Camión HD 465 Komatsu PDF [PDF]

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SEN01081-20



DUMP TRUCK



HD465 -7E0 HD605 -7E0 SERIAL NUMBERS



HD465- 10001-10037 HD465- 10101 and up HD6058001-8032 HD605- 10101 and up



SEN01083-20



DUMP TRUCK 1SHOP MANUAL



HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



00 Index and foreword



1



Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4



HD465-7E0, HD605-7E0



1



SEN01083-20



00 Index and foreword



Composition of shop manual



1



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



Form Number



Shop Manual, contents binder, binder label and tabs



SEN01081-20



00 Index and foreword Index Foreword and general information



SEN01082-20 SEN01083-20 q SEN01084-06



01 Specification Specification and technical data



SEN01085-04 SEN01086-04



10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Brake system Undercarriage and frame Hydraulic system Work equipment (Body) Cab and its attachments Electrical system, Part 1 Electrical system, Part 2 Electrical system, Part 3 Electrical system, Part 4



SEN01087-11 SEN01088-02 SEN01089-04 SEN01090-01 SEN01091-01 SEN01092-02 SEN01093-03 SEN01094-03 SEN04679-00 SEN01095-03 SEN01096-05 SEN01097-05 SEN01098-02 SEN01099-06



20 Standard value table Standard service value table



SEN01100-03 SEN01649-03



30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4 Testing and adjusting, Part 5



SEN01101-08 SEN01650-06 q SEN01651-07 q SEN01652-05 SEN01653-02 SEN01654-04



40 Troubleshooting General information on troubleshooting



SEN01102-09 SEN01661-05



2



HD465-7E0, HD605-7E0



00 Index and foreword



Failure code table and fuse locations Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 Troubleshooting by failure code, Part 5 Troubleshooting by failure code, Part 6 Troubleshooting by failure code, Part 7 Troubleshooting by failure code, Part 8 Troubleshooting by failure code, Part 9 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)



SEN01083-20



SEN01660-05 SEN01662-04 SEN01663-05 SEN01664-05 SEN01665-05 SEN01666-06 SEN01667-06 SEN01668-03 SEN01669-02 SEN01670-03 SEN01671-05 q SEN01672-01 SEN01673-03



50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Brake system Undercarriage and frame Hydraulic system Body Cab and its attachments Electrical system



SEN01103-06 SEN02483-05 SEN02484-04 SEN02485-02 SEN02486-02 SEN02487-01 SEN02488-02 SEN02489-03 SEN02490-01 SEN02491-02 SEN02492-03 SEN02493-01



90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings



SEN01104-12 SEN01105-05 q SEN01106-10 q



HD465-7E0, HD605-7E0



q



q q q



3



SEN01083-20



00 Index and foreword



Table of contents



1



00 Index and foreword Index SEN01083-20 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN01084-06 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard.......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines.......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN01086-04 Specification drawing................................................................................................................... 2 Specifications .............................................................................................................................. 4 Weight table ................................................................................................................................ 12 Fuel, coolant and lubricants ........................................................................................................ 13 10 Structure, function and maintenance standard Engine and cooling system SEN01088-02 Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler........... 2 Fuel system ................................................................................................................................. 4 Brake oil cooler............................................................................................................................ 5 Output shaft................................................................................................................................. 6 Power train, Part 1 SEN01089-04 Power train skeleton.................................................................................................................... 2 Drive shaft ................................................................................................................................... 4 Torque converter and transmission hydraulic piping ................................................................... 6 Brake cooling oil control valve (BCV) .......................................................................................... 8 Torque converter ......................................................................................................................... 10 Torque converter valve ................................................................................................................ 17 Transmission ............................................................................................................................... 19 Transmission control valve .......................................................................................................... 35 ECMV .......................................................................................................................................... 36 Power train, Part 2 SEN01090-01 Axle ............................................................................................................................................. 2 Differential ................................................................................................................................... 4 Final drive.................................................................................................................................... 5 Wheels ........................................................................................................................................ 6 Steering system SEN01091-01 Steering column........................................................................................................................... 2 Steering linkage........................................................................................................................... 3 Brake system SEN01092-02 Brake piping ................................................................................................................................ 2 Brake valve.................................................................................................................................. 4 Secondary brake valve................................................................................................................ 7 Relay valve.................................................................................................................................. 8



4



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01083-20



Front brake off valve ................................................................................................................... 9 Accumulator charge valve........................................................................................................... 10 Accumulator ................................................................................................................................ 14 Slack adjuster.............................................................................................................................. 15 Brake........................................................................................................................................... 17 Parking brake solenoid valve ...................................................................................................... 21 Undercarriage and frame SEN01093-03 Suspension ................................................................................................................................. 2 Suspension cylinder .................................................................................................................... 4 Rear axle support........................................................................................................................ 12 Hydraulic system SEN01094-03 Steering and hoist hydraulic piping ............................................................................................. 2 Dump body control ...................................................................................................................... 4 Hydraulic tank ............................................................................................................................. 5 Steering valve.............................................................................................................................. 6 Crossover relief valve.................................................................................................................. 10 Steering cylinder.......................................................................................................................... 11 Steering control valve.................................................................................................................. 12 Hoist valve................................................................................................................................... 18 Dump control valve (EPC valve) ................................................................................................. 24 Hoist cylinder............................................................................................................................... 28 Hydraulic pump ........................................................................................................................... 29 Work equipment (Body) SEN04679-00 Auto greasing system.................................................................................................................. 2 Cab and its attachments SEN01095-03 ROPS cab ................................................................................................................................... 2 Air conditioner ............................................................................................................................. 3 Rear view monitor ....................................................................................................................... 9 Electrical system, Part 1 SEN01096-05 Machine monitor system ............................................................................................................. 2 Electrical system, Part 2 SEN01097-05 Automatic shift control system .................................................................................................... 2 Transmission controller ............................................................................................................... 6 External power supply heater...................................................................................................... 20 Automatic emergency steering system ....................................................................................... 22 Automatic suspension system..................................................................................................... 26 Retarder control system .............................................................................................................. 29 Battery disconnector switch ........................................................................................................ 40 Dump control lever ...................................................................................................................... 46 Electrical system, Part 3 SEN01098-02 Payload meter (Card type) ...................................................................................................... 2 Electrical system, Part 4 SEN01099-06 VHMS controller related .............................................................................................................. 2 ASR system (If equipped) ........................................................................................................... 26 Sensors, switches ....................................................................................................................... 32 20 Standard value table Standard service value table SEN01649-03 Standard value table for engine .................................................................................................. 2 Standard value table for machine................................................................................................ 4 30 Testing and adjusting Testing and adjusting, Part 1 SEN01650-06 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Sketch of special tool .................................................................................................................. 9



HD465-7E0, HD605-7E0



5



SEN01083-20



00 Index and foreword



Testing engine speed .................................................................................................................. 10 Testing air supply pressure (boost pressure) .............................................................................. 11 Testing exhaust temperature ....................................................................................................... 12 Testing exhaust gas color............................................................................................................ 14 Adjustment of valve clearance .................................................................................................... 16 Testing of compression pressure................................................................................................. 18 Testing blow-by pressure............................................................................................................. 21 Testing engine oil pressure.......................................................................................................... 22 Testing EGR valve and bypass valve drive oil pressure.............................................................. 23 Handling of fuel system devices.................................................................................................. 25 Releasing residual pressure from fuel system ............................................................................ 25 Testing of fuel pressure ............................................................................................................... 26 Reduced cylinder mode operation............................................................................................... 27 No-injection cranking................................................................................................................... 27 Testing of fuel return rate and fuel leakage ................................................................................. 28 Bleeding air from fuel circuit ........................................................................................................ 30 Testing the fuel circuit for leakage ............................................................................................... 31 Replacement and adjustment of fan belt..................................................................................... 32 Replacement and adjustment of alternator and air conditioner compressor belt ........................ 33 Testing and adjusting, Part 2 SEN01651-07 Testing torque converter stall speed............................................................................................ 3 Testing power train oil pressure................................................................................................... 4 Adjusting transmission speed sensor.......................................................................................... 11 Testing and adjusting brake oil pressure ..................................................................................... 12 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................................................. 15 Testing brake performance.......................................................................................................... 23 Releasing remaining pressure in brake circuit ............................................................................ 24 Bleeding air from brake circuit..................................................................................................... 25 Testing wear of front brake pad ................................................................................................... 26 Testing wear of rear brake disc ................................................................................................... 27 Method of releasing parking brake in an emergency .................................................................. 28 Testing and adjusting front suspension cylinder.......................................................................... 29 Testing and adjusting rear suspension cylinder........................................................................... 33 Testing and adjusting front suspension cylinder (Automatic suspension specification) .............. 37 Testing and adjusting hydraulic pressure in steering, hoist circuit............................................... 38 Testing and adjusting oil pressure in dump EPC circuit .............................................................. 41 Air bleeding from steering cylinder .............................................................................................. 42 Procedure for raising dump body in emergency.......................................................................... 43 Procedure for lowering dump body in emergency....................................................................... 44 Adjusting body positioner sensor ................................................................................................ 46 Resetting method for dump body seating control........................................................................ 47 Adjustment of tilt lock lever of steering wheel ............................................................................. 48 Handling of voltage circuit of engine controller............................................................................ 49 Adjusting transmission controller................................................................................................. 49 Method for emergency escape at electrical system failure ......................................................... 50 Testing and adjusting, Part 3 SEN01652-05 Setting and adjusting of devices.................................................................................................. 2 Special functions of machine monitor (EMMS)............................................................................ 14 Testing and adjusting, Part 4 SEN01653-02 Special functions of machine monitor (EMMS)............................................................................ 2 Testing and adjusting, Part 5 SEN01654-04 Request for opening ORBCOMM terminal .................................................................................. 2 VHMS controller initial setting procedure .................................................................................... 4 Using method of KOMTRAX functions of ORBCOMM terminal .................................................. 24 Precautions for replacing VHMS controller ................................................................................. 27 Pm Clinic check sheet ................................................................................................................. 33



6



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01083-20



Initial setting of payload meter .................................................................................................... 37 Setting of payload meter built in VHMS ...................................................................................... 38 Setting of card-type payload meter (PLM- ) after installation or replacement ........................... 46 40 Troubleshooting General information on troubleshooting SEN01661-05 Points to remember when troubleshooting.................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Check before troubleshooting ..................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Contents of troubleshooting table................................................................................................ 6 Connection table for connector pin numbers .............................................................................. 8 T-branch box and T-branch adapter table ................................................................................... 44 Failure code table and fuse locations SEN01660-05 Failure codes table ...................................................................................................................... 2 Fuse locations ............................................................................................................................. 13 Troubleshooting by failure code, Part 1 SEN01662-04 Failure code [1500L0] (Dual engagement).................................................................................. 3 Failure code [15B0NX] (Transmission oil filter: Clogging)........................................................... 4 Failure code [15F0KM] (R o F shifting abuse 1: Mistake in operation) ...................................... 6 Failure code [15F0MB] (R o F shifting abuse 2: Mistake in operation) ...................................... 6 Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)................. 7 Failure code [15G0MW] (R clutch: Slipping) ............................................................................... 8 Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting) ................ 10 Failure code [15H0MW] (Hi clutch: Slipping) .............................................................................. 12 Failure code [15J0MW] ( Lo clutch: Slipping).............................................................................. 14 Failure code [15K0MW] (1st clutch: Slipping) ............................................................................. 16 Failure code [15L0MW] (2nd clutch: Slipping) ............................................................................ 18 Failure code [15M0MW] (3rd clutch: Slipping) ............................................................................ 20 Failure code [15N0MW] (4th clutch: Slipping) ............................................................................. 22 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)....... 24 Failure code [15SBMA] (R clutch solenoid: Malfunction) ............................................................ 26 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)...... 27 Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ........................................................... 30 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF) ..... 31 Failure code [15SDMA] (Lo clutch solenoid: Malfunction) .......................................................... 34 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)..... 35 Failure code [15SEMA] (1st clutch solenoid: Malfunction) .......................................................... 38 Troubleshooting by failure code, Part 2 SEN01663-05 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF.... 4 Failure code [15SFMA] 2nd clutch solenoid: Malfunction ........................................................... 7 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF .... 8 Failure code [15SGMA] 3rd clutch solenoid: Malfunction ........................................................... 11 Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF .... 12 Failure code [15SHMA] 4th clutch solenoid: Malfunction ............................................................ 15 Failure code [15SJMA] Lockup clutch solenoid: Malfunction ...................................................... 16 Failure code [2C4MNX] Retarder cooling oil filter: Clogging ....................................................... 18 Failure code [2F00KM] Parking brake: Mistake in operation or setting....................................... 20 Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front).......................................... 23 Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) .......................................... 23 Failure code [6014NX] Hydraulic oil filter: Clogging.................................................................... 24 Failure code [989A00] Engine over run prevention command signal: Operating ........................ 26 Failure code [989D00] Rear section tipping over alarm: Alarm is activated................................ 26 Failure code [A570NX] Engine oil filter: Clogging ....................................................................... 27 Failure code [AA10NX] Air cleaner element: Clogging ............................................................... 28 Failure code [AB00MA] Alternator: Malfunction .......................................................................... 30 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure ... 32 Failure code [B@BAZK] Engine oil: Level too low ...................................................................... 33 HD465-7E0, HD605-7E0



