay ground terResistance Max. 1 z minal – chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between emergency steering reResistance Max. 1 z lay terminal M – motor (+) terminal Wiring harness between emergency steering reResistance Max. 1 z lay drive terminal – timer drive terminal


Disconnection in wiring harness (Disconnection in 7 wiring or defective contact in connector)

Wiring harness between fuse BT2 (26) – timer Resistance Max. 1 z power supply input terminal Wiring harness between fuse BT3 (16) – PSW Resistance Max. 1 z (female) (1) Wiring harness between PSW (female) (2) – Resistance Max. 1 z CJN – H01 (female) (2) Wiring harness between H01 (female) (1) – timer Resistance Max. 1 z inlet terminal Wiring harness between emergency steering reResistance Max. 1 z lays (All of 4) Wiring harness between emergency steering reResistance Max. 1 z lay (-) terminal – CJK – chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between emergency steering reResistance Min. 1 Mz lay terminal M – motor (+) terminal

Ground fault in wiring 8 harness (Short circuit with GND circuit)

Wiring harness between emergency steering reResistance Min. 1 Mz lay drive terminal – timer drive terminal Wiring harness between fuse BT2 (26) – timer Resistance Min. 1 Mz power supply input terminal Wiring harness between fuse BT3 (16) – PSW Resistance Min. 1 Mz (female) (1) Wiring harness between PSW (female) (2) – Resistance Min. 1 Mz CJN – H01 (female) (2) Wiring harness between H01 (female) (1) – timer Resistance Min. 1 Mz inlet terminal

a If "the emergency steering system operates by itself (while the switch is not turned ON)", check the following possible causes. 1) The emergency steering relay is fixed to the ON position because of some vibration. (Replace the emergency steering relay.) 2) The voltage at the (+) terminal of the emergency steering relay is 20 – 30 V. (This terminal should be grounded.) 3) The wiring on the M side of the emergency steering relay is in contact with the wiring on the B side. (Open the battery box and check the wiring.) 4) The parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.) 5) The steering flow switch is stuck. (Replace the steering flow switch.)

20-1206 (11)

HD465-7, HD605-7

E-1

TROUBLESHOOTING


a How to distinguish the emergency steering relays and the ordinary battery relay. When the battery box is opened, the 2 relays on the left side (on the front side of the machine) are the emergency steering relays.

HD465-7, HD605-7

20-1207 (11)

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

HD465-7, HD605-7

20-1251 (12)

TROUBLESHOOTING

ELECTRICAL SYSTEM DIAGRAM RELATED ABS CONTROL


20-1252 (12)

HD465-7, HD605-7

TROUBLESHOOTING

HD465-7, HD605-7


20-1253 (12)


TROUBLESHOOTING



Display on panel


Contents of trouble Contents of trouble detected by machine monitor or controller

Action of machine Action taken by controller to protect system or devices when machine monitor or controller detects troumonitor or controller ble Problem that appears on machine as result of action taken by machine monitor or controller Problem that appears on machine (shown above) Related information Information related to the detected trouble or troubleshooting

Cause

1

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

• Disconnection Connector is connected imperfectly or wiring harness is broken. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. 2 • Hot short Wiring harness, which is not connected to power source (24 V) circuit, is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnorPossible causes Possible causes of troubles mally. and standard value (Given numbers are refer3 in normal state ence numbers, which do not indicate priority.) (1) Method of indicating connector No. and handling of T-adapter

• 4 • (2)

5

• •

20-1254 (12)

Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. if connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (-) lead of tester as explained below for troubleshooting, unless otherwise specified. Connect positive (+) lead to pin No. or wiring harness entered on front side. Connect negative (-) lead to pin No. or wiring harness entered on rear side side.

HD465-7, HD605-7


TROUBLESHOOTING

Related circuit diagram

Part of electric circuit diagram related to trouble • Connector No.: Indicates (Model - Number of pins) and (Color). • Arrows ( ): Indicate rough location of connector in machine.

PHENOMENON CODE TABLE Phenomenon code

Contents

KA

Disconnection is wiring

KB

Short circuit

KK

Supply voltage reduction

KM

Operation or setting error

KR


KX


KY

Hot short (short-circuit with power source)

KZ


MA

Malfunction

HD465-7, HD605-7

20-1255 (12)

[D1E5KZ]

TROUBLESHOOTING

[D1E5KZ] ABS CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code



D1E5KZ

ABS

Trouble

ABS cut relay: Disconnection or short circuit on ABS cut relay (KZ)

• Excessive current is conducted or no current is conducted as output is generated to ABS cut relay circuit. • Current is conducted after the output is turned off.

Action of controller • Stops ABS control. • ABS doesn't work. Problem that appears on machine • Usual brake is operable. Related information

Cause


1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS1 (female) (14) – Resistance Max. 1 z (Disconnection or defective RABS (female) (1) contact) Between chassis ground – wiring harness Resistance Max. 1 z RABS (female) (2)



1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. 3) Connect T-adapter. Wiring harness between ABS1 (female) (14), RABS (female) (1) – chassis ground


1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (14), RABS (female) (1) – chassis ground

Voltage

4 Defective ABS cut relay

Replacing ABS cut relay restores the normal state.

5 Defective ABS controller

1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (14) – Resistance chassis ground

20-1256 (12)

Max. 1 V

250 – 350 z

HD465-7, HD605-7

TROUBLESHOOTING

[D1E5KZ]


HD465-7, HD605-7

20-1257 (12)

[DBC0KK]

TROUBLESHOOTING

[DBC0KK] ABS CONTROLLER: SUPPLY VOLTAGE REDUCTION (KK) Action code


E03

DBC0KK

ABS

Trouble

ABS controller: Supply voltage reduction in main and direct supply voltage circuits (KK)

Contents of trouble • Both the main supply voltage and direct supply voltage circuits went below 17 V.


Cause


1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS1. ness 3) Connect T-adapter. 1 (Disconnection or defective Wiring harness between ABS1 (female) (8), contact) (16) – chassis ground Possible causes and standard value in normal state

2

Defective battery or defective charging


Resistance Max. 1 z

Battery voltage shall be 24 V minimum and specific gravity shall be 1.26. 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (7) – ABS1 (female) (8), (16)

Voltage

20 – 30 V

Wiring harness between ABS1 (female) (9), (17) – ABS1 (female) (8), (16)

Voltage

20 – 30 V


20-1258 (12)

HD465-7, HD605-7

[DBC1KK]

TROUBLESHOOTING

[DBC1KK] ABS CONTROLLER MAIN POWER LINE: SUPPLY VOLTAGE REDUCTION (KK) Action code



DBC1KK

ABS

Trouble ABS controller main power line: Supply voltage reduction (KK)

• Difference of voltage between the main supply voltage circuit and direct supply voltage circuit became 5 V or greater.


Cause


1) Turn off starting switch. 2) Disconnect connector ABS1. Possible causes Disconnection in wiring har- 3) Connect T-adapter. and standard value ness 4) Connect the connector. 1 in normal state (Disconnection or defective 5) Turn on starting switch. contact) Wiring harness between ABS1 (female) (9), (17) – ABS1 (female) (8), (16)

Voltage

20 – 30 V

Related electric circuit diagram

HD465-7, HD605-7

20-1259 (12)

[DBC2KK]

TROUBLESHOOTING

[DBC2KK] ABS CONTROLLER LOAD POWER LINE: SUPPLY VOLTAGE REDUCTION (KK) Action code E03

Failure code Controller code DBC2KK

ABS

Trouble

ABS controller load power line: Voltage reduction in solenoid supply voltage (KK)

• Solenoid supply voltage went 17 V or below while controller supply voltage circuit was operating norContents of trouble mally. Action of controller • Stops ABS control. • ABS doesn't work. Problem that appears on machine • Usual brake is operable. Related information

Cause 1 Defective ABS cut relay Disconnection in wiring harness 1 2 (Disconnection or defective contact)

Standard value in normal state/Remarks on troubleshooting Replace it with other relay to restore normal state. 1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. 4) Turn on starting switch. Wiring harness between RABS (female) (5) – chassis ground

Voltage

20 – 30 V

1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors RABS and ABS1. Possible causes ness 2 3) Connect T-adapter. and standard value 3 (Disconnection or defective Wiring harness between RABS (female) (3) – in normal state contact) Resistance Max. 1 z ABS1 (female) (9), (17)


20-1260 (12)

1) Turn off starting switch. 2) Disconnect connectors ABS1 and ABS2. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (1) – ABS1 (female) (8), (16)

Voltage

20 – 30 V

Wiring harness between ABS2 (female) (12) – ABS1 (female) (8), (16)

Voltage

20 – 30 V

HD465-7, HD605-7

TROUBLESHOOTING

[DBC2KK]


HD465-7, HD605-7

20-1261 (12)

[DBC3KK]

TROUBLESHOOTING

[DBC3KK] ABS CONTROLLER BATTERY DIRECT POWER SUPPLY: SUPPLY VOLTAGE REDUCTION (KK) Action code E03

Failure code Controller code DBC3KK

ABS

Trouble

ABS controller battery direct power supply: Supply voltage reduction (KK)

Contents of trouble • Voltage of battery direct power supply circuit went 5 V or below.

Action of controller • Continues ABS control. Problem that • Remains unchanged. appears on machine Related information

Cause


1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS1. 3) Connect T-adapter. ness 1 (Disconnection or defective 4) Turn on starting switch. contact) Possible causes Wiring harness between ABS1 (female) (7) – and standard value ABS1 (female) (8), (16) in normal state 1) Turn off starting switch. 2) Disconnect connectors ABS1 and ABS2. 3) Connect T-adapter. 2 Defective ABS controller 4) Turn on starting switch. Wiring harness between ABS2 (female) (12) – ABS1 (female) (8), (16)

Voltage

20 – 30 V

Voltage

20 – 30 V


20-1262 (12)

HD465-7, HD605-7

[DBC9KM]

TROUBLESHOOTING

[DBC9KM] ABS CONTROLLER WIRE WIRING HARNESS: SETTING OPERATION ERROR (KM) Action code



DBC9KM

ABS

Trouble ABS controller wiring harness: Setting operation error (KM)

• Connector-check signal to be entered at turning on of starting switch does not match the internal setting of controller.


Cause Possible causes and standard value in normal state

1

Wrong connection of controller connector

Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. Connectors ABS3A and ABS5A are appropriately installed.

1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connector ABS5A. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between ABS5A (female) (1) – contact) Resistance Max. 1 z chassis ground


HD465-7, HD605-7

20-1263 (12)

[DBCSKR]

TROUBLESHOOTING

[DBCSKR] ABS CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR) Action code E03

Failure code Controller code DBCSKR

ABS

Trouble

ABS controller S-NET communication: Communication failure (KR)

Contents of trouble • Input of communication information from monitor to ABS controller is unavailable.


Cause


1) Turn off starting switch. 2) Disconnect connector ABS4. Disconnection in wiring har- 3) Connect T-adapter. ness 4) Connect the connector. 1 (Disconnection or defective 5) Turn on starting switch. contact) Possible causes Wiring harness between ABS4 (female) (6), and standard value (12) – chassis ground in normal state 1) Turn off starting switch.


Voltage

6–9V

Voltage

6–9V

2) Disconnect connector ABS4. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS4 (female) (6), (12) – chassis ground


20-1264 (12)

HD465-7, HD605-7

[DDD9KA]

TROUBLESHOOTING

[DDD9KA] ABS SYSTEM SWITCH: DISCONNECTION (KA) Action code


E03

DDD9KA

ABS

Trouble ABS system switch: Disconnection (KA)

Contents of trouble • ON-input and OFF-input of ABS system switch were turned off.


Cause


1) Turn off starting switch. 2) Disconnect connectors ABS and DPC2B. 1 Hot short on wiring harness 3) Connect T-adapter. Wiring harness between DPC2B (female) (2) – Resistance Max. 1 z ABS (female) (3)

Defective ABS system 2 Possible causes switch and standard value in normal state

3 Defective machine monitor

1) Turn off starting switch. 2) Replace ABS system switch with a normal one. 3) Turn on starting switch. Normal state After replacing ABS system was not restored switch with a normal one: Normal state was restored

System switch is normal System switch is defective

1) Turn off starting switch. 2) Disconnect connector DPC2B. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between DPC2B (female) (2) – chassis ground

Turn on ABS system switch

Voltage

20 – 30 V

Turn off ABS system switch

Voltage

Max. 1 V


HD465-7, HD605-7

20-1265 (12)

[DDD9KB]

TROUBLESHOOTING

[DDD9KB] ABS SYSTEM SWITCH: SHORT CIRCUIT (KB) Action code E03

Failure code Controller code DDD9KB

ABS

Trouble ABS system switch: Short circuit (KB)

Contents of trouble • ON-input and OFF-input of ABS system switch were turned on.


Cause

1


Defective ABS system 2 Possible causes switch and standard value in normal state

3 Defective machine monitor

Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS and DPC2B. 3) Connect T-adapter. Wiring harness between DPC2B (female) (2) – Resistance Min. 1 Mz ABS (female) (3) 1) Turn off starting switch. 2) Replace ABS system switch with a normal one. 3) Turn on starting switch. Normal state After replacing ABS system was not restored switch with a normal one: Normal state was restored

System switch is normal System switch is defective

1) Turn off starting switch. 2) Disconnect connector DPC2B. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between DPC2B (female) (2) – chassis ground

Turn on ABS system switch

Voltage

20 –30 V

Turn off ABS system switch

Voltage

Max. 1 V


20-1266 (12)

HD465-7, HD605-7

[DHU6KX]

TROUBLESHOOTING

[DHU6KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL RIGHT (FR): OUTSIDE INPUT SIGNAL RANGE (KX) Action code E03 Contents of trouble

Failure code Controller code DHU6KX

ABS

ABS control valve pressure sensor front wheel right (FR): Trouble Outside input signal range (KX)

• Input voltage to ABS control valve pressure sensor (FR) signal circuit went 0.3 V or below or 4.7 V or above.

Action of controller • Stops ABS control. Problem that • ABS doesn't work. appears on machine • Usual brake is operable. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS2, ABS3A and BPFR. 3) Connect T-adapter.

1

Disconnection in wiring har- Wiring harness between ABS3A (female) (16) Resistance Max. 1 z ness – BPFR (female) (1) (Disconnection or defective Wiring harness between ABS3A (female) (9) – contact) Resistance Max. 1 z BPFR (female) (3) Wiring harness between ABS2 (female) (16) – Resistance Max. 1 z BPFR (female) (2)



1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (9), Resistance Min. 1 Mz BPFR (female) (3) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFR. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (9), BPFR (female) (3) – chassis ground 4 Defective sensor

5 Defective ABS control

(12)

Max. 4.7 V

Replacing pressure sensor (Front wheel right: BPFR) with (Front wheel left: BPFL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (9) – ABS3A (female) (16)

20-1268

Voltage

Voltage

0.3 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHU6KX]


HD465-7, HD605-7

20-1269 (12)

[DHU7KX]

TROUBLESHOOTING

[DHU7KX] ABS CONTROL VALVE PRESSURE SENSOR FRONT WHEEL LEFT (FL): OUTSIDE INPUT SIGNAL RANGE (KX) Action code E03


ABS

Trouble

ABS control valve pressure sensor front wheel left (FL): Outside input signal range (KX)

• Input voltage to ABS control valve pressure sensor (FL) signal circuit went 0.3 V or below or 4.7 V or Contents of trouble above. Action of controller • Stops ABS control. • ABS doesn't work. Problem that appears on machine • Usual brake is operable. Related information

Cause

Standard value in normal state/Remarks on troubleshooting 1) Turn off the starting switch. 2) Disconnect connectors ABS2, ABS3 and BPFL. 3) Connect T-adapter.

Disconnection in wiring har- Wiring harness between ABS3A (female) (16) Resistance Max. 1 z ness – BPFL (female) (1) 1 (Disconnection or defective Wiring harness between ABS3A (female) (10) contact) Resistance Max. 1 z – BPFL (female) (3) Wiring harness between ABS2 (female) (16) – Resistance Max. 1 z BPFL (female) (2)



1) Turn off the starting switch. 2) Disconnect connectors ABS3 and BPFL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (10), Resistance Min. 1 Mz BPFL (female) (3) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPFL. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (10), BPFL (female) (3) – chassis ground 4 Defective pressure sensor

5 Defective ABS control

(12)

Max. 4.7 V

Replacing pressure sensor (Front wheel left: BPFL) with (Front wheel right: BPFR) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (10) – ABS3A (female) (16)

20-1270

Voltage

Voltage

0.3 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHU7KX]


HD465-7, HD605-7

20-1271 (12)

[DHU8KX]

TROUBLESHOOTING

[DHU8KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL RIGHT (RR): OUTSIDE INPUT SIGNAL RANGE (KX) Action code E03


ABS

Trouble

ABS control valve pressure sensor rear wheel right (RR): Outside input signal range (KX)

• Input voltage to ABS control valve pressure sensor (RR) signal circuit went 0.5 V or below or 4.7 V or Contents of trouble above. Action of controller • Stops ABS control. • ABS doesn't work. Problem that appears on machine • Usual brake is operable. Related information

Cause

Disconnection in wiring harness 1 1 (Pressure sensor circuit) (Disconnection or defective contact)

Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS1, ABS3A and BPRR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (16) Resistance Max. 1 z – BPRR (female) (1) Wiring harness between ABS3A (female) (19) Resistance Max. 1 z – BPRR (female) (3) Wiring harness between ABS1 (female) (13) – Resistance Max. 1 z BPRR (female) (2)

Ground fault in wiring har2 ness (Pressure sensor circuit)

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (19), Resistance Min. 1 Mz BPRR (female) (3) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRR. 3) Connect T-adapter. Hot short on wiring harness 4) Connect the connector. 3 (Pressure sensor circuit) 5) Turn on starting switch. Possible causes and standard value in normal state

Wiring harness between ABS3A (female) (19), BPRR (female) (3) – chassis ground

Voltage

Max. 4.7 V

1) Turn off starting switch. 2) Disconnect connectors ABS5A and S01F. Disconnection in wiring har3) Connect T-adapter. ness 2 4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) – Resistance Max. 1 z (Disconnection or defective S01F(female) (1) contact) Wiring harness between S01M (male) (2) – Resistance Max. 1 z S01F (female) (2) 1) Turn off starting switch. 2) Disconnect connectors ABS5A and BRC5A. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ABS5A (female) (5) – 5 (Retarder switch circuit) Resistance Max. 1 z (Disconnection or defective BRC5A (F) (female) (4) contact) Wiring harness between BRC5A (M) (male) (4) Resistance Max. 1 z – BRC5A (F) (female) (4) 6 Defective pressure sensor


Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel left: BPRL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (19) – ABS3A (female) (16)

20-1272 (12)

Voltage

0.5 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHU8KX]


HD465-7, HD605-7

20-1273 (12)

[DHU9KX]

TROUBLESHOOTING

[DHU9KX] ABS CONTROL VALVE PRESSURE SENSOR REAR WHEEL LEFT (RL): OUTSIDE INPUT SIGNAL RANGE (KX) Action code E03


ABS

Trouble

ABS control valve pressure sensor rear wheel left (RL): Outside input signal range (KX)

• Input voltage to ABS control valve pressure sensor (RL) signal circuit went 0.5 V or below or 4.7 V or Contents of trouble above. Action of controller • Stops ABS control. • ABS doesn't work. Problem that appears on machine • Usual brake is operable. Related information

Cause

Disconnection in wiring harness 1 1 (Pressure sensor circuit) (Disconnection or defective contact)

Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connectors ABS1, ABS3A and BPRL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (16) Resistance Max. 1 z – BPRL (female) (1) Wiring harness between ABS3A (female) (20) Resistance Max. 1 z – BPRL (female) (3) Wiring harness between ABS1 (female) (13) – Resistance Max. 1 z BPRL (female) (2)

Ground fault in wiring har2 ness (Pressure sensor circuit)

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (20), Resistance Min. 1 Mz BPRL (female) (3) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and BPRL. 3) Connect T-adapter. Hot short on wiring harness 4) Connect the connector. 3 (Pressure sensor circuit) 5) Turn on starting switch. Possible causes and standard value in normal state

Wiring harness between ABS3A (female) (20), BPRL (female) (3) – chassis ground

Voltage

Max. 4.7 V

1) Turn off starting switch. 2) Disconnect connectors ABS5A and S01F. Disconnection in wiring har3) Connect T-adapter. ness 2 4 (Service brake switch circuit) Wiring harness between ABS5A (female) (6) – Resistance Max. 1 z (Disconnection or defective S01F(female) (1) contact) Wiring harness between S01M (male) (2) – Resistance Max. 1 z S01F (female) (2) 1) Turn off starting switch. 2) Disconnect connectors ABS5A and BRC5A. Disconnection in wiring har- 3) Connect T-adapter. ness 3 Wiring harness between ABS5A (female) (5) – 5 (Retarder switch circuit) Resistance Max. 1 z (Disconnection or defective BRC5A (F) (female) (4) contact) Wiring harness between BRC5A (M) (male) (4) Resistance Max. 1 z – BRC5A (F) (female) (4) 6 Defective pressure sensor


Replacing pressure sensor (Rear wheel right: BPRR) with (Rear wheel left: BPRL) restores the normal state. 1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3A (female) (20) – ABS3A (female) (16)

20-1274 (12)

Voltage

0.5 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DHU9KX]


HD465-7, HD605-7

20-1275 (12)

[DK11KX]

TROUBLESHOOTING

[dk11KX] ACCELERATOR SENSOR: OUTSIDE INPUT SIGNAL RANGE (KX) Action code


E03

dk11KX

ABS

Trouble Accelerator sensor: Outside input signal range (KX)

Contents of trouble • Voltage of accelerator sensor signal circuit went 0.6 V or below or 4.7 V or above.


Cause


1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3B (female) (14) 1 (Disconnection or defective Resistance Max. 1 z – BRC3B (F) (female) (11) contact) Wiring harness between BRC3B (M) (male) Resistance Max. 1 z (11) – BRC3B (F) (female) (11)



1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. 3) Connect T-adapter. Wiring harness between ABS3B (female) (14), Resistance Min. 1 Mz BRC3B (F) (female)(11), BRC3B (M) (male) (11) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3B. 3) Connect T-adapter. 4) Connect the connector. 3 Hot short on wiring harness 5) Turn on starting switch. Wiring harness between ABS3B (female) (14), BRC3B (F) (female)(11), BRC3B (M) (male) (11) – chassis ground

Voltage

Max. 4.7 V

4 Defective accelerator sensor Replacing failed accelerator sensor restores the normal state.


1) Turn off starting switch. 2) Disconnect connectors ABS3B and BRC3A. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Across terminals between ABS3B (female) (14) – ABS3A (female) (16)

20-1276 (12)

Voltage

0.6 – 4.7 V

HD465-7, HD605-7

TROUBLESHOOTING

[DK11KX]


HD465-7, HD605-7

20-1277 (12)

[DLF6KA]

TROUBLESHOOTING

[DLF6KA] WHEEL SPEED SENSOR FRONT WHEEL RIGHT (FR): DISCONNECTION (KA) Action code


E03

DLF6KA

ABS

Trouble Wheel speed sensor front wheel right (FR): Disconnection (KA)

Contents of trouble • Input of pulse signal to wheel speed sensor (FR) signal circuit is unavailable.


Cause


1) Turn off starting switch. 2) Disconnect connector WSFR. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSFR (male) (1) – WSFR (male) (2)

Resistance

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFR. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (2) – 2 (Disconnection or defective Resistance Max. 1 z WSFR (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z – WSFR (female) (2) Possible causes and standard value in normal state

3


1) Turn off starting switch.Connect the connector.Connect the connector. 2) Disconnect connectors ABS3A and WSFR. 3) Connect T-adapter. Wiring harness between ABS3A (female) (2), Resistance Min. 1 Mz WSFR (female) (1) – chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSFR (female) (2) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFR. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (2), WSFR (female) (1) – chassis ground


Voltage

1) Turn off starting switch. 2) Disconnect connectors ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (2) Resistance – ABS3A (female) (14)

20-1278 (12)

Max. 5 V

1,150 – 1,450 z

HD465-7, HD605-7

TROUBLESHOOTING

[DLF6KA]


HD465-7, HD605-7

20-1279 (12)

[DLF7KA]

TROUBLESHOOTING

[DLF7KA] WHEEL SPEED SENSOR FRONT WHEEL LEFT (FL): DISCONNECTION (KA) Action code


E03

DLF7KA

ABS

Trouble Wheel speed sensor front wheel left (FL): Disconnection (KA)

Contents of trouble • Input of pulse signal to wheel speed sensor (FL) signal circuit is unavailable.


Cause


1) Turn off starting switch. 2) Disconnect connector WSFL. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSFL(male) (1) – WSFL (male) (2)

Resistance

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (3) – 2 (Disconnection or defective Resistance Max. 1 z WSFL (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z – WSFL (female) (2) Possible causes and standard value in normal state

3


1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. 3) Connect T-adapter. Wiring harness between ABS3A (female) (3), Resistance Min. 1 Mz WSFL (female) (1) – chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSFL (female) (2) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSFL. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (3), WSFL (female) (1) – chassis ground


Voltage

1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (3) Resistance – ABS3A (female) (14)

20-1280 (12)

Max. 5 V

1,150 – 1,450 z

HD465-7, HD605-7

TROUBLESHOOTING

[DLF7KA]


HD465-7, HD605-7

20-1281 (12)

[DLF8KA]

TROUBLESHOOTING

[dLF8KA] WHEEL SPEED SENSOR REAR WHEEL RIGHT (RR): DISCONNECTION (KA) Action code


E03

dLF8KA

ABS

Trouble Wheel speed sensor rear wheel right (RR): Disconnection (KA)

Contents of trouble • Input of pulse signal to wheel speed sensor (RR) signal circuit is unavailable.


Cause


1) Turn off starting switch. 2) Disconnect connector WSRR2. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (FR) Wiring harness between WSRR2 (male) (1) – Resistance WSRR2 (male) (2)

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (12) 2 (Disconnection or defective Resistance Max. 1 z – WSRR2 (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z – WSRR2 (female) (2) Possible causes and standard value in normal state

3


1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. 3) Connect T-adapter. Wiring harness between ABS3A (female) (12), Resistance Min. 1 Mz WSRR2 (female) (1) – chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSRR2 (female) (2) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRR2. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (12), WSRR2 (female) (1) – chassis ground


(12)

Max. 5 V

Resistance

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (12) – ABS3A (female) (14)

20-1282

Voltage

HD465-7, HD605-7

TROUBLESHOOTING

[DLF8KA]


HD465-7, HD605-7

20-1283 (12)

[DLF9KA]

TROUBLESHOOTING

[dLF9KA] WHEEL SPEED SENSOR REAR WHEEL LEFT (RL): DISCONNECTION (KA) Action code


E03

dLF9KA

ABS

Trouble Wheel speed sensor rear wheel left (RL): Disconnection (KA)

Contents of trouble • Input of pulse signal to wheel speed sensor (RL) signal circuit is unavailable.


Cause


1) Turn off starting switch. 2) Disconnect connector WSRL2. Defective wheel speed sen- 3) Connect T-adapter. 1 sor (RL) Wiring harness between WSRL2 (male) (1) – Resistance WSRL2 (male) (2)

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS3A (female) (13) 2 (Disconnection or defective Resistance Max. 1 z – WSRL2 (female) (1) contact) Wiring harness between ABS3A (female) (14) Resistance Max. 1 z – WSRL2 (female) (2) Possible causes and standard value in normal state

3


1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. 3) Connect T-adapter. Wiring harness between ABS3A (female) (13), Resistance Min. 1 Mz WSRL2 (female) (1) – chassis ground Wiring harness between ABS3A (female) (14), Resistance Min. 1 Mz WSRL2 (female) (2) – chassis ground

1) Turn off starting switch. 2) Disconnect connectors ABS3A and WSRL2. 3) Connect T-adapter. 4 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS3A (female) (13), WSRL2 (female) (1) – chassis ground


(12)

Max. 5 V

Resistance

1,150 – 1,450 z

1) Turn off starting switch. 2) Disconnect connector ABS3A. 3) Connect T-adapter. Across terminals between ABS3A (female) (13) – ABS3A (female) (14)

20-1284

Voltage

HD465-7, HD605-7

TROUBLESHOOTING

[DLF9KA]


HD465-7, HD605-7

20-1285 (12)

[DWNDKZ]

TROUBLESHOOTING

[DWNDKZ] ABS CUT VALVE (F): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E03 Contents of trouble

Failure code Controller code DWNDKZ

ABS

Trouble ABS cut valve (F): Disconnection or short circuit (KZ)

• Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (F) circuit. • Current is conducted after the output is turned off.

Action of controller • Stops ABS control (front wheels). • ABS doesn't work (front wheels). Problem that appears on machine • Usual brake is operable. Related information

Cause


1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS 1(female) (1) – 1 (Disconnection or defective CVF (female) (1) contact) Wiring harness between CVF (female) (2) – chassis ground




1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. 3) Connect T-adapter. Wiring harness between ABS1 (female) (1), CVF (female) (1) – chassis ground


1) Turn off starting switch. 2) Disconnect connectors ABS1 and CVF. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (1), CVF (female) (1) – chassis ground

Voltage

Max. 1 V

4 Defective ABS cut valve (F): Replacing ABS cut valve (F) restores the normal state.


1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (1) – chassis ground

20-1286 (12)


HD465-7, HD605-7

TROUBLESHOOTING

[DWNDKZ]


HD465-7, HD605-7

20-1287 (12)

[DWNDMA]

TROUBLESHOOTING

[DWNDMA] ABS CUT VALVE (F): MALFUNCTION (MA) Action code E03

Failure code Controller code DWNDMA

ABS

Trouble ABS cut valve (F): Malfunction (MA)

Contents of trouble • ABS cut valve (F) does not operate normally.

Action of controller • Stops ABS control (front wheel). • ABS doesn't work (front wheels). Problem that appears on machine • Usual brake is operable. Related information

Cause Defective ABS cut valve 1 pressure switch (F)

Standard value in normal state/Remarks on troubleshooting Replacing it with ABS cut valve pressure switch (R) restores the normal state.

2 Defective ABS cut valve (F) Replacing ABS cut valve (F) restores the normal state. 1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSF. Possible causes 3) Connect T-adapter. and standard value 3 ness (Disconnection or defective in normal state Wiring harness between ABS5A (female) (2) – contact) Resistance Max. 1 z CVSF (female) (1)

4


1) Turn off starting switch. 2) Disconnect connectors ABS5A and CVSF. 3) Connect T-adapter. Wiring harness between ABS5A (female) (2), Resistance Min. 1 Mz CVSF (female) (1) – chassis ground


20-1288 (12)

HD465-7, HD605-7

[DWNEKZ]

TROUBLESHOOTING

[DWNEKZ] ABS CUT VALVE (R): DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E03 Contents of trouble

Failure code Controller code DWNEKZ

ABS

Trouble ABS cut valve (R): Disconnection or short circuit (KZ)

• Excessive current is conducted or no current is conducted as output is generated to ABS cut valve (R) circuit. • Current is conducted after the output is turned off.

Action of controller • Stops ABS control (rear wheels). • ABS doesn't work (rear wheels). Problem that appears on machine • Usual brake is operable. Related information

Cause


1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. Disconnection in wiring har- 3) Connect T-adapter. ness Wiring harness between ABS1 (female) (10) – 1 (Disconnection or defective Resistance Max. 1 z RABS2 (female) (1) contact) Wiring harness between RABS2 (female) (2) – Resistance Max. 1 z chassis ground



1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. 3) Connect T-adapter. Wiring harness between ABS1 (female) (10), RABS2 (female) (1) – chassis ground


1) Turn off starting switch. 2) Disconnect connectors ABS1 and RABS2. 3) Connect T-adapter. 3 Hot short on wiring harness 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS1 (female) (10), RABS2 (female) (1) – chassis ground

Voltage

Max. 1 V

4 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state.


1) Turn off starting switch. 2) Disconnect connector ABS1. 3) Connect T-adapter. Wiring harness between ABS1 (female) (10) – Resistance 10 – 30z chassis ground

20-1290 (12)

HD465-7, HD605-7

TROUBLESHOOTING

[DWNEKZ]


HD465-7, HD605-7

20-1291 (12)

[DWNEMA]

TROUBLESHOOTING

[DWNEMA] ABS CUT VALVE (R): MALFUNCTION (MA) Action code E03

Failure code Controller code DWNEMA

ABS

Trouble ABS cut valve (R): Malfunction (MA)

Contents of trouble • ABS cut valve (R) does not operate normally.


Cause Defective ABS cut valve 1 pressure switch (R)

Standard value in normal state/Remarks on troubleshooting Replacing it with ABS cut valve pressure switch (F) restores the normal state.

2 Defective ABS cut valve (R) Replacing ABS cut valve (R) restores the normal state. 1) Turn off starting switch. Disconnection in wiring har- 2) Disconnect connectors ABS5A and CVSR. Possible causes ness 3) Connect T-adapter. and standard value 3 (Disconnection or defective Wiring harness between ABS5A (female) (3) – in normal state contact) Resistance Max. 1 z CVSR (female) (1)

4


1) Turn off starting switch. 2) Disconnect connectors ABS5A and CVSR. 3) Connect T-adapter. Wiring harness between ABS5A (female) (3) , Resistance Min. 1 Mz CVSR (female) (1) – chassis ground


20-1292 (12)

HD465-7, HD605-7

[DX21KA]

TROUBLESHOOTING

[DX21KA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): DISCONNECTION (KA) Action code


E03

DX21KA

ABS

Trouble ABS control valve front wheel right (FR): Disconnection (KA)

Contents of trouble • Current is not conducted as output is generated to ABS control valve (FR) circuit.


Cause



1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (7) – Resistance Max. 1 z (Disconnection or defective ABSFR (female) (1) contact) Wiring harness between ABS2 (female) (17) – Resistance Max. 1 z ABSFR (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSFR. Defective ABS control valve 3) Connect T-adapter. 2 (FR) Across terminals between ABSFR (male) (1) – Resistance 10 – 30 z ABSFR (male) (2)


1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (7) – Resistance 10 – 30 z ABS2 (female) (17)


HD465-7, HD605-7

20-1293 (12)

[DX21KB]

TROUBLESHOOTING

[DX21KB] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT CIRCUIT (KB) Action code


E03

DX21KB

ABS

Trouble ABS control valve front wheel right (FR): Short circuit (KB)

Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (FR) circuit.


Cause

1


Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. 3) Connect T-adapter. Wiring harness between ABS2 (female) (7) – chassis ground


Wiring harness between ABS2 (female) (17) – Resistance Min. 1 Mz chassis ground Possible causes and standard value in normal state

1) Turn off starting switch. 2) Disconnect connector ABSFR. 3) Connect T-adapter.

2

Defective ABS control valve Across terminals between ABSFR (male) (1) – Resistance 10 – 30 z (FR) ABSFR (male) (2) Wiring harness between ABSFR (male) (1) – chassis ground





20-1294 (12)

HD465-7, HD605-7

[DX21KY]

TROUBLESHOOTING

[DX21KY] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): SHORT-CIRCUITED TO POWER SUPPLY (KY) Action code


E03

DX21KY

ABS

Trouble

ABS control valve front wheel right (FR): Short-circuited with power supply (KY)

Contents of trouble • Current is conducted after output to ABS control valve (FR) circuit is turned off.


Cause


1 Hot short on wiring harness


Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFR. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (7), ABSFR (female) (1) – chassis ground

Voltage

Max. 1 V

Wiring harness between ABS2 (female) (17), ABSFR (female) (2) – chassis ground

Voltage

Max. 1 V



HD465-7, HD605-7

20-1295 (12)

[DX21MA]

TROUBLESHOOTING

[DX21MA] ABS CONTROL VALVE FRONT WHEEL RIGHT (FR): MALFUNCTION (MA) Action code E03

Failure code Controller code DX21MA

ABS

Trouble ABS control valve front wheel right (FR): Malfunction (MA)

Contents of trouble • ABS cut valve (FR) does not operate normally.


Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FL) restores the and standard value 1 pressure sensor (FR) normal state. in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FL) restores the normal state. (FR)


20-1296 (12)

HD465-7, HD605-7

[DX22KA]

TROUBLESHOOTING

[DX22KA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): DISCONNECTION (KA) Action code


E03

DX22KA

ABS

Trouble ABS control valve front wheel left (FL): Disconnection (KA)

Contents of trouble • Current is not conducted as output is generated to ABS control valve (FL) circuit.


Cause



1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (8) – Resistance Max. 1 z (Disconnection or defective ABSFL (female) (1) contact) Wiring harness between ABS2 (female) (18) – Resistance Max. 1 z ABSFL (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSFL. Defective ABS control valve 3) Connect T-adapter. 2 (FL) Across terminals between ABSFL (male) (1) – Resistance 10 – 30 z ABSFL (male) (2)




HD465-7, HD605-7

20-1297 (12)

[DX22KB]

TROUBLESHOOTING

[DX22KB] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT CIRCUIT (KB) Action code


E03

DX22KB

ABS

Trouble ABS control valve front wheel left (FL): Short circuit (KB)

Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (FL) circuit.


Cause

1


Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. 3) Connect T-adapter. Wiring harness between ABS2 (female) (8) – chassis ground



1) Turn off starting switch. 2) Disconnect connector ABSFL. 3) Connect T-adapter.

2

Defective ABS control valve Across terminals between ABSFL (male) (1) – Resistance 10 – 30 z (FL) ABSFL (male) (2) Wiring harness between ABSFL (male) (1) – chassis ground





20-1298 (12)

HD465-7, HD605-7

[DX22KY]

TROUBLESHOOTING

[DX22KY] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): SHORT-CIRCUITED TO POWER SUPPLY (KY) Action code


E03

DX22KY

ABS

Trouble

ABS control valve front wheel left (FL): Short-circuit to power supply

Contents of trouble • Current is conducted after output to ABS control valve (FL) circuit is turned off.


Cause




Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSFL. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (8), ABSFL (female) (1) – chassis ground

Voltage

Max. 1 V

Wiring harness between ABS2 (female) (18), ABSFL (female) (2) – chassis ground

Voltage

Max. 1 V



HD465-7, HD605-7

20-1299 (12)

[DX22MA]

TROUBLESHOOTING

[DX22MA] ABS CONTROL VALVE FRONT WHEEL LEFT (FL): MALFUNCTION (MA) Action code E03


ABS

Trouble ABS control valve front wheel left (FL): Malfunction (MA)

Contents of trouble • ABS cut valve (FL) does not operate normally.


Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (FR) restores the and standard value 1 normal state. pressure sensor (FL) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FR) restores the normal state. (FL)


20-1300 (12)

HD465-7, HD605-7

[DX23KA]

TROUBLESHOOTING

[DX23KA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): DISCONNECTION (KA) Action code


E03

DX23KA

ABS

Trouble ABS control valve rear wheel right (RR): Disconnection (KA)

Contents of trouble • Current is not conducted as output is generated to ABS control valve (RR) circuit.


Cause



1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (9) – Resistance Max. 1 z (Disconnection or defective ABSRR (female) (1) contact) Wiring harness between ABS2 (female) (19) – Resistance Max. 1 z ABSRR (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSRR. Defective ABS control valve 3) Connect T-adapter. 2 (RR) Across terminals between ABSRR (male) (1) – Resistance 10 – 30 z ABSRR (male) (2)




HD465-7, HD605-7

20-1301 (12)

[DX23KB]

TROUBLESHOOTING

[DX23KB] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT CIRCUIT (KB) Action code


E03

DX23KB

ABS

Trouble ABS control valve rear wheel right (RR): Short circuit (KB)

Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (RR) circuit.


Cause

1


Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. 3) Connect T-adapter. Wiring harness between ABS2 (female) (9) – chassis ground



1) Turn off starting switch. 2) Disconnect connector ABSRR. 3) Connect T-adapter.

2

Defective ABS control valve Across terminals between ABSRR (male) (1) – Resistance 10 – 30 z (FR) ABSRR (male) (2) Wiring harness between ABSRR (male) (1) – Resistance Min. 1 Mz chassis ground




20-1302 (12)

HD465-7, HD605-7

[DX23KY]

TROUBLESHOOTING

[DX23KY] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): SHORT-CIRCUITED TO POWER SUPPLY (KY) Action code


E03

DX23KY

ABS

Trouble

ABS control valve rear wheel right (RR): Short-circuited to power supply (KY)

Contents of trouble • Current is conducted after output to ABS control valve (RR) circuit is turned off.


Cause




Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRR. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (9), ABSRR (female) (1) – chassis ground

Voltage

Max. 1 V

Wiring harness between ABS2 (female) (19), ABSRR (female) (2) – chassis ground

Voltage

Max. 1 V



HD465-7, HD605-7

20-1303 (12)

[DX23MA]

TROUBLESHOOTING

[DX23MA] ABS CONTROL VALVE REAR WHEEL RIGHT (RR): MALFUNCTION (MA) Action code E03


ABS

Trouble ABS control valve rear wheel right (RR): Malfunction (MA)

Contents of trouble • ABS control valve (RR) does not operate normally.


Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RL) restores the and standard value 1 normal state. pressure sensor (RR) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (RL) restores the normal state. (RR)


20-1304 (12)

HD465-7, HD605-7

[DX24KA]

TROUBLESHOOTING

[DX24KA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): DISCONNECTION (KA) Action code


E03

DX24KA

ABS

Trouble ABS control valve rear wheel left (RL): Disconnection (KA)

Contents of trouble • Current is not conducted as output is generated to ABS control valve (RL) circuit.


Cause



1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. Disconnection in wiring har- 3) Connect T-adapter. ness 1 Wiring harness between ABS2 (female) (10) – Resistance Max. 1 z (Disconnection or defective ABSRL (female) (1) contact) Wiring harness between ABS2 (female) (20) – Resistance Max. 1 z ABSRL (female) (2) 1) Turn off starting switch. 2) Disconnect connector ABSRL. Defective ABS control valve 3) Connect T-adapter. 2 (RL) Across terminals between ABSRL (male) (1) – Resistance 10 – 30 z ABSRL (male) (2)


1) Turn off starting switch. 2) Disconnect connector ABS2. 3) Connect T-adapter. Across terminals between ABS2 (female) (10) Resistance 10 – 30 z – ABS2 (female) (20)


HD465-7, HD605-7

20-1305 (12)

[DX24KB]

TROUBLESHOOTING

[DX24KB] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT CIRCUIT (KB) Action code


E03

DX24KB

ABS

Trouble ABS control valve rear wheel left (RL): Short circuit (KB)

Contents of trouble • Excessive current is conducted as output is generated to ABS control valve (RL) circuit.


Cause

1


Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. 3) Connect T-adapter. Wiring harness between ABS2 (female) (10) – Resistance Min. 1 Mz chassis ground Wiring harness between ABS2 (female) (20) – Resistance Min. 1 Mz chassis ground


1) Turn off starting switch. 2) Disconnect connector ABSRL. 3) Connect T-adapter.

2

Defective ABS control valve Across terminals between ABSRL (male) (1) – Resistance 10 – 30 z (RL) ABSRL (male) (2) Wiring harness between ABSRL (male) (1) – chassis ground





20-1306 (12)

HD465-7, HD605-7

[DX24KY]

TROUBLESHOOTING

[DX24KY] ABS CONTROL VALVE REAR WHEEL LEFT (RL): SHORT-CIRCUITED WITH POWER SUPPLY (KY) Action code


E03

DX24KY

ABS

Trouble

ABS control valve rear wheel left (RL): Short-circuited with power supply (KY)

Contents of trouble • Current is conducted after output to ABS control valve (RL) circuit is turned off.


Cause




Standard value in normal state/Remarks on troubleshooting 1) Turn off starting switch. 2) Disconnect connector ABS2 and ABSRL. 3) Connect T-adapter. 4) Connect the connector. 5) Turn on starting switch. Wiring harness between ABS2 (female) (10), ABSRL (female) (1) – chassis ground

Voltage

Max. 1 V

Wiring harness between ABS2 (female) (20), ABSRL (female) (2) – chassis ground

Voltage

Max. 1 V



HD465-7, HD605-7

20-1307 (12)

[DX24MA]

TROUBLESHOOTING

[DX24MA] ABS CONTROL VALVE REAR WHEEL LEFT (RL): MALFUNCTION (MA) Action code E03


ABS

Trouble ABS control valve rear wheel left (RL): Malfunction

Contents of trouble • ABS control valve (RL) does not operate normally.


Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective ABS control valve Replacing it with ABS control valve pressure sensor (RR) restores the and standard value 1 normal state. pressure sensor (RL) in normal state Defective ABS control valve 2 Replacing it with ABS control valve (FR) restores the normal state. (RL)


20-1308 (12)

HD465-7, HD605-7

[DX25MA]

TROUBLESHOOTING

[DX25MA] ABS CONTROL VALVE (FRONT WHEEL SYSTEM): MALFUNCTION (MA) Action code


E03

DX25MA

ABS

Trouble ABS control valve (front wheel system): Malfunction (MA)

Contents of trouble • ABS control valve (FR) or ABS control valve (FL) does not operate normally.


Cause Defective ABS control valve (FR) Possible causes Defective ABS control valve and standard value (FL) in normal state 1 Defective ABS control valve pressure sensor (FR) Defective ABS control valve pressure sensor (FL)


Turn on ABS system check and locate from the failure code (DX21MA and DX22MA) which of front wheel right or left is responsible for malfunction of ABS control valve. After confirmation, inspect and repair the valve according to the failure code.


HD465-7, HD605-7

20-1309 (12)

[DX26MA]

TROUBLESHOOTING

[DX26MA] ABS CONTROL VALVE (REAR WHEEL SYSTEM): MALFUNCTION (MA) Action code E03


ABS

Trouble ABS control valve (rear wheel system): Malfunction (MA)

Contents of trouble • ABS control valve (RR) or ABS control valve (RL) does not operate normally.


Cause Defective ABS control valve (RR) Possible causes Defective ABS control valve and standard value (RL) in normal state 1 Defective ABS control valve pressure sensor (RR) Defective ABS control valve pressure sensor (RL)


Turn on ABS system check and locate from the failure code (DX23MA and DX24MA) which of front wheel right or left is responsible for malfunction of ABS control valve. After confirmation, inspect and repair the valve according to the failure code.


20-1310 (12)

HD465-7, HD605-7

30 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL ...................30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION .......................................30- 4 SPECIAL TOOL LIST................................. 30-5-1 SKETCH OF SPECIAL TOOL.................... 30-5-4 FUEL INJECTION PUMP Removal and Installation ..........................30- 6 RADIATOR Removal....................................................30- 7 Installation.................................................30- 8 ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER Removal and Installation ..........................30- 9 ENGINE FRONT SEAL Removal and Installation ..........................30-10 OUTPUT SHAFT Removal and Installation ..........................30-11 Disassembly .............................................30-12 Assembly ..................................................30-13 ENGINE REAR SEAL Removal and Installation ..........................30-15 CYLINDER HEAD Removal....................................................30-17 Installation.................................................30-19 ENGINE Removal....................................................30-22 Installation.................................................30-24 TORQUE CONVERTER AND TRANSMISSION Removal....................................................30-25 Installation.................................................30-27 TRANSMISSION AND TORQUE CONVERTER Separation and Coupling ..........................30-28 TORQUE CONVERTER Disassembly .............................................30-29 Assembly ..................................................30-33 TRANSMISSION Disassembly .............................................30-39 Assembly ..................................................30-52 DIFFERENTIAL Removal....................................................30-67 Installation.................................................30-68 Disassembly .............................................30-69 HD465-7, HD605-7

Assembly.................................................. 30-73 FRONT WHEEL Removal and Installation.......................... 30-81 REAR WHEEL Removal ................................................... 30-82 Installation ................................................ 30-83 FRONT BRAKE CALIPER PADS Removal and Installation.......................... 30-84 FRONT BRAKE CALIPERS Removal and installation .......................... 30-85 Disassembly and Assembly ..................... 30-86 FRONT WHEEL HUB Disassembly............................................. 30-88 Assembly.................................................. 30-89 FINAL DRIVE CARRIER Removal and installation .......................... 30-91 Disassembly and Assembly ..................... 30-92 FINAL DRIVE AND REAR BRAKE Removal ................................................... 30-93 Installation ................................................ 30-95 FINAL DRIVE, REAR BRAKE AND PARKING BRAKE Removal and Installation ......................... 30-97 Disassembly............................................. 30-98 Assembly................................................ 30-103 FRONT SUSPENSION CYLINDER Removal ................................................. 30-109 Installation .............................................. 30-110 Disassembly (Standard cylinder).............30-111 Assembly (Standard cylinder) ................ 30-112 Disassembly (Cylinder with buffer ring) .. 30-113-1 Assembly (Cylinder with buffer ring) ... 30-113-2 REAR SUSPENSION CYLINDER Removal and Installation........................ 30-114 Disassembly (Standard cylinder)............ 30-115 Assembly (Standard cylinder) ................ 30-116 Disassembly (Cylinder with buffer ring) .. 30-117-1 Assembly (Cylinder with buffer ring) ... 30-117-2 RETARDER COOLING PUMP Removal and Installation........................ 30-118

30-1 (10)

STEERING, HOIST, AND HOIST CONTROL PUMP Removal and Installation ........................30-119 TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP Removal and Installation ........................30-120 STEERING VALVE Removal and Installation ........................30-121 Disassembly ...........................................30-122 Assembly ................................................30-125 DEMAND VALVE Removal and Installation ........................30-132 HOIST VALVE Removal and Installation ........................30-133 STEERING CYLINDER Disassembly ...........................................30-134 Assembly ................................................30-135 HOIST CYLINDER Disassembly ...........................................30-137 Assembly ................................................30-138 DUMP BODY Removal..................................................30-141 Installation...............................................30-142 OPERATOR'S SEAT Disassembly ...........................................30-144 Assembly ................................................30-149

30-2 (10)

HD465-7, HD605-7

METHOD OF USING MANUAL

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL 1. When removing or installing unit assemblies When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. Any special techniques applying only to the installation procedure are marked , and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF ASSEMBLY .....Title of operation ..............................................................Precautions related to safety when carrying out the operation 1. X X X X (1) ...........................................Step in operation ★...........................................................Technique or important point to remember when removing XXXX (1). 2.

(2): ....................................

3.

assembly (3)

Indicates that a technique is listed for use during installation

..................................................Quantity of oil or water drained INSTALLATION OF cccc ASSEMBLY ....Title of operation • Carry out installation in the reverse order to removal. ....................................................Technique used during installation ★...........................................................Technique or important point to remember when installing (2). • Adding water, oil ...............................Step in operation ★...........................................................Point to remember when adding water or oil ...................................................Quantity when filling with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

HD465-7, HD605-7

30-3 ➂

PRECAUTIONS WHEN CARRYING OUT OPERATIONL


PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1)

Face seal type hoses and tubes Nominal number 02 03 04 05 06

2)

30-4 ➂

Nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628

02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24 27

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34

HD465-7, HD605-7


1. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, follow the same procedure. 2. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. ★ For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

HD465-7, HD605-7

30-5 ➂

SPECIAL TOOL LIST


SPECIAL TOOL LIST a Tools with part number 79 Tcan not be supplied (they are items to be locally manufactured). a Necessity: t : .......Cannot be substituted, should always be installed (used) q : .......Extremely useful if available, can be substituted with commercially available part. New/remodel:N : .......Tools with new part numbers, newly developed for this model. R : .......Tools with upgraded part numbers, remodeled from items already available for other models. Blank....Tools already available for other models, used without any modification a Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component

Symbol

Part No.

Part Name

795-799-5410

Adapter

t

1

795-799-5420

Remover

t

1

795-621-1140

Push tool

t

1

795-902-1460

Bolt

t

3

01582-02218

Nut

t

3

795-621-1130

Push tool

t

1

01050-32280

Bolt

t

5

792-420-1110

Centering tool

t

1

• 792-420-1120

• Flange

2

• 790-413-1120

• Color

1

• 01010-51230

• Bolt

8

A

A2

Engine assembly

New/ SkeNece remo -ssity Q’ty del tch

A3

Torque convertor transmission assembly

Transmission assembly

t

1

790-901-3011

Plate

t

1

2

790-101-1871

Nut wrench

t

1

3

792-103-5110

Wrench

t

1

792-420-1110

Centering tool

t

1

• 792-420-1120

• Flange

2

• 790-413-1120

• Color

1

• 01010-51230

• Bolt

8

799-301-1600

Oil leak tester

t

1

790-501-5000

Unit repair stand

t

1

C

C4

D1

(10)

790-901-5110

Bracket

t

1

790-901-3420

Plate

t

1

790-425-1660

Wrench

t

1

H 2

30-5-1

1

Bracket

1 Diffelential assembly

t

790-901-2110

1 Torque convertor assembly

Unit repair stand

Removal, installation of injector assembly

Installation of engine front seal

Installation of engine rear seal

C4

790-501-5000

Nature of work, remarks

Centring engine assembly and torque converter, transmission assembly

Disassembly, assembly of trque converter assembly

Removal, installation of PTO nut Removal, installation of pump nut

Centring engine assembly and torque converter, transmission assembly

Checking actuation of piston

Disassembly, assembly of differential assembly

Adjust side bearing preload

HD465-7, HD605-7

SPECIAL TOOL LIST


Component

Diffelential assembly

Symbol

Part Name

t

1

4

797-101-1171

Power wrench

t

1

792T-422-1610

Spacer

t

4

01010-61620

Bolt

t

4

01643-31645

Washer

t

4

795-102-2102

Spring washer

t

1

Removal, installation of spring

792-520-2110

Installer

t

1

792-520-1600

Push tool

t

1

Removal, installation of floatin seal (for small diameter)

791-585-1510

Installer

t

1

792-530-1700

Push tool

t

1

792-103-4102

Push tool

t

1

792-625-1300

Push tool

t

1

H

2 J

1

N

Q

Removal, installation of floatin seal (for large diameter)

Press fitting of bushing (for front) (for rear)

790-101-5421

Grip

t

1

01010-81240

Bolt

t

1

792-610-1000

Suspension tool

t

1

• 792-610-1100

• Pump assembly

1

• 792-610-1200

• Charging tool

1

1

790-452-1200

Pilot ring tool

t

1

Centering valve body and upper case

2

790-452-1100

Tool installer set

t

1

Installation of spacer

790-502-1003

Repair stand

t

1

790-101-1102

Hydraulic pump

t

1

2

790-102-3802

Wrench

t

1

Removal of cylinder head

3

790-302-1270

Socket

t

1

Removal of piston nut

790-201-1702

Push tool KIT

t

1

• 790-101-1771

• Push tool KIT

t

1

• 790-101-5021

• Grip

t

1

• 01010-50816

• Bolt

t

1

790-201-1500

Push tool KIT

t

1

• 790-101-1580

• Push tool KIT

t

1

• 790-101-5021

• Grip

t

1

• 01010-50816

• Bolt

t

1

Q

2

T

1

Steering cylinder assembly U 4

5

HD465-7, HD605-7

Removal, installation of bearing cap bolt Removal, installation of pinion bearing lock nut

Power wrench

4

Steerin valve assembly


790-102-1130

3

Suspension cylinder assembly


3

1

Final drive and rear brake, parking brake assembly

Part No.

Adjusting of suspension cylinder

Disassembly and assembly steering cylinder

Press fitting of bushing

Press fitting of dust seal

30-5-2 (10)

SPECIAL TOOL LIST


Component

Symbol

Part No.