7



SEN01083-20



00 Index and foreword



Failure code [B@BCNS] Engine: Overheat ................................................................................ 34 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level.................................... 36 Failure code [B@BFZK] Lowering of fuel level............................................................................ 38 Failure code [B@C7NS] Brake cooling oil: Overheating (Rear).................................................. 40 Failure code [B@CENS] Overheating of torque converter oil ..................................................... 42 Failure code [B@GAZK] Battery electrolyte level: Lowering of level........................................... 43 Failure code [B@JANS] Steering oil temperature: Overheat ...................................................... 44 Troubleshooting by failure code, Part 3 SEN01664-05 Failure code [CA111] Abnormality in engine controller................................................................ 4 Failure code [CA115] Engine Ne or Bkup speed sensor error .................................................... 6 Failure code [CA122] Charge (boost) pressure sensor high error .............................................. 8 Failure code [CA123] Charge (boost) pressure sensor low error................................................ 10 Failure code [CA131] Throttle sensor high error ......................................................................... 12 Failure code [CA132] Throttle sensor low error........................................................................... 15 Failure code [CA135] Engine oil pressure sensor high error....................................................... 18 Failure code [CA141] Engine oil pressure sensor low error ........................................................ 20 Failure code [CA144] Coolant temperature sensor high error..................................................... 22 Failure code [CA145] Coolant temperature sensor low error ...................................................... 24 Failure code [CA153] Charge (boost) temperature sensor high error ......................................... 26 Failure code [CA154] Charge (boost) temperature sensor low error .......................................... 28 Failure code [CA187] Sensor power supply 2 low error .............................................................. 30 Failure code [CA212] Engine oil temperature sensor high error ................................................. 32 Failure code [CA213] Engine oil temperature sensor low error................................................... 34 Failure code [CA221] Atmospheric pressure sensor high error .................................................. 36 Failure code [CA222] Atmospheric pressure sensor low error.................................................... 38 Failure code [CA227] Sensor power supply 2 high error............................................................. 40 Failure code [CA234] Engine overspeed..................................................................................... 41 Failure code [CA238] Ne speed sensor power supply error........................................................ 42 Failure code [CA263] Fuel Temp Sensor High Error ................................................................... 44 Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 46 Failure code [CA271] PCV1 Short circuit .................................................................................... 48 Failure code [CA272] PCV1 Disconnection................................................................................. 49 Failure code [CA273] PCV2 Short circuit .................................................................................... 50 Failure code [CA274] PCV2 Disconnection................................................................................. 51 Failure code [CA322] Injector #1 open/short error ...................................................................... 52 Failure code [CA323] Injector #5 open/short error ...................................................................... 54 Failure code [CA324] Injector #3 open/short error ...................................................................... 56 Failure code [CA325] Injector #6 open/short error ...................................................................... 58 Failure code [CA331] Injector #2 open/short error ...................................................................... 60 Failure code [CA332] Injector #4 open/short error ...................................................................... 62 Failure code [CA342] Calibration code inconsistency ................................................................. 64 Failure code [CA351] Injectors drive circuit error ........................................................................ 65 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 66 Failure code [CA386] Sensor power supply 1 high error............................................................. 68 Troubleshooting by failure code, Part 4 SEN01665-05 Failure code [CA431] Idle validation switch error ........................................................................ 3 Failure code [CA432] Idle validation action error ........................................................................ 7 Failure code [CA441] Battery voltage low error........................................................................... 10 Failure code [CA442] Battery voltage high error ......................................................................... 11 Failure code [CA449] Common rail pressure high error 2........................................................... 12 Failure code [CA451] Rail Press Sensor High Error ................................................................... 14 Failure code [CA452] Rail Press Sensor Low Error .................................................................... 16 Failure code [CA553] Common rail pressure high error 1........................................................... 18 Failure code [CA554] Common rail pressure sensor in range error............................................ 19 Failure code [CA559] Supply pump pressure very low error 1.................................................... 20 Failure code [CA689] Engine Ne speed sensor error.................................................................. 24 Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 26 Failure code [CA757] All continuous data lost error .................................................................... 27



8



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01083-20



Failure code [CA778] Engine Bkup speed sensor error.............................................................. 28 Failure code [CA1228] EGR valve servo error 1 ......................................................................... 30 Failure code [CA1625] EGR valve servo error 2 ......................................................................... 31 Failure code [CA1626] (Bypass valve solenoid current high error) ............................................. 32 Failure code [CA1627] (Bypass valve solenoid current low error) .............................................. 34 Failure code [CA1628] Bypass Valve Servo Error 1.................................................................... 36 Failure code [CA1629] Bypass Valve Servo Error 2.................................................................... 37 Failure code [CA1631] (Bypass valve lift sensor high error) ....................................................... 38 Failure code [CA1632] (Bypass valve lift sensor low error)......................................................... 40 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 42 Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 44 Failure code [CA2186] Throttle sensor power supply low error .................................................. 46 Failure code [CA2249] Supply pump pressure very low error 2.................................................. 48 Failure code [CA2271] EGR valve lift sensor high error ............................................................. 50 Failure code [CA2272] EGR valve lift sensor low error ............................................................... 52 Failure code [CA2351] EGR valve solenoid operation short circuit ............................................ 54 Failure code [CA2352] EGR valve solenoid operation disconnect.............................................. 56 Failure code [CA2555] Intake air heater relay open circuit error................................................. 58 Failure code [CA2556] Intake air heater relay short circuit error................................................. 60 Troubleshooting by failure code, Part 5 SEN01666-06 Failure code [D19HKB] Stop lamp relay output system: Short circuit ......................................... 3 Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line.......................................... 4 Failure code [DAF9KM] Wrong connection of connector ............................................................ 6 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication .................................................................................................... 7 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of supply voltage .................................................................................................. 8 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller ...................................................................................................... 10 Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low .............................................................................................. 12 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection .................. 14 Failure code [DAQRKR] Abnormality in CAN communication (Transmission)............................ 15 Failure code [DAQRMA] Transmission controller option setting: Malfunction............................. 20 Failure code [DAQV00] Neutral coast caution ............................................................................ 21 Failure code [DAQW00] Neutral over speed caution .................................................................. 22 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller ........ 23 Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble ............................................................................................... 24 Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low .............................................................................................. 26 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 28 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled .... 29 Failure code [DB1RMA] Disagreement of option setting (Retarder controller)............................ 33 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled...... 34 Failure code [DBB0KK] or VHMS_LED display: "n9" o "01" VHMS controller: Low power supply voltage (input) ........................................................................................ 40 Failure code [DBB0KQ] or VHMS_LED display: "nF" o "11" VHMS controller: Disagreement of model selection signals ............................................................................ 42 Failure code [DBB3KK] or VHMS_LED display: "n9" o "05" VHMS controller battery power supply: Low power supply voltage (input) ................................................................ 44 Failure code [DBB5KP] or VHMS_LED display: "n9" o "04" VHMS controller 5 V power supply output: Low output voltage............................................................................. 46 Failure code [DBB6KP] or VHMS_LED display: "n9" o "02" VHMS controller 24 V power supply output: Low output voltage............................................................................. 48 Failure code [DBB7KP] or VHMS_LED display: "n9" o "03" VHMS controller 12 V power supply output: Low output voltage............................................................................. 50 HD465-7E0, HD605-7E0



9



SEN01083-20



00 Index and foreword



Failure code [DBQRKR] or VHMS_LED display: "n8" o "02" VHMS controller CAN communication: Defective communication (Abnormality in target component system) ....... 51 Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ....................................... 51 Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble... 52 Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low............................................................................................... 54 Failure code [DBC9KQ] Disagreement of model selection (ABS controller) ............................... 56 Failure code [DBCRKR] Abnormality in CAN communication (ABS) .......................................... 57 Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................. 61 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range ...................................................................................................... 62 Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) .................. 64 Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped) ...................... 66 Failure code [DDD9KA] ABS system switch system: Disconnection .......................................... 68 Failure code [DDD9KB] ABS system switch system: Short circuit .............................................. 70 Failure code [DDDAKA] ASR system switch: Disconnection ..................................................... 72 Failure code [DDDAKB] ASR system switch: Short circuit.......................................................... 74 Failure code [DDP6L4] Service brake pressure switch trouble (Rear)........................................ 76 Failure code [DDTHKA] Hi clutch fill switch: Disconnection ........................................................ 78 Failure code [DDTJKA] Lo clutch fill switch: Disconnection ........................................................ 80 Failure code [DDTKKA] 1st clutch fill switch: Disconnection....................................................... 82 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection ...................................................... 84 Failure code [DDTMKA] 3rd clutch fill switch: Disconnection...................................................... 86 Failure code [DDTNKA] R clutch fill switch: Disconnection......................................................... 88 Failure code [DDTPKA] 4th clutch fill switch: Disconnection....................................................... 90 Failure code [DF10KA] Gear shift lever: Disconnection .............................................................. 92 Failure code [DF10KB] Gear shift lever: Short circuit.................................................................. 95 Failure code [DGE5KX] or VHMS_LED display: "n4" o "01" Atmospheric temperature sensor: Out of input signal range ...................................................................................................... 100 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range ........... 102 Failure code [DGR2KZ] Retarder oil temperature sensor system trouble : Ground fault (Rear wheel).................................................................................................... 104 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range ................... 106 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range ..... 108 Troubleshooting by failure code, Part 6 SEN01667-06 Failure code [DGT4KA] or VHMS_LED display: "n3" o "12" Exhaust gas temperature sensor (F): Disconnection .................................................................................................... 3 Failure code [DGT4KB] or VHMS_LED display: "n3" o "11" Exhaust gas temperature sensor (F): Short circuit........................................................................................................ 6 Failure code [DGT5KA] or VHMS_LED display: "n3" o "22" Exhaust gas temperature sensor (R): Disconnection.................................................................................................... 9 Failure code [DGT5KB] or VHMS_LED display: "n3" o "21" Exhaust gas temperature sensor (R): Short circuit ....................................................................................................... 12 Failure code [DHE5KB] or VHMS_LED display: "n3" o "32" Blow-by pressure sensor: Short circuit .......................................................................................................................... 15 Failure code [DHE5KY] or VHMS_LED display: "n3" o "31" Blow-by pressure sensor: Short circuit with power supply line ...................................................................................... 18 Failure code [DHP4KY] or VHMS_LED display: "n5" o "44" Short circuit in suspension pressure sensor system (Front right) .................................................................................. 20 Failure code [DHP4KZ] or VHMS_LED display: "n5" o "43" Disconnection or ground fault in suspension pressure sensor system (Front right) ............................................................ 22 Failure code [DHP5KY] or VHMS_LED display: "n5" o "54" Short circuit in suspension pressure sensor system (Front left) .................................................................................... 24 Failure code [DHP5KZ] or VHMS_LED display: "n5" o "53" Disconnection or ground fault in suspension pressure sensor system (Front left)....................................................... 26 Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) ........ 28 Failure code [DHP6KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Right rear)................................................................................... 29