Part Name


6

790-720-1000

Expander

t

1

Steering cylinder assembly U 7

796-720-1650

Ring

t

1

07281-01029

Clamp

t

1

790-502-1003

Repair stand

t

1

790-101-1102

Hydraulic pump

t

1

2

790-102-3802

Wrench

t

1

3

790-720-1000

Expander

t

1

4

796-720-1680

Ring

t

1

5

07281-01580

Clamp

t

1

792-201-7310

Push tool

t

1

790-101-5421

Grip

t

1

01010-81240

Bolt

t

1

790-201-1702

Push tool KIT

t

1

• 790-201-1851

• Push tool

t

1

• 790-101-5021

• Grip

t

1

• 01010-50816

• Bolt

t

1

792-201-7410

Plate

t

1

790-101-5021

Grip

t

1

01010-80816

Bolt

t

1

790-201-1500

Push tool KIT

t

1

• 790-201-1660

• Push tool

t

1

• 790-201-5021

• Grip

t

1

• 01010-50816

• Bolt

t

1

790-441-1320

Hook

t

1

799-703-1200

Service KIT tool

t

1

799-703-1100

Vacuum pump

t

1

799-703-1111

Vacuum pump (220V) Vacuum pump (240V)

t

1

t

1

t

1

8 1

6 Hoist cylinder assembly

H

7

Dump body assembly

Air conditioner assembly

V1

X

799-703-1121 799-703-1401

30-5-3 (11)

Gas leak detector


Removal of steerig cylinder

Disassembly, assembly of hoist cylinder Removal, installation of cylinder dead

Removal of piston ring

Press fitting of bushing (for cylinder )

Press fitting of bushing (for cylinder )

Press fitting of dust seal (for cylinder )

Press fitting of dust seal (for cylinder )

Lifting of dump body

Charging of air conditioner gas

HD465-7, HD605-7


SKETCH OF SPECIAL TOOL

SKETCH OF SPECIAL TOOL J1 Spacer

HD465-7, HD605-7

30-5-4 (10)


FUEL INJECTION PUMP

REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative (–) terminal of the battery. 1. Close the fuel supply valve. 2. Remove the clamp and move hose (1). 3. Disconnect wiring connector (2). 4. Disconnect fuel hose (3) and fuel tubes (4) and (5). 5. Remove mounting bolts (6) and fuel pump assembly (7).

INSTALLATION •

Carry out installation in the reverse order to removal.

★ Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.

30-6 ➂

HD465-7, HD605-7

RADIATOR


REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

6. Disconnect wiring connector (5) and hose (6) from the left side of the radiator and move hose (7).

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative (–) terminal of the battery. 1. Remove the engine underguard. 2. Drain the coolant. Radiator: 69

7. Disconnect hose (8) from the left bottom of the radiator.

3. Bleed air conditioner refrigerant gas. 4. Remove radiator mask (1) and guard (2). Mask : 30 kg Guard : 100 kg

8. Remove tube (9). 9. Disconnect hose (10). 10. Remove hose (11) form the clamp and move it. 5. Disconnect hoses (3) and (4).

HD465-7, HD605-7

30-7 (10)

RADIATOR


11. Disconnect wiring connector (12) of the coolant level sensor above the radiator.

15. Remove air conditioner condenser (18), fuel cooler (19), steering oil cooler (20), and air aftercooler (21) from the radiator assembly.

12. Disconnect hoses (13) and (14) above the radiator and remove pipe (15). 13. Remove guard (16).

INSTALLATION •


•

Charge the air conditioner circuit with refrigerant gas (R134a). , Hose clamp: 13.7 ± 0.5 Nm {140 ± 5 kgcm}

a When using 2 hose clamps to the same place, set their clamps at an angle of 180° to each other.

14. Lift off radiator assembly (17). Radiator assembly: 310 kg

•

Refilling with coolant Add coolant through the filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69

30-8 (10)

HD465-7, HD605-7

ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER


REMOVAL AND INSTALLATION OF ENGINE AND TORQUE CONVERTER AND TRANSMISSION OIL COOLER ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. 1. Remove the engine underguard. 2. Drain the engine oil and hydraulic oil. Engine oil pan: 57 Hydraulic tank: 122 3. Disconnect hose (1) from the underside of the cooling fan.

INSTALLATION •


Mounting bolt: Adhesive (LT-2) Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} [Target: 279 Nm {28.5 kgm}]

4. Disconnect hoses (2) and (3). 5. Remove tubes (4) and (5). 6. Supporting the engine and torque converter and transmission oil cooler assembly (6) with jacks, etc., remove them. Engine and torque converter and transmission oil cooler assembly: 140 kg

•

Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Engine oil pan: 57

(EO10-CD or EO30-CD)

Hydraulic tank: 122

HD465-7, HD605-7

(EO10-CD)

30-9 (10)

ENGINE FRONT SEAL


REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

INSTALLATION 1. Using tool A2, press fit engine front seal (3) and dust seal (2) together to the front cover. a Press fitting dimension a of dust seal: 4 mm

A2

795-621-1140

Push tool

795-902-1460

Bolt

01582-02218

Nut

t t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 3 3

REMOVAL 1. Remove the radiator assembly. For details, see REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY. 2. Remove the fan belt.

2. Install crank pulley (1). Mounting bolt: 1st time : 73.5 ± 19.6 Nm {7.5 ± 2 kgm} 2nd time : 245.0 ± 19.6 Nm {25 ± 2 kgm} 3rd time : 637.0 ± 19.6 Nm {65 ± 2 kgm}

3. Remove crank pulley (1). Crank pulley: 55 kg

3. Carry out the rest of installation work in the reverse order to removal.

4. Remove dust seal (2) and engine front seal (3).

30-10 (10)

HD465-7, HD605-7

OUTPUT SHAFT


REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Remove drive shaft assembly (1). Drive shaft assembly: 30 kg

INSTALLATION •

Carry out installation in the reverse order to removal. a For application of ENS grease to each part, see DISASSEMBLY AND ASSEMBLY.

Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

2. Remove coupling (2). 3. Remove cover (3).



4. Remove snap ring (4). 5. Remove the bearing and cover (5) together. a Use the guide bolt and forcing screws to remove the bearing and cover. Cover assembly: 35 kg 6. Lift off output shaft assembly (6). Output shaft assembly: 90 kg

HD465-7, HD605-7

30-11 (3)


OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY

DISASSEMBLY 1. Oil cage assembly Remove oil seal (1) from cover (2). 2. Cover assembly Remove bearing (3) from cover (4). 3. Disassembly of damper assembly (5) 1) Before disassembling, make marks of flange (6), body assembly (7), and body outer (9) for balancing them for reassembly. 2) Remove body assembly (7) and rubber pieces (8) from body outer (9). a There are 2 rubber pieces (8), large one and small one. Check their locations. 3) Remove bearing (10) from the flywheel.

30-12 (10)

HD465-7, HD605-7

OUTPUT SHAFT


ASSEMBLY

3. Install damper assembly (5) to the flywheel. Spline of body assembly shaft: ENS grease 4. Press fit bearing (3) to cover (4). Bearing: ENS grease 5. Install cover assembly to the flywheel. Cover assembly: 55 kg Mating faces of cover assembly and flywheel: Gasket sealant (LG-6) Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 6. Fit oil seal (1) to cover (2). Insertion part of cover and outside of oil seal: LOCTITE 648 (287-01-12830) a Degrease and dry the above parts before applying gasket sealant. Mating faces of covers (2) and (4): Gasket sealant (LG-6) Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

1. Using the push tool, press fit bearing (10) to the flywheel. Bore of bearing: ENS grease 2. Assembly of damper assembly 1) Apply gasket sealant to body outer (9) and the mating face of flange (6), then install them. Mating face of flange: Gasket sealant (LG-6) 2) Install body assembly (7). 3) Install body outer (9), body assembly (7), and rubber pieces (8). a When installing large and small rubber pieces (8), check their locations. a Before installing these parts, apply grease to them. Body outer, body assembly, and rubber pieces: Grease (G2-LI) Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 4) Install flange (6). Mating face of flange: Gasket sealant (LG-6) Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} a When installing the body outer, body inner, and flange, match them to their marks.

HD465-7, HD605-7

30-13 (10)


OUTPUT SHAFT

7. Install the cage assembly to the cover assembly. •

Procedure for filling ENS grease 1) Part No. of ENS grease: 427-12-11871 2) Parts to be filled with ENS grease, quantity of ENS grease to be supplied (Total: Approx. 500 g), and parts to be coated with ENS grease are shown below.

30-14 (3)

HD465-7, HD605-7

ENGINE REAR SEAL


REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

INSTALLATION 1. Using tool A3, press fit engine rear seal (2) until it comes to the end of the housing.

A3

795-621-1130

Push tool

01050-32280

Bolt

t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 5

REMOVAL 1. Remove the output shaft assembly. For details, see REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY. 2. Install guide bolt [1] and lift off flywheel (1). Since the faucet joint part of the flywheel is shallow, the flywheel may fall suddenly. Take care. Flywheel: 45 kg

2. Install flywheel (1). a Secure the flywheel and housing with a stopper, etc. a Check each mounting bolt head for punch marks. If there are 5 punch marks, replace the bolt. a Tighten the mounting bolts to the specified torque in the following order. Mounting bolt: Engine oil (EO30-CD) Mounting bolt: 1st time : 198 ± 19.6 Nm {20 ± 2 kgm} 2nd time : 460.6 ± 19.6 Nm {47 ± 2 kgm} 3rd time : 90° +30° 0 a When reusing a bolt, make a punch mark on its head after tightening it.

3. Remove engine rear seal (2).

HD465-7, HD605-7

30-15 (10)


ENGINE REAR SEAL

a Using dial gauge [2], check the flywheel for radial runout and facial runout. • Radial runout: Max. 0.15 mm • Facial runout: Max. 0.20 mm

3. Carry out the rest of installation work in the reverse order to removal.

30-16 (3)

HD465-7, HD605-7

CYLINDER HEAD


REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

9. Loosen the hose clamp and remove air intake connector (9).

A

795-799-5410

Adapter

795-799-5420

Remover

t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 1

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative (–) terminal of the battery.

10. Remove air intake tube (10). 11. Remove covers (11) and (12). 12. Disconnect lubrication tubes (13) and (14). 13. Disconnect exhaust tube (15).

1. Drain the coolant. Radiator: 69 2. Open the engine top cover and remove the battery case in the rear and engine cover. 3. Remove fuel filter bracket assembly (1). 4. Disconnect fuel tubes (2) and (3). 5. Remove corrosion resistor and bracket assembly (4). 6. Disconnect each wiring connector and ground wire and move wiring harness (4). 7. Remove air intake connectors (6) and (7).

14. Remove turbocharger and exhaust manifold assembly (16). Turbocharger and exhaust manifold assembly: 60 kg

8. Remove air intake manifold (8). Reference: The same parts are used in the front and rear sections.

HD465-7, HD605-7

30-17 (10)


15. Remove spill tube (30).

CYLINDER HEAD

20. Remove the mounting bolts and rocker arm housing (37).

16. Remove cylinder head cover (32).

17. Remove rocker arm assembly (33). ★ Loosen the locknut, then loosen adjustment screw 2 – 3 turns.

21. Remove cylinder head mounting bolts (38). Using the sling bolts, remove cylinder head assembly (39). Cylinder head assembly: 60 kg

18. Remove cross heads (34) and push rods (35).

19. Using tool A, remove injector assembly (36).

30-18 ➂

HD465-7, HD605-7


CYLINDER HEAD

INSTALLATION •


Fuel tube sleeve nut (2): 43 – 47 Nm {4.4 – 4.8 kgm} Fuel tube sleeve nut (3): 24 – 27 Nm {2.4 – 2.8 kgm}

★ Tighten the mounting bolts of the air intake manifold in the following order.

Mounting bolt of cylinder head cover: 9.8 ± 1.0 Nm {1 ± 0.1 kgm}

★ Clean the mounting bolt holes before installing the bolts. ★ Check that the ball of the adjustment screw is fitted to the socket of the push rod. Rocker arm mounting bolt: Engine oil (EO30-CD) Rocker arm mounting bolt: 235.2 – 254.8 Nm {24 – 26 kgm} Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}

★ Adjust each cross head according to the following procedure.

★ Tighten the mounting bolts of the turbocharger and exhaust manifold in the following order.

1) Loosen the locknut and return the adjustment screw until it does not touch the valve stem. 2) Hold the contact face of the cross head against the rocker arm and keep the cross head in contact with the valve stem on the push rod side. 3) Tighten the adjustment screw gradually. After it touches the valve stem, tighten it 20° – 30° further. 4) Tighten the locknut. Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm}

Mounting bolt of turbocharger and exhaust manifold assembly: 1st time : 39.2 – 58.8 Nm {4 – 6 kgm} 2nd time : 112.8 – 122.5 Nm {11.5 – 12.5 kgm}

HD465-7, HD605-7

30-19 ➂


CYLINDER HEAD

1) Using tool A, insert injector (60) in the cylinder head. O-ring: Engine oil (EO30-CD) ★ When inserting the injector, check that the gasket at its end will not fall. ★ Direct the draft hole of the injector toward the diagonal point of the holder and set the holder to the installation position, too. ★ Insert the injector straight in the cylinder head hole. Using the cylinder side of tool A, press the injector top and set the seal of its end to the cylinder head.

Rocker arm housing: Gasket sealant (LG-7) ★ Apply the gasket sealant in a line 2 – 3 mm in diameter along the housing groove as shown below. Mounting bolt: 78.4 – 93.2 Nm {8.0 – 9.5 kgm}

2) Tighten the holder mounting bolts. ★ Measure stem length a of each mounting bolt. If it is 80 mm or longer, do not use the bolt but use new one. Threads and seat of mounting bolt: Engine oil (EO30-CD) Mounting bolt: 1st time: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 2nd time: Retighten 90° +30° 0

30-20 ➂

HD465-7, HD605-7

CYLINDER HEAD


a Check that there is not foreign matter on the fitting face of the cylinder head and in the cylinder. a When fitting the gasket, check that the grommet is not removed. a Check each mounting bolt head for punch marks. If there are 3 punch marks, replace the bolt. a Tighten the cylinder head mounting bolts in the following order. Mounting bolt: Molybdenum disulfide grease (LM-P) Cylinder head mounting bolts ((1) – (7)): 1st time : 245 ± 9.8 Nm {25 ± 1 kgm} 2nd time : 382.5 ± 9.8 Nm {39 ± 1 kgm} 3rd time : Make marks on bolts and cylinder head with paint, then retighten the bolts 90° – 120°. Mounting bolts ((8), (9)) 93.2 – 103 Nm {9.5 – 10.5 kgm}

a After tightening the bolts, make a punch a mark a on the main bolt (Do not make the punch mark if the bolts are new).

•

Refilling with coolant Add coolant through the filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69

HD465-7, HD605-7

30-21 (10)

ENGINE


REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

C4

1

Centering tool

792-420-1120

• Flange

2

790-413-1120

• Collar

1

01010-51230

• Bolt

8

Sketch

t

792-420-1110

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

5. Disconnect exhaust tube (5). 6. Disconnect wiring connector E13A (6) and E13B (7).

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks.

7. Remove engine oil cooler tubes (8) and (9).

Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative (–) terminal of the battery. 1. Remove battery box (1), engine top cover (2) (2A), air cleaner (3), and air intake tube.

8. Disconnect wiring connectors SIG (10), POW (11), and ENG (12) from the left rear part of the engine and remove bracket (13). 9. Disconnect hoses (15) and (16).

2. Remove the radiator assembly. For details, see REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY. 3. Remove the radiator cross bar. 4. Remove washer tank (4).

30-22 (10)

HD465-7, HD605-7


ENGINE

10. Remove oil filter bracket assembly (17). 11. Disconnect hoses (18) and (19). 12. Disconnect air conditioner pipe (20).

13. Remove plate (21) and drive shaft (22). Drive shaft: 30 kg

14. Sling the engine assembly temporarily. 15. Remove engine mounting bolts (23) and (24) and pull out engine assembly (25) forward to remove it. a When removing the engine assembly, check that the all wires and pipes are disconnected and take care that the engine assembly will not interfere with the chassis. Engine assembly: 2,750 kg

HD465-7, HD605-7

30-23 (10)

ENGINE


INSTALLATION •


a When tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke. Mounting bolt: Adhesive (LT-2)

•

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Radiator: 69


a Center the engine assembly and torque converter and transmission assembly according to the following procedure. 1. Install flange (C4-1) and collar (C4-2) of tool C4 between coupling (20) on the engine side and coupling (21) on the torque converter side. 2. Center the engine assembly and torque converter and transmission assembly by moving the engine assembly so that collar (C4-2) will move smoothly between both flanges while coupling (21) on the torque converter side makes a full turn. Reference: The allowable vertical and lateral deviation between both flanges is 3 mm maximum.

Engine mount mounting bolt (Both front and rear): 343 – 426.3 Nm {35.0 – 43.5 kgm} a If the engine mount bracket was removed from the chassis, tighten its mounting bolts to the following torque. Mounting bolt of front engine mount bracket: 343 – 426.3 Nm {35.0 – 43.5 kgm} Mounting bolt of rear engine mount bracket: 450 – 608 Nm {50 – 62 kgm}

30-24 (10)

HD465-7, HD605-7

TORQUE CONVERTER AND TRANSMISSION


REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY

6. Disconnect hose (4) and tube (5).

C4

792-420-1110

Centering tool

792-420-1120

• Flange

t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 2

790-413-1120

• Collar

1

01010-51230

• Bolt

8

REMOVAl

7. Remove drive shaft (6). Drive shaft: 30 kg 8. Disconnect hoses (7), (8), (9), (10), and (11).

Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. Disconnect the cable from the negative (–) terminal of the battery. 1. Remove the transmission underguard. 2. Drain the transmission oil and hydraulic oil. Transmission case: 190 Hydraulic tank: 122 3. Disconnect wiring connectors (1) (TM2 and TM3). 4. Remove drive shaft (2). Drive shaft: 65 kg 5. Disconnect hose (3).

HD465-7, HD605-7

30-25 (3)


9. Disconnect hoses (12), (13), and (14) and tubes (15) and (16) from the left underside of the transmission.


11. Remove mounting bolts (17) and (18) of the front and rear mounts, then remove torque converter and transmission assembly (19). a When removing the torque converter and transmission assembly, check that the all wires and pipes are disconnected and take care that the assembly will not interfere with the chassis. a Check the thickness and quantity of the shims set in the rear mount. • Standard thickness of shims: 2 mm • Thickness of each shim: 0.5 mm (1 type) Torque converter and transmission assembly: 1,600 kg

10. Sling the torque converter and transmission assembly temporarily.

30-26 (10)

HD465-7, HD605-7



a If the transmission mount bracket was removed from the chassis, tighten its mounting bolts to the following torque.

INSTALLATION •

Carry out installation in the reverse order to removal. , a When tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke.

Mounting bolt: Adhesive (LT-2) Mounting bolt: 157 – 198 Nm {16.0 – 20.1 kgm}

Mounting bolt: 450 – 608 Nm {50 – 62 kgm} •

Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190

(EO30-CD or EO10W-CD)

Hydraulic tank: 122

(EO10-CD)


a Center the engine assembly and torque converter and transmission assembly according to the following procedure. 1. Install flange (C4-1) and collar (C4-2) of tool C4 between coupling (20) on the engine side and coupling (21) on the torque converter side. 2. Center the engine assembly and torque converter and transmission assembly by moving the engine assembly so that collar (C4-2) will move smoothly between both flanges while coupling (21) on the torque converter side makes a full turn. Reference: The allowable vertical and lateral deviation between both flanges is 3 mm maximum.

HD465-7, HD605-7

30-27 (10)

TRANSMISSION AND TORQUE CONVERTER


SEPARATION AND COUPLING OF TRANSMISSION ASSEMBLY AND TORQUE CONVERTER ASSEMBLY

5. Lift off torque converter assembly (9). Torque converter assembly: 410 kg 6. Remove seal rings (10) and (11).

SEPARATION 1. Remove pump assemblies (1), (2), and (3) and their pipes. Retarder cooling pump assembly (1): 30 kg Steering hoist and hoist control pump assembly (2): 35 kg Torque converter, transmission, retarder cooling, and brake pump assembly (3): 25 kg 2. Remove plate (4) and trunnion (5). 3. Remove cover (6) and disconnect torque converter oil temperature sensor connector (7) and torque converter intermediate oil pressure sensor connector (8).

COUPLING •

Carry out coupling in the reverse order to separation.

Torque converter assembly mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}

Outside of seal ring: Grease (G2-LI)

4. Sling the torque converter and transmission assembly, then place it with the torque converter side up.

30-28 ➂

HD465-7, HD605-7

TORQUE CONVERTER


DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY

Unit repair stand

■

1

790-901-2110

Bracket

■

1

790-901-3011

Plate

■

1

2

790-101-1871

Nut wrench

■

1

3

792-103-5110

Wrench

■

1

C

Part name

Sketch

Q'ty

790-501-5000 1

Part No.

New/Remodel

Necessity

Symbol

Special tools

DISASSEMBLY

2) Using 2 forcing screws [1], lift off PTO case assembly (10). ★ Before removing the PTO case assembly, make match marks on it.

1. Set the torque converter assembly to tool C1. 2. Remove control valve assembly (1). 3. Remove torque converter oil temperature sensor (2) and torque converter intermediate oil pressure sensor (3). 4. Remove elbows (4) and (5) and tube (6).

6. Disassembly of PTO case assembly 1) Using tool C2, remove nuts (9). 2) Remove snap ring (12) and plate (13).

5. PTO case assembly 1) Remove holder (7) and coupling (8). ★ Before removing the holder and coupling, loosen 3 nuts (9) with tool C2 (Use the coupling as a stopper).

HD465-7, HD605-7

30-29 ➂


3) Press the shaft to remove PTO gear and bearing assembly (14). ★ If the PTO gear and bearing assembly comes off, bearing (15) comes off, too. 4) Remove inner race spacer (16) and bearing (17) from the PTO gear. 5) Remove outer races (18) and (19) and outer race spacer (20) from the PTO case. ★ Since parts (15) – (20) form an assembly, do not replace any of them with one of another assembly. (The combination symbol is stamped on each part.)

TORQUE CONVERTER

9) Remove bushing (25) and outer race (26) from the PTO case.

7. Turbine and clutch assembly 1) Remove mounting bolts (27) on the pump side. 2) Remove turbine and clutch assembly (28).

6) Remove snap ring (21). 7) Using forcing screws [2], remove cage (22).

8. Disassembly of turbine and clutch assembly 1) Input shaft i) Using forcing screws [3], remove input shaft (29). ii) Remove bearing (30) from the input shaft. 8) Remove oil seal (23) and dust seal (24) from the cage.

30-30 ➂

HD465-7, HD605-7


2) Turn over the drive case and remove the mounting bolts and turbine (31).

3) Remove drive case (32) from clutch housing assembly (33). 4) Remove 2 discs (34) and plate (35).

5) Turn over the clutch housing and remove snap ring (36) and plate (37).

HD465-7, HD605-7

TORQUE CONVERTER

6) Using push tool [4], remove shaft (38) from clutch housing assembly (33), then remove piston (39).

7) Remove seal rings (40) from piston (39).

8) Using push tool [5], remove bearing (41) from the clutch housing. 9) Remove pin (42) and seal ring (43).

30-31 ➂


9. Stator assembly Pull up and remove stator assembly (44).

TORQUE CONVERTER

11. Disassembly of pump, stator shaft, and rear housing assembly 1) Remove snap ring (51) and inner race (52). 2) Using tool C3, remove nuts (53).

10. Disassembly of stator assembly 1) Remove stator (45). 3) Remove the pump, stator shaft, and rear housing assembly from tool C1. 4) Remove the mounting bolts and push out and remove stator shaft (54). a At this time, inner race (55) comes off.

2) Remove bushings (47) and (48) and free wheel (49) from outer race (46). a Take care not to lose balls (50).

5) Remove seal ring (56), inner race (57), and sleeve (58) from stator shaft (54).

30-32 (10)

HD465-7, HD605-7

TORQUE CONVERTER


6) Remove retainer (60) and guide (61) from pump (59). 7) Remove bearing (62) from guide (61).

ASSEMBLY 1. Assembly of pump, stator shaft and rear housing assembly 1) Install bearing (62) to guide (61) and install them to pump (59). a Bearing (62) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating inner race. 2) Install retainer (60) to pump (59). Retainer mounting bolt: Adhesive (LT-2) Retainer mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

3) Press fit inner race (57) to stator shaft (54). a Inner race (57) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating bearing. 4) Fit sleeve (58) and seal ring (57). a Fit sleeve (58) by expansion fit. Outside of seal ring: Grease (G2-LI)

HD465-7, HD605-7

30-33 (3)


5) Install stator shaft assembly (54) to rear housing (63). Mounting bolt: Adhesive (LT-2) Mounting bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm}

TORQUE CONVERTER

8) Using tool C3, tighten nuts (53). a Drop about 6 CC of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns. Threads of nut: Adhesive (LT-2) Nut: 441.3 – 490.3 Nm {45 – 50 kgm} 9) Install inner race (52) and snap ring (51). a Install the inner race with the wider end face up.

6) Install the stator shaft and rear housing assembly to tool C1. 7) Install pump assembly (64) and inner race (55) to stator shaft (54). a Inner race (55) is an assembly. Check that the serial No. and match symbol (A or B) on its end face are the same as those on the mating bearing.

2. Assembly of stator assembly 1) Install free wheel (49) to outer race (46). a Install the free wheel with its arrow mark end on the input side. Check the revolving direction of the outer race, seeing it from the input side. Clockwise: Free rotation Counterclockwise: Locked Sliding surface: Engine oil (EO10-CD or EO30-CD) 2) Install balls (50) to outer race (46), then install bushings (48) and (47) by expansion fit. Sliding surface: Engine oil (EO10-CD or EO30-CD)

30-34 (10)

HD465-7, HD605-7


3) Install stator (45). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

TORQUE CONVERTER

3) Using push tool [6], install bearing (41) to the clutch housing. ★ Press fit the bearing until it is stopped by the clutch housing. ★ Drop about 6 cc of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns.

3. Stator assembly Install stator assembly (44). 4) Install seal ring (40) to piston (39). ★ For the installing direction, see the following figure. Outside of seal ring: Grease (G2-LI)

4. Assembly of turbine and clutch assembly 1) Install seal ring (43) to the clutch housing. ★ For the installing direction, see the following figure. Outside of seal ring: Grease (G2-LI) 2) Install pin (42) by expansion fit.

HD465-7, HD605-7

5) Install piston (39) to clutch housing assembly (33). 6) Using push tool [7], press fit shaft (38) to clutch housing assembly (33). ★ Press fit the shaft until it is stopped by the bearing.

30-35 ➂


TORQUE CONVERTER

7) Install plate (37) to the shaft, then install snap ring (36).

8) Install 2 discs (34) and plate (35). Sliding surface of disc: Engine oil (EO10-CD or EO30-CD) 9) Install drive case (32) to clutch housing assembly (33). ★ Watch through holes A (at 6 places on the periphery) and check that plate (35) is meshed with the gear of drive case (32). Mounting bolt: Adhesive (LT-2)

11) Input shaft i) Using push tool [8], install bearing (30). ★ Drop about 6 cc of engine oil (EO10-CD or EO30-CD) over the bearing and rotate the bearing 10 turns. ii) Install input shaft assembly (29) to clutch housing assembly (33). Mounting bolt: Adhesive (LT-2) Mounting bolt: 269.7 – 308.9 Nm {27.5 – 31.5 kgm}

Mounting bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm}

10) Install turbine (31). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

30-36 ➂

5. Turbine and clutch assembly 1) Install turbine and clutch assembly (28). 2) Tighten mounting bolts (27) (30 pieces). Mounting bolt: Adhesive (LT-2) Mounting bolt: 49.0 – 58.8 Nm {5 – 6 kgm}

HD465-7, HD605-7


TORQUE CONVERTER

6. Assembly of PTO case assembly 1) Press fit outer race (26) and bushing (25) to the PTO case. ★ After press fitting bushing (25), bend the PTO case end (by 4 points equally spaced on the periphery) with a punch, etc. until it is over the bushing.

3) Fit the O-ring to cage (22) and install them to the PTO case. 4) Install snap ring (21). ★ Install the snap ring so that its closed gap will be on the left side (in the direction of 9 o'clock) when it is on the truck and seen from the engine side.

2) Using push tool [9], install dust seal (24) and oil seal (23) to cage (22). i) Thinly apply gasket sealant (LG-5) to the seal fitting surface inside the cage.ii) ii) Install the seals so that the distances from the cage top to their tops will be as follows. • Distance a: 23.6 ± 0.2 mm • Distance b: 8.75 ± 0.25 mm ★ After installing, wipe off the projected gasket sealant thoroughly. iii) Fill the space between the oil seal and dust seal and the space between the lips of the oil seal with silicone grease (ThreeBond 1855) ★ Supply grease of quantity equivalent to 40 – 60% of the space between the lips so that it will not be projected.

5) Install outer race spacer (20) and outer races (18) and (19) to the PTO case. 6) Install bearing (17) and inner race spacer (16) to the PTO gear. 7) Install PTO gear and bearing assembly (14) to the PTO case, then install bearing (15) to the shaft. ★ Since parts (20) – (15) form an assembly, do not replace any of them with one of another assembly. (The combination symbol is stamped on each part.) ★ Apply grease (G2-LI) to the inside spline of the PTO gear shaft.

HD465-7, HD605-7

30-37 ➂


TORQUE CONVERTER

8) Install plate (13) and snap ring (12). 9) Using tool C2, tighten nuts (9) temporarily. a Install the nuts with the chamfered side down. a Tighten the nuts fully after installing the PTO case assembly. After this, follow the procedure: 7-3 (making coupling serve as a stopper). Threads of nut: Adhesive (LT-2)

8. Install elbows (5) and tube (6). a When installing elbows (5), check that there are stamps of <2> on their outside. Elbow: 34.3 – 63.8 Nm {3.5 – 6.5 kgm}

7. PTO case assembly 1) Sling PTO case assembly (10) and fit the Oring. Using guide bolt [10], install the PTO case assembly. a When installing the PTO case assembly, match the match marks. Mounting bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm}

9. Install elbows (4). Threads of elbow: Gasket sealant (LG-5) Elbow: 16.7 – 29.4 Nm {1.7 – 3.0 kgm} 10. Install torque converter intermediate pressure sensor (3). Threads of sensor: Gasket sealant (LG-5) Sensor: 9.8 – 19.6 Nm {1 – 2 kgm} 11. Install torque converter oil temperature sensor (2). Threads of sensor: Gasket sealant (LG-5) Sensor: 29.4 – 49.0 Nm {3.0 – 5.0 kgm} 12. Install control valve assembly (1). Mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 Kgm}

2) Install coupling (8) and holder (7). Mounting bolt: Adhesive (LT-2) Mounting bolt: 245.2 – 308.9 Nm {25 – 31.5 kgm} 3) Using tool C2, tighten the nuts (9) to the following torque which were tightened temporarily in steps 6-9). a Use the coupling as a stopper. Nut: 392.4 – 441.5 Nm {40 – 45 kgm}

30-38 (10)

HD465-7, HD605-7

TRANSMISSION


DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY

4) Remove cover (7) and lubricating oil temperature sensor (8). 5) Remove block (9).

799-301-1600

Oil leak tester kit

1

Sketch

t

New/Remodel

Part name

Q'ty

D1

Part No.

Necessity

Symbol

Special tools

DISASSEMBLY 1. Transmission mount, cover, wiring harness, and sensors 1) Remove both transmission mounts (1). 2) Remove covers (2) and (3).

2. Control valve assembly 1) Separate the connector of each control valve and remove wiring harness (10). 2) Install a sling bolt to position A and remove control valve assembly (11) and valve seat together. a After removing the control valve, cover the oil holes on the mating face of the transmission case with tapes, etc. to prevent foreign matter from entering the transmission case. 3) Remove each control valve (12) and filter assembly (13) from the valve seat.

3) Remove input shaft speed sensor (4), intermediate shaft speed sensor (5), and output shaft speed sensor (6).

3. Sleeve Using a forcing screw, remove 5 sleeves (14).

HD465-7, HD605-7

30-39 (3)


4. Oil pan 1) Sling transmission assembly (15) and remove oil pan (16).

TRANSMISSION

5. Check of operation of pistons Using tool D1, blow air into the clutch ports and check the operation of the pistons of No. 1, 2, and 3 clutches. (Since you cannot check the operation of the pistons of No. 2 and 3 clutches directly, check it by movement of the discs or plates.) a The locations of the clutch ports are shown below. • No. 1 clutch port: A • No. 2 clutch port: B • No. 3 clutch port: C a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2} • Standard stroke of clutch No. 1 piston: 4.2 mm

2) Remove cover (17) from the oil pan, then remove spring (18) and magnet assembly (19).

6. No. 1 clutch plates 1) Using sling bolts, remove No. 1 clutch plates (24). a There are 2 bolts installed from the transmission case side. 3) Remove blocks (20) and (21) from the oil pan, then remove relief valves (22) and (23).

30-40 (10)

HD465-7, HD605-7


2) Remove bearing (25) from No. 1 clutch plates.

7. No. 1 clutch spring and guide Remove spring (26) and guide (27). 8. Discs, plates, and springs Remove discs (28), plates (29), and spring (30).

9. No. 1 clutch drum and piston 1) Using hanging bolts, remove clutch No. drum (31) and piston (32) together, then separate them from each other.

HD465-7, HD605-7

TRANSMISSION

2) Remove seal rings (100) and (101) from piston (32).

10. Input shaft and No. 1 ring gear assembly 1) Sling the input shaft and remove the input shaft and No. 1 ring gear assembly (33).

2) Pull up and remove No. 1 ring gear (34). 3) Remove seal rings (206) and (207) from the input shaft.

30-41 (10)


4) Remove inner race (35) from No. 1 ring gear (34).

TRANSMISSION

7) Remove snap ring (39), then remove bearing (40) from input shaft (41).

5) Remove snap ring (36) and press down and remove gear (37).

11. No. 2 clutch assembly Lift off No. 2 clutch assembly (42).

6) Remove inner race (38) from gear (37).

12. Disassembly of No. 2 clutch assembly 1) Turn over No. 2 clutch assembly and remove housing (43).

30-42 (10)

HD465-7, HD605-7


2) Remove mounting bolts, cover (44), and piston (45).

3) Remove seal ring (46) from piston (45).

4) Housing assembly i) Remove seal rings (47) and (48). ii) Remove snap ring (49), bushing (50), and ball (205). aTake care not to lose ball (205). iii) Remove inner race (51) and bearing (52).

HD465-7, HD605-7

TRANSMISSION

5) Remove snap ring (53) and ring gear (54).

6) Remove discs (55), plates (56), and spring (57). 7) Using sling bolts, remove drum (58).

8) Remove plates (59) from carrier (60).

30-43 (10)

TRANSMISSION


9) Carrier assembly i) Remove shaft (61). a Take care not to lose ball (62). ii) Remove planetary gears (63), thrust washer (64), and bearing (65).

13. Transmission case 1) Remove cage assembly mounting bolts (69) and lift off transmission case (70) vertically.

2) Remove the following parts from the transmission case. i) Remove the assembly of cage (71) and bearings (72), then remove the bearings from the cage. ii) Remove collars (73) and bearings (74) from the case. iii) Remove seal ring (204) from the collar.

iii) Remove seal ring (66), inner race (67), and bearing (68) from carrier (60).

14. Check of operation of piston Using tool D1, check the operation of pistons of No. 4, 5, 6, and 7 clutches. a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2} Standard strokes of pistons

30-44 (10)

Piston No.

Stroke (mm)

4

4.8

5

5.8

6

5.0

7

5.0

HD465-7, HD605-7

TRANSMISSION


17. No. 3 clutch ring gear 1) Remove No. 3 clutch ring gear (80). 2) Remove inner race (81) and seal ring (82) from the ring gear.

15. No. 3 clutch housing assembly Remove the housing mounting bolts and No. 3 clutch housing assembly (75). a For disassembly, see Step 12, DISASSEMBLY OF NO. 2 CLUTCH ASSEMBLY, 1) - 4). (No. 3 clutch assembly has the same structure as No. 2 clutch assembly.)

18. Tie bolts Remove tie bolts (83). 16. No. 3 clutch drum, discs, and plates 1) Using hanging bolts, remove No. 3 clutch drum (76), discs, plates, and spring together. 2) Remove discs (77), plates (78), and spring (79).

HD465-7, HD605-7

19. No. 4 clutch plates and sun gear 1) Remove plates (84). 2) Remove snap ring (85) and sun gear (86).

30-45 (10)


3) Remove seal ring (200) from No. 4 sun gear (86).

20. No. 4 clutch discs, plates, and springs Remove discs (87), plates (88) and (101), and springs (89) and (90). a Distinguish plates (88) and (101) from each other. a Since springs (90) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.

TRANSMISSION

21. No. 4 housing, piston, and ring gear 1) Using hanging bolts, remove No. 4 housing (91), piston (92), and ring gear (93) together. a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage.

2) Remove seal rings (93) and (94) from No. 4 housing (91) and piston (92).

22. No. 5 clutch discs, plates, and springs Remove discs (95), plates (96), and springs (97) and (98). a Since springs (97) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.

30-46 (10)

HD465-7, HD605-7


TRANSMISSION

4) Remove sleeve (203) for tie bolt (83) from No. 5 housing and check the direction of the sleeve (slit A).

23. No. 5 housing, piston, ring gear, and guide pins 1) Using sling bolts, remove No. 5 housing (99), piston (102), and ring gear (103) together. a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage. 2) Remove guide pins (202).

24. No. 6 clutch discs, plates, and springs Remove discs (108), 4 plates (109) and (110), and springs (111) and (112). a Since springs (111) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line. a Distinguish plates (109) and (110) from each other.

3) Remove seal rings (106) and (107) from No. 5 housing (99) and piston (102).

HD465-7, HD605-7

30-47 (10)


25. No. 4 and No. 5 carriers assembly Using hanging bolts, remove No. 4 and No. 5 carriers assembly (201).

26. Disassembly of No. 4 and No. 5 carriers assembly 1) Remove No. 5 sun gear (113).

TRANSMISSION

4) Drive out shaft (117) from the ball side and remove No. 5 planetary gears (119), bearing (120), collar (121), and thrust washer (122). a At this time, 4 of 8 No. 5 planetary gears come off.

5) Drive out shaft (123) toward No. 4 carrier and remove ball (124). a Take care not to lose ball (124). 6) Drive out shaft (123) further and remove it. 7) Remove No. 4 planetary gears (300), bearing (125), thrust washer (126), No. 5 planetary gear (119), bearing (120), collar (121), and thrust washer (122). 8) Remove snap ring (127) and ring gear (129).

2) Turn over the carrier assembly and remove bearing (115) and seal ring (116).

3) Drive out shaft (117) toward the ball and remove ball (118). a Take care not to lose the ball.

30-48 (10)

HD465-7, HD605-7


TRANSMISSION

27. No. 6 and No. 7 housings, pistons, and springs 1) Using sling bolts, remove No. 6 and No. 7 housings (131) and pistons (132) and (133). a If the dowel pin is hard to remove and it may cuff the housing, take care not to cause damage.

29. No. 6 and No. 7 carriers assembly Using sling bolts, sling the shaft and remove No. 6 and No. 7 carriers assembly (142). 2) Remove seal rings (134), (135), and (136) from No. 6 and No. 7 housings and pistons (132) and (133).

30. Disassembly of No. 6 and No. 7 carriers assembly 1) Remove collar (143). 2) Remove inner race (144) and snap ring (145) from collar (143). 28. No. 7 clutch discs, plates, and springs Remove discs (138), plates (139), and springs (140) and (141). a Since springs (141) of a clutch line have a part No. different from those of another clutch line, store them for each clutch line.

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30-49 (10)

DISASSEMBLY AND ASSEMBLY 3) Tighten forcing screws [1] to remove plates (146). 4) Remove seal ring (147) and bearing (148) from the plates.

TRANSMISSION a Hit both shafts evenly to drive out the above parts gradually. 9) Remove seal ring (170) from collar (159). 10) Remove planetary gear No. 7 (162), bearing (163), and thrust washer (164). 11) Remove snap ring (165), collar (166), and ball (167). a Take care not to lose ball (167).

5) Remove intermediate shaft (149) and No. 6 sun gear (150) together. 6) Remove snap ring (151) and inner race (152) from intermediate shaft (149).

31. Guide pins and No. 7 clutch ring gear 1) Remove guide pins (168). 2) Remove No. 7 clutch ring gear (169).

7) Pull out shaft (153) and remove No. 6 planetary gear (154), bearing (155), thrust washer (156), and ball (157). a Take care not to lose ball (157). 32. Cage assembly 1) Using forcing screws [3], remove cover (172) from cage assembly (171). 2) Remove seal ring (173) from the cover. 3) Remove bearing (174) from the cage.

8) After removing No. 6 planetary gear, drive out shaft (158), collar (159), inner race (160), and ball (161), using drive shafts [2] (14 mm or less in diameter and about 200 mm in length). a Take care not to lose ball (161).

30-50 (10)

HD465-7, HD605-7


33. Output shaft and cage assembly 1) Remove mounting bolts (301) and output shaft and cage assembly (175). ★ Since the whole transmission is being disassembled now, the output shaft and cage assembly are removed at this time. You can remove only the output shaft assembly for repair of a leaking oil seal, etc., however, if you remove the speedometer gear (optional) in advance.

TRANSMISSION

3) Support cage (178) and press the output shaft (179) with a press to drive it out of the bearing.

4) Remove bearing (180) from output shaft (179).

2) Remove worm (176) and collar (177) from the output shaft. ★ The collar consists of 2 semicircular pieces.

5) Remove oil seal (181) and bearing (182) from cage (178).

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30-51 ➂


ASSEMBLY ★ Clean the all parts and check them for dirt or damage before installing. ★ Coat the sliding surfaces of each part with engine oil before installing. ★ Soak the discs in clean engine oil (EO-10CD) for at least 2 minutes. ★ Install each piston seal ring (a) of the clutch assembly with its pressure receiving side (side b) directed toward housing (c). ★ Apply grease (G2-LI) to the periphery of the all seal rings. ★ When fitting a bearing by expansion fit, drop engine oil (EO10-CD or EO30-CD) over it and rotate it 10 turns before chilling it in dry ice, etc.

TRANSMISSION

1. Output shaft and cage assembly 1) Install bearing (182) and oil seal (181) to cage (178). Oil seal lip: Silicone grease (ThreeBond 1855) Press fitting surface on cage side: Gasket sealant (LG-5) ★ After press fitting, wipe off the excessive gasket sealant.

2) Press fit bearing (180) to output shaft (179).

★ Securely fit springs (A) of No. 4 – No. 7clutches to the seats of the piston and housing.

3) Set output shaft (179) on the press stand and press the inner race side of the bearing to install cage (178).

30-52 ➂

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4) Install collar (177) and worm (176) to the output shaft. ★ The collar consists of 2 semicircular pieces.

5) Fit the O-ring to the cage and install output shaft and cage assembly (175).

TRANSMISSION

3. Guide pins and No. 7 clutch ring gear 1) Install guide pins (168) to the cage. 2) Install No. 7 clutch ring gear (169).

4. No. 7 clutch discs, plates, and springs Install discs (138), plates (139), and springs (140) and (141). ★ Install the 4 discs and 3 plates. ★ Securely fit springs (141) to the seats of the housing.

2. Cage assembly 1) Using the push tool, press fit bearing (174) to cage (171). 2) Install cover (172) to cage (171). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 3) Install seal ring (173) to cover (172). Periphery of seal ring: Grease (G2-LI)

HD465-7, HD605-7

30-53 ➂


5. No. 7 clutch piston Install seal ring (134) to piston (133), then matching it to the springs. ★ Install the seal ring as shown below. Periphery of seal ring: Grease (G2-LI) 6. No. 6 and No. 7 housings and No. 6 piston 1) Install seal rings (134), (135), and (136) to housing (131) and piston (132). ★ Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)

TRANSMISSION

7. Assembly of No. 6 and No. 7 carriers assembly 1) Install bearing (163) to No. 7 planetary gear (162). Fit thrust washers (164) to both sides of them and set them to the carrier. 2) Press fit shaft (158) and set ball (161) to secure the shaft. ★ When press fitting the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. 3) Install seal ring (170) to collar (159) and press fit inner race (160). Periphery of seal ring: Grease (G2-LI) 4) Install ball (167) and collar (166) to the carrier and secure them with snap ring (165). 5) Check that No. 7 planetary gear rotates smoothly.

2) Using sling bolts, sling No. 6 and No. 7 housings (131), matching them to piston (133). ★ If the dowel pin is hard, drive it with a plastic hammer.

30-54 ➂

6) Install bearing (155) to No. 6 planetary gear (154). Fit thrust washers (156) to both sides of them and set them to the carrier. 7) Drive shaft (153) and set ball (157) to secure the shaft. ★ When driving the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. 8) Check that No. 6 planetary gear rotates smoothly.

HD465-7, HD605-7


9) Press fit inner race (152) to intermediate shaft (149). 10) Install snap ring (151). a Check that the snap ring is fitted to the groove. 11) Install No. 6 and No. 7 carrier intermediate shaft (149) and sun gear (150).

12) Press fit bearing (148) to plate (146). a Securely press fit the bearing to the specified stopper position. 13) Install seal ring (147). Periphery of seal ring: Grease (G2-LI) 14) Install plate (146) to No. 6 and No. 7 carriers. Mounting bolts: Adhesive (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

HD465-7, HD605-7

TRANSMISSION

15) Install snap ring (145) to collar (143). a Check that the snap ring is fitted to the collar groove. 16) Press fit inner race (116) to collar (115) and install them to the intermediate shaft.

8. No. 6 and No. 7 carriers assembly Using sling bolts, sling the shaft. Install No. 6 and No. 7 carriers assembly (142), matching the gear to the bearing.

30-55 (10)


9. Assembly of No. 4 and No. 5 carriers assembly 1) Install bearing (125) to No. 4 planetary gear (300). Fit thrust washers (126) to both sides of them and set them to the carrier. 2) Set collar (121) between 2 bearings (120) and install them to No. 5 planetary gear (119). Fit thrust washers (122) to both sides of them and set them to the carrier. 3) Chill shaft (123) in dry ice, then install it to the carrier. a Check that the shaft, bearing, thrust washers, and carrier are aligned and take care that the bearing and thrust washers will not be damaged. a Match the ball fitting hole of the shaft to the hole of the carrier. 4) Fit ball (124) and install shaft (123) securely. 5) Check that the gear rotates smoothly. 6) Install ring gear (129) to the carrier and secure it with snap ring (127). a Mesh the external teeth on the carrier side with the internal teeth on the ring gear side, then align the carrier with the ring gear so that the snap ring will be inside the 45° chamfering diameter of the ring gear. a Check that the external teeth are meshed with the internal teeth and the whole snap ring is inside the chamfering diameter of the ring gear, then press in the ring gear until it is locked. a Check that the clearance between the bottom of the external teeth of the carrier and the inside diameter of the fitted snap ring is 2.0 – 3.2 mm through the circumference. a Hold the ring gear and move it up and down. Check that carrier does not come off at this time.

TRANSMISSION

7) Set collar (121) between 2 bearings (120) and install them to No. 5 planetary gear (119). Fit thrust washers (122) to both sides of them and set them to the carrier. 8) Drive shaft (117), matching the bearing to the thrust washer. 9) Drive out shaft (117) until the ball hole is seen perfectly, then fit ball (118) and drive the shaft into the carrier. a When driving the shaft, align it with the bearing and avoid hitting it strongly so that the bearing cage will not be deformed. a Check that the gear rotates smoothly.

10) Install bearing (115) and seal ring (116) to the carrier assembly. Periphery of seal ring: Grease (G2-LI)

30-56 (10)

HD465-7, HD605-7

TRANSMISSION


10. No. 4 and No. 5 carriers assembly Using hanging bolts, sling the shaft. Install No. 4 and No. 5 carriers assembly (201), matching the gear to the bearing. ★ You can install the "No. 4, No. 5 carriers, No. 6, and No. 7 assembly", too, as you removed. If this assembly is slung and moved, however, the bearing in the intermediate position may come off. Accordingly, divide this assembly.

11. No. 5 clutch sun gear Install sun gear (113). ★ Take care not to have your fingers caught in the gears.

2) Install gear (86). 3) Install snap ring (85).

13. No. 6 clutch discs, plates, and springs Install plate (110), discs (108), plates (109), and springs (111) and (112). ★ Install the 4 discs, 4 plates (109), and 1 plate (110). ★ Install one of plates (109) on the top. ★ Check that springs (111) are fitted to the seats of the piston and housing. ★ Securely install 6 springs (112) to each disc.

12. No. 4 clutch sun gear 1) Install seal ring (200) to gear (86). Periphery of seal ring: Grease (G2-LI)

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30-57 ➂


TRANSMISSION

14. No. 5 housing, piston, ring gear, and guide pins 1) Install tie bolt sleeves (203) to No. 5 housing (99). ★ When installing the sleeve, set slit A at the position checked when removed. ★ When tie bolts (83) are installed, they become hard because of the cushion sleeves. At this time, do not drive them forcibly with a hammer. (For prevention of breakage)

15. No. 5 clutch, discs, plate, and springs Install discs (95), plate (96), and springs (97) and (98). ★ Install the 5 discs and 4 plate. ★ Securely install 6 springs (98) to each disc.

2) Install seal rings (106) and (107) to housing (99) and piston (102), then install the piston to the housing. ★ Install the seal ring as shown in the following figure. Periphery of seal ring: Grease (G2-LI)

3) Set No. 5 clutch ring gear (103). ★ Set the gear with the chamfered side up. 4) Using hanging bolts, install No. 5 housing (99), matching it to the spring. ★ If the dowel pin is hard, drive it with a plastic hammer. 5) Install guide pins (202).

30-58 ➂

HD465-7, HD605-7


TRANSMISSION

16. No. 4 housing, piston, and ring gear 1) Install seal rings (93) and (94) to housing (91) and piston (92), then install the piston to the housing. ★ Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)

2) Using sling bolts, install No. 4 housing, matching it to the spring. ★ Check that the springs are fitted to the seats of the piston and plate. ★ If the dowel pin is hard, drive it with a plastic hammer. 3) Install ring gear (93). ★ Set the gear with the chamfered side up. 18. No. 4 clutch plate Install plate (84). ★ Check that the springs are fitted to the seats of the piston and plate.

17. No. 4 clutch, discs, plate, and springs Install plate (101), discs (87), plates (88), and springs (89) and (90). ★ Install the 4 discs, 3 plates (88), and 1 plate (101). ★ Securely install 6 springs (89) to each disc.

HD465-7, HD605-7

19. Tie bolts Install tie bolts (83). ★ Press in each bolt to the end of the cup hole. Do not use a hammer at this time. ★ Do not use an impact wrench until the bolt catches the threads. Tie bolt: 156.9 – 176.5 Nm {16 – 18 kgm}

30-59 ➂

TRANSMISSION


20. No. 3 clutch ring gear 1) Install inner race (81) and seal ring (82) to the ring gear. Periphery of seal ring: Grease (G2-LI)

2) Install No. 3 clutch ring gear (80). Mounting bolt: Adhesive (LT-2) Mounting bolt: 156.9 – 196 Nm {16 – 20 kgm}

22. Check of operation of piston Using tool D1, check the operation of pistons of No. 4, 5, 6, and 7 clutches. a Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2} Standard stroke of piston Piston No.

Stroke (mm)

4

4.8

5

5.8

6

5.0

7

5.0

a If the pistons do not move smoothly, apply engine oil to them.

21. No. 3 clutch housing assembly a For sassembly, see Step 24, assembly of No. 2 clutch assembly, 5) – 8). (No. 3 clutch assembly has the same structure as No. 2 clutch assembly.) a The plates, discs, and springs are each 1 less than those of No. 2 clutch assembly. a Using hanging bolts, sling and install housing assembly (75), matching the internal teeth of the disc to the external teeth of the ring gear. Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}

30-60 (10)

23. Transmission case 1) Install the following parts to the transmission case. i) Install seal ring (204) to the outer groove of collars (73), then install them, matching to the dowel pin of the transmission case. Periphery of seal ring: Grease (G2-LI) ii) Install cage (71). iii) Install bearings (72) and (74) to both sides. a Press fit the bearings until they are stopped by collars (73).

HD465-7, HD605-7


TRANSMISSION

★ When driving the shaft, align it with th e b ear in g a nd av oid hi tti ng it strongly so that the bearing cage will not be deformed. iv) Fit ball (64) and install shaft (61) securely. ★ If the shaft moves out, caulk the carrier side with a punch. ★ Check that the gear rotates smoothly.

2) Install the O-ring to the transmission case. 3) Sling and install transmission case (70) and tighten cage assembly mounting bolts (69).

2) Install plate (59) to carrier (60). Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}

24. Assembly of No. 2 clutch assembly 1) Carrier assembly i) Install inner race (67), bearing (68), and seal ring (66) to carrier (60). Periphery of seal ring: Grease (G2-LI)

3) Turn over the carrier assembly. Using sling bolts, install drum (58), matching it to the gear of the carrier.

ii) Install bearing (65) to gear (63). Fit thrust washers (64) to both sides of them and set them to the carrier. iii) Matching the thrust washer to the bearing, drive shaft (61).

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30-61 ➂


4) Install the ring gear (54), matching it to the carrier, and secure it with snap ring (53). 5) Discs, plates, and springs Install discs (55), plates (56), and springs (57) between the drum and ring gear. ★ Install the 5 discs, 4 plates, and 5 springs.

6) Housing assembly i) Install inner race (51) and bearing (52) to the housing. ii) Install ball (205) and bushing (50), then secure them with snap ring (49). iii) Install seal rings (47) and (48). ★ Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI)

TRANSMISSION

8) Install piston (45) to the housing, then install cover (44). Mounting bolt: Adhesive (LT-2) Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

9) Install housing (43) to the drum. Mounting bolt: Adhesive (LT-2) Mounting bolt: 98 – 122.5 Nm {10 – 12.5 kgm}

25. No. 2 clutch assembly Using sling bolts, sling and install No. 2 clutch assembly (42), matching the external teeth of the piston to the internal teeth of the drum. 7) Install seal ring (46) to piston (45). ★ Install the seal ring as shown below. Periphery of seal ring: Grease (G2-LI)

30-62 ➂

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26. Input shaft and No. 1 ring gear assembly 1) Press fit bearing (40) to input shaft (41) and install snap ring (39).

2) Install inner race (38) to gear (37).

3) Install gear (37) to the outer race side of the bearing, then install snap ring (36).

HD465-7, HD605-7

TRANSMISSION

4) Install inner race (35) to No. 1 ring gear (34).

5) Install ring gear (34) and seal rings (206) and (207) to the input shaft. Periphery of seal ring: Grease (G2-LI)

6) Sling the input shaft and install the input shaft and No. 1 ring gear assembly (33), matching the gear to the bearing.

30-63 ➂


27. No. 1 clutch, drum, and piston 1) Install seal rings (100) and (101) to piston (32), then install them to the drum (31). ★ Install the seal rings as shown below. Periphery of seal ring: Grease (G2-LI) 2) Using sling bolts, install No. 1 clutch drum (31) and piston (32) together.

TRANSMISSION

29. No. 1 clutch plate 1) Install bearing (25) to No. 1 clutch plate.

2) Using sling bolts, install plate (24), matching it to the spring and guide. Mounting bolt: 156.9 -– 196 Nm {16 – 20 kgm}

28. No. 1 clutch discs, plates, and springs Install discs (28), plates (29), springs (26) and (30), and guide (27). ★ Install the 3 discs and 2 plates.

30-64 ➂

30. Check of operation of piston Using tool D1, blow air into the clutch ports and check the operation of the pistons of No. 1, 2, and 3 clutches. (Since you cannot check the operation of the pistons of No. 2 and 3 clutches directly, check it by movement of the discs or plates.) ★ The locations of the clutch ports are shown below. • No. 1 clutch port: A • No. 2 clutch port: B • No. 3 clutch port: C ★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2} • Standard stroke of clutch No. 1 piston 4.2 mm

HD465-7, HD605-7


31. Oil pan 1) Install relief valves (22) and (23) to the oil pan, then install blocks (20) and (21).

2) Install magnet assembly (19) and spring (18) to the oil pan, then fit the O-ring and install cover (17).