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00 Index and foreword



SEN01083-20



Failure code [DHP6KY] or VHMS_LED display: "n5" o "64" Suspension pressure sensor system: Short circuit (Right rear) ............................................................................. 32 Failure code [DHP6KZ] or VHMS_LED display: "n5" o "63" Suspension pressure sensor system: Disconnection or ground fault (Right rear).................................................. 34 Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)........... 36 Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear) .................................................................................... 38 Failure code [DHP7KY] or VHMS_LED display: "n5" o "74" Suspension pressure sensor system: Short circuit (Left rear) ................................................................................ 40 Failure code [DHP7KZ] or VHMS_LED display: "n5" o "73" Suspension pressure sensor system: Disconnection or ground fault (Left rear) .................................................... 42 Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range........... 44 Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal .............................................................................................. 46 Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range ........ 48 Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range ......... 50 Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................. 52 Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) .................... 54 Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right) .................. 56 Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right) .................. 58 Failure code [DHUTKX] Trouble in ABS cut valve pressure sensor............................................ 60 Failure code [DJF1KA] Fuel level sensor: Disconnection ........................................................... 62 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)......................... 64 Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal .................................................................................................................. 65 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ........... 68 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal... 70 Failure code [DK54KX] Body positioner sensor: Out of input signal range................................. 72 Failure code [DKD0L6] Failure in steering speed sensor............................................................ 74 Failure code [DKH0KX] Clinometer sensor signal out of range .................................................. 76 Failure code [DKH1KX] or VHMS_LED display: "n4"o"33" Abnormality in clinometer sensor .... 78 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection ......................... 80 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal......................................................................................................................... 82 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............. 84 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal .................................................................................................... 86 Troubleshooting by failure code, Part 7 SEN01668-03 Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)................................ 3 Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) ........................................... 4 Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) .................................. 5 Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................. 6 Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear) ................................ 8 Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)............................................ 10 Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear)............................... 12 Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)................................ 13 Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear)................................... 14 Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear) .............................................. 16 Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear) ................................. 18 Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear) .................................. 19 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system......... 20 Failure code [DLT3LC] Trouble in transmission output shaft speed sensor ................................ 22 Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor ..................... 24 Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor..................... 26 Failure code [DV00KB] Short circuit in buzzer output ................................................................. 28 Failure code [DW2AKA] Disconnection in main pressure variable valve output ......................... 30 Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit ................. 32 Failure code [DW2AKY] Hot short in main pressure variable valve output circuit....................... 34 HD465-7E0, HD605-7E0



11



SEN01083-20



00 Index and foreword



Failure code [DW2AL1] Defective reset of main pressure variable valve ................................... 36 Failure code [DW2ALH] Malfunction of main pressure variable valve ........................................ 38 Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit)............................................................................................. 40 Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit)............................................................................................. 42 Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit)............................................................................................. 44 Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit)............................................................................................. 46 Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit)............................................................................................. 48 Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating) ........................ 50 Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit .............................. 52 Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit ................................. 54 Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit .................................. 56 Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate) ..................... 57 Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system ........................................ 58 Failure code [DWNDMA] Defective ABS cut-off valve (Front)..................................................... 60 Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system ......................................... 62 Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ..................................................... 64 Troubleshooting by failure code, Part 8 SEN01669-02 Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid valve (Valve keeps operating)................................................................................ 4 Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid valve output circuit ................................................................................................. 6 Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve ...................................................................................................................... 7 Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid valve output circuit ................................................................................................. 8 Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid valve (Valve does not operate) .............................................................................. 9 Failure code [DX13KA] Disconnection in hoist EPC valve output circuit..................................... 10 Failure code [DX13KB] Short circuit in hoist EPC valve output circuit ........................................ 12 Failure code [DX13KY] Short circuit in hoist EPC valve output circuit ........................................ 14 Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating) ............................................................................................. 16 Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit .............................................................................................................. 18 Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit .............................................................................................................. 20 Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit .............................................................................................................. 22 Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)............................................................................................ 22 Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating) ............................................................................................... 24 Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit................................................................................................................. 26 Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit................................................................................................................. 28 Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit................................................................................................................. 30 Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate) .............................................................................................. 30 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).............. 31 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)................. 32 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...................... 33



12



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01083-20



Failure code [DX21MA] Defective ABS control valve (Front right) .............................................. 34 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) ................ 35 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)................... 36 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) ........................ 37 Failure code [DX22MA] Defective ABS control valve (Front left) ................................................ 38 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) .............. 39 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................. 40 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ...................... 41 Failure code [DX23MA] Defective ABS control valve (Rear right) .............................................. 42 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)................. 43 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ................... 44 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)......................... 45 Failure code [DX24MA] Defective ABS control valve (Rear left)................................................. 46 Failure code [DX25MA] Defective ABS front wheel system control valve................................... 47 Failure code [DX26MA] Defective ABS rear wheel system control valve ................................... 47 Troubleshooting by failure code, Part 9 SEN01670-03 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection............................ 4 Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit .............................. 6 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line ................................................................................................................. 8 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection .................................... 10 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit ....................................... 12 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line....... 14 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection ................................... 18 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit....................................... 20 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line ...... 22 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .................................. 26 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit ...................................... 28 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line ..... 30 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection ................................. 34 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit ..................................... 36 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line .... 38 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection .................................. 42 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit...................................... 44 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line ..... 46 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection..................................... 50 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit ........................................ 52 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line ....... 54 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.................................. 56 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit ..................................... 58 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line .... 60 Failure code [F@BBZL] or VHMS_LED display: "n3"o"38" Blow-by pressure: High error......... 63 Failure code [F@BYNR] or VHMS_LED display: "n3"o"62" Exhaust gas temperature (F): Abnormal heat...................................................................................................................... 64 Failure code [F@BYNS] or VHMS_LED display: "n3"o"61" Exhaust gas temperature (F): Overheat .............................................................................................................................. 66 Failure code [F@BZNR] or VHMS_LED display: "n3"o"72" Exhaust gas temperature (R): Abnormal heat...................................................................................................................... 68 Failure code [F@BZNS] or VHMS_LED display: "n3"o"71" Exhaust gas temperature (R): Overheat .............................................................................................................................. 70 Troubleshooting of electrical system (E-mode) SEN01671-05 Before troubleshooting of electric system ................................................................................... 3 Contents of troubleshooting table................................................................................................ 4 E-1 Engine does not start............................................................................................................ 5 E-2 Automatic preheating does not operate................................................................................ 8



HD465-7E0, HD605-7E0



13



SEN01083-20



00 Index and foreword



E-3 Machine monitor does not display all, when starting switch is turned ON ............................ 12 E-4 Machine monitor does not operate when starting switch is OFF .......................................... 14 E-5 Alarm buzzer does not sound ............................................................................................... 16 E-6 Alarm buzzer does not stop sounding .................................................................................. 18 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly............................................................................................. 20 E-8 A selection of the display in character display section cannot be changed .......................... 21 E-9 Power mode selecting function does not operate properly................................................... 24 E-10 AISS function does not operate properly ............................................................................ 25 E-11 Seat belt caution lamp does not display properly ............................................................... 26 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly................................ 27 E-13 Night illumination (lighting) does not work properly ............................................................ 30 E-14 Emergency steering does not operate................................................................................ 42 E-15 Hoist lever does not operate normally ................................................................................ 56 E-16 Electric priming pump does not operate or does not stop automatically ............................ 58 Troubleshooting of hydraulic and mechanical system (H-mode) SEN01672-01 Contents of troubleshooting table................................................................................................ 3 H-1 Machine does not start ......................................................................................................... 4 H-2 Machine does not travel smoothly (hunting)......................................................................... 6 H-3 Lockup cannot be cancelled ................................................................................................. 6 H-4 Excessive shock when starting or shifting excessive ........................................................... 7 H-5 Transmission does not shift up ............................................................................................. 8 H-6 Machine lacks power or speed when traveling..................................................................... 10 H-7 Time lag is excessive when starting or shifting gear ............................................................ 14 H-8 Torque converter oil temperature is high .............................................................................. 16 H-9 Torque converter oil pressure is low ..................................................................................... 17 H-10 Front brake is ineffective .................................................................................................... 18 H-11 Rear brake is ineffective ..................................................................................................... 19 H-12 Steering wheel is heavy...................................................................................................... 20 H-13 Steering wheel does not work............................................................................................. 21 H-14 Steering wheel vibrates ...................................................................................................... 22 H-15 Dump body lifting speed is slow ......................................................................................... 23 H-16 Dump body does not work.................................................................................................. 24 H-17 Excessive hydraulic drift of dump body .............................................................................. 25 Troubleshooting of engine (S-mode) SEN01673-03 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance of engine is poor................................................................................. 8 S-2 Engine does not start............................................................................................................ 10 S-3 Engine does not pick up smoothly ........................................................................................ 14 S-4 Engine stops during operation .............................................................................................. 15 S-5 Engine does not rotate smoothly .......................................................................................... 16 S-6 Engine lack output (or lacks power)...................................................................................... 17 S-7 Exhaust gas is black (incomplete combustion)..................................................................... 18 S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20 S-9 Oil becomes dirty quickly ...................................................................................................... 21 S-10 Fuel consumption is excessive ........................................................................................... 22 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 23 S-12 Oil pressure drops .............................................................................................................. 24 S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 26 S-14 Coolant temperature becomes too high (Overheating)....................................................... 28 S-15 Abnormal noise is made ..................................................................................................... 29 S-16 Vibration is excessive ......................................................................................................... 30 S-17 Air cannot be bled from fuel circuit ..................................................................................... 32 50 Disassembly and assembly General information on disassembly and assembly SEN02483-05 How to read this manual.............................................................................................................. 2



14



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01083-20



Coating materials list................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketches of special tools............................................................................................................. 11 Engine and cooling system SEN02484-04 Removal and installation of fuel supply pump assembly............................................................. 2 Removal and installation of fuel injector assembly ..................................................................... 5 Removal and installation of cylinder head assembly .................................................................. 9 Removal and installation of engine front seal ............................................................................. 21 Removal and installation of engine rear seal .............................................................................. 24 Removal and installation of engine assembly ............................................................................. 28 Removal and installation of radiator assembly............................................................................ 35 Removal and installation of output shaft assembly ..................................................................... 39 Disassembly and assembly of output shaft assembly................................................................. 40 Removal and installation of brake and power train oil cooler assembly...................................... 43 Power train, Part 1 SEN02485-02 Removal and installation of torque converter and transmission assembly ................................. 2 Separation and coupling of transmission assembly and torque converter assembly.................. 5 Disassembly and assembly of torque converter and control valve assembly ............................. 14 Disassembly and assembly of torque converter assembly ......................................................... 16 Disassembly and assembly of transmission assembly ............................................................... 29 Removal and installation of transmission control valve assembly (ECMV assembly)................. 62 Disassembly and assembly of transmission control valve assembly (ECMV assembly) ............ 63 Power train, Part 2 SEN02486-02 Removal and installation of differential assembly ....................................................................... 2 Disassembly and assembly of differential assembly ................................................................... 4 Removal and installation of final drive carrier assembly ............................................................. 16 Disassembly and assembly of final drive carrier assembly ......................................................... 17 Disassembly and assembly of front wheel hub assembly........................................................... 18 Steering system SEN02487-01 Disassembly and assembly of steering cylinder assembly ......................................................... 2 Brake system SEN02488-02 Removal and installation of front brake caliper pads................................................................... 2 Removal and installation of front brake calipers assembly ......................................................... 3 Disassembly and assembly of front brake calipers assembly ..................................................... 4 Removal and installation of final drive and rear brake assembly ................................................ 6 Removal and installation of final drive, rear brake, and parking brake assembly ....................... 9 Disassembly and assembly of final drive, rear brake, and parking brake assembly ................... 10 Undercarriage and frame SEN02489-03 Removal and installation of front wheel assembly ...................................................................... 2 Removal and installation of rear wheel assembly ....................................................................... 4 Removal and installation of front suspension cylinder assembly ................................................ 6 Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)... 8 Removal and installation of rear suspension cylinder assembly ................................................. 11 Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) ... 12 Hydraulic system SEN02490-01 Disassembly and assembly of hoist cylinder assembly .............................................................. 2 Body SEN02491-02 Removal and installation of body assembly ................................................................................ 2 Cab and its attachments SEN02492-03 Disassembly and assembly of operator's seat assembly............................................................ 2 Removal and installation of air conditioner unit assembly .......................................................... 11 Electrical system SEN02493-01 Removal and installation of engine controller assembly ............................................................. 2 3 Removal and installation of transmission controller assembly .................................................... Removal and installation of retarder controller assembly............................................................ 4