3) Fit the plate gasket to oil pan (16) horizontally, then sling and install transmission assembly (15). Both sides of plate gasket: Gasket sealant (LG-1)

HD465-7, HD605-7

TRANSMISSION

32. Sleeve Fit the O-rings to sleeves (14) and install them to the transmission.

33. Control valve assembly 1) Install each control valve (12) to the valve seat. Control valve: 8.0 – 10.0 Nm {0.8 – 1.0 kgm} 2) Install filter assembly (13). ★ If the filter case and filter bracket plug were removed, tighten them to the following torque. Filter case: 34.3 – 44.1 Nm {3.5 – 4.5 kgm} Plug: 15.7 – 19.2 Nm {1.6 – 2.0 kgm} 3) Install sling bolts to A, then install the valve seats and control valve assembly (11) together. Mounting bolt: Gasket sealant (LG-5) 4) Install wiring harness (10) and connect the connectors to each control valve.

30-65 ➂


TRANSMISSION

34. Sensors, wiring harness, covers, and transmission mounts 1) Install block (9). 2) Install lubricating oil temperature sensor (8) and cover (7).

3) Install output shaft speed sensor (6), intermediate shaft speed sensor (5), and input shaft speed sensor (4). ★ For installation procedure, see TESTING AND ADJUSTING, Adjusting transmission speed sensors.

4) Install covers (2) and (3). 5) Install both transmission mounts (1).

30-66 ➂

HD465-7, HD605-7


REMOVAL AND INSTALLATION OF DIFFERENTIAL ASSEMBLY

DIFFERENTIAL

5. Remove guard (3) and drive shaft (4). 6. Disconnect hoses (5), (6), and (7) and remove slack adjuster (8).

REMOVAL Apply the parking brake and put blocks under the wheels. 1. Remove the dump body assembly. For details, see REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY". 2. Drain oil from the differential case and final drive case. Differential case: 95 Final drive case (Each side): 21 3. Using guide bolts [1], remove cover (1). (The rear wheel assembly is removed in the following photo. It does not need to be removed, however.)

7. Using forcing screws [2] and guide bolt [3], pull out differential assembly (9) forward. Differential assembly: 850 kg

4. Pull out drive shaft (2). ★ Install a hanging bolt to the shaft end to pull out the shaft. Drive shaft: 110 kg

HD465-7, HD605-7

30-67 ➂

DIFFERENTIAL


INSTALLATION •


Drain plug (Center of cover on final drive case side): 127.4 – 176.4 Nm {13.0 – 17.9 kgm} (Periphery of cover on final drive case side): 24.5 – 34.3 Nm {2.5 – 3.4 kgm}

★ Before tightening the bolts, check that the key way of the spider cap is fitted to the key way of the mating yoke. Mounting bolt: Adhesive (LT-2) Mounting bolt: 157 – 196 Nm {16.0 – 19.9 kgm}

Mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm}

Refilling with oil Differential case: 95

(EO30-CD)

Final drive case (Each side): 21

30-68 ➂

(EO30-CD)

HD465-7, HD605-7

DIFFERENTIAL


DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY

4. Bevel pinion and cage assembly 1) Lift off bevel pinion and cage assembly (5). ★ Before removing the bevel pinion and cage assembly, make match marks on the cage and differential case. ★ Check the thickness, quantity, and location of shim (6).

Unit repair stand

■

1

790-901-5110

Bracket

■

1

790-901-3420

Plate

■

1

2

790-425-1660

Wrench

■

1

3

790-102-1130

Power wrench assembly ■

1

4

797-101-1171

Wrench

■

1

1 H

Part name

Sketch

Q'ty

790-501-5000

Part No.

New/Remodel

Necessity

Symbol

Special tools

DISASSEMBLY 1. Tool of differential assembly Set the differential assembly to tool H1. 2. Coupling Remove holder (1) and coupling (2).

2) Using press [2], press down bevel pinion assembly (7) and remove it and bearing (8) together from cage assembly (9). ★ Set a block, etc. under the bevel pinion assembly to prevent the assembly from falling to the floor.

3. Cage 1) Using forcing screws [1], remove cage (3). ★ Before removing the cage, make match marks on it and differential case. 2) Remove oil seal (4) from cage (3).

HD465-7, HD605-7

30-69 ➂


DIFFERENTIAL

3) Disassembly of bevel pinion assembly Remove spacer (11) and bearing (12) from bevel pinion assembly (10).

4) Disassembly of cage assembly Remove outer races (14) and (15) from cage (13).

4) Sling differential gear assembly (20) temporarily. 5) Using tool H3, remove 4 bearing cap bolts (21). 6) Remove bearing caps (22) and (23) and adjustment nuts (18) and (19). 5. Removal of differential gear assembly 1) Turn over tool H1. 2) Remove locks (16) and (17). 3) Using tool H2, loosen adjustment nuts (18) and (19) until you can turn them with the hand.

30-70 ➂

HD465-7, HD605-7

DIFFERENTIAL


7) Remove outer races (24) and (25) from both bearings and lift off differential gear assembly (20).

3) Remove bearing (29) from case (27).

4) Remove side gear (30). 6. Disassembly of differential gear assembly 1) Lift off case and bearing assembly (26). ★ Before removing the assembly, make match marks on the top and bottom of the case.

5) Remove cross shaft and pinion gear assembly (31).

2) Remove washer (28) from inside of case (27).

HD465-7, HD605-7

30-71 ➂

DIFFERENTIAL


6) Remove pinion gear assembly (33) from cross shaft (32).

10) Remove washer (38).

11) Turn over the case and bevel gear assembly. 7) Using tool H4, remove nut (34). 8) Remove sleeve (35) and the bearing. ★ The bearing is an assembly of large bearing A, small bearing B, outer race spacer C, and inner race spacer D.

12) Remove bevel gear (39) from case (40). ★ Before removing the bevel gear, make match marks on it and the case. 13) Remove bearing (41).

9) Remove side gear (37).

30-72 ➂

HD465-7, HD605-7

DIFFERENTIAL


ASSEMBLY ★ Clean the all parts and check them for dirt or damage. ★ Coat the sliding surfaces with engine oil (EO30CD) before installing.

★ After installing the washer, check that distance a between the washer surface and the end of dowel pin E is 0.35 – 0.75 mm. (If the dowel pin has been removed, drive it to the above dimension.)

1. Assembly of differential gear assembly 1) Install bearing (41) to case (40) by shrink fit. ★ Shrink fit temperature of bearing: Keep at 120°C for 30 min. ★ After installing the bearing, drop engine oil (EO30-CD) over it. 2) Install bevel gear (39) to case (40). ★ When installing, match the match marks. Mounting bolt: Adhesive (LT-2) Mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm}

5) Install side gear (37).

3) Turn over the case and bevel gear assembly. 4) Install washer (38). ★ Install the washer with the grooved side up.

HD465-7, HD605-7

30-73 ➂

DIFFERENTIAL


6) Install the bearing to the pinion gear. ★ Drop engine oil (EO30-CD) over the sliding parts. ★ The bearing is an assembly of large bearing A, small bearing B, outer race spacer C, and inner race spacer D. ★ Do not change the combination of the above parts. (The same combination mark is stamped on each part.) 7) Install sleeve (35) as shown in the following figure. 8) Using tool H4, tighten nut (34). Nut: 490 – 408 Nm {50.0 – 61.9 kgm} ★ After tightening the nut, rotate the bearing 5 turns or more to check that it rotates lightly.

10) Install cross shaft and pinion gear assembly (31).

9) Install pinion gear assembly (33) to cross shaft (32).

12) Install bearing (29) to case (27) by shrink fit. ★ Shrink fit temperature of bearing: Keep at 120°C for 30 min. ★ After installing the bearing, drop engine oil (EO30-CD) over it.

30-74 ➂

11) Install side gear (30).

HD465-7, HD605-7


13) Turn over case (27) and install washer (28). ★ Install the washer with the grooved side up.

DIFFERENTIAL

2. Installation of differential gear assembly 1) Sling differential gear assembly (20) to the installation position of the differential case. ★ Keep the differential gear assembly above the differential case. 2) Install outer races (24) and (25) to both bearings. ★ Drop sufficient amount of engine oil (EO30-CD) over the bearings. 3) Install adjustment nuts (18) and (19) to the differential case temporarily.

★ After installing the washer, check that distance a between the washer surface and the end of dowel pin E is 0.35 - 0.75 mm. (If the dowel pin has been removed, drive it to the above dimension.)

14) Sling and install case and bearing assembly (26). ★ When installing, match the match marks.

HD465-7, HD605-7

4) Install bearing caps (22) and (23). 5) Using tool H3, tighten 4 bearing cap bolts (21). ★ Before tightening the bearing cap bolts, rotate the bevel gear 20 - 30 turns to fit the bearing. Mounting bolt: Adhesive (LT-2) Mounting bolt: 2,450 – 3,040 Nm {249.9 – 309.9 kgm} ★ Before installing the locks for fixing the adjustment nuts, finish the following "Adjusting preload on bearing", "Adjusting backlash", "Testing tooth contact", and "Adjusting tooth contact".

30-75 ➂


DIFFERENTIAL

4. Bevel pinion and cage assembly 1) Assembly of cage assembly Install outer races (14) and (15) to cage (13). ★ Press fit the outer races until they are stopped by the cage.

3. Adjusting preload on bearing Press push-pull scale [3] against the periphery of bevel gear (39) and measure the starting tangential force in the tangential direction. • Standard starting tangential force: 39.2 – 62.8 N {4.0 – 6.4 kg} [Target: 51.0 N {5.2 kg}] ★ If the starting tangential force is below the standard value, tighten the adjustment nuts on both sides with tool H2. If the former exceeds the standard value, loosen the adjustment nuts on both sides. ★ When adjusting, rotate the bevel gear so that the bearings will be fitted sufficiently.

30-76 ➂

2) Assembly of bevel pinion assembly i) Install bearing (12) to bevel pinion (10) by shrink fit or press fit it to the end with the push tool. ★ Shrink fit temperature of bearing: Keep at 120°C for 30 min. ★ After installing the bearing, drop engine oil (EO30-CD) over it. ii) Install spacer (11). Reference: This spacer is a part of cage assembly (13) shown above.

HD465-7, HD605-7


3) Place cage assembly (9) on bevel pinion assembly (7). 4) Install bearing (8). 5) Using push tool [4] and revolving cage assembly (9), press fit bearing (8) to the end. ★ Drop engine oil (EO30-CD) over bearing (8). ★ Do not use a press to press fit the bearing. 6) Hold bevel pinion assembly (7) and revolve cage assembly (9) with the push-pull scale and measure the starting tangential force in the tangential direction. • Standard starting tangential force: Max. 24.5 N {2.5 kg} ★ If the starting tangential force exceeds the standard value, replace bearings (8) and (12) or cage assembly (9) and measure again. Check that the starting tangential force is in the standard range.

7) Install shim (6) of the thickness and quantity checked when disassembled. Fit the O-ring and sling and install bevel pinion cage assembly (5). • Thicknesses of shims: 0.2 mm, 0.3 mm, 1.0 mm ★ When installing, match the match marks.

HD465-7, HD605-7

DIFFERENTIAL

5. Cage 1) Install oil seal (4) to cage (3). ★ Press fit the oil seal until it is stopped by the cage. Outer ring of oil seal: SEALEND 242 or equivalent Lip of oil seal: Grease (G2-LI) 2) Fit the O-ring and cage (3). ★ When installing, match the match marks. Mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm}

3) Set dial gauge [5] on the top of bevel pinion assembly (7). Move the bevel pinion assembly in the thrusting direction and measure the end play. • Standard end play: 0 – 0.15 mm ★ If the end play exceeds the standard value, replace bearings (8) and (12) or cage assembly (9) and measure again. Check that the end play is in the standard range.

30-77 ➂


6. Coupling 1) Install coupling (2), O-ring, and holder (1). ★ Rotate the bevel gear to rotate the bevel pinion 20 – 30 turns and tighten the mounting bolts gradually. Mounting bolt: Adhesive (LT-2) Mounting bolt: 1,520 – 1,910 Nm {155.0 – 194.7 kgm} 2) Rotate the coupling 20 – 30 turns, and then check that the holder mounting bolts are tightened to the specified torque.

DIFFERENTIAL

3) If the backlash is out of the standard range, adjust it by moving the bevel gear. ★ Move the bevel gear with tool H2 and adjustment nuts (18) and (19). ★ If either adjustment nut is tightened (loosened), loosen (tighten) the other adjustment nut by the same angle so that the preload applied to bearings (29) and (41) (in Step 3) will not change.

7. Adjusting backlash 1) Apply the probe of dial gauge [5] to a tooth tip of the bevel gear at right angles. 2) Fix the bevel pinion and move the bevel gear forward and backward (in the revolving directions) and read the dial gauge. • Standard backlash: 0.41 – 0.56 mm ★ Measure the backlash at 3 – 4 places and check that the difference between the measured values is 0.1 mm or less.

30-78 ➂

HD465-7, HD605-7


•

•

When the backlash is below standard value Loosen adjustment nut (19) on the bevel gear side and tighten adjustment nut (18) on the right side by the same angle (to move the bevel gear in the direction of A). When the backlash is above standard value Loosen adjustment nut (18) on the right side and tighten adjustment nut (19) on the bevel gear side by the same angle (to move the bevel gear in the direction of B).

DIFFERENTIAL

9. Adjusting tooth contact If the tooth contact pattern is not proper, adjust the tooth contact according to the procedure shown in the following page. ★ Adjust the toot contact by increasing or decreasing shim (6) (to move the bevel pinion) and revolving the adjustment nuts (to move the bevel gear: See Adjusting backlash). ★ After adjusting the tooth contact, check the backlash again.

8. Testing tooth contact Apply red lead thinly to the surfaces of 7 – 8 teeth of the bevel gear and turn the bevel gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear. ★ The center of the tooth contact must be as follows. • Middle of tooth height • Point on tooth at distance of x from small end C (x = 46 ± 6 mm) ★ Width y of the tooth contact must be 41 – 82 mm. ★ Check that there is not a strong contact at tip A, bottom B, small end C, or large end D.

HD465-7, HD605-7

30-79 ➂

DIFFERENTIAL


Tooth contact

Cause

Adjusting method

Bevel pinion is too far from bevel gear.

1. Reduce shim (6) to move bevel pinion close to bevel gear. 2. Move bevel gear away from bevel pinion.

Bevel pinion is too close to bevel gear.

1. Increase shim (6) to move bevel pinion away from bevel gear. 2. Move bevel gear close to bevel pinion.

Bevel gear is too close to bevel pinion.

1. Reduce shim (6) to move bevel pinion close to bevel gear. 2. Move bevel gear away from bevel pinion.

Bevel gear is too far from bevel pinion.

1. Increase shim (6) to move bevel pinion away from bevel gear. 2. Move bevel gear close to bevel pinion.

10. Locks Install locks (17) and (16) of the adjustment nuts.

30-80 ➂

HD465-7, HD605-7

FRONT WHEEL


REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY

4. Remove wheel assembly (3) with a forklift, etc. Wheel assembly: 1,000 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down. ★ Take care not to break the air valves.

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the rear wheels with blocks. 1. Set a hydraulic jack (50 t) under arm (1) and raise the front wheel assembly.

INSTALLATION •


2. Support the frame on a stand, etc. ★ Tighten the hub nuts evenly in the diagonal order. ★ Tighten the hub nuts permanently after lowering the truck body. Hub nut: 1,519 – 1,617 Nm {154.9 – 164.8 kgm} ★ After installing the wheel assembly, drive the truck about 5 - 6 km, then check that the hub nuts are tightened to the specified torque.

3. Remove hub nuts (2).

HD465-7, HD605-7

30-81 ➂

REAR WHEEL


REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the front wheels with blocks. 1. Set a hydraulic jack (50 t) under either rear axle and raise the rear wheel assembly.

5. Remove inner hub nuts (4).

2. Loosen the locknut of the air valve and remove lock plate (1). 3. Remove outer hub nuts (2).

6. Remove wheel assembly (5) with a forklift, etc. Wheel assembly: 850 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down.

4. Remove wheel assembly (3) with a forklift, etc. Wheel assembly: 850 kg Rest the removed wheel assembly against a safe place and put blocks under it to prevent it from falling down.

30-82 ➂

HD465-7, HD605-7


REAR WHEEL

INSTALLATION •

Carry out installation in the reverse order to removal. , ★ Tighten the hub nuts evenly in the diagonal order. ★ Tighten the hub nuts permanently after lowering the truck body. Hub nut: 1,519 – 1,617 Nm {154.9 – 164.8 kgm} ★ After installing the wheel assembly, drive the truck about 5 - 6 km, then check that the hub nuts are tightened to the specified torque.

HD465-7, HD605-7

30-83 ➂

FRONT BRAKE CALIPER PADS


REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPER PADS REMOVAL 1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Pull out torque pin (1). a Pin fixing bolt (2) and pull out pin (1) to a degree that you can remove the pads.

INSTALLATION •


a Push in the torque pin and fix it with the bolt securely. a Adjust the clearance between the pin and disc to 1.5 – 3 mm. Pin fixing bolt: 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm} a For precautions for installing the pin fixing bolt, see DISASSEMBLY, ASSEMBLY OF FRONT BRAKE CALIPERS ASSEMBLY. a Bleed air from the front brake circuit. For details, see TESTING AND ADJUSTING, Bleeding air from brake circuit.

3. Remove pads (3). 1) Install a vinyl hose to bleeder screw (4) so that the brake oil will be drained. 2) Loosen the bleeder screw and return pistons (5) with a bar to the bottoms of the cylinders.

30-84 (10)

HD465-7, HD605-7

FRONT BRAKE CALIPERS


REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS ASSEMBLY REMOVAL 1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Disconnect hose (1). 3. Sling the calipers assembly temporarily and

INSTALLATION •


Mounting bolt: Adhesive (LT-2) Mounting bolt: 785 – 980 Nm {80.1 – 100 kgm} a Bleed air from the front brake circuit. For details, see TESTING AND ADJUSTING, Bleeding air from brake circuit.

remove bolts (2).

4. Remove calipers assembly (3). a Sling the calipers assembly, adjusting it with a lever block, etc. Calipers assembly: 75 kg

HD465-7, HD605-7

30-85 (10)



DISASSEMBLY AND ASSEMBLY OF FRONT BRAKE CALIPERS ASSEMBLY

ASSEMBLY

DISASSEMBLY 1. Pin fixing bolts (1) and (2) and remove torque pins (3), (4), and (5) and pads (6). 2. Remove plate (7), plug (8), backup ring (9), and seal (10). 3. Remove dust seal (11) and piston (12). 4. Remove seal (13) and backup ring (14). a Disassemble the other pistons similarly.

1. Fit backup ring (14), seal (13), and dust seal (11) to the grooves of torque plate (15). 2. Install piston (12). a Fit the dust seal lip to the groove of the piston. 3. Install seal (10), backup ring (9), plug (8), and plate (7). 4. Install pads (6) and torque pins (5), (4), and (3) and tighten pin fixing bolts (2) and (1). Bolt: 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm} a Unlike a usual bolt, each of the above bolts has pointed end (part "a"). The pointed end bites in the surface of torque pin (5) (deforms the pin plastically) (Bitten part: "b", Trace of biting: "c) to fix the pin. (The bolt must be tightened further after resistance is felt.) Accordingly, if the bolt is not tightened to the specified torque, it cannot bite in and fix the pin sufficiently. a Move the pin in the axial direction, tightening the pin fixing bolts, check that the bolts are fitted in the grooves of the torque pin.

30-86 (4)

HD465-7, HD605-7



a Be sure to install torque pin (4), (5) which is shorter than torque pin (5) to the plate side. a Assemble the other pistons similarly. 5. Install the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. a Install the front brake calipers assembly so that clearance "d" between disc plate (16) and torque pin (3) will be 1.5 to 3.0 mm.

HD465-7, HD605-7

30-87 (10)

FRONT WHEEL HUB


DISASSEMBLY AND ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY DISASSEMBLY 1. Front brake calipers assembly Remove the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. 2. Cover Remove cover (1). 3. Wheel hub assembly 1) Support wheel hub assembly (2) with a forklift. 2) Remove retainer (3). a Check the quantity of the shims and store them.

5) Disassemble wheel hub assembly according to the following procedure. i) Remove the mounting bolts and brake disc (5). ii) Remove oil seal (6). iii) Remove outer race (7). iv) Remove outer race (8).

4. Bearing and retainer 1) Remove bearing (10). 2) Remove retainer (11).

3) Slant wheel hub assembly (2) lightly from the rear and press it and bearing (4) out together. 4) Remove bearing (4) and wheel hub assembly (2). Wheel hub assembly: 330 kg

30-88 (10)

HD465-7, HD605-7

FRONT WHEEL HUB


ASSEMBLY 1. Retainer and bearing 1) Install retainer (11). 2) Install bearing (10).

2. Wheel hub assembly 1) Assemble the wheel hub assembly according to the following procedure. i) Using the push tool, press fit outer race (8). ii) Using the push tool, press fit outer race (7). iii) Using the push tool, press fit oil seal (6). a Degrease the sealing side of wheel hub A and periphery of the seal. a Degrease part B. Periphery of seal: Adhesive: (Loctite No. 648) Space c of seal lip: Fill with grease (See Table 1). Table 1 No.

Manufacturer

1

NIHON KOYU

HIREX HD-2

2

SHELL OIL

Super Duty Grease 2

3

ESSO OIL

RONEX MP

4

BP

Energrease LS-EP2

HD465-7, HD605-7

Brand of grease

iv) Set brake disc (5) and tighten the mounting bolts. 2) Support and install wheel hub assembly (2) with a forklift.

Fill the shaded parts in the following figure with sufficient amount of grease. (Grease: 9 for each wheel hub assembly) a Take care not to damage the oil seal on the inside of the hub. a Select the grease from Table 1. Table 1 No.

Manufacturer

1

NIHON KOYU

HIREX HD-2

Brand of grease

2

SHELL OIL

Super Duty Grease 2

3

ESSO OIL

RONEX MP

4

BP

Energrease LS-EP2

30-89 (3)


FRONT WHEEL HUB

a Fill the hatched space between the rollers of the bearing until it is projected from the opposite side of the retainer.

3) Install bearing (4).

4) Adjust the preload on the bearing according to the following procedure. i) Install retainer (3) without inserting any shim with 3 mounting bolts. Revolving the hub 20 – 30 turns, tighten the bolts evenly to the specified torque. Mounting bolt (For adjustment): 103 – 113 Nm {10.5 – 11.5 kgm} ii) Measure distance c between the retainer and axle end with depth micrometer [1]. a Measure at 2 places and obtain the average. iii) Remove retainer (3) and measure its thickness T. Add 0.3 mm to the difference between above distance c and thickness d (c – T), then use the result as the shim thickness. a Measure at 2 places and obtain the average. a Combine the shims so that their quantity will be minimum. a When removing the retainer, take care that the bearing will not come off.

30-90 (10)

5) Install the shims and retainer (3). Revolving the hub 20 – 30 turns, tighten the bolts evenly to the specified torque.. Mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm} a After tightening the bolts, rotate the hub and check that it rotates normally.

3. Cover Fit the O-ring and install cover (1). Fill the inside of cover (hatched part) with grease. a Use grease of the brand used for the wheel hub in 2-2).

4. Front brake calipers assembly Install the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS. HD465-7, HD605-7

FINAL DRIVE CARRIER


REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY REMOVAL •

5. Using guide bolts [2] and forcing screws [3], pull out and remove carrier assembly (6). ★ When the carrier assembly comes off the guide bolts, it is unbalanced suddenly. Accordingly, insert a bar in the center shaft hole to balance the carrier assembly. Carrier assembly: 220 kg

The rear wheel assembly is removed in the following photo. It does not need to be removed, however.

1. Remove the drain plug of the cover and drain oil from the final drive case. Final drive case: 32

(Each side)

2. Using guide bolts [1], remove cover (1).

INSTALLATION •


Drain plug (Center of cover on final drive case side): 127.4 – 176.4 Nm {13.0 – 17.9 kgm} (Periphery of cover on final drive case side): 24.5 – 34.3 Nm {2.5 – 3.4 kgm}

3. Pull out drive shaft (2). ★ Install a sling bolt to the shaft end to pull out the shaft. Drive shaft: 110 kg 4. Remove snap ring (3), sun gear (4), and spacer (5).

Carrier assembly mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm} •

Refilling with oil Final drive case (Each side): 32

HD465-7, HD605-7

(EO30-CD)

30-91 ➂

FINAL DRIVE CARRIER


DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE CARRIER ASSEMBLY DISASSEMBLY 1. Drive out shaft (1) by hitting it outward. ★ Take care not to lose ball (2). 2. Remove planetary gear (3) and bearing (4).

ASSEMBLY 1. Install bearing (4) to planetary gear (3). 2. Set planetary gear (3) to the case. ★ Securely match the planetary gear to the hose on the case side. 3. Matching the ball hole of shaft (1) to the cut for the ball on the case side, press fit the shaft until the ball hole comes in contact with the case end. 4. Install ball (2) and press fit shaft (1) to the end.

30-92 ➂

HD465-7, HD605-7

FINAL DRIVE AND REAR BRAKE


REMOVAL AND INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY

a Fix outer gear (5) and wheel hub (6) at following points a, b, c and d (4 points in total).

J

1

792T-422-1610

Spacer

01011-61620

Bolt

01643-31645

Washer

t t t

4

N

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

4 4

REMOVAL 1. Remove the dump body assembly. For details, see REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY". 2. Remove the (outer and inner) rear wheel assemblies on the side of the final drive and rear brake assembly to be removed. For details, see REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY.

6. Remove retainer (7) and shim (8). a Before removing the retainer completely, pass a guide bolt through the retainer, and then pull out the retainer and ring gear assembly together slowly and sling them. a Check the thickness and quantity of the shims.

3. Remove the final drive carrier assembly. For details, see REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY. 4. Release the parking brake. For details, see TESTING AND ADJUSTING, method of releasing parking brake in an emergency. 5. Using tool J1, fix outer gear (5) and wheel hub (6). a Be sure to install tool J1 to protect the floating seal before removing the retainer.

HD465-7, HD605-7

7. Remove ring gear assembly (9). Ring gear assembly: 100 kg

30-93 (10)


8. When disassembling the ring gear assembly, remove bolt (10) and take the assembly apart into holder (11), inner hub (12), and ring gear (13).

9. Sling final drive and rear brake assembly (14) temporarily.


a Since bearing (16) comes off, take care not to drop it.

a For disassembly and assembly, see DISASS E M B LY A N D A S S E M B LY O F F I N A L DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY.

10. Remove 31 bolts (15) and pull out final drive and rear brake assembly (14) sideway to remove it. Final drive and rear brake assembly: 800 kg

30-94 (3)

HD465-7, HD605-7



INSTALLATION •

Carry out installation in the reverse order to removal. After installing, be sure to remove tool J1 and parking brake releasing bolt.

• Adjusting preload on bearing 1) Install retainer (7) without inserting any shim and tighten 3 mounting bolts to the following torque. a Rotating the hub 20 – 30 turns, tighten the bolts evenly to the specified torque. Retainer mounting bolt: 181 – 191 Nm {18.5 – 19.4 kgm} [Target: 186 Nm {18.9 kgm} 2) Measure distance a between the end of tube (17) and end of retainer (7) with depth micrometer [2]. a Measure at 2 places and obtain the average. 3) Remove retainer (7) and measure its thickness b. a Measure at 2 places and obtain the average. 4) Calculate shim thickness c by the following expression. c (mm) = a – b + 0.3 5) Install the shim of the calculated thickness and retainer (7) with the all mounting bolts (6 bolts). a Rotating the hub 20 – 30 turns, tighten the bolts evenly to the specified torque. Mounting bolt: 785 – 980 Nm {80.1 – 99.9 kg} 6) Rotate the wheel hub again and check that it revolves normally.