HD465-7E0, HD605-7E0



15



SEN01083-20



00 Index and foreword



90 Diagrams and drawings Hydraulic diagrams and drawings SEN01105-05 Power train hydraulic circuit diagram .......................................................................................... 2 Steering and hoist hydraulic circuit diagram................................................................................ 3 Brake hydraulic circuit diagram ................................................................................................... 9 Brake hydraulic circuit diagram for ASR specification (If equipped)............................................ 11 Brake hydraulic circuit diagram for ABS specification (If equipped), for ABS + ASR specification (If equipped) .................................................................................. 13 Electrical diagrams and drawings SEN01106-10 Electrical circuit diagram inside cab ............................................................................................ 3 Electrical circuit diagram outside cab .......................................................................................... 15 Electrical circuit diagram for VHMS............................................................................................. 21 Electrical circuit diagram for ASR (If equipped)........................................................................... 23 Electrical circuit diagram for ABS (If equipped) .......................................................................... 25 Air conditioner electrical circuit diagram...................................................................................... 29 Electrical circuit diagram for auto greasing (If equipped) ............................................................ 31 Connectors table and arrangement drawing ............................................................................... 33



16



HD465-7E0, HD605-7E0



00 Index and foreword



HD465-7E0, HD605-7E0



SEN01083-20



17



SEN01083-20



00 Index and foreword



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01083-20



© 2018 KOMATSU All Rights Reserved Printed in Japan 08-18 (01)



18



HD465-7E0, HD605-7E0



SEN01084-06



DUMP TRUCK 1SHOP MANUAL



HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



00 Index and foreword



1



Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36



HD465-7E0, HD605-7E0



1



SEN01084-06



00 Index and foreword



Safety notice



(Rev. 2008/08) 1



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



2



General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 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 warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.



7)



8) 9)



If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.



Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5



Prohibition of operation and handling by unlicensed workers



6 Safety check before starting work 7



Wearing protective goggles (for cleaning or grinding work)



8



Wearing shielding goggles and protectors (for welding work)



9 Good physical condition and preparation 10



Precautions against work which you are not used to or you are used to too much



HD465-7E0, HD605-7E0



00 Index and foreword



2.



3.



SEN01084-06



Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock 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. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) 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 m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.



6)



Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.



11)



HD465-7E0, HD605-7E0



7)



8)



9) 10)



12)



13) 14) 15)



16)



When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 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 and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 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. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 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. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.



3



SEN01084-06



4.



4



Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 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. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.



00 Index and foreword



8)



When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.



11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.



HD465-7E0, HD605-7E0



00 Index and foreword



If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.



SEN01084-06



13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.



q



5.



6.



Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.



HD465-7E0, HD605-7E0



7.



Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.



Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4



a



The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).



5



SEN01084-06



8.



Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)



6



00 Index and foreword a



Example of O-ring (Fitted to every joint of hoses and tubes)



a



For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".



Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.



HD465-7E0, HD605-7E0



00 Index and foreword



How to read the shop manual q q q



1.



SEN01084-06



1



Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.



2.



Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.



HD465-7E0, HD605-7E0



7



SEN01084-06



3.



4.



00 Index and foreword



Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q



Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)



q



Revisions Revised brochures are shown in the shop manual composition table.



Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol



Item



k



Safety



a



Caution



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



4



Weight



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



3



Tightening torque



2



Coat



5



Oil, coolant



6



Drain



Remarks Special safety precautions are necessary when performing work.



Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.



5.



Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.



8



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



Explanation of terms for maintenance standard



1



The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.



Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q



Example: Standard size



Tolerance –0.022 –0.126



120 a



The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)



q



Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them



q



Example: Standard size 60



Tolerance Shaft Hole –0.030 +0.046 –0.076 +0



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9



SEN01084-06



2.



Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.



00 Index and foreword



5.



q



3.



Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.



4.



Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.



10



Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q



6.



Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q



HD465-7E0, HD605-7E0



00 Index and foreword



Handling of electric equipment and hydraulic component



SEN01084-06



1



To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, 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. 2.



Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)



Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.



HD465-7E0, HD605-7E0



11



SEN01084-06



12



3)



Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.



4)



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



5)



Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating 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.



00 Index and foreword



HD465-7E0, HD605-7E0



00 Index and foreword



3.



SEN01084-06



Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q



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



q



When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.



3]



Action to take after removing 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.



HD465-7E0, HD605-7E0



13



SEN01084-06



2)



14



00 Index and foreword



Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or 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. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] 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. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.



HD465-7E0, HD605-7E0



00 Index and foreword



3)



Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks



HD465-7E0, HD605-7E0



SEN01084-06



q



Disconnection



q



Connection (Example of incomplete setting of (a))



15



SEN01084-06



4)



16



00 Index and foreword



Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the 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 conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.



HD465-7E0, HD605-7E0



00 Index and foreword



4.



Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.



5.



Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected 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.



HD465-7E0, HD605-7E0



SEN01084-06



17



SEN01084-06



00 Index and foreword



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



Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.



2.



Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.



3.



Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.



4.



Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil 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.



18



HD465-7E0, HD605-7E0



00 Index and foreword



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 ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.



HD465-7E0, HD605-7E0



SEN01084-06



19



SEN01084-06



00 Index and foreword



Handling of connectors newly used for engines a



1.



Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)



2.



1



Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.



q



Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.



20



HD465-7E0, HD605-7E0



00 Index and foreword



3.



SEN01084-06



Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q



q



114 engine



q



107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)



3)



While pressing lock (D), pull out connector (4) in the direction of the arrow.



107 engine



a



2)



If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.



HD465-7E0, HD605-7E0



21



SEN01084-06



q



4)



95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)



00 Index and foreword



4.



Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.



q



1)



Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.



2)



Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.



Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)



Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.



22



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



How to read electric wire code a



1



The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.



In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX



0.85



L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)



1.



Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.



(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile



Symbol AV



AVS



Heat-resistant low-voltAEX age wire for automobile



Material Conductor Insulator Conductor



Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance



Insulator



Soft polyvinyl chloride



Conductor



Annealed copper for electric appliance Heat-resistant crosslinked polyethylene



Insulator



HD465-7E0, HD605-7E0



Using temperature range (°C)



Example of use General wiring (Nominal No. 5 and above)



–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place



23



SEN01084-06



2.



00 Index and foreword



Dimensions



(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6



Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard



8



15



20



30



40



50



60



85



100



50/0.45



84/0.45



41/0.80



70/0.80



85/0.80



7.95



13.36



20.61



35.19



42.73



54.29



63.84



84.96



109.1



3.7 – 5.5 5.3



4.8 – 7.0 7.0



6.0 – 8.2 8.2



8.0 – 10.8 10.8



8.6 – 11.4 11.4



9.8 – 13.0 13.0



10.4 – 13.6 13.6



12.0 – 16.0 16.0



13.6 – 17.6 17.6



108/0.80 127/0.80 169/0.80 217/0.80



“f” of nominal No. denotes flexible”.



24



HD465-7E0, HD605-7E0



00 Index and foreword



3.



SEN01084-06



Color codes table



(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR



Color of wire



Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW



Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red



Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White



Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.



Types of circuits and color codes



(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others



HD465-7E0, HD605-7E0



AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch



AEX



–



R B R D Y G L



–



–



WG



–



–



–



–



–



–



–



–



–



– –



–



–



–



–



–



RB YR GW LW BrW LgR



RY YB GR LR BrR LgY



RG YG GY LY BrY LgB



RL YL GB LB BrB LgW



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



–



YW GL



– –



Gr Br – –



25



SEN01084-06



00 Index and foreword



Precautions when carrying out operation



1



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



a



Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit 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 plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)



26



Sleeve nut (elbow end)



07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234



02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234



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



07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430



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



07049-02734



27



22.5



34



HD465-7E0, HD605-7E0



00 Index and foreword



2. q q q q q q q q q q q q q



a



a 3.



SEN01084-06



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 and fix them with intermediate clamps, if there are any. 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 idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.



HD465-7E0, HD605-7E0



27



SEN01084-06



4)



5)



28



00 Index and foreword



Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



Method of disassembling and connecting push-pull type coupler k k



1



Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.



Type 1 1.



Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.



2.



Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.



HD465-7E0, HD605-7E0



29



SEN01084-06



00 Index and foreword



Type 2 1.



2.



Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)



Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)



q



30



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



Type 3 1.



2.



Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)



Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)



q



HD465-7E0, HD605-7E0



31



SEN01084-06



00 Index and foreword



Standard tightening torque table 1.



1



Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a



The following table applies to the bolts in Fig. A.



Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a



Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630



kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370



The following table applies to the bolts in Fig. B.



Thread diameter of bolt mm 6 8 10 12 a Fig. A



Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60



Width across flats mm 10 12 14 17



Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B



Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)



32



HD465-7E0, HD605-7E0



00 Index and foreword



2.



Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.



Thread diameter of bolt mm 10 12 16



3.



Width across flats mm 14 17 22



Tightening torque Nm 59 – 74 98 – 123 235 – 285



kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5



Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.



Nominal No. 02 03,04 05,06 10,12 14



4.



SEN01084-06



Thread diameter mm 14 20 24 33 42



Width across flats mm



Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}



Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52



Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52



HD465-7E0, HD605-7E0



Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –



Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}



33



SEN01084-06



5.



00 Index and foreword



Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}



Nominal No. of hose



Width across flats



02



19



03 04 05 06 (10) (12) (14)



6.



22 24 27 32 36 41 46 55



Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}



Target



44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}



Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42



Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –



Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).



Outer diameter of pipe (mm)



Width across flats (mm)



8 10 12 15 (16) 22 (20)



19 22 24 (27) 30 (32) 36



Tightening torque Nm {kgm} Range



Target



14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}



15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}



Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2



Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification. 7.



Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts



Thread size mm 6 8 10 12 14



34



Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —



kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —



HD465-7E0, HD605-7E0



00 Index and foreword



8.



Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14



9.



SEN01084-06



Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5



kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51



Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.



Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4



HD465-7E0, HD605-7E0



Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51



35



SEN01084-06



00 Index and foreword



Conversion table



1



Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.



Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a 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 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.



2.