HD465-7, HD605-7

30-95 (3)


FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE

REMOVAL AND INSTALLATION OF FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY REMOVAL 1. Perform Steps 1 - 7 of REMOVAL AND INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY. a If the final drive, rear brake, and parking brake assembly does not need to be disassembled after removed, the parking brake does not need to be released. a Since bearing (16) comes off, take care not to drop it.

2. Disconnect hoses (1) and (2) and remove pipes (3) and (4).

3. Sling final drive, rear brake, and parking brake assembly (5) temporarily. 4. Remove 30 nuts (6) and pull out final drive, rear brake, and parking brake assembly (5) sideway to remove it.

INSTALLATION •

Final drive, rear brake, and parking brake assembly: 1,100 kg

Mounting nut of final drive, rear brake, and parking brake assembly: 455 – 565 Nm {46.4 – 57.6 kgm} •

HD465-7, HD605-7


Adjusting preload on bearing See REMOVAL, INSTALLATION OF FINAL DRIVE AND REAR BRAKE ASSEMBLY.

30-97 (10)



DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE ASSEMBLY

3. Parking brake assembly 1) Check that the parking brake is released. (See TESTING AND ADJUSTING, Method of releasing parking brake in an emergency.) 2) Remove parking brake assembly (1). a Make match marks on parking brake assembly (1) and outer gear (5) for reference for installation.

1

J

2 3

4

•

Spacer Bolt

01643-31645

Washer

795-102-2102

Spring washer

792-520-2110

Installer

792-530-1600

Push tool

791-585-1510

Installer

791-530-1700

Push tool

t t t t t t t t

Sketch

792T-422-1610 01011-61620

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

4

N

Q

4 4 1 1 1 1 1

For the sketch of tool J1, see SKETCH OF SPECIAL TOOL.

DISASSEMBLY Remove the internal parts (piston, damper, disc, plate, floating seal, etc.) carefully so that they will not be damaged by impacts, fall, etc. 1. Place the final drive, rear brake, and parking brake assembly with the parking brake side up. Using blocks, etc., place the assembly stably.

4. Disassembly of parking brake assembly Since the installing load on the internal spring is large, disassemble the assembly carefully according to the following procedure. 1) Gradually loosen and remove parking brake releasing bolts A (10 pieces). a Loosen all releasing bolts A evenly so that the internal brake piston will not slant. Reference: Total installing load on spring: Approx. 199 kN {20.3 ton}

2. Remove tool J1 which is fixing outer gear (5) and wheel hub (6).

30-98 (10)

HD465-7, HD605-7


2) Turn over the parking brake assembly. 3) Gradually and evenly loosen and remove 13 cylinder mounting bolts (4).

4) Remove cylinder (7). a Make match marks on cylinder (7) and piston assembly (3) for reference for installation.

5) Remove piston assembly (3). a Make match marks on piston assembly (3) and cylinder (2) for reference for installation.

HD465-7, HD605-7


6) Remove seal rings (8) and (9) from cylinder (7).

7) Remove 30 springs (10) from cylinder (2). a There are 22 double springs and 8 single springs. a Make distinction marks at locations of the single springs (8 places) with paint for reference for installation.

8) Turn over the piston assembly disassembled in Step 5). 9) Using tool J2, compress the springs and remove pin (11), washer (12), spring (13), and guide (14).

30-99 (10)



5. Dampers, discs, plates, and spacer 1) Remove plates (19).

10) Remove parking brake piston (15). ★ Make match marks on parking brake piston (15) and brake piston (16) for reference for installation.

2) Remove damper (20), 12 discs (21), 11 plates (22), and damper (23).

11) Remove seal rings (17) and (18) from brake piston (16).

30-100 ➂

HD465-7, HD605-7


3) Install bolts [3] to the sling taps and remove spacer (24).

6. Outer gear 1) Remove outer gear (5). ★ Take care not to drop the floating seal from the bottom.

2) Remove oil seal (25) and floating seal (26) from outer gear (5).

HD465-7, HD605-7


7. Inner gear 1) Remove inner gear (27).

2) Remove floating seal (28) on the outside of the inner gear, retainer (29), and floating seal (30) on the inside of the inner gear.

8. Wheel hub assembly 1) Remove retainer and floating seal assembly (31). ★ Retainer and floating seal assembly (31) is free when the inner gear (in the previous section) is removed.

30-101 ➂



2) Remove floating seal (33) from retainer (32).

3) Remove bearing (34).

4) Remove outer races (35) and (36).

30-102 ➂

HD465-7, HD605-7



ASSEMBLY ★ Clean the all parts and check them for dirt or damage. ★ Coat the sliding surfaces with engine oil before installing. ★ Remove the white powder from the O-ring surface of the floating seal with engine oil, etc. Even a slight flaw of the floating seal made by an impact, fall, etc. can cause oil leakage. Accordingly, install the floating seal carefully. 1. Wheel hub assembly 1) Install outer races (35) and (36).

4) Set retainer and floating seal assembly (31) to the center. ★ Set the assembly with the floating seal side up.

2) Install bearing (34).

2. Inner gear 1) Using tool J3, install floating seal (30) to the inside of inner gear (27).

3) Using tool J3, install floating seal (33) to retainer (32). ★ Thinly apply grease (G2-LI) to the top of the floating seal. 2) Install retainer (29) to inner gear (27). 3) Using tool J4, install floating seal (28). ★ Thinly apply grease (G2-LI) to the top of the floating seal.

HD465-7, HD605-7

30-103 ➂



3. Outer gear 1) Using tool J4, install floating seal (26).

★ After installing, measure distance a between the end of retainer (29) and end of seal (28) at 4 points on the periphery. Check that the difference between the values at the 4 points does not exceed 1 mm.

4) Install inner gear (27). ★ When installing the inner gear, match it to the retainer and floating seal assembly installed in Step 1-4). ★ Take care not to damage the floating seal. Inner gear mounting bolt: 455 – 565 Nm {46.4 – 57.6 kgm}

30-104 ➂

★ After installing, measure distance b between the end of outer gear (5) and end of seal (26) at 4 points on the periphery. Check that the difference between the values at the 4 points does not exceed 1 mm.

2) Install oil seal (25). ★ Apply grease to part P shown below. Part P: Grease (G2-LI)

HD465-7, HD605-7



3) Install outer gear (5). ★ Take care not to drop the floating seal from the bottom. ★ Take care that the oil seal at the bottom will not be rolled up.

3) Install discs (21) and plates (22) alternately in order. ★ Install the 12 discs and 11 plates. 4) Install damper (20). 4. Dampers, discs, plates, and spacer 1) Install bolts [3] to the sling taps, and then install spacer (24).

★ Install damper (20) with seat b (projected part: 4.5 mm thick) up. ★ Install spacer (24) with the chamfered side down. 2) Install damper (23). ★ Install damper (23) with seat a (projected part: 1 mm thick) down.

If the damper is installed reversely, the disc will be worn abnormally. Accordingly, be sure to install it in the correct direction.

If the damper is installed reversely, the disc will be worn abnormally. Accordingly, be sure to install it in the correct direction.

HD465-7, HD605-7

30-105 ➂


5) Install plates (19).


3) Pass guide (14) through spring (13) and install them to the parking brake piston. 4) Using tool J2, compress spring (13) and install washer (12) from the underside of the brake piston. Pass pin (11) through guide (14) to fix the guide.

5. Assembly of parking brake assembly Since the installing load on the internal spring is large, assemble the assembly carefully according to the following procedure. 1) Install seal rings (17) and (18) to brake piston (16). Periphery of seal ring: Grease (G2-LI)

2) Install parking brake piston (15) to brake piston (16). ★ Match the match marks made when the piston was removed.

30-106 ➂

HD465-7, HD605-7


5) Install 30 springs (10) to cylinder (2). ★ For the locations of the 8 single springs, see the distinction marks made when they were removed.

6) Install seal rings (8) and (9) to cylinder (7). Periphery of seal ring: Grease (G2-LI)

7) Install piston assembly (3) to cylinder (2). ★ Match the match marks made when the piston assembly was removed.

HD465-7, HD605-7


★ When installing the piston assembly, match it to dowel pin C.

8) Install guide bolt [2] and cylinder (7). ★ Match the match marks made when the cylinder was removed. ★ Match the faucet joint portion of cylinder (7) to that of cylinder (2) by hitting cylinder (7) evenly with a plastic hammer, etc.

9) Tighten 13 cylinder mounting bolts (4) gradually and evenly to the specified torque. Mounting bolt: Adhesive (LT-2) Mounting bolt: 153 – 190 Nm {15.6 – 19.3 kgm}

30-107 ➂


10) Apply hydraulic pressure to parking brake releasing port P (20 x 1.5) and check that the piston is pulled up and the parking brake works. • Parking brake releasing pressure: 8.7 MPa {85 kg/cm2}


7. Using tool J1, fix outer gear (5) and wheel hub (6).

★ Fix outer gear (5) and wheel hub (6) at following points a, b, c, and d (4 places in total). 11) Tighten parking brake releasing bolts A (10 pieces) gradually and evenly.

6. Install parking brake assembly (1) to outer gear (5). ★ Match the match marks made when the parking brake assembly was removed.

30-108 ➂

HD465-7, HD605-7


FRONT SUSPENSION CYLINDER

REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY REMOVAL 1. Remove the front wheel assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL ASSEMBLY. 2. Remove the front brake calipers assembly. For details, see REMOVAL AND INSTALLATION OF FRONT BRAKE CALIPERS ASSEMBLY. 3. Remove the wheel hub assembly. For details, see REMOVAL AND INSTALLATION OF FRONT WHEEL HUB ASSEMBLY. 4. Release nitrogen gas. For details, see TESTING AND ADJUSTING, Testing and adjusting front suspension cylinder.

9. Remove 4 bolts (8). 1) Revolve the knuckle arm toward the truck body about 40 degrees and remove the bolt marked with q. 2) Return the knuckle arm to its original position and jack up the king pin and remove the bolts marked with .

5. Disconnect hose (1).

6. Disconnect tubes (2) and (3). 7. Pull out pin (4) and disconnect tie rod (5). 8. Pull out pin (6) and remove steering cylinder (7).

HD465-7, HD605-7

10. Using a forklift, etc., sling the front suspension cylinder assembly and pull out pin (9) on the rod side. 11. Disconnect and remove front suspension cylinder assembly (10) from the knuckle arm. Front suspension cylinder assembly: 500 kg

30-109 (10)



INSTALLATION •

Carry out installation in the reverse order to removal. k Never align the pin with the pin hole by starting the engine and operating the steering wheel. It is very dangerous. When aligning the pin and pin hole, disconnect the hoses on the head side and bottom side of the steering cylinder so that you can adjust the length of the steering cylinder rod. Use a lever block or a bar to align them. k Before operating the steering system after finishing installation, be sure to refill the front suspension cylinder with nitrogen gas and adjust it. For details, see TESTING AND ADJUSTING, Testing and adjusting front suspension cylinder.

30-110 (10)

HD465-7, HD605-7



DISASSEMBLY AND ASSEMBLY OF FRONT SUSPENSION CYLINDER ASSEMBLY (Standard cylinder)

1 Q 2

t t t t

792-103-4102

Push tool

790-101-5421

Grip

01010-81240

Bolt

792-610-1000

Suspension tool

792-610-1100

• Pump assembly

1

792-610-1200

• Charging tool

1

1 1 1 1

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

2. Remove feed valve (1) and valve (2). 3. Removal of cylinder rod assembly. 1) Remove flange mounting bolts (3) and air bleeding valve (4). 2) Sling cylinder rod assembly (5), plate (6), retainer (7), and flange (8) together. 4. Disassembly of flange 1) Remove plate (6), retainer (7), and flange (8) from rod assembly (5). 2) Remove dust seal (9) and bushing (10) from retainer (7). 3) Remove U-packing (11) and bushing (12) from flange (8). 5. Remove wear ring (13) from cylinder rod (5).

DISASSEMBLY •

Using a block, erect the cylinder assembly.

1. Cover Remove the dust cover.

HD465-7, HD605-7

30-111 (10)


ASSEMBLY (See the figure for disassembly, too.) 1. Installation of wear ring Install wear ring (13) to cylinder rod (5). Outside of wear ring: Engine oil (EO10-CD) 2. Assembly of flange 1) Using tool Q1, press fit bushing (12) to flange (8) and install U-packing (11). Inside of bushing: Engine oil (EO10-CD) a When installing the U-packing, check that there are 4 projections on the top of the inside lip.

a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent).


2) Press fit bushing (10) to retainer (7) and install dust seal (9). a When press fitting the bushing, take care not to deform it. Periphery of seal: Adhesive (LT-2) 3. Assembly of cylinder rod assembly 1) Install flange (8), retainer (7), and plate (6) to the cylinder rod. Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.

2) Using a block, erect the cylinder. a Fill the cylinder with engine oil. Cylinder: Approx. 16.5

(EO10-CD)

3) Sling cylinder rod assembly (5) and install it to the cylinder. a If the rod assembly is inserted too deep, the oil spouts out. Stop it to a position where the oil does not spout out. a After installing the front suspension assembly to the truck body, adjust the oil and gas, using tool Q2. For details, see TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER. 4) Install flange (8), retainer (7), and plate (6) to the cylinder with bolts (3). Mounting bolt: 58.9 – 73.6 Nm {6.0 – 7.5 kgm}

30-112 (3)

HD465-7, HD605-7



5) Install air bleeding valve (4). Valve: 39.2 – 49.0 Nm {4 – 5 kgm} 4. Install valve (2) and feed valve (1). Oil level valve and air intake valve: 39.2 – 49.0 Nm {4 – 5 kgm} 5. Cover Install the dust cover. a The dust cover consists of 2 pieces. Reduce the clearance between them to 0.5 mm or less.

HD465-7, HD605-7

30-113 (10)



DISASSEMBLY AND ASSEMBLY OF FRONT SUSPENSION CYLINDER ASSEMBLY (Cylinder with buffer ring)

1 Q 2

792-103-4102

Push tool

790-101-5421

Grip

01010-81240

Bolt

t t t t

1 1 1

792-610-1000

Suspension tool

792-610-1100

• Pump assembly

1

792-610-1200

• Charging tool

1

1

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

2. Remove feed valve (1) and valve (2). 3. Removal of cylinder rod assembly. 1) Remove flange mounting bolts (3) and air bleeding valve (4). 2) Sling cylinder rod assembly (5), plate (6), retainer (7), and flange (8) together. 4. Disassembly of flange 1) Remove plate (6), retainer (7), and flange (8) from rod assembly (5). 2) Remove dust seal (9) and bushing (10) from retainer (7). 3) Remove U-packing (11), buffer ring (14) and bushing (12) from flange (8). 5. Remove wear ring (13) from cylinder rod (5).

DISASSEMBLY •

Using a block, erect the cylinder assembly.

1. Cover Remove the dust cover.

30-113-1 (10)

HD465-7, HD605-7


ASSEMBLY (See the figure for disassembly, too.) 1. Installation of wear ring Install wear ring (13) to cylinder rod (5). 2 Outside of wear ring: Engine oil (EO10-CD)

FRONT SUSPENSION CYLINDER k Buffer ring (14) is made of 2 parts. When installing it, set the round corner of part [2] (Black) inside of part [1] (Blue). • The side indicated by the arrow is the pressure side.

2. Assembly of flange 1) Using tool Q1, press fit bushing (12) to flange (8) and install U-packing (11) and buffer ring (14). 2 Inside of bushing: Engine oil (EO10-CD) a When installing the U-packing, check that there are 4 projections on the top of the inside lip.

2) Press fit bushing (10) to retainer (7) and install dust seal (9). a When press fitting the bushing, take care not to deform it. 2 Periphery of seal: Adhesive (LT-2) 3. Assembly of cylinder rod assembly 1) Install flange (8), retainer (7), and plate (6) to the cylinder rod.

a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent).

2 Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.

2) Using a block, erect the cylinder. a Fill the cylinder with engine oil. 5 Cylinder: Approx.

HD465-7, HD605-7

16.5 l (EO10-CD)

30-113-2 (8)



3) Sling cylinder rod assembly (5) and install it to the cylinder. a If the rod assembly is inserted too deep, the oil spouts out. Stop it to a position where the oil does not spout out. a After installing the front suspension assembly to the truck body, adjust the oil and gas, using tool Q2. For details, see TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER. 4) Install flange (8), retainer (7), and plate (6) to the cylinder with bolts (3).

3 Mounting bolt: 58.9 – 73.6 Nm {6.0 – 7.5 kgm}

5) Install air bleeding valve (4).

3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}

4. Install valve (2) and feed valve (1).

3 Oil level valve and air intake valve: 39.2 – 49.0 Nm {4 – 5 kgm}

5. Cover Install the dust cover. a The dust cover consists of 2 pieces. Reduce the clearance between them to 0.5 mm or less.

30-113-3 (10)

HD465-7, HD605-7

REAR SUSPENSION CYLINDER


REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Disconnect the cable from the negative (–) terminal of the battery. 1. Release nitrogen gas. For details, see TESTING AND ADJUSTING, Testing and adjusting rear suspension cylinder.

INSTALLATION •

Carry out installation in the reverse order to removal. , When aligning the pin holes, never insert your fingers in them. # Refill the rear suspension cylinder with nitrogen gas and adjust it. For details, see TESTING AND ADJUSTING, Testing and adjusting rear suspension cylinder.

2. Remove protector (1). 3. Using a forklift, etc., sling the rear suspension cylinder assembly and pull out pin (2) on the bottom side. 4. Pull out pin (3) on the rod side and remove rear suspension cylinder assembly (4). Rear suspension cylinder assembly: 180 kg

30-114 "

HD465-7, HD605-7



DISASSEMBLY AND ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY (Standard cylinder)

1 Q 2

t t t t

792-625-1300

Push tool

790-101-5421

Grip

01010-81240

Bolt

792-610-1000

Suspension tool

792-610-1100

• Pump assembly

1

792-610-1200

• Charging tool

1

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 1 1 1

DISASSEMBLY 1. Guard Sling the cylinder assembly and loosen clamp (1), and then unbutton and remove guard (2).

5. Flange and retainer 1) Remove retainer (6) and flange (8) from cylinder rod assembly (7). 2) Remove U-packing (10), backup ring, and Oring (11) from flange (8). 3) Remove bushing (12) from flange (8). 4) Remove seal (13) and bushing (14) from retainer (6).

2. Drain oil from the cylinder. 3. Feed valve and valve Remove cover (3), feed valve (4), and valve (5).

6. Wear ring Remove wear ring (15) from rod (16).

4. Cylinder rod assembly 1) Erect the cylinder assembly upside down. 2) Remove the mounting bolt of retainer (6). 3) Slowly sling and remove cylinder rod assembly (7), retainer (6), and flange (8) as 1 unit from cylinder (9) with a crane.

HD465-7, HD605-7

30-115 (10)


ASSEMBLY 1. Wear ring Install wear ring (15) to rod (16).


3. Retainer 1) Using tool Q1, install bushing (14) to retainer (6). 2) Install seal (13) to retainer (6). Periphery of seal: Adhesive (LT-2)

2. Flange 1) Using tool Q1, install bushing (12) to flange (8). 2) Install U-packing (10) to flange (8). a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent). 3) Install backup ring and O-ring (11) to flange (8).

30-116 (3)

4. Cylinder rod assembly 1) Using a block, erect cylinder (9). 2) Sling cylinder rod assembly (7) and install it to cylinder (9). 3) Install flange (8) and retainer (6) to cylinder rod assembly (7). Mating faces of flange and retainer: Gasket sealant (LG-6) a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.

HD465-7, HD605-7


DIFFERENTIAL

4) Install retainer (6) and flange (8) together to cylinder (9) with the mounting bolts.

6. Guard 1) Install guard (2) and secure it with clamp (1).

Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}

5. Air intake valve and oil level valve 1) Set the cylinder assembly upside down. 2) Sling the cylinder so that dimension D on its bottom side will be 140 ± 3 mm.

3) Supply oil through the oil level port with the oil level pump and spout oil from the air intake port until bubbles do not come out any more. 4) After supplying oil, install level (5) and feed valve (4). Air intake valve and oil level: 39.2 – 49.0 Nm {4 – 5 kgm} 5) Install cover (3).

HD465-7, HD605-7

30-117 (10)



DISASSEMBLY AND ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY (Cylinder with buffer ring)

1 Q 2

792-625-1300

Push tool

790-101-5421

Grip

t t t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

1 1 1

01010-81240

Bolt

792-610-1000

Suspension tool

792-610-1100

• Pump assembly

1

792-610-1200

• Charging tool

1

1

DISASSEMBLY 1. Guard Sling the cylinder assembly and loosen clamp (1), and then unbutton and remove guard (2).

5. Flange and retainer 1) Remove retainer (6) and flange (8) from cylinder rod assembly (7). 2) Remove U-packing (10), buffer ring (17), backup ring and O-ring (11) from flange (8). 3) Remove bushing (12) from flange (8). 4) Remove seal (13) and bushing (14) from retainer (6).

2. Drain oil from the cylinder. 3. Feed valve and valve Remove cover (3), feed valve (4), and valve (5).

6. Wear ring Remove wear ring (15) from rod (16).

4. Cylinder rod assembly 1) Erect the cylinder assembly upside down. 2) Remove the mounting bolt of retainer (6). 3) Slowly sling and remove cylinder rod assembly (7), retainer (6), and flange (8) as 1 unit from cylinder (9) with a crane.

30-117-1 (10)

HD465-7, HD605-7



ASSEMBLY 1. Wear ring Install wear ring (15) to rod (16).

2. Flange 1) Using tool Q1, install bushing (12) to flange (8). 2) Install U-packing (10) and buffer ring (17) to flange (8). a Apply rust-preventive oil to part A indicated with 2-dot chain lines on the periphery of the U-packing (NISSEKI P1300 or equivalent). k Buffer ring (17) is made of 2 parts. When installing it, set the round corner of part [2] (Black) inside of part [1] (Blue). 3) Install backup ring and O-ring (11) to flange (8).

3. Retainer 1) Using tool Q1, install bushing (14) to retainer (6). 2) Install seal (13) to retainer (6). 2 Periphery of seal: Adhesive (LT-2)

4. Cylinder rod assembly 1) Using a block, erect cylinder (9). 2) Sling cylinder rod assembly (7) and install it to cylinder (9). 3) Install flange (8) and retainer (6) to cylinder rod assembly (7).

2 Mating faces of flange and retainer: Gasket sealant (LG-6)

HD465-7, HD605-7

30-117-2 (8)


a Apply the gasket sealant evenly to hatched part B and apply it thinly to Upacking C so that it will not be projected.


5. Feed valve and valve 1) Set the cylinder assembly upside down. (Set the rod down.) 2) Sling the cylinder so that dimension D on the rod side will be as follows. When buffer ring is not installed: 140 ± 3 mm When buffer ring is installed: 124 ± 3 mm

3) Supply oil through the oil level port with the oil level pump and spout oil from the air intake port until bubbles do not come out any more. 4) After supplying oil, install level (5) and feed valve (4). 3 Air intake valve and oil level: 39.2 – 49.0 Nm {4 – 5 kgm} 5) Install cover (3).

4) Install retainer (6) and flange (8) together to cylinder (9) with the mounting bolts.

3 Mounting bolt: 98 – 123 Nm {10.0 – 12.5 kgm}

6. Guard 1) Install guard (2) and secure it with clamp (1).

3 Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}

30-117-3 (10)

HD465-7, HD605-7


RETARDER COOLING PUMP

REMOVAL AND INSTALLATION OF RETARDER COOLING PUMP ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Disconnect tubes (1) and (2) and hose (3). a Prepare a pan to receive oil from the joints. 2. Remove retarder cooling pump assembly (4). Retarder cooling pump assembly: 30 kg

INSTALLATION •


•

Refilling with oil Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Transmission case: 190 (EO30-CD or EO10W-CD) Hydraulic tank: 122

30-118 (10)

(EO10-CD)

HD465-7, HD605-7


STEERING, HOIST, AND HOIST CONTROL PUMP

REMOVAL AND INSTALLATION OF STEERING, HOIST, AND HOIST CONTROL PUMP ASSEMBLY

INSTALLATION

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin.

•


•



Hydraulic tank: 122

(EO10-CD)

1. Disconnect tubes (1) and (2) and hoses (3), (4), and (5). a Prepare a pan to receive oil from the joints. 2. Remove steering, hoist and hoist control pump assembly (6). Steering, hoist and hoist control pump assembly: 35 kg

HD465-7, HD605-7

30-119 (10)


TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP

REMOVAL AND INSTALLATION OF TORQUE CONVERTER, TRANSMISSION AND RETARDER COOLING, AND BRAKE PUMP ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Disconnect tubes (1), (2), and (3) and block (4). a Prepare a pan to receive oil from the joints. 2. Remove torque converter, transmission and retarder cooling, and brake pump assembly (5). Torque converter, transmission and retarder cooling, and brake pump assembly: 25 kg

INSTALLATION •


•



Hydraulic tank: 122

30-120 (10)

(EO10-CD)

HD465-7, HD605-7

STEERING VALVE


REMOVAL AND INSTALLATION OF STEERING VALVE ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks.

INSTALLATION •


★ Since the yoke fixing bolt has fine threads, do not apply excessive force to it to damage the threads.

loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. 1. Remove yoke fixing bolt (1). ★ Fix yoke (2) to the upper part with ropes, etc. so that it will not come off the spline of the column shaft. 2. Remove cover (3). 3. Disconnect hoses (4), (5), (6), (7), and (8). 4. Remove steering valve assembly (9). ★ Using ropes, etc., lift off the steering valve assembly.

HD465-7, HD605-7

30-121 ➂

STEERING VALVE


DISASSEMBLY AMD ASSEMBLY OF STEERING VALVE ASSEMBLY ★ Securing of clean working condition 1. Cleanliness is essential to maintenance of the power steering system. The hydraulic circuit must be isolated from impurities.

DISASSEMBLY 1. Remove 7 mounting bolts (1). Insert a screwdriver between end cover assembly (2) and case (3) to remove end cover assembly (2). ★ After removing the end cover assembly, check the edges of the end cover hole for breakage.

2. When disassembling any part of the unit, prepare a clean worktable. 3. Before disconnecting a pipe, wipe off the external dirt from it. 4. Before placing the unit on the worktable, be sure to wipe off the external dirt from it. 5. After disassembling the unit, clean the parts in kerosene-based solvent free of impurities and dry them by blowing dry compressed air free of impurities against them. ★ If any solvent other than the above is used, it can deteriorate the rubber seals. Never wipe the parts with cloths or blow steam against the unit. ★ Since the solvent is combustible material, handle it carefully and keep it off fire.

2. Remove commutator (5) and washer (6). ★ Do not remove pin (4).

PREPARATION 1. Stop up the 5 ports of the valve body with plugs and clean the outside of the valve, and then remove the plugs. 2. Install tube nut [1] to one of the ports. 3. Install the valve body to vise [2] with the end cover up. ★ Do not hold the valve body directly with the vise. If it is held so, the unit may be broken.

T

1

790-452-1200

Pilot ring tool

■

1

2

790-452-1100

Tool installer set

■

1

30-122 ➂

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

HD465-7, HD605-7


3. Using 2 mounting bolts (1), remove commutator ring (7) and manifold (8). 4. Using 2 mounting bolts (1), remove rotor assembly (9) and wear plate (10) similarly to the commutator ring and manifold.

STEERING VALVE

9. Install valve body (11) to the vise with input shaft (18) up and make match marks A on upper case (19) and valve body (11). 10. Remove 4 mounting bolts (20) and raise input shaft (18) to remove input shaft, upper case, and valve spool assembly (23). ★ The valve spool is fitted to the body with very narrow clearance between them. Accordingly, if it is pressed sideway, it cannot be pulled out completely. When removing it from the housing, never apply an excessive force to it.