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



Millimeters to inches



(A)



36



(B)



0 10 20 30 40



0 0 0.394 0.787 1.181 1.575



1 0.039 0.433 0.827 1.220 1.614



2 0.079 0.472 0.866 1.260 1.654



3 0.118 0.512 0.906 1.299 1.693



4 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 0.236 0.630 1.024 1.417 1.811



7 0.276 0.669 1.063 1.457 1.850



2.205 2.598 2.992 3.386 3.780



2.244 2.638 3.032 3.425 3.819



1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858



2.323 2.717 3.110 3.504 3.898



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



Millimeters to inches



0 10 20 30 40



0 0 0.394 0.787 1.181 1.575



1 0.039 0.433 0.827 1.220 1.614



2 0.079 0.472 0.866 1.260 1.654



3 0.118 0.512 0.906 1.299 1.693



4 0.157 0.551 0.945 1.339 1.732



5 0.197 0.591 0.984 1.378 1.772



6 0.236 0.630 1.024 1.417 1.811



1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929



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



2.165 2.559 2.953 3.346 3.740



2.205 2.598 2.992 3.386 3.780



2.244 2.638 3.032 3.425 3.819



1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03



2.283 2.677 3.071 3.465 3.858



2.323 2.717 3.110 3.504 3.898



Kilogram to pound



0 10 20 30 40



0 0 22.05 44.09 66.14 88.18



1 2.20 24.25 46.30 68.34 90.39



2 4.41 26.46 48.50 70.55 92.59



3 6.61 28.66 50.71 72.75 94.80



4 8.82 30.86 51.91 74.96 97.00



5 11.02 33.07 55.12 77.16 99.21



50 60 70 80 90



110.23 132.28 154.32 176.37 198.42



112.44 134.48 156.53 178.57 200.62



114.64 136.69 158.73 180.78 202.83



116.85 138.89 160.94 182.98 205.03



119.05 141.10 163.14 185.19 207.24



121.25 143.30 165.35 187.39 209.44



123.46 145.51 167.55 189.60 211.64



125.66 147.71 169.76 191.80 213.85



127.87 149.91 171.96 194.01 216.05



130.07 152.12 174.17 196.21 218.26



Liters to U.S. Gallons



0 10 20 30 40



0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095



3 0.793 3.434 6.076 8.718 11.359



4 1.057 3.698 6.340 8.982 11.624



1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944



50 60 70 80 90



13.209 15.850 18.492 21.134 23.775



14.001 16.643 19.285 21.926 24.568



14.265 16.907 19.549 22.190 24.832



14.529 17.171 19.813 22.455 25.096



13.473 16.115 18.756 21.398 24.040



HD465-7E0, HD605-7E0



13.737 16.379 19.020 21.662 24.304



14.795 17.435 20.077 22.719 25.361



15.058 17.700 20.341 22.983 25.625



15.322 17.964 20.605 23.247 25.889



15.586 18.228 20.870 23.511 26.153



37



SEN01084-06



00 Index and foreword



Liters to U.K. Gallons



0 10 20 30 40



0 0 2.200 4.399 6.599 8.799



1 0.220 2.420 4.619 6.819 9.019



2 0.440 2.640 4.839 7.039 9.239



3 0.660 2.860 5.059 7.259 9.459



4 0.880 3.080 5.279 7.479 9.679



5 1.100 3.300 5.499 7.699 9.899



50 60 70 80 90



10.998 13.198 15.398 17.598 19.797



11.281 13.418 15.618 17.818 20.017



11.438 13.638 15.838 18.037 20.237



11.658 13.858 16.058 18.257 20.457



11.878 14.078 16.278 18.477 20.677



12.098 14.298 16.498 18.697 20.897



1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117



12.528 14.738 16.938 19.137 21.337



12.758 14.958 17.158 19.357 21.557



12.978 15.178 17.378 19.577 21.777



kgm to ft.lb



0 10 20 30 40



0 0 72.3 144.7 217.0 289.3



1 7.2 79.6 151.9 224.2 296.6



2 14.5 86.8 159.1 231.5 303.8



3 21.7 94.0 166.4 238.7 311.0



4 28.9 101.3 173.6 245.9 318.3



5 36.2 108.5 180.8 253.2 325.5



6 43.4 115.7 188.1 260.4 332.7



1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4



50 60 70 80 90



361.7 434.0 506.3 578.6 651.0



368.9 441.2 513.5 585.9 658.2



376.1 448.5 520.8 593.1 665.4



383.4 455.7 528.0 600.3 672.7



390.6 462.9 535.2 607.6 679.9



397.8 470.2 542.5 614.8 687.1



405.1 477.4 549.7 622.0 694.4



412.3 484.6 556.9 629.3 701.6



419.5 491.8 564.2 636.5 708.8



426.8 499.1 571.4 643.7 716.1



100 110 120 130 140



723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7



150 160 170 180 190



1084.9 1157.3 1129.6 1301.9 1374.3



38



1092.2 1164.5 1236.8 1309.2 1381.5



1099.4 1171.7 1244.1 1316.4 1388.7



1106.6 1179.0 1251.3 1323.6 1396.0



1113.9 1186.2 1258.5 1330.9 1403.2



1121.1 1193.4 1265.8 1338.1 1410.4



1128.3 1200.7 1273.0 1345.3 1417.7



1135.6 1207.9 1280.1 1352.6 1424.9



1142.8 1215.1 1287.5 1359.8 1432.1



1150.0 1222.4 1294.7 1367.0 1439.4



HD465-7E0, HD605-7E0



00 Index and foreword



SEN01084-06



kg/cm2 to lb/in2



0 10 20 30 40



0 0 142.2 284.5 426.7 568.9



1 14.2 156.5 298.7 440.9 583.2



2 28.4 170.7 312.9 455.1 597.4



3 42.7 184.9 327.1 469.4 611.6



4 56.9 199.1 341.4 483.6 625.8



5 71.1 213.4 355.6 497.8 640.1



6 85.3 227.6 369.8 512.0 654.3



1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9



50 60 70 80 90



711.2 853.4 995.6 1,138 1,280



725.4 867.6 1,010 1,152 1,294



739.6 881.8 1,024 1,166 1,309



753.8 896.1 1,038 1,181 1,323



768.1 910.3 1,053 1,195 1,337



782.3 924.5 1,067 1,209 1,351



796.5 938.7 1,081 1,223 1,365



810.7 953.0 1,095 1,237 1,380



825.0 967.2 1,109 1,252 1,394



839.2 981.4 1,124 1,266 1,408



100 110 120 130 140



1,422 1,565 1,707 1,849 1,991



1,437 1,579 1,721 1,863 2,005



1,451 1,593 1,735 1,877 2,020



1,465 1,607 1,749 1,892 2,034



1,479 1,621 1,764 1,906 2,048



1,493 1,636 1,778 1,920 2,062



1,508 1,650 1,792 1,934 2,077



1,522 1,664 1,806 1,949 2,091



1,536 1,678 1,821 1,963 2,105



1,550 1,693 1,835 1,977 2,119



150 160 170 180 190



2,134 2,276 2,418 2,560 2,702



2,148 2,290 2,432 2,574 2,717



2,162 2,304 2,446 2,589 2,731



2,176 2,318 2,460 2,603 2,745



2,190 2,333 2,475 2,617 2,759



2,205 2,347 2,489 2,631 2,773



2,219 2,361 2,503 2,646 2,788



2,233 2,375 2,518 2,660 2,802



2,247 2,389 2,532 2,674 2,816



2,262 2,404 2,546 2,688 2,830



200 210 220 230 240



2,845 2,987 3,129 3,271 3,414



2,859 3,001 3,143 3,286 3,428



2,873 3,015 3,158 3,300 3,442



2,887 3,030 3,172 3,314 3,456



2,901 3,044 3,186 3,328 3,470



2,916 3,058 3,200 3,343 3,485



2,930 3,072 3,214 3,357 3,499



2,944 3,086 3,229 3,371 3,513



2,958 3,101 3,243 3,385 3,527



2,973 3,115 3,257 3,399 3,542



HD465-7E0, HD605-7E0



39



SEN01084-06



00 Index and foreword



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 (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.



°C



°F



°C



°F



°C



°F



°C



1°C = 33.8°F °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



177.8 179.6 181.4 183.2 185.0



–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 60



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



40



HD465-7E0, HD605-7E0



00 Index and foreword



HD465-7E0, HD605-7E0



SEN01084-06



41



SEN01084-06



00 Index and foreword



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01084-06



© 2008 KOMATSU All Rights Reserved Printed in Japan 11-08 (02)



42



HD465-7E0, HD605-7E0



SEN01086-04



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



01 Specification



1



Specification and technical data Specification drawing ...................................................................................................................................... 2 Specifications .................................................................................................................................................. 4 Weight table .................................................................................................................................................. 12 Fuel, coolant and lubricants .......................................................................................................................... 13



HD465-7E0, HD605-7E0



1



SEN01086-04



Specification drawing



01 Specification



1



HD465-7E0



HD605-7E0



2



HD465-7E0, HD605-7E0



01 Specification



q



SEN01086-04



For EU (Stairway specifications)



HD465-7E0



HD605-7E0



HD465-7E0, HD605-7E0



3



SEN01086-04



01 Specification



1 Machine model



HD465-7E0



Serial No.



10001 – 10037, 10101 and up



Empty



kg



43,180



Max. load



kg



55,000



Gross



kg



98,180



(front)



kg



20,295 (47%)



(rear)



kg



22,885 (53%)



(front)



kg



31,420 (32%)



(rear)



kg



66,760 (68%)



Empty



Weight distribution



Weight



Specifications



Gross 3



Struck



m



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



604



Dimensions



Performance



Dump body capacity



Tread Ground clearance Model



KOMATSU SAA6D170E-5



Type



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



No. of cylinders – Bore x stroke Piston displacement



mm



6 – 170 x 170



{cc}



23.15 {23,150}



Engine



Rated horsepower SAE J1995 (gross)



-1



551{739} / 2,000{2,000}



ISO 14396



kW{HP}/min {rpm}



551{739} / 2,000{2,000}



ISO 9249/SAE J1349 (net)



kW{HP}/min-1{rpm}



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



Nm/rpm{kgm/rpm}



3,324/1,400 {339/1,400}



g/kWh {g/HPh}



200 {149}



Max. torque Fuel consumption (Min.) Stating motor Alternator Battery



4



kW{HP}/min-1{rpm}



24V, 7.5 kW x 2 units 24V, 90A 12V, 200Ah x 2 units



HD465-7E0, HD605-7E0



SEN01086-04



Machine model



HD465-7E0 For EU (Stairway specifications)



Serial No.



10101 and up



Empty



kg



43,460



Max. load



kg



54,640



Gross



kg



98,180



(front)



kg



20,560 (47%)



(rear)



kg



22,900 (53%)



(front)



kg



31,420 (32%)



(rear)



kg



66,760 (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



10,120



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



604



Empty



Weight distribution



Weight



01 Specification



Gross



Dimensions



Performance



Dump body capacity



Tread Ground clearance Model



KOMATSU SAA6D170E-5



Type



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



No. of cylinders – Bore x stroke Piston displacement



mm {cc}



6 – 170 x 170 23.15 {23,150}



Engine



Rated horsepower SAE J1995 (gross)



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 14396



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 9249/SAE J1349 (net)



kW{HP}/min-1{rpm}



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



Nm/rpm{kgm/rpm}



3,324/1,400 {339/1,400}



g/kWh {g/HPh}



200 {149}



Max. torque Fuel consumption (Min.) Stating motor Alternator Battery



HD465-7E0, HD605-7E0



24V, 7.5 kW x 2 units 24V, 90A 12V, 200Ah x 2 units



5



SEN01086-04



01 Specification



Machine model



HD465-7E0



Serial No.



10001 – 10037, 10101 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 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



Breke system



Front wheel



kPa {kg/cm2}



470 {4.75} Single dry disc type, Hydraulically controlled



Service brake Rear axle Parking brake Retarder



6



4.737



Oil cooled multiple disc brake, Hydraulically controlled Multiple disc wet type disc brake, Hydraulically released spring type Oil cooled multiple disc type, Hydraulically controlled



HD465-7E0, HD605-7E0



01 Specification



SEN01086-04



Machine model



HD465-7E0



Serial No.



10001 – 10037, 10101 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



HD465-7E0, HD605-7E0



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



7



01 Specification



Machine model



HD605-7E0



Serial No.