5. Insert a screwdriver between case (3) and valve body (11) to remove case (3). 6. Remove drive link (12).

7. Remove ball (13). 8. Remove rod (14), roller (15), rod (16), and spring (17).

HD465-7, HD605-7

30-123 ➂


11. Remove upper case assembly (22) from input shaft and valve spool assembly (23), and then remove shim (24) and spacer (25). ★ Check the thickness and quantity of the shims.

12. Remove seal (26) and snap ring (27), and then remove spacer (28), ring (29A), seal (29), and seal ring (30) from upper case (19). ★ Usually, seal (29) and seal ring (30) are in 1 unit.

STEERING VALVE

14. Using pin [3] (ø 3.0 mm, = Min. 16 mm), remove needle roller (36) from input shaft (18). ★ Perform this work on a wood block so that the input shaft will not be damaged.

15. Direct valve spool (37) down and remove torsion bar (38) and spacer (39) from the input shaft and valve spool assembly. ★ Do not remove needle roller (40) from the torsion bar.

13. Remove snap ring (31), thrust washer (32), thrust bearing (33), thrust washer (34), and wave washer (35) from input shaft (18).

30-124 ➂

HD465-7, HD605-7

STEERING VALVE


16. Direct valve spool (37) down and revolve input shaft (18) until drive link (41) comes off. 17. Direct valve spool (37) down and rotate input shaft (18) clockwise until ball (42) comes off. ★ Since ball (42) may come off by itself, take care not to lose it.

ASSEMBLY ★ Before assembling, clean the parts in basedbased solvent free of impurities and dry them by blowing dry compressed against them. Never wipe them with cloths. ★ Check the edges of the lapped surface for paint. ★ Do not apply oil to the parts to be installed, unless otherwise specified. ★ Replace the all seals with new ones. 1. Set thrust washer (34), thrust bearing (35), and thrust washer (32) in order to input shaft (18), and then install snap ring (31). ★ Thrust washer (32) is larger than thrust washer (34).

★ Remove ball retaining spring (43) only when replacing it. When removing it, hold its flat end with priers and raise it until it is removed from valve spool (37). Take care not to damage the periphery of the valve spool and control edge.

2. Install wave washer (35) to thrust bearing (33) and thrust washer (34). 3. Install ball (42) to inside of valve spool (37).

HD465-7, HD605-7

30-125 ➂


4. Insert input shaft (18) in valve spool (37), rotating it counterclockwise so that the ball will be fitted to its groove. ★ Keep the spool horizontally during this work.

5. Set the intermediate part of torsion bar (38) between thrust washer (34) and valve spool (37). ★ If the torsion bar is set as above, the valve spool and input shaft is positioned.

30-126 ➂

STEERING VALVE

6. Check the splines of drive link (41) and input shaft (18), and then install drive link (41), matching the spline of valve spool (37).

★ If the splines of the drive link and input shaft are not meshed with each other, rotate the input shaft a little to mesh them, and then insert the drive link. ★ Set the torsion bar securely. ★ Rotate the input shaft in the spool projecting direction (clockwise) until it stops. If the drive link is installed correctly, a clearance of 8 – 9 mm is made between the thrust washer and valve spool.

HD465-7, HD605-7


STEERING VALVE

7. Measure diameter of needle roller (40) of torsion bar (38) at several points. Check that the difference between measured diameters does not exceed 0.025 mm.

11. Install spacer (25) to the input shaft and valve spool. ★ When installing the spacer, direct lip surface "B" in it toward washer (35).

8. Set spacer (39) to torsion bar (38) and insert them in valve spool and input shaft assembly (23).

12. Install input shaft and valve spool assembly (23) to valve body (11). ★ The valve spool is fitted to the body with very narrow clearance between them. Accordingly, if it is pressed sideway when installed, it may not operate normally. 13. Set shim (24) on thrust washer (32). Apply grease to new seal (19B) and fix it to the groove of upper case (19). Install upper case (19), matching match marks A, and tighten mounting bolts (20) lightly.

9. Using pin [3] (Outside diameter: 3 mm), align the pin holes of torsion bar (38) and input shaft (18). 10. Using pin [3], drive needle roller (36) in input shaft to a depth of 0.8 mm. ★ Check that needle roller (36) is not projected from the inspection sheet.

HD465-7, HD605-7

30-127 ➂


14. Set tool T1 so that the valve body will be aligned with the upper case.

STEERING VALVE

17. Pull down and fix input shaft (18) and mesh drive link (12) with the spline of the valve spool, and then rotate the spool so that its end will be flush with the valve body. 18. Remove drive link (12) again and adjust its position so that needle roller (40) of the torsion bar will be in its groove. Then, insert drive link (12) in spool (37).

15. Tighten 4 upper case mounting bolts and remove tool T1. Mounting bolt: 24.40 – 29.80 Nm {2.49 – 3.04 kgm} ★ Install the valve body to a vise with the input shaft down. 16. Measure groove width of drive link (12) at several points over the length and check that the difference between the obtained values does not exceed 0.025 mm.

19. Using depth gauge [4], measure fitting height h of the valve spool above the valve body.

★ If fitting height h is below 0.063 mm, do not adjust the shim. If fitting height h is larger than 0.063 mm, adjust the shim by repeating Steps 12 – 19 so that h will be below 0.063 mm.

30-128 ➂

HD465-7, HD605-7


20. Install ball (13). 21. Set rod (16) to spring (17) and install them to valve body (11). Then, install roller (15) and rod (14).

22. Before installing the rotor, check it according to the following procedure. 1) Set end cover assembly (2) with the pin side up and set rotor assembly (9) with the rotor spline side down, and then check that the rotor rotates freely in the stator.

STEERING VALVE

23. Lubricate a new seal and the seal groove with grease and install ring (11A) and seal (11B) to valve body (11) in order.

24. Using guide pin [6], install wear plate (10), rotor assembly (9), manifold (8), and commutator ring (7).

2) Measure thickness of rotor A and that of stator B at several points and check that the each difference between them is below 0.18 mm. 3) Using filler gauge [5], the clearance between stator B and rotor A is below 0.18 mm.

HD465-7, HD605-7

30-129 ➂


25. Lubricate the inside of both ends of case (3) and the seal installed to valve body (11) with grease.

STEERING VALVE

a Set the oval hole of the commutator and one of the bolt holes of the end cover assembly in line.

26. Install case (3) to valve body (11). a Install end cover (2) to the end of the case and tighten the mounting bolts (1) evenly so that the case will be inserted straight. 27. Remove end cover (2) and lubricate a new seal and the seal groove with grease, and then install ring (2A) and seal (2B) to the end cover in order.

29. Rotate the input shaft so that the end of drive link (12) will be inserted in the oval hole of the commutator. a Lubricate the seal in the end cover with grease. 30. Set end cover assembly (2) on cover (3) and tighten the 5 mounting bolts evenly. 28. Apply grease to end cover assembly (2) and fit washer (6) and commutator (5) so that they will not fall even if they are set down. a Install the commutator so that its hollow C will be on the end cover assembly side.

Mounting bolt: 61.0 – 74.5 Nm {6.22 – 7.6 kgm} a Tighten the mounting bolts in the diagonal order so that the sleeve and end cover will not slant while they are being installed. 31. Remove guide pin [6] and tighten the remaining 2 bolts evenly. Mounting bolt: 61.0 – 74.5 Nm {6.22 – 7.6 kgm}

30-130 (10)

HD465-7, HD605-7

STEERING VALVE


32. Direct the input side up and wind tapes onto the serrated part. ★ Seal (26), spacer (28), ring (29A), seal (29), and seal ring (30) are the parts of a kit. ★ Seal (29) and seal ring (30) have been installed as 1 unit.

33. Apply grease to the inside and outside of seal (29) and seal ring 30 and install them with the lip side in the valve. 34. Install ring (29A). 35. Using tool T2, install spacer (28) from the small diameter end.

36. Install snap ring (27) with its rounded side in the valve. 37. Install seal (26) to the upper case. ★ When installing seal (26), apply grease to its inside and outside.

HD465-7, HD605-7

30-131 ➂


DEMAND VALVE

REMOVAL AND INSTALLATION OF DEMAND VALVE ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Drain hydraulic oil. Hydraulic tank: 122 2. Disconnect tubes (1), (2), (3), and (4). 3. Remove demand valve assembly (5). Demand valve assembly: 30 kg

INSTALLATION •


•

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic tank: 122

•

(EO10-CD)

Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder (for steering).

30-132 ➂

HD465-7, HD605-7


HOIST VALVE

REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then lock the wheels with blocks. Raise the dump body and lock it with the safety pin. 1. Drain hydraulic oil. Hydraulic tank: 122 2. Disconnect the tube and hose from the underside of hoist valve assembly (1). 3. Disconnect tubes (2), (3), and (4) and hose (5). 4. Hoist valve assembly (1). Hoist valve assembly: 35 kg

INSTALLATION •


•

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic tank: 122

HD465-7, HD605-7

(EO10-CD)

30-133 ➂

STEERING CYLINDER


DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY

1

790-502-1003

Repair stand

■

1

790-101-1102

Hydraulic pump

■

1

2

790-102-3802

Wrench assembly

■

1

3

790-302-1270

Socket

■

1

790-201-1702

Push tool kit

■

1

790-101-1771

• Push tool

■

1

790-101-5021

• Grip

■

1

4 U

5

6

01010-50816

• Bolt

■

1

790-201-1500

Push tool kit

■

1

790-101-1580

• Push tool

■

1

790-101-5021

• Grip

■

1

01010-50816

• Bolt

■

1

790-720-1000

Expander

■

1

7

796-720-1650

Ring

■

1

8

07281-01029

Clamp

■

1

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

4. Remove cylinder (4) from tool U1. 5. Disassembly of piston rod assembly 1) Set tool U1 to piston rod assembly (3). 2) Using tool U3, remove nut (5). ★ Width across flats of nut: 50 mm

DISASSEMBLY 1. Set cylinder assembly (1) to tool U1. 2. Raise the lock of the cylinder head nut. Using tool U2, remove cylinder head assembly (2). 3) Remove piston assembly (6) and cylinder head assembly (7) from rod (8).

3. Pull cylinder head and piston rod assembly (3) out of cylinder (4). ★ Prepare a container to receive oil which flows out when the piston rod assembly is pulled out of the cylinder.

30-134 ➂

HD465-7, HD605-7

STEERING CYLINDER


6. Disassembly of piston assembly 1) Remove wear ring (9) from piston (10). 2) Remove piston ring (11) from piston (10).

7. Disassembly of cylinder head assembly 1) Remove snap ring (12) and dust seal (13). 2) Remove rod packing (14). 3) Remove bushing (15) from cylinder head (16). 4) Remove O-ring (17) and backup ring (18).

ASSEMBLY ★ Apply engine oil to the sliding surfaces of each part. When assembling, take care not damage the packing, dust seal, and O-ring. 1. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (15) to cylinder head (16). ★ When press fitting the bushing, take extreme care not to deform it. 2) Install rod packing (14). ★ Install the rod packing as shown in the following figure. 3) Install backup ring (18) and O-ring (17) in order. ★ Do not install the backup ring forcibly. Warm it in water at 50 – 60°C before installing it. 4) Using tool U5, install dust seal (13) to cylinder head (16), and then install snap ring (12).

2. Assembly of piston assembly 1) Using tool U6, expand piston ring (11). ★ Set the piston ring to the tool and rotate the handle 8 – 10 turns to expand the piston ring. 2) Remove the piston ring from the tool and install it to piston (10).

HD465-7, HD605-7

30-135 ➃


3) Set tool U7. Using tool U8, shrink the piston ring.

4) Install wear ring (9).

STEERING CYLINDER

3) Remove piston rod assembly (3) from tool U1.

4. Set the cylinder to tool U1. 5. Install cylinder head and piston rod assembly (3) to cylinder (4).

3. Assembly of piston rod assembly 1) Install cylinder head assembly (7) and piston assembly (6) to piston rod (8). 6. Using tool U2, tighten cylinder head assembly (2). Cylinder head nut: 637.5 ± 63.7 Nm {65 ± 6.5 kgm}

2) Using tool U3, tighten nut (5). Nut: Adhesive (Loctite No. 262) Nut: 1,078.8 ± 107.9 Nm {110 ± 11.0 kgm} ★ Width across flats of nut: 50 mm

30-136 ➂

HD465-7, HD605-7

HOIST CYLINDER


DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY

Repair stand

■

1

790-101-1102

Hydraulic pump

■

1

2

790-102-3802

Wrench assembly

■

1

3

790-720-1000

Expander

■

1

4

796-720-1680

) ■

1

■

1

■

1

Part name

Sketch

Q'ty

790-502-1003

Part No.

New/Remodel

Necessity

Symbol

Special tools

1

5

07281-01580 792-201-7310

6

) )

790-101-5421

Grip (For cylinder

) ■

1

01010-81240

Bolt (For cylinder

) ■

1

Push tool (For cylinder ) • Push tool (For cylinder ) • Grip (For cylinder ) • Bolt (For cylinder )

■

1

■

1

■

1

■

1

792-201-7410

Plate (For cylinder

) ■

1

790-101-5021

Grip (For cylinder

) ■

1

01010-80816

Bolt (For cylinder

)

■

1

■

1

■

1

■

1

■

1

790-201-1702

U 790-201-1851 790-101-5021 01010-50816

7

Ring (For cylinder Clamp (For cylinder Push tool (For cylinder

790-201-1500 790-201-1660 790-201-5021 01010-50816

Push tool kit (For cylinder ) • Plate (For cylinder ) • Grip (For cylinder ) • Bolt (For cylinder )

3. Remove cylinder cylinder (2).

and rod assembly (3) from

4. Remove piston nut (4) and lift down rod (6) from cylinder (5). 5. Pull cylinder assembly (1) out of rod (6).

DISASSEMBLY •

When disassembling, take care not to damage the rod packing, dust seal, piston ring, wear ring, etc.

1. Set the cylinder assembly to tool U1. 2. Using tool U2, remove cylinder head assembly (1) from cylinde (2).

HD465-7, HD605-7

30-137 ➂

HOIST CYLINDER


6. Disassembly of cylinder head assembly 1) Remove snap ring (7) and dust seal (8) from cylinder head assembly (1). 2) Remove rod packing (9) and bushing (10). 3) Remove backup ring (11) and O-ring (12).

ASSEMBLY ★ Check each part for dirt, flaw, etc. and apply engine oil to the sliding surfaces before assembling. 1. Using tool U6, press fit bushing (21) to cylinder (5).

7. Disassembly of piston assembly and cylinder 1) Remove wear ring (13). 2) Remove snap ring (14) and pull out piston assembly (15). 3) Remove piston ring (16) and wear ring (17) from piston assembly (15). 4) Remove snap ring (18) from cylinder (5), and then remove dust seal (19). 5) Remove rod packing (20) and bushing (21).

2. Install rod packing (20) to cylinder (5). ★ Install the rod packing as shown in the following figure. 3. Using too U7, install dust seal (19).

4. Install snap ring (18).

30-138 ➂

HD465-7, HD605-7

HOIST CYLINDER


5. Assembly of piston assembly 1) Using tool U3, expand piston ring (16) and install it to piston (15). ★ Set the piston ring to tool U3 and rotate the handle 8 – 10 turns to expand the piston ring. 2) Set tool U4. Using tool U5, shrink piston ring (16).

7. Install wear ring (13) to cylinder

(5).

8. Assembly of cylinder head assembly 1) Using tool U6, press fit bushing (10).

3) Install wear ring (17).

9. Install rod packing (9) to cylinder head (1). ★ Install the rod packing as shown in the following figure.

6. Install piston assembly (15) to cylinder and then install snap ring (14).

HD465-7, HD605-7

(5),

30-139 ➂

HOIST CYLINDER


10. Using tool U7, install dust seal (8).

11. Install snap ring (7), O-ring (12), and backup ring (11).

15. Install cylinder der (2).

12. Install head assembly (1) to rod (6).

16. Using tool U2, tighten cylinder head assembly (1).

13. Sling rod (6) and install it to cylinder (5). ★ Align the bolt holes of the piston assembly and rod.

and rod assembly (3) to cylin-

Cylinder head assembly: 1,569.1 ± 156.9 Nm {160 ± 16 kgm}

14. Tighten piston mounting nut (4). ★ Degrease the fitting parts of the bolt and nut sufficiently. ★ Width across flats of bolt: 24 mm Threads of piston rod: Adhesive (Loctite No. 262) Mounting nut: 274 ± 27.4 Nm {28 ± 2.8 kgm}

30-140 ➂

HD465-7, HD605-7

DUMP BODY


REMOVAL AND INSTALLATION OF DUMP BODY ASSEMBLY

5. Lift off dump body assembly (5). Dump body assembly HD465-7: 10,750 kg HD605-7: 13.450 kg

Hook

t

4

Sketch

790-441-1320

New/Remodel

V1

Part name

Q'ty

Part No.

Necessity

Symbol

Special tools

REMOVAL Stop the truck on level ground and set the parking brake switch to the PARK position, then put blocks under the wheels. 1. Using tool V1, sling the dump body assembly temporarily by 4 points. 2. Remove hoist cylinder bottom pin (1) and fix it with a lever block, etc. so that hoist cylinder (2) will not fall down.

3. Disconnect body positioner rod (3) from the body. 4. Remove body hinge pins (4) on both sides. a Check the thickness, quantity, and location of the shims.

HD465-7, HD605-7

30-141 (10)


DUMP BODY

INSTALLATION •


When aligning the pin holes, never insert your fingers in them. Bottom pin: 157 – 196 Nm {16 – 30 kgm}

★ Adjust the body positioner sensor. For details, see TESTING AND ADJUSTING, Adjusting body positioner sensor.

★ Install the shims as removed. When aligning the pin holes, never insert your fingers in them. Hinge pin: 245 – 309 Nm {25 – 31.5 kgm}

After installing the dump body assembly, deviation z of the dump body assembly from the cab assembly is in the following range. • Standard range of dimension z: 58 ± 12 mm

1. Adjust the shim of the dump body bottom mount. 1) Insert spacer 29 mm thick [1] at the end of dump body (5) (1 each on both sides). 2) Measure clearance x between the center of installing part of bottom mount (6) and top of rear frame (7). ★ Measure the clearance at parts A, B, and C, 6 parts in total on both sides. 3) Calculate the respective shim thicknesses for 6 parts of A, B, and C on both sides. • Shim thickness = (x – 26) mm 4) Set shims (8) calculated in 3) above to the bottom mount (6). • Standard shim thickness: 3 mm • Thicknesses of shims: 1 mm, 3.2 mm 5) Remove spacer [1] and lower the dump body and check that the all 6 parts of A, B, and C of the bottom mount are in contact with the top of the rear frame.

★ If dimension z is out of the standard range, adjust it with shims (11) of body hinge pins on both sides. • Thicknesses of shims: 1 mm, 6 mm

30-142 ➂

HD465-7, HD605-7


DUMP BODY

2. After adjusting the shims on the bottom mount, adjust the shims on the left front mount. 1) Lower the dump body and measure thickness Y of pad (9). • Standard thickness Y : 50 mm 2) If the pad thickness exceeds 50 mm or there is a clearance between the dump body and pad, add shim (10) to adjust the pad thickness properly.

HD465-7, HD605-7

30-143 !

OPERATOR'S SEAT


DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY ! The procedure for disassembling and assembling the operator's seat assembly (air suspension (ISRING HAUSEN)) is shown below.

A: B: C: D:

Headrest Seatback Seat cushion Right-hand armrest

E : Left-hand armrest F : Suspension cover G : Rails

DISASSEMBLY 1. Headrest 1) Referring to the figure, check the positions of the 2 clips (2) of headrest stay (1) on both sides.

30-144 (7)

HD465-7, HD605-7


2) Apply force b to part a of each clip (2) in the direction of the arrow to turn the clip. Release headrest stay (1) from part d of the clip and pull out up headrest (3).

OPERATOR'S SEAT

2. Seatback 1) Disconnect 3 air hoses (5) from the rear left of seatback (4). ★ Before disconnecting the air hoses, check their types.

2) Remove seatback hinge mounting bolt (6) (M8 bolt).

★ Pushing in both clips (2) simultaneously, remove headrest (3). 3) Bring seatback (4) down forward.

HD465-7, HD605-7

30-145 ➃


4) Apply force E to the right side of seatback (4) in the direction of the arrow. 5) Applying the force to seatback (4), pull its right side up. 6) Slide seatback (4) sideway and remove it.

3. Seat cushion 1) Push cushion adjuster lever (7) inward and slide seat cushion (8) to the front end.

30-146 ➃

OPERATOR'S SEAT

2) Push cushion stopper wire (9) down with screwdriver [1], etc. 3) Pull out seat cushion (8) forward and remove it.

4. Armrest • The procedure for disassembling right-hand armrest (10) is shown below. (Disassemble lefthand armrest (11) similarly.)

HD465-7, HD605-7


OPERATOR'S SEAT

1) Remove plastic cap (12) from the armrest hinge. a Use a flat-head screwdriver, etc. to remove the cap. 2) Loosen armrest hinge mounting bolt (13).

6) Remove right-hand armrest (10). a There are 2 position adjustment washers (16) installed to each bolt between the armrest and seatback. Take care not to lose them.

3) Remove plastic cap (14), and then remove lower mounting bolt (15A) (M8 bolt) of righthand armrest (10).

5. Suspension cover 1) Remove right-hand hinge cover (17). 2) Remove plastic plate (18) from the rear with screwdriver [1], etc. a Take care not to damage the plastic plate by prying it off forcibly with a screwdriver, etc.

4) Turn right-hand armrest (10) up by 180 degrees. a If the armrest is not turned, you cannot apply the tool to upper mounting bolt (15B). 5) Remove plastic cap (14) and upper mounting bolt (15B)

HD465-7, HD605-7

30-147 (10)


3) Remove 4 suspension cover fixing rings (19).

OPERATOR'S SEAT

6) Remove 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small) (25): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large) (26): Front lower part; 2 places 7) Remove suspension cover (27). a If you remove the suspension cover without performing the work in steps 5) and 6), the suspension cover may be broken.

4) Remove 4 mounting bolts (20), cushion rear fixing plate (21), 2 cushion rails (22), and 4 bushings (23).

6. Rails 1) Turn over the seat assembly to set rails (28) on the upside.

5) Remove 3 metallic suspension cover clips (24).

30-148 (4)

HD465-7, HD605-7

OPERATOR'S SEAT


2) Slide rails (28) to the rear end. 3) Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the front part of each rail.

4) Slide rails (28) to the front end. 5) Remove 1 hexagon socket head bolt (29) and 1 lock washer (30) from the rear part of each rail, and then remove rails (28).

a Take care not to lose height adjustment washers (31) between the rails and suspension.

HD465-7, HD605-7

ASSEMBLY 1. Skide rails 1) Put height adjustment washers (31) between slide rails (28) and suspension, and then set slide rails (28) in position.

2) Set slide rails (28) to the front end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each slide rail. Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

3) Set slide rails (28) to the rear end and install 1 lock washer (30) and 1 hexagon socket head bolt (29) to each slide rail. Hexagon socket head bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

30-149 (10)


2. Suspension cover 1) Set suspension cover (27) in position and install 6 plastic suspension cover clips (small) (25) and 2 plastic suspension cover clips (large) (26). a Clips (small) (25): Front upper part; 2 places Each side; 1 place Rear lower part; 2 places Clips (large) (26): Front lower part; 2 places

OPERATOR'S SEAT

3) Set 4 bushings (23) and 2 cushion rails (22), and then install cushion rear fixing plate (21), and 4 mounting bolts (20). Cushion rail mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

4) Install 4 suspension cover fixing rings (19).

2) Install 3 metallic suspension cover clips (24).

5) Install plastic plate (18) to the rear. 6) Install right-hand hinge cover (17).

30-150 (4)

HD465-7, HD605-7


3. Armrest • The procedure for assembling right-hand armrest (10) is shown below. (Assemble left-hand armrest (11) similarly.)

1) Install 2 position adjustment washers (16) for each bolt and set right-hand armrest (10) in position.

OPERATOR'S SEAT

6) Tighten armrest hinge mounting bolt (13). a Tighten the bolt so that the arm will move smoothly. • Operating effort at armrest end: 49 – 78.4 N {5 – 8 kg} 7) Install plastic cap (12).

4. Seat cushion 1) Slide in the seat cushion from the front of the fitting position. a If seat cushion (8) is slid to the rear, it is locked by cushion stopper wire (9).

2) Tighten lower mounting bolt (15A) lightly and turn armrest (10) by 180 degrees. 3) Tighten upper mounting bolt (15B) lightly. 4) Tighten lower mounting bolt (15A) and upper mounting bolt (15A) permanently. Upper and lower armrest mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm} 5) Install 2 plastic caps (14).

HD465-7, HD605-7

30-151 (4)


5. Seatback 1) Insert the left side of seatback (4), and then lower and set the right side.

OPERATOR'S SEAT

3) Connect 3 air hoses (5) to the rear left of the seatback (4).

6. Headrest 1) Insert headrest (3) in seatback (4). a Check that 2 clips (2) on both sides are locked securely.

2) Install seatback hinge mounting bolt (6). Seatback hinge mounting bolt: 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

30-152 (10)

HD465-7, HD605-7

90 OTHERS Power train hydraulic circuit diagram ....................................................90- 2 Steering and hoist hydraulic circuit diagram..........................................90- 3 Brake hydraulic circuit diagram .............................................................90- 5 Electrical circuit diagram (1/6) ...............................................................90- 7 Electrical circuit diagram (2/6) ...............................................................90- 9 Electrical circuit diagram (3/6) ...............................................................90-11 Electrical circuit diagram (4/6) ...............................................................90-13 Electrical circuit diagram (5/6) ...............................................................90-15 Electrical circuit diagram (6/6) ...............................................................90-17 Electrical system diagram related to transmission control ....................90-19 Electrical system diagram related to monitor ........................................90-21 Electrical circuit diagram (A1 size) (1/2)................................................90-23 Electrical circuit diagram (A1 size) (2/2)................................................90-25 Electrical system diagram related to ABS controller ......................... 90-26-1 Electrical circuit diagram related to ABS ........................................... 90-26-3 Connectors table (A1 size) ....................................................................90-27 Arrangement drawing (A1 size).............................................................90-29

HD465-7, HD605-7

90-1 (12)

OTHERS

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

90-2

HD465-7, HD605-7

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM

*1 EMERGENCY STEERING FLOW SWITCH HD465-7 Serial No.: 7001 – 7151 HD605-7 Serial No.: 7001 – 7059 *2 EMERGENCY STEERING OIL PRESSURE SWITCH HD465-7 Serial No.: 7152 and up HD605-7 Serial No.: 7060 and up HD465-7, HD605-7

90-3 (12)

BRAKE HYDRAULIC CIRCUIT DIAGRAM

*1 HD465-7 Serial No.: 7266 and up HD605-7 Serial No.: 7113 and up

HD465-7, HD605-7

90-5 (12)

ELECTRICAL CIRCUIT DIAGRAM (1/6)

HD465-7, HD605-7

90-7


HD465-7, HD605-7

90-9


HD465-7, HD605-7

90-11


HD465-7, HD605-7

90-13


HD465-7, HD605-7

90-15


HD465-7, HD605-7

90-17

ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

HD465-7, HD605-7

90-19 (7)

ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

HD465-7, HD605-7

90-21 (7)

ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) (1/2)

HD465-7, HD605-7

HD465, 605-7


HD465, 605-7

90-23


HD465-7, HD605-7

HD465, 605-7


HD465, 605-7

90-25

ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER

HD465-7, HD605-7

ELECTRICAL SYSTEM DIAGRAM RELATED TO ABS CONTROLLER HD465-7, HD605-7

90-26-1 (12)

ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS

HD465-7, HD605-7

ELECTRICAL CIRCUIT DIAGRAM RELATED TO ABS HD465-7, HD605-7

90-26-3 (12)

CONNECTORS TABLE (A1 SIZE)

CONNECTORS TABLE (A1 SIZE)

HD465, 605-7

ABS control related Connector No.