8001 – 8032, 10101 and up



Empty



kg



46,280



Max. load



kg



63,000



Gross



kg



109,280



(front)



kg



21,750 (47%)



(rear)



kg



24,530 (53%)



(front)



kg



34,970 (32%)



(rear)



kg



74,310 (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



604



Empty



Weight distribution



Weight



SEN01086-04



Gross



Dimensions



Performance



Dump body capacity



Tread Ground clearance Model



KOMATSU SAA6D170E-5



Type



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



No. of cylinders – Bore x stroke Piston displacement



mm {cc}



6 – 170 x 170 23.15 {23,150}



Engine



Rated horsepower SAE J1995 (gross)



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 14396



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 9249/SAE J1349 (net)



kW{HP}/min-1{rpm}



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



Nm/rpm{kgm/rpm}



3,324/1,400 {339/1,400}



g/kWh {g/HPh}



200 {149}



Max. torque Fuel consumption (Min.) Stating motor Alternator Battery



8



24V, 7.5 kW x 2 units 24V, 90A 12V, 200Ah x 2 units



HD465-7E0, HD605-7E0



SEN01086-04



Machine model



HD605-7E0 For EU (Stairway specifications)



Serial No.



10101 and up



Empty



kg



46,560



Max. load



kg



62,715



Gross



kg



109,280



(front)



kg



22,020 (47%)



(rear)



kg



24,540 (53%)



(front)



kg



34,970 (32%)



(rear)



kg



74,310 (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



10,120



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



604



Empty



Weight distribution



Weight



01 Specification



Gross



Dimensions



Performance



Dump body capacity



Tread Ground clearance Model



KOMATSU SAA6D170E-5



Type



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



No. of cylinders – Bore x stroke Piston displacement



mm {cc}



6 – 170 x 170 23.15 {23,150}



Engine



Rated horsepower SAE J1995 (gross)



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 14396



kW{HP}/min-1{rpm}



551{739} / 2,000{2,000}



ISO 9249/SAE J1349 (net)



kW{HP}/min-1{rpm}



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



Nm/rpm{kgm/rpm}



3,324/1,400 {339/1,400}



g/kWh {g/HPh}



200 {149}



Max. torque Fuel consumption (Min.) Stating motor Alternator Battery



HD465-7E0, HD605-7E0



24V, 7.5 kW x 2 units 24V, 90A 12V, 200Ah x 2 units



9



SEN01086-04



01 Specification



Machine model



HD605-7E0



Serial No.



8001 – 8032, 10101 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



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



Suspension method



Size and No. Front and rear tire Front wheel



Breke system



24.00 R35 aa x 4



Rear tire Tire pressure



2



kPa {kg/cm }



686 {7.0} Single dry disc type, Hydraulically controlled



Service brake Rear axle Parking brake Retarder



10



4.737



Oil cooled multiple disc brake, Hydraulically controlled Multiple disc wet type disc brake, Hydraulically released spring type Oil cooled multiple disc type, Hydraulically controlled



HD465-7E0, HD605-7E0



01 Specification



SEN01086-04



Machine model



HD605-7E0



Serial No.



8001 – 8032, 10101 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



HD465-7E0, HD605-7E0



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



11



SEN01086-04



01 Specification



Weight table



1



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



HD465-7E0



HD605-7E0



Serial Number



10001 – 10037, 10101 and up



8001 – 8032, 10101 and up



3,120



3,120



Output shaft assembly



123



123



Radiator assembly



405



405



Fuel tank



294



294



Torque converter assembly



412



412



1,264



1,264



Drive shaft assembly (front)



26



26



Drive shaft assembly (rear)



62



62



6,293



6,293



774



774



• Final drive (one-side)



1,421



1,421



• Rear brake (one-side)



721



721



Front axle (one-side)



330



330



Front brake (one-side)



142



142



Front suspension cylinder



460



460



Rear suspension cylinder



176



176



Frame



4,680



4,680



Cab (Platform)



1,104



1,104



Operator's seat



63



63



Steering cylinder



44



44



Hoist cylinder



206



206



Demand valve



26



26



Steering valve



20



20



Hoist valve



34



34



Hydraulic pump (SDR(30)–100+100)



40



40



Hydraulic pump (SDR(30)–80+80(1)6)



38



38



Hydraulic pump (SDR(30)100+(1)25)



26



26



10,730



13,418



Engine assembly



Transmission assembly



Rear axle assembly



• Differential



Dump body



1



12



HD465-7E0, HD605-7E0



01 Specification



SEN01086-04



Fuel, coolant and lubricants a



1



Regarding the details of notes (note 1, note 2, …), refer to "Operation and Maintenance Manual".



HD465-7E0, HD605-7E0



13



SEN01086-04



01 Specification



Engine Oil Pan



Transmission Case



Steering, Hoist Oil Tank



Front Suspension



Rear Suspension



Differential Case



Specified capacity ( )



76



318



180



16.5 each for right and left



11.3 each for right and left



95



Refill capacity ( )



70



215



122



—



—



95



Final drive case



Fuel tank



Cooling system



Specified oil level ( )



32 each for right and left



780



157



Refill capacity ( )



21 each for right and left



—



—



Fuel and oil Select fuel and oil according to the above table. Coolant Since Komatsu genuine Supercoolant (AF-NAC) 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 engine oil of SAE10W, SAE 10W-30 or SAE15W-40, even through the atmospheric temperature goes up to 10°C or above during the day.



14



HD465-7E0, HD605-7E0



01 Specification



HD465-7E0, HD605-7E0



SEN01086-04



15



SEN01086-04



01 Specification



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01086-04



© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)



16



HD465-7E0, HD605-7E0



SEN01088-02



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Engine and cooling system Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler .............................. 2 Fuel system..................................................................................................................................................... 4 Brake oil cooler ............................................................................................................................................... 5 Output shaft .................................................................................................................................................... 6



HD465-7E0, HD605-7E0



1



SEN01088-02



10 Structure, function and maintenance standard



Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler 1



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



Pick-up for radiator coolant level sensor Upper tank Lower tank Core Work equipment oil cooler After cooler Aircon conditioner



A: B:



Coolant inlet port Coolant outlet port



2



Specifications Radiator AL. Louver 4 Lines Total radiation surface: 142.86 m2 Work equipment oil cooler Core type: CF40-1 Radiation surface: 2.90 m2 After cooler Heat radiation area: 52.13 m2



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01088-02



3



SEN01088-02



Fuel system



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



4



10 Structure, function and maintenance standard



1



Fuel main filter Fuel pre-filter (with water separator) Over flow Nozzle spill Feed pump Fuel tank



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Brake oil cooler



1.



Cooler element



A: B: C: D:



Oil inlet Oil outlet Coolant inlet Coolant outlet



HD465-7E0, HD605-7E0



SEN01088-02



1



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



5



SEN01088-02



Output shaft



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



6



Rubber cushion Outer body Flange Shaft Coupling Inner body Cover



10 Structure, function and maintenance standard



1



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01088-02



Unit: mm No.



1



Check item Clearance between flywheel and bearing



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



Clearance limit



100



–0.015 –0.015



–0.010 –0.045



–0.045 – 0.005



0.02



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



Backlash at spline



Standard size



Repair limit



110



–0.1 –0.1



Standard backlash



Backlash limit



0.080 – 0.231



0.4



Original dimension: Lo 7



Defomation of rubber cushion



90



HD465-7E0, HD605-7E0



Repair or replace



Standard backlash (Dimension at smallest width: L) Replace 81



75 External



Replace



67 No cracks



7



SEN01088-02



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01088-02



© 2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)



8



HD465-7E0, HD605-7E0



SEN01089-04



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Power train, Part 1 Power train skeleton ....................................................................................................................................... 2 Drive shaft ....................................................................................................................................................... 4 Torque converter and transmission hydraulic piping....................................................................................... 6 Brake cooling oil control valve (BCV).............................................................................................................. 8 Torque converter ........................................................................................................................................... 10 Torque converter valve.................................................................................................................................. 17 Transmission................................................................................................................................................. 19 Transmission control valve............................................................................................................................ 35 ECMV............................................................................................................................................................ 36



HD465-7E0, HD605-7E0



1



SEN01089-04



Power train skeleton



2



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



1. 2. 3. 4. 5.



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



SEN01089-04



Engine Output shaft Front drive shaft Brake cooling pump (SDR(30)100+100) Torque converter transmission charge pump and brake cooling brake control pump (SDR(30)100+SA(1)25) PTO Torque converter Transmission Rear drive shaft Differential gear Drive shaft Brake Tire Final drive Parking brake Steering, hoist and hoist control pump (SDR(30)80+80+SB(1)6)



HD465-7E0, HD605-7E0



3



SEN01089-04



Drive shaft



1. 2.



4



Front drive shaft Rear drive shaft



10 Structure, function and maintenance standard



1



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01089-04



5



SEN01089-04



10 Structure, function and maintenance standard



Torque converter and transmission hydraulic piping



6



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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



SEN01089-04



Torque converter Transmission Oil filler tube Hydraulic pump (SDR(30)100+25) Torque converter valve Transmission oil filter Brake cooling oil control valve (BCV)



HD465-7E0, HD605-7E0



7



SEN01089-04



10 Structure, function and maintenance standard



Brake cooling oil control valve (BCV)



1. 2. 3. 4.



Pilot relief valve assembly Body Solenoid valve Main valve spool



A: B: S: P: Q: R:



Pilot port Pilot port To tank Pilot port From pump To tank



8



1



Function When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the power loss when traveling. The main valve spool is actuated by switching the solenoid vavle ON/OFF. If any abnormal pressure is generated in the hydraulic circuit, which caused by abnormal in the rear retarder or in the oil cooler etc., the pilot relief valve is actusted, and this actuates the main relief valve, so the brake cooling valve also acts as an unload valve.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01089-04



9



SEN01089-04



Torque converter



A: B: C: D: E: F: G: H:



Main oil pressure pickup port Torque converter oil inlet port Torque converter inlet oil pressure pickup port Torque converter oil outlet port To the transmission control valve To the lockup clutch Torque converter outlet oil pressure pickup port To the transmission lubrication circuit



1. 2. 3.



PTO gear (number of teeth: 91) Brake cooling pump mounting port Steering, hoist, hoist control pump mounting port Torque converter, transmission charge, brake cooling, transmission lubrication, brake control pump mounting port Torque converter valve Torque converter intermediate oil pressure sensor Torque converter outlet oil temperature sensor



4.



5. 6. 7.



10



10 Structure, function and maintenance standard



1



Specifications Type : 3-element, 1-stage, 2-phase with modulation and lockup clutch Lockup clutch : Wet type multiple disc clutch hydraulic control (with modulation valve) Stall torque ratio: 2.25



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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



Coupling Input shaft (number of teeth: 108) Case Drive case Boss Turbine Outer race Pump Retainer



HD465-7E0, HD605-7E0



SEN01089-04



10. 11. 12. 13. 14. 15. 16. 17. 18.



Stator shaft Sleeve Inner race Free wheel Stator Lockup clutch disc Lockup clutch piston Lockup clutch housing Retainer



11



SEN01089-04



12



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Unit: mm No.