Number of pin

Address

Connector No.

Type of connector

Number of pin

Buzzer

R1

E16B

Terminal

1


Q9

E17A

DT-T

2


Q9

E17B

DT-T

CAN connector

AJ6

E2B

VHMS CAN connector

T9

Resistor

Q1

Cigarette lighter

1

Connector No.

Type of connector

Number of pin

01

Terminal

1

Battery relay (B)

B9

BZ2

M

2

02

Terminal

1

Battery relay (M)

B9

CAB1

DT-T (Gray)

8

03

Terminal

1

Battery relay (B)

B9

CAB2

DT-T (Black)

8

04

Terminal

1

Battery relay (M)

B9

CAN

DT

3

05

Terminal

1


A8

CAN1

DT-T

3

06

Terminal

1


A8

CAN2

DT-T

3

07

Terminal

1


A8

CG1

One-pin connector

1

08

Terminal

1


A9

CG2

—

Location

Address

Type of connector

Address

Connector No.

Grounding

AH9

OP5

M

1

Diode

AJ8

OP6

M

1

2

Diode

AJ8

OP7

M

1


DT

2

Diode

AE5

OPS

DT-T

2

Seat heater

ECM A

DRC26

40

Engine controller

AG5

PL01

M

2

ECM B

DRC26

40

Engine controller

AG9

PL02

M

2

M5

EG4

DT-T (Brown)

12


V9

PL03

One-pin connector

Cigarette lighter

M5

ENG

DT-T (Gray)

8


AJ7

PL04

Location

Location

Number of pin

Address

Connector No.

Type of connector

Number of pin


M8, O9

SLG

Terminal

1


N8, O8

SLL

M

1

N8, O8

SLR

M

T2

S-NET

MS3102A 14S

Left head lamp (LOW)

D1

SP1

PACKARD

2

Left head lamp (HIGH)

D2

SP2

PACKARD

2

1

Clearance lamp

E1

SPA1

DT-T

4

One-pin connector

1

Clearance lamp

E1

SPA2

DT-T

Type of connector

Location

Address

Connector No.

Type of connector

Number of pin

Grounding

J2


J2

ABS ABS1

M MIC

6 17

ABS system switch ABS controller

BK7 BR3

1


C7

ABS1

DT-T

6

Joint connector

BF9

5

S-NET monitor

T1

ABS2

MIC

21

ABS controller

BR3

Engine speed sensor (Master)

AJ8

ABS2

DT-T

8

Joint connector

BD2

Engine speed sensor (Backup)

AJ8

ABS3

DT-T

6

Joint connector

BE2

Spare connector 1

ABS3A

40

20

ABS controller

BR8

12

Spare connector 2

ABS3B

40

16

ABS controller

BQ9

Location

Location

Address

11

Terminal

1

Battery relay (E)

B8

CH1

S

8


M1

ER

Terminal

1

Grounding

C9, C8, E9, G9

PL05

One-pin connector

1

Turn signal

E1

SPA3

DT-T

6

Spare connector 3

F1

ABS4

40

12

ABS controller

BR8

12

Terminal

1

Battery relay (BR)

B8

CH2

S

8


M1

ER1

Terminal

1

Grounding

P1

PL06

One-pin connector

1

Fog lamp (If equipped)

D1

SPL

YAZAKI

2

Speaker (Left)

G9

ABS4

DT-T

6

Joint connector

BE2

12

KES0

2

Washer tank motor

—

CJA

DT-T

6

Joint connector

D8

ER2

Terminal

1

Grounding

X7

PL07

Terminal

1

Grounding

D2

SPR

YAZAKI

2

Speaker (Right)

F9

ABS5

DT

6

Joint connector

BF3

13

Terminal

1

Battery relay (E)

C8

CJB

DT-T (Black)

8

Joint connector

B7

ER3

Terminal

1

Grounding

O2

PM1

MIC

21

VHMS wiring harness

T9

SR2

X

3

Steering speed sensor

P1

ABS5A

40

20

ABS controller

BR8

14

Terminal

1

Battery relay (BR)

C8

CJB

DT-T

6

Joint connector

E8

FBC

M

6

Front brake cutting switch

N3

PM3

DT-T

3

Pitch angle sensor

X7

SR3

X

2

Pitch angle sensor

X7

ABS6

DT-T

6

Joint connector

BG8

15

Terminal

1


A8

CJC

DT-T

6

Joint connector

D8

FL01

DT-T

2

Radiator coolant level sensor

B3

PM4

S (Natural color)

16

VHMS wiring harnes

T9

SUFL

DT-T

3

Suspension oil pressure sensor(FL) (If equipped)

H1

ABS7

DT-T

6

Joint connector

BH8

16

Terminal

1


A7

CJD

DT

6

Joint connector

D8

FL04

YAZAKI

2

Washer motor

B3

PM5

MIC

13


T9

SUFR

DT-T

3

Suspension oil pressure sensor(FR) (If equipped)

B7

ABS8

DT-T

6

Joint connector

BE9

17

Terminal

1


B7

CJE2

DT-T

6

Joint connector

AI9

FL05

DT-T

2

Air conditioner dual switch

B2

PM6

AMP040

12


U9

SURL

DT-T

3

Suspension oil pressure sensor(RL) (If equipped)

L8

ABSFL

DT-T

2

ABS valve

AX9

18

Terminal

1


B7

CJE3

DT-T (Black)

8

Joint connector

A12

FLB

—

1

Flasher

R1

PM7

AMP

9

VHMS wiring harnes

SURR

DT-T

3

Suspension oil pressure sensor(RR) (If equipped)

J9

ABSFR

DT-T

2

ABS valve

AX9

20

—

1

Circuit breaker

A9

CJH1

DT-T (Black)

8

Joint connector

—

FLL

—

1

Flasher

R1

PM7

AMP

9


N7

T01

DT-T

2

Fuel level gauge sensor

G9

ABSRL

DT-T

2

ABS valve

BH7

21

—

1

Circuit breaker

A9

CJH2

DT-T

6

Joint connector

—

FLTP

PACKARD

2

Fuel temperature sensor

AF9

PM8

BENDIX

5

Connector

N7

T02

DT-T

6


H9

ABSRR

DT-T

2

ABS valve

BF9

22

—

1

Circuit breaker

A9

CJK

DT

6

Joint connector

B8

FOG

M

6

Fog lamp switch (If equipped)

N1

PM9

MIC

21

VHMS wiring harness

T9

T05

Terminal

1

Grounding

I9

BPFL

DT-T

3

Brake oil pressure

AW9

23

—

1

Circuit breaker

B9

CJL

DT-T

6

Joint connector

L7

FR01

DT-T

2

Air cleaner clogging sensor

B7

PM10

S (Natural color)

16

VHMS wiring harnes

T9

T1

Terminal

1

Grounding

AC9

BPFR

DT-T

3

Brake oil pressure

AX9

1939

HD30

9

Connector for connecting J1939 device

—

CJN

DT (Black)

8

Joint connector

J3

FS2

One-pin connector

2

Spare terminal

X6

PM11

MIC

21


V9

TEST

One-pin connector

1

TEST switch

V8

BPRL

DT-T

3

Brake oil pressure

BH8

A

One-pin connector

1


—

CJP

DT-T

6

Joint connector

I9

FS3

One-pin connector

2

Spare terminal

X7

PMLA

DT-T (Gray)

12


H9

TG

One-pin connector

1

Tachograph

S9

BPRR

DT-T

3

Brake oil pressure

BG9

A

One-pin connector

1


—

CJP1

DT-T

6

Joint connector

H9

FS4

One-pin connector

2

Spare terminal

X7

PMPR

PACKARD

3

Fuel pump pressure sensor

AF5

TG2

One-pin connector

1

Tachograph

S9

BRC3B

40

16

Retarder controller

BO9

A1

M

1


X6

CJP2

DT-T

6

Joint connector

I9

FS5

One-pin connector

2

Spare terminal

X7

PMRA

DT-T

6


D8

TIMG

PACKARD

3

Timing rail actuator

AG9

A2

M

1


V8

CJPR

DT-T

6

Joint connector

C8

FS8

One-pin connector

2

Spare terminal

X6

POW

HD30

21


AJ7

TM2

HD30

21


AD8

BRC4 BRC5A

40 40

12 20

Retarder controller Retarder controller

BP9 BQ9

AAPR

PACKARD

3

Air pressure sensor

AH5

CJS

DT-T

6

Joint connector

L7

FSO-

Terminal

1

Fuel shut-off valve -

AE7

PR01

M

2

Right head lamp (LOW)

A5

TM3

HD30

31


AD8

CHK

Yazaki

6

System check switch

BL8

ABS

M

6

ABS system switch

O2

CJSL

DT-T

6

Joint connector

I9

FSO+

Terminal

1

Fuel shut-off valve +

AE7

PR02

M

2

Right head lamp (HIGH)

A4

TMF

DT-T

2

Transmission oil filter sensor

J3

CVF

DT-T

2

ABS cut solenoid

AZ8

AC1

One-pin connector

1


M3

CJT

DT (Black)

8

Joint connector

L8

FUA

Terminal

—

Fuse box (30 A)

C9

PR03

One-pin connector

1

Clearance lamp

A5

TPR

PACKARD

3

Timing rail pressure sensor

AI6

CVR

DT-T

2

ABS cut solenoid

BG9

ACBM

YAZAKI

2

Air conditioner blower motor

T2

CJT1

DT-T (Black)

8

Joint connector

L7

FUB

Terminal

—

Fuse box (120 A x 2)

C9

PR04

One-pin connector

1

Clearance lamp

A5

TR

-

6

Brake lamp timer

X7

CVSF

DT-T

3

ABS cut switch

AY8

ACCF

DT-T

3

ACC oil pressure sensor (Front)

L4

CJT2

DT-T

6

Joint connector

H9

G

One-pin connector

1


—

PR05

One-pin connector

1

Turn signal

A5

VHM

DT-T (Black)

8


C2

CVSR

DT-T

3

ABS cut switch

BH8

ACCR

DT-T

3

ACC oil pressure sensor (Rear)

K3

CJW

DT-T

6

Joint connector

G

One-pin connector

1


—

PR06

One-pin connector

1

Fog lamp (Optional)

A6

WFM

M

6

Front wiper motor

Q1

DA1

DT-T

2

Diode

BE9

ACM1

AMP

5

Temperature regulation servomotor

V3

CK1

YAZAKI

6

Bulb breakage check switch

M2

G21

Terminal

1

Grounding

S1

PR07

Terminal

1

Grounding

A4

WFR

Relay

6

Front wiper relay

R1

DPC2B

AMP070

12

Machine monitor

P1

ACM2

AMP

5

Air outlet mode selection servomotor

M6

CLTP

PACKARD

2

Coolant temperature sensor

AE8

GND

Terminal

1

Engine block GND

AF8

PSOL

DT-T

2

Parking brake solenoid

L6

WPS

DT-T (Black)

12

Wiper switch

Q8

FOGF

M

6

Fog lamp switch

BM1

ACM3

AMP

5

Recirculated/Fresh air selection servomotor

W3

CM

DT-T (Green)

8

Lighting switch, passing switch, turn switch

Q8

H01

DT-T

2

Steering flow switch

K3

PSW

DT-T

2


K3

WSRL

DT-T

2

Wheel speed sensor (RL)

K1

FOGM

M

6

Fog lamp switch

BK8

ACP1

AMP

16


O7

CN3

DT-T

2

Input shaft speed sensor

AC9

H10

One-pin connector

1

Heater unit

M4

PUMP

PACKARD

3

Fuel pump actuator

AF5

WSRR

DT-T

2

Wheel speed sensor (RR)

K1

J06

HD30

31


BD1

JABS

DT-T

12


BA9

KES1

6

ABS cut relay

BS7

VHMS controller related

ACP2

AMP

12


O7

CN4

DT-T

2

Intermediate shaft speed sensor

AC9

H20

One-pin connector

1

Heater unit

M4

PWL

One-pin connector

1

Power window motor (Left)

I2

ACPS

SUMITOMO

2

Air conditioner pressure switch

U2

CN5

DT-T

2

Output shaft speed sensor

AD7

HAZ

M

6

Hazard switch

O7

PWM

M

6

Power mode switch

M4

CAN1

DT-T

3


AU2

RABS

ACR1

Relay

4

Blower main relay

W3

CN6

DT-T

2

Solenoid for transmission 1st clutch

AB9

HEAT

DT

2

Heater control

AJ7

PWR

One-pin connector

1

Power window motor (Right)

C7

DLSW

Terminal

1


AO1

RABS2

KES1

6

ABS cut valve relay

BS7

ACR2

Relay

4

Blower Hi relay

W4

CN7

DT-T

2

Fill switch for transmission 1st clutch

AB9

HEPC

DT-T

2

Hoist EPC valve

L5

R

One-pin connector

1


EG4

DT-T

12


AV3

S01F

DT-T

3


BC1

ACR3

Relay

4

Blower M2 relay

W4

CN8

DT-T

2

Solenoid for transmission 2nd clutch

AB9

HES

Terminal

1

Grounding

—

R

One-pin connector

1


GDL

DT-T

12


AP4

S01M

DT-T

3


AZ1

ACR4

Relay

4

Blower M1 relay

W4

CN9

DT-T

2

Fill switch for transmission 2nd clutch

AA9

HN

One-pin connector

1

Horn switch

Q8

R01

Relay

5

Engine starting relay

AB4

GR1

Terminal

1


AP2

S02F

DT-T

3


BC9

ACR5

Relay

4

Compressor clutch relay

W4

CN10

DT-T

2

Solenoid for transmission R clutch

AA9

HN1A

—

1

Horn valve

A4

R02

Relay

5

Transmission Neutral relay

AB3

GR2

Terminal

1


AP2

S02M

DT-T

3


BC9

ACRE

AMP

4

Air conditioner blower resistor

U2

CN11

DT-T

2

Fill switch for transmission R clutch

AA9

HN1B

—

1

Horn valve

A4

R03

Relay

5

Parking brake relay

AB3

HM-12

DT-T

3

Blow-by sensor

AM6

WSFL

DT-T

2

Wheel speed sensor

BC1

ACTH

YAZAKI

2

Thermistor

U3

CN12

DT-T

2

Solenoid for transmission 3rd clutch

AA9

HN2A

—

1

Horn valve

A4

R04

Relay

5

Brake lamp relay (RL)

AB3

HM-21A

DT

2


AN8

WSFR

DT-T

2

Wheel speed sensor

AY7

AISS

M

6

AISS switch

M3

CN13

DT-T

2

Fill switch for transmission 3rd clutch

AA9

HN2B

—

1

Horn valve

A3

R05

Relay

6

Backup lamp, buzzer relay

AB2

HM-21B

DT

2


AN7

WSRL2

DT-T

2

Wheel speed sensor

BG9

ARC

M

3

ARSC set switch

P8

CN14

DT-T

2

Solenoid for transmission 4th clutch

AA9

HSL

DT-T

4


V3

R06

Relay

6

Fog lamp relay

AC4

HM-22A

DT

2

Exhaust temperature sensor - amp intermediate connector

AR8

WSRR2

DT-T

2

Wheel speed sensor

BF9

ARSC

M

6

ARSC system switch

N3

CN15

DT-T

2

Fill switch for transmission 4th clutch

Z9

HSL

DT-T

4

Hoist lever potentiometer

V3

R07

Relay

5

AISS relay

AB4

HM-22B

DT

2

Exhaust temperature sensor - amp intermediate connector

AQ7

AS1

SWP

6

Acceleration sensor

N2

CN16

DT-T

2

Solenoid for transmission L clutch

Z8

HSOL

DT-T

3

Hoist selector valve

L5

R08

Relay

5

Brake lamp relay (CTR)

AB3

HM-23A

DT-T

3

VHMS - exhaust temperature amp intermediate connector

AR8

AS2

X

3

Acceleration sensor

O2

CN17

DT-T

2

Fill switch for transmission L clutch

Z8

HTA

DT-T (Gray)

8


L6

R09

Relay

5

Brake lamp timer relay

AB2

HM-23B

DT-T

3

VHMS - exhaust temperature amp intermediate connector

AQ7

ASR

M

6

ASR system switch

O2

CN18

DT-T

2

Solenoid for transmission H clutch

Y8

HTB

DT-T (Black)

8


L6

R10

Relay

5

PLM GDL relay

AC4

HM-31

DT

2


AN1

ASR1

DT-T-T

2

Steering angle sensor

C2

CN19

DT-T

2

Fill switch for transmission H clutch

Y7

IMPR

PACKARD

3

Intake air pressure sensor

AF8

R11

Relay

5

Horn relay

AC4

HM-35

DT

2

Ambient temperature sensor

AM1

ASR2

DT-T-T

2

Shut off valve

L2

CN20

DT-T

2

Solenoid for torque converter lockup clutch

Z8

IMTP

PACKARD

2

Intake air temperature sensor

AF8

R14

Relay

5

Brake cutting relay

AB4

HM50

DT-T

3

Short connector

AU2

ASR3

DT-T-T

2

ASR valve (R)

K3

CN21

DT-T

2

Fill switch for torque converter lockup clutch

Z8

J01

HD30

9


I2

R15

Relay

5

Transmission cutting relay

A2

HM55

DT-T

3

Short connector

AQ6

ASR4

DT-T-T

2

ASR valve (L)

L3

CN22

DT-T

3

Torque converter intermediate pressure sensor

Z5

J02

HD30

31


I2

R16

Relay

6

Hazard relay 1

AB1

HM81

M

8

VHMS - Orbcomm controller intermediate connector

AT2

ASR5

DT-T

2

ASR oil pressure switch (R)

K3

CN23

DT-T

2


AA5

J03

HD30

31


I2

R17

Relay

5

Hazard relay 2

AC1

HM-2130

YAZAKI

2

Resistor

AQ2

AC5

ASR6

DT-T

2

ASR oil pressure switch (L)

L2

CN24

DT-T

2


J04

HD30

31


H1, AN6

R19

Relay

5

Parking brake safety relay

AC4

HM-2140

YAZAKI

2

Resistor

AR2

ASR7

DT-T

2

ASR oil ptessure switch (Main)

K1

CNS1

DT-T (Brown)

12

Intermediate connector (Power window switch)

J05

HD30

31


H1, AN6

R21

Relay

6

Side lamp relay

AC4

HM-CN1

AMP070

20

VHMS controller

AS8

ASS

DT-T

2

Air suspension seat

T2

CNS2

DT-T (Green)

12

Intermediate connector (Gear shift lever)

J07

HD30

14


H1

R22

Relay

5

Rotary lamp relay

AD3

HM-CN2A

AMP070

18

VHMS controller

AT7

ATC1

MIC

17


Z1

CNS3

DT-T (Black)

12

Intermediate connector (Parking brake switch)

J08

HD30

31


G1

R25

YAZAKI

11

Power window relay

AC1

HM-CN2B

AMP070

12

VHMS controller

AU7

AMP070

18

VHMS controller

AT8

ATC2

MIC

21


Z1

COM

One-pin connector

1


M3

J09

HD30

31


G1

R29

Relay

5

Head lamp Hi relay

AD2

HM-CN3A

ATC3A

AMP040

20


Z4

D01

DT-T

2

Diode

W8

J10

HD30

31


G1

R30

Relay

5

Head lamp Lo relay

AD1

HM-CN3B

AMP070

12

VHMS controller

AS8

ATC3B

AMP040

16


Z4

D02

DT-T

2

Diode

W8

JC01

DT

6

Joint connector

AI6

R32

Relay

5

Dust indicator relay

AC1

HM-CN4A

AMP070

14

VHMS controller

AU7

ATC4

AMP040

12


AA4

D03

DT-T

2

Diode

W8

JC02

DT (Black)

8

Joint connector

AI5

R33

Relay

6

Parking brake manual switch

R9

HM-CN4B

AMP070

10

VHMS controller

AT8

ATC5A

AMP040

20


AA1

D04

DT-T

2

Diode

M6

JC03

DT (Black)

8

Joint connector

AH5

R34

YAZAKI

7

Power window switch (Left)

S1

LM1

Terminal

1

Ground level download box lamp terminal

AP3

ATC5B

AMP040

16


AA4

D05

DT-T

2

Diode

V8

JC04

DT (Black)

8

Joint connector

AG5

R35

YAZAKI

7

Power window switch (Right)

S9

LM2

Terminal

1

Ground level download box lamp terminal

AP3

ATC6

X

4

Software rewriting connector (Transmission controller)

W4

D07

DT-T

2

Diode

P2

JC11

DT

6

Joint connector

AG5

R37

Relay

5

Auto preheater relay

AD3

ORB-A

AMP070

14

Orbcomm controller

AS2

B01

DT-T

6


K9

D08

DT-T

2

Diode

W8

JC12

DT

6

Joint connector

AH5

R40

Relay

6

Payload meter relay (If equipped)

AD2

ORB-B

AMP070

10

Orbcomm controller

AS2

MS

5

Ground level download box PLM connector

AP2

B02

DT-T

6


K8

DL

DT-T (Black)

12


X6

JC13

DT (Black)

8

Joint connector

AI5

R43

Relay

5

Green outside pilot lamp relay of payload meter

AD2

PDL

B03

DT-T

6

Winker lamp, stop lamp, tail lamp

J9

DPC1

AMP070

20

Machine monitor

P8

JC14

DT (Black)

8

Joint connector

AI6

R44

Relay

5

Yellow outside pilot lamp relay of payload meter

AD2

PLM

MS

5

PLM II download connector

AQ6

B04

Terminal

1

Backup lamp

J9

DPC2A

AMP070

18

Machine monitor

P1

JC15

DT

6

Joint connector

AI6

R45

Relay

5

Red outside pilot lamp relay of payload meter

AD1

PM1

MIC

21


AV3

B05

Terminal

1

Backup alarm buzzer

J9

DPC2B

AMP070

12

Machine monitor

P1

JCA

DT-T (Black)

8

Joint connector

X5

RAD

YAZAKI

9

AM/FM radio

O2

PM4

S

16


AU7

B06

Terminal

1

Backup alarm buzzer

J9

DPC3A

AMP070

18

Machine monitor

P8

JCB

DT-T (Black)

8

Joint connector

X5

RAIL

PACKARD

3

Fuel rail actuator

AF5

PM11

MIC

21


AV6

B07

DT-T

3

Body position sensor

K9

DPC4

AMP070

12

Machine monitor

Q1

JCC

DT-T (Black)

8

Joint connector

X5

RDC

YAZAKI

9

Cassette stereo

O2

SPA1

DT-T

4

Ambient temperature sensor intermediate connector

AO6

B1

One-pin connector

1


—

DPC6

AMP040

8

Machine monitor

O7

JCD

DT-T (Black)

8

Joint connector

X4

RE1

YAZAKI

2

Resistor

S9

SPA2

DT-T

12


AO6

B1

One-pin connector

1


—

DPC7

X

4

Software rewriting connector (Machine monitor)

N3

JCE

DT-T (Black)

8

Joint connector

X4

RE2

YAZAKI

2

Resistor

S9

VDL

MS

5

Ground level download box VHMS connector

AP3

DT-T

8

Blow-by, oil temperature sensor intermediate connector

AM6

B10

Terminal

1

Grounding

K8

DSL

—

1

Door switch (Left)

F1

JCF

DT-T (Black)

8

Joint connector

S9

RE3

YAZAKI

2

Resistor

P8

VHM

B11

Terminal

1

Grounding

L8

DSR

—

1

Door switch (Right)

T2

JCG

DT-T (Black)

8

Joint connector

V3

RE4

YAZAKI

2

Resistor

P8

VHMS

MS

5

VHMS download connector

AT2

B2

One-pin connector

1


—

DT7

DT-T

12


T2

JT1

DT-T

6

Joint connector

AD7

RESW

DT-T

2

Retarder switch

L4

WAKE

Terminal

1


AP2

B2

One-pin connector

1


—

DT8

DT-T

4


J2

JT2

DT-T

6

Joint connector

AD7

RETV

DT-T

2

Retarder valve

L4

B3

One-pin connector

1


—

E

Terminal

1


LINK

DT

6

Data link crossover

AJ6

RL

YAZAKI

2

Room lamp

E9

B3

One-pin connector

1


—

E01

Terminal

1

Alternator

AE7

LKO

DT-T

2


U3

RL2

One-pin connector

1

Room lamp 2

G9

BCOM

One-pin connector

1

Beacon lamp

T9

E02A

DT-T

2

Starting motor

AH1

LKO

DT-T

2

Lever kick-out solenoid

V3

RP

DT-T

6


A6

BK

DT-T (Gray)

8


F9

E02B

DT-T

2

Starting motor

AH1

LP

DT (Gray)

12


I2

RPR

PACKARD

3

Fuel rail pressure sensor

AI6

M1

RT2

Terminal

1


M4

RT6

Terminal

1


M5

BL

One-pin connector

1


C7

E03

DT-T

2

Engine speed sensor

AF1

LS

M

3

Rheostat

BLS

M

6

Rotary lamp switch (If equipped)

N1

E04

DT-T

2

Oil level switch (If equipped)

AH5

M

Terminal

1


BR

One-pin connector

1


M4

E05

Terminal

1

Oil filter switch

C2

MON1

One-pin connector

1


N7

RT7

Terminal

1


M5

BRC1

MIC

17

Retarder controller

Y2

E06

Terminal

1

Alternator

AE6, AF1

MON2

One-pin connector

1


N7

RT8

Terminal

1


M4

BRC2

MIC

21

Retarder controller

Y2

E07

DT-T

2

Compressor

AF8

MON3

One-pin connector

1


O7

RTL

DT-T

6

Retarder potentiometer

P8

BRC3A

AMP040

20

Retarder controller

Y4

E08

DT-T

2

Diode

AG9

MS11

M

1

Model selection connector (Transmission controller)

U9

S01

DT-T

2


B7

BRC3B

AMP040

16

Retarder controller

Y4

E09

Terminal

1

Alternator

AE6

MS12

M

1


U9

S02

DT-T

2


E9

BRC4

AMP040

12

Retarder controller

Z4

E10

Terminal

1

Grounding

AG9

MS21

M

1


U9

S03

DT-T

2

Front brake cutting solenoid (If equipped)

E9

BRC5A

AMP040

20

Retarder controller

Y1

E11A

Terminal

1

Heater relay

AJ9

MS22

M

1


U9

S04

DT-T

2

Auto suspension solenoid 1 (If equipped)

F9

BRC5B

AMP040

16

Retarder controller

Y2

E11B

Terminal

1

Ribbon heater

AH9

MS31

M

1


U9

S05

DT-T

2

Auto suspension solenoid 2 (If equipped)

F9

BRC6

X

4

Software rewriting connector (Retarder controller)

S9

E12A

Terminal

1

Heater relay

AJ9

MS32

M

1


V3

SBS

DT-T

2

Seat belt switch

U2

BT

DT

6


C9

E12B

Terminal

1

Ribbon heater

AG9

OLPR

PACKARD

3

Engine oil pressure sensor

AE5

SDE

M

6

Side lamp switch (If equipped)

N2

BT1

—

—

Fuse box

X5

E13A

DTHD (#4)

1


AG1

OP1

M

1


M8, N9

SF1

DT-T (Green)

12

Shift lever

R9

BT2

—

—

Fuse box

X7

E13B

DTHD (#4)

1


AG1

OP2

M

1


M8, N9

SF2

DT-T

2

Shift lever

Q9

BT3

—

—

Fuse box

X6

E15

Terminal

1

Grounding

AI2

OP3

M

1


M8, O9

SIG

HD30

31


AJ7

BT4

—

—

Fuse box

X6

E16A

Terminal

1

Grounding

AI9

OP4

M

1


M8, O9

SLG

Terminal

1

Grounding

C8

HD465-7, HD605-7

90-27 (12)

ARRANGEMENT DRAWING (A1 SIZE)

HD465-7, HD605-7

ARRANGEMENT DRAWING (A1 SIZE)

HD465, 605-7

90-29 (12)

HD465 7 Shop Manual SN 7001 Up

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