Check item



1



Outer diameter of oil seal contact surface of the coupling



2



Inner diameter of the seal ring contact surface of the input shaft



3



Clearance between clutch housing and piston (outside)



Criteria



Remedy



Standard size



Tolerance



Repair limit



110



–0.087 –0.087



109.8



35



+0.025 +0.025



35.1



Standard size



Tolerance Shaft



Hole



Standard clearance



Clearance limit



420



–0.5 –0.7



+0.097 +0.097



0.500 – 0.797



0.88



295



–0.110 –0.191



+0.081 +0.081



0.110 – 0.272



0.30



4



Clearance between clutch housing and piston (inside)



5



Inner diameter of the seal ring contact surface of the retainer



135



+0.040 +0.040



135.5



6



Inner diameter of the seal ring contact surface of the sleeve



75



+0.030 +0.040



75.1



7



Wear of the stator shaft seal ring



Width



3.95



–0.1 –0.1



3.55



Thickness



5.1



±0.1



4.59



8



Inner diameter of outer race free wheel transmission surface



127.844



±0.009



127.874



9



Outer diameter of inner race free wheel transmission surface



108.883



±0.013



108.853



10



Inner diameter of sliding portion of bushing (*1)



109



+0.012 –0.010



109.04



11



Thickness of sliding portion of bushing (*1)



5



–0.1 –0.1



4.5



5.4



±0.1



4.8



12 Thickness of the clutch disc Backlash between input shaft 13 and PTO gear



14



15



Clearance between PTO gear and bearing Clearance between bearing and case



Replace



0.17 – 0.45 Standard size



Tolerance Shaft



Hole



Standard clearance



Clearance limit



50



+0.018 +0.002



–0.015 –0.012



–0.030 – –0.002



—



90



–0.015 –0.015



+0.004 –0.018



–0.018 – 0.019



—



*1. Refer to “Method of measuring dimension of bushing sliding portion“



HD465-7E0, HD605-7E0



13



SEN01089-04



10 Structure, function and maintenance standard



Method of measuring dimension of bushing sliding portion Measure inner diameter (A) and thickness (B) of bushing sliding portion with output side bushing (2) and input side bushing (3) installed to outer race (1).



14



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Power transmitting route When lockup clutch is "disengaged"



q



As drive case (4) and turbine (6) are disconnected from each other by lockup clutch (9), the torque converter works as an ordinary torque converter. Power generated by engine O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Oil is used as medium O Turbine (6) and boss (7) O Transmission input shaft (8)



HD465-7E0, HD605-7E0



When lockup clutch is "engaged"



q



Drive case (4) is connected to turbine (6) by lockup clutch (9) to perform the lockup function. Power generated by engine O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Lockup clutch (9) O Boss (7) O Transmission input shaft (8)



15



SEN01089-04



10 Structure, function and maintenance standard



Oil flow



q



q



q



16



The oil flows through the main relief valve and its pressure is reduced to below the set pressure by the torque converter relief valve. It then flows into inlet port (A), goes through the oil passages of stator shaft (1), and flows into pump (2). The oil is given centrifugal force by pump (2) and flows into turbine (3) to transmit its energy to turbine (3). The oil from turbine (3) is sent to stator (4) and flows into pump (2) again. However, part of the oil passes between turbine (3) and stator (4) and is sent from outlet port (B) to the oil cooler to be cooled. It is then used to lubricate the transmission.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Torque converter valve



1



Unit: mm No.



Check item



1



Clearance between the torque converter relief valve and the valve body



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



Clearance limit



32



–0.035 –0.045



+0.016 +0.016



0.035 – 0.061



0.081



2



Clearance between the main relief valve and the valve body



32



–0.035 –0.045



+0.016 +0.016



0.035 – 0.061



0.081



3



Clearance between the main pressure variable valve and the valve body



14



–0.030 –0.040



+0.011 +0.016



0.030 – 0.051



0.071



Standard size 4



Main relief valve spring



Installation Free length length



Repair limit



123



99.5



1213.2 N {123.8 kg}



119.3



1153.8 N {117.6 kg}



5



Torque converter relief valve spring



137



93.5



331.2 N {33.8 kg}



132.9



315.0 N {32.1 kg}



6



Poppet spring (T/C relief and main relief)



26



17.0



32.0 N {3.3 kg}



25.2



30.8 N {3.1 kg}



7



Main pressure variable valve spring



40.5



33.0



108.0 N {11.0 kg}



39.3



102.4 N {10.5 kg}



HD465-7E0, HD605-7E0



Replace



Installation Installation Free length load load



17



SEN01089-04



10 Structure, function and maintenance standard



Main relief valve Outline This valve has a main relief pressure changing function. It lowers the main relief pressure in the high gear speeds (F4 – F7) where the clutch holding pressure is low to reduce the pump load, thus the fuel consumption is reduced. Principle of operation When solenoid is "deenergized"



q



q



While no current is supplied to solenoid (1), chambers (A) and (B) are connected and the oil pressure decreases. If the oil pressure in chambers (A) and (B) is low, the hydraulic force in chamber (C) of main relief valve (4) is balanced with the force of spring (5), thus the oil pressure is regulated.



When solenoid is "energized"



q



q



q



18



If a current is supplied to solenoid (1), the oil pressure in chamber (A) increases and valve (2) is pushed to the left. As a result, the drain circuit of chamber (B) is blocked and the oil pressure in chamber (B) increases. If the oil pressure in chamber (B) increases, the hydraulic force in chamber (B) of main relief valve (4) is balanced with the force of spring (5), thus the oil pressure is regulated. Since the diameter of piston (3) is larger than that of chamber (C), the oil pressure is regulated lower when solenoid (1) is "energized" than when solenoid (1) is "deenergized".



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Transmission



A: B: C: D: E: F: G: H: J: K: L: M: N: P:



Speed sensor (for input shaft speed) Speed sensor (for intermediate shaft speed) Speed sensor (for output shaft speed) Lubricating oil temperature sensor Lubricating oil pressure pickup port To pump (suction) To lockup From torque converter (main circuit) From torque converter (lubrication circuit) From oil cooler From torque converter (drain circuit) Retarder relief valve Lubricating oil relief valve To breather



HD465-7E0, HD605-7E0



1



1. 2. 3. 4. 5.



Transmission input shaft Transmission control valve Transmission output shaft Strainer Drain valve



19



SEN01089-04



20



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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 H sun gear (number of teeth: 34) H ring gear (hub) H clutch H planetary pinion (number of teeth: 32) H Carrier L ring gear (hub) L clutch H ring gear (number of teeth: 98) L clutch housing 4th clutch housing 4th clutch drum 4th clutch 4th ring gear (hub) 3rd planetary pinion (number of teeth: 21) 3rd clutch 3rd ring gear (number of teeth: 93) 3rd sun gear (number of teeth: 51) R clutch R planetary pinion (number of teeth: 21) R sun gear (number of teeth: 41) R ring gear (number of teeth: 93) 2nd clutch 2nd ring gear (number of teeth: 105) 2nd planetary pinion (number of teeth: 30) 2nd sun gear (number of teeth: 45) 2nd and 1st carrier 1st clutch 1st ring gear (number of teeth: 104) Transmission output shaft 1st planetary pinion (number of teeth: 38) 1st clutch piston 2nd clutch piston Intermediate shaft (1st sun gear number of teeth: 28) R clutch piston R planetary pinion (number of teeth: 21) 3rd and R carrier 4th clutch piston L clutch piston H clutch piston 3rd clutch piston



HD465-7E0, HD605-7E0



SEN01089-04



Outline q The transmission consists of planetary gear systems and disc clutches and has “7 forward gear speeds and 1 reverse gear speeds“. q Among the 7 sets of planetary gear system and disc clutches of the transmission, 2 clutches are fixed hydraulically with the ECMV to select 1 rotating direction and gear speed. q The transmission transmits the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-7th or reverse 1st) by any combination of the H, L, R clutches and 4 speed clutches. Number of plates and disc used Clutch No.



Number of plates



Number of discs



H clutch



2



3



L clutch



4



5



4th clutch



3



4



3rd clutch



3



4



R clutch



5



5



2nd clutch



4



4



1st clutch



4



4



Combinations of clutches at respective gear speeds and reduction ratio Gear speed Forward 1st speed Forward 2nd speed Forward 3rd speed Forward 4th speed Forward 5th speed Forward 6th speed Forward 7th speed Reverse 1st speed



Operated clutches



Reduction ratio



L x 1st



4.714



L x 2nd



3.333



H x 2nd



2.475



L x 3rd



1.825



H x 3rd



1.355



L x 4th



1.000



H x 4th



0.742



LxR



3.969



21



SEN01089-04



22



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Unit: mm No.



Check item



Criteria Standard size



1



H clutch spring



Remedy Repair limit



Free length



Installation length



Installation Installation Free length load load



40.4



32.0



70.6 N {7.2 kg}



38.0



60.0 N {6.1 kg}



2



3rd clutch spring



52.0



49.1



48.9 N {5.0 kg}



48.9



41.6 N {4.2 kg}



3



R clutch spring



87.5



79.5



113.5 N {11.6 kg}



82.3



96.6 N {9.9 kg}



4



2nd clutch spring



68.0



57.85



113.8 N {11.6 kg}



63.9



97.1 N {9.9 kg}



5



1st clutch spring



75.0



64.4



157.8 N {16.1 kg}



70.5



134.1 N {13.7 kg}



6



Total thickness of 3 discs and 2 plates for H clutch



7



Total thickness of 5 discs and 4 plates for L clutch



8



Standard size



Tolerance



Repair limit



27.8



±0.22



25.8



45.0



±0.30



42.0



Total thickness of 4 discs and 3 plates for 4th clutch



35.0



±0.26



32.3



9



Total thickness of 4 discs and 3 plates for 3rd clutch



36.6



±0.26



33.9



10



Total thickness of 5 discs and 5 plates for R clutch



52.0



±0.32



47.7



11



Total thickness of 4 discs and 4 plates for 2nd clutch



44.8



±0.28



42.1



12



Total thickness of 4 discs and 4 plates for 1st clutch



44.8



±0.28



42.1



H,3rd,R, 2nd,1st



5.4



±0.10



4.8



L,4th



5.0



±0.10



4.4



H,2nd,1st



5.8



±0.10



5.6



L,4th, 3rd,R



5.0



±0.10



4.8



Wear of the transWidth 15 mission input shaft seal ring (small) Thickness



2.56



–0.01 –0.03



2.30



1.7



±0.10



1.55



Wear of the transWidth 16 mission input shaft seal ring (large) Thickness



3.0



–0.01 –0.03



2.70



3.1



±0.10



2.95



13 Thickness of a disc



14



Thickness of a plate



HD465-7E0, HD605-7E0



Replace



23



SEN01089-04



10 Structure, function and maintenance standard



Unit: mm No.



Check item



Criteria



Remedy



Standard size



Tolerance



Repair limit



Width



3.95



–0.01 –0.01



3.56



Thickness



4.95



±0.1



4.8



Width



4.0



–0.01 –0.03



3.6



Thickness



4.6



±0.12



4.45



Width



4.0



–0.01 –0.03



3.6



Thickness



5.1



±0.12



4.95



Width



4.0



–0.01 –0.04



3.6



Thickness



6.3



±0.15



6.15



Wear of the 2nd Width 21 and 1st carrier seal ring Thickness



4.0



–0.01 –0.04



3.6



4.0



±0.15



3.85



3.95



–0.1 –0.1



3.56



5.25



±0.1



5.1



4.0



–0.01 –0.04



3.6



4.0



±0.15



3.85



Wear of the H car17 rier and 4th ring gear seal ring



18



Wear of the 3rd sun gear seal ring



Wear of the L and 19 4th clutch collar seal ring Wear of the 3rd 20 and R carrier seal ring



Wear of the 2nd Width 22 and 1st carrier seal ring Thickness Wear of the 2nd Width 23 and 1st carrier seal ring Thickness 24



Backlash between H sun gear and planetary pinion



0.13 – 0.36



25



Backlash between H planetary pinion and ring gear



0.16 – 0.41



26



Backlash between 3rd sun gear and planetary pinion



0.14 – 0.36



27



Backlash between 3rd planetary pinion and ring gear



0.15 – 0.39



28



Backlash between R sun gear and planetary pinion



0.14 – 0.36



29



Backlash between R planetary pinion and planetary pinion



0.13 – 0.34



30



Backlash between R planetary pinion and ring gear



0.15 – 0.39



31



Backlash between 2nd sun gear and planetary pinion



0.16 – 0.41



32



Backlash between 2nd planetary pinion and ring gear



0.16 – 0.41



33



Backlash between 1st sun gear and planetary pinion



0.13 – 0.36



34



Backlash between 1st planetary pinion and ring gear



0.17 – 0.44



24



Replace



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Unit: mm No.



Check item



Criteria



Deterioration of disc internal 35 teeth 36



Thickness of thrust washer (H, 3rd and R planetary pinion)



37



Thickness of thrust washer (2nd, 1st planetary pinion)



38



Side clearance of planetary pinion



Remedy



Repair limit: 0.3 Standard size



Tolerance



Repair limit



2



±0.1



1.6



3



±0.1



2.4



Location



Standard clearance



Clearance limit



H gear train



0.30 – 0.80



1.5



3rd gear train



0.30 – 0.80



1.5



R gear train



0.30 – 0.80



1.5



2nd gear train



0.30 – 0.80



1.5



1st gear train



0.30 – 0.80



1.5



Replacement of thrust washer or carrier



39



Stepped-type wear of seal ring mating surface



Standard size



Amount of wear



—



Max 0.05



40



Contact surface of output shaft oil seal



Standard size



Amount of wear



120



119.8



41



Clutch No.



Standard size



H (outside)



Tolerance Shaft



Hole



Standard clearance



Clearance limit



430



–0.5 –0.7



+0.097 +0.097



0.5 – 0.797



0.88



H (inside)



405



–0.135 –0.232



+0.097 +0.097



0.135 – 0.329



0.36



L and 4th (outside)



275



–0.5 –0.7



+0.081 +0.097



0.5 – 0.781



0.86



L and 4th (Middle)



255



–0.110 –0.191



+0.081 +0.097



0.110 – 0.272



0.30



Clearance between L and 4th cylinder and piston (inside)



175



–0.5 –0.7



+0.063 +0.097



0.5 – 0.763



0.84



3rd, R, 2nd and 1st (outside)



430



–0.5 –0.7



+0.063 +0.097



0.5 – 0.763



0.87



3rd (inside)



395



–0.125 –0.214



+0.089 +0.097



0.125 – 0.303



0.33



R and 1st (inside)



380



–0.125 –0.214



+0.089 +0.097



0.125 – 0.303



0.33



2nd (inside)



375



–0.125 –0.214



+0.089 +0.097



0.125 – 0.303



0.33



HD465-7E0, HD605-7E0



Replace



Replace



In case there is damage on the surface such as streaks by seizure, but the clearance can be maintained within the specified limit after the repair, the parts can be reused. Replace if damaged severely.



25



SEN01089-04



10 Structure, function and maintenance standard



Disc clutch Structure



q



q q



Disc clutch is used for fixing ring gear (1). It consists of piston (2), plate (3), disc (4), pin (5), return spring (6) and washer (8). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) is assembled to clutch housing (7) with pin (5).



Operation When clutch is "engaged" (fixed)



q



q



q



The oil from ECMV is sent with pressure to the rear side of piston (2) through oil the passage of housing (7) and pushes piston (2) leftward. Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), move of ring gear (1) is stopped.



When clutch is "disengaged" (released)



q q q



26



As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). The friction force between plates (3) and discs (4) is released and ring gear (1) is released. Washer spring (8) is installed between plate (3) of the pin block and plate (3). This spring quickens return of piston (2) as the clutch is disengaged by providing smooth separation of plate (3) and disc (4). At the same time, it is used for preventing the dragging.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Power transmitting route Forward 1st speed



L clutch (5) and 1st clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O L ring gear (3) O L clutch (5) O H ring gear (6) O L clutch housing (7)



HD465-7E0, HD605-7E0



O Intermediate shaft (8) O 1st planetary pinion (22) O 1st, 2nd carrier (23) O Output shaft (24)



27



SEN01089-04



10 Structure, function and maintenance standard



Forward 2nd speed



L clutch (5) and 2nd clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O L ring gear (3) O L clutch (5) O H ring gear (6) O L clutch housing (7)



28



O Intermediate shaft (8) O 2nd sun gear (20) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Forward 3rd speed \



H clutch and 2nd clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O H planetary pinion (4) O H ring gear (6) O L clutch housing (7)



HD465-7E0, HD605-7E0



O Intermediate shaft (8) O 2nd sun gear (20) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



29



SEN01089-04



10 Structure, function and maintenance standard



Forward 4th speed



L clutch (5) and 3rd clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O L ring gear (3) O L clutch (5) O H ring gear (6) O L clutch housing (7)



30



O Intermediate shaft (8) O 3rd sun gear (13) O 3rd planetary pinion (14) O 3rd, R carrier (18) O 2nd ring gear (19) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



o O



O 2nd sun gear (20) i



i



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Forward 5th speed



H clutch and 3rd clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O H planetary pinion (4) O H ring gear (6) O L clutch housing (7)



HD465-7E0, HD605-7E0



O Intermediate shaft (8) O 3rd sun gear (13) O 3rd planetary pinion (14) O 3rd, R carrier (18) O 2nd ring gear (19) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



o O



O 2nd sun gear (20) i



i



31



SEN01089-04



10 Structure, function and maintenance standard



Forward 6th speed



L clutch (5) and 4th clutch (11) are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O L ring gear (3) O L clutch (5) O H ring gear (6) O L clutch housing (7)



32



O Intermediate shaft (8) O 4th clutch housing (9) O 4th clutch drum (10) O 4th clutch (11) O 4th ring gear (12) O 3rd, R carrier (18) O 2nd ring gear (19) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



o O



O 2nd sun gear (20)



i



i



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Forward 7th speed



H clutch and 4th clutch (11) are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O H planetary pinion (4) O H ring gear (6) O L clutch housing (7)



HD465-7E0, HD605-7E0



O Intermediate shaft (8) O 4th clutch housing (9) O 4th clutch drum (10) O 4th clutch (11) O 4th ring gear (12) O 3rd, R carrier (18) O 2nd ring gear (19) O 2nd planetary pinion (21) O 1st, 2nd carrier (23) O Output shaft (24)



o O



O 2nd sun gear (20)



i



i



33



SEN01089-04



10 Structure, function and maintenance standard



Reverse 1st speed



L clutch (5) and R clutch are fixed hydraulically. Power from torque converter O Input shaft (1) O H carrier (2) O L ring gear (3) O L clutch (5) O H ring gear (6) O L clutch housing (7)



34



O Intermediate shaft (8) O R sun gear (15) i i O R planetary pinion A (16) O R planetary pinion B (17) O 3rd, R carrier (18) (R ring gear is fixed with R clutch = 3rd, R carrier (18) is rotated reverse to input shaft (1)) O 2nd ring gear (19) 2nd sun gear (20) O I 2nd planetary pinion (21) o O 1st, 2nd carrier (23) O Output shaft (24)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01089-04



Transmission control valve



A: B: C: D: E: F: G: H: J: K:



H clutch oil pressure pickup port Lockup clutch oil pressure pickup port L clutch oil pressure pickup port 4th clutch oil pressure pickup port 3rd clutch oil pressure pickup port R clutch oil pressure pickup port 2nd clutch oil pressure pickup port 1st clutch oil pressure pickup port To breather To main pressure variable valve



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



H clutch ECMV Lockup clutch ECMV L clutch ECMV 4th clutch ECMV 3rd clutch ECMV R clutch ECMV 2nd clutch ECMV 1st clutch ECMV Last chance filter Valve seat



HD465-7E0, HD605-7E0



1



Operation table of ECMV ECMV sgear speed



L



F1



Q



F2



Q



Q Q Q



F7



2nd



3rd



4th



R



Q



Q



F5 F6



1st



Q



F3 F4



H



L/U Q



Q



Q



Q



Q Q



Q



Q



Q Q



Q



Q



Q



N R1



Q



Q



L/U: lockup clutch ECMV Outline q Lockup clutch ECMV operates when traveling forward at the speed higher than the set speed of transmission controller.



35



SEN01089-04



10 Structure, function and maintenance standard



ECMV



1



For H, L, 4th, 3rd, R, 2nd, 1st clutches a Don't try to disassemble it since adjustment for maintaining the performance will be needed.



A: P: T: Dr: P1:



To clutch From pump Drain Drain Clutch oil pressure pickup port



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



Fill switch connector Proportional solenoid connector Flow detection valve Fill switch Proportional solenoid Pressure control valve (*1) Nameplate (*2)



36



*1: Pressure control valve spool of the unit for H, 3rd, R, 2nd and 1st clutches is different from one for L and 4th clutches. *2: Nameplate stamp of the unit for H, 3rd, R, 2nd and 1st clutch is different from one for L and 4th clutches. Operated clutches



Stamp of the nameplates



H, 3rd, R, 2nd, 1st



D*******



L, 4th



Q*******



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.



SEN01089-04



ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current - propulsion force characteristics of proportional solenoid



Propulsion force - Hydraulic pressure characteristics of proportional solenoid



Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a



ECMV and fill switch For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned “ON“ by the pressure of the clutch. The oil pressure is built up according to this signal.



q



The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D).



HD465-7E0, HD605-7E0



37



SEN01089-04



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



10 Structure, function and maintenance standard



Before shifting gear (when draining) (Range A in chart)



q



While no current is flowing in proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). At this time, since no oil pressure is applied to flow rate pickup valve (4), fill switch (5) is turned "OFF".



Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a



38



The logic is so made that the controller will not recognize completion of filling even if the fill switch is turned "ON" during triggering (Range D).



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



During filling (Range B in chart)



q



If a current is given to proportional solenoid (1) while there is no oil in the clutch, a hydraulic force balanced with the solenoid force is applied to chamber (B) and it pushes pressure control valve (3) to the left. This conducts oil through pump port (P) and orifice (a) of flow rate pickup valve (4) to start filling the oil to the clutch chamber. At this time, differential pressure is generated between the upper stream and down stream of orifice (a) of flow rate pickup valve (4). This differential pressure pushes flow rate pickup valve (4) leftward. As the clutch chamber is filled up with oil and oil flow from pump port (P) to clutch port (A) is stopped, differential pressure before and after orifice (a) of flow rate pickup valve (4) disappears. As the result, flow rate pickup valve (4) is pushed rightward, turning “ON“ fill switch (5).



HD465-7E0, HD605-7E0



SEN01089-04



Pressure adjustment (Range C in chart)



q



As current is conducted to proportional solenoid (1), the solenoid generates thrust in proportion to the current. The pressure is settled as the sum of this thrust of the solenoid, thrust generated by the oil pressure in clutch port and the repulsive force of pressure control valve spring (2) is balanced.



39



SEN01089-04



10 Structure, function and maintenance standard



For lockup clutch a Don't try to disassemble it since adjustment for maintaining the performance will be needed.



A: P: T: Dr: P1:



To clutch From pump Drain Drain Clutch oil pressure pickup port



1. 2. 3. 4. 5.



Proportional solenoid connector Sleeve Proportional solenoid Pressure control valve Nameplate (*1)



40



*1: Operated clutches



Stamp of the nameplates



Lockup



K*******



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Outline q This valve is used to switch the clutch in order to regulate the clutch oil pressure to the set pressure. Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of connecting the lockup clutch smoothly, thereby reducing shocks resulting from gear shift. Above also prevents generation of peak torque in the power train. These arrangements make the machine comfortable to operator and enhance durability of the power train.



SEN01089-04



Operation When traveling in torque converter range



When changing from torque converter travel to direct travel



At gear shift (in direct travel)



HD465-7E0, HD605-7E0



q



While no current is flowing in to proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).



41



SEN01089-04



10 Structure, function and maintenance standard



When traveling in direct range (Torque converter travel o direct travel)



q



q



42



As current is conducted to proportional solenoid (1), the oil pressure being balanced with the solenoid force is applied to chamber (B), pushing pressure control valve (3) leftward. Above opens pump port (P) and clutch port (A) to start filling oil to the clutch. If the clutch is filled with the oil, the trust of the solenoid is balanced with the sum of the hydraulic thrust in the clutch port and the reaction force of pressure control valve spring (2), thus the pressure is regulated.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01089-04



43



SEN01089-04



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01089-04



© 2011 KOMATSU All Rights Reserved Printed in Japan 06-11



44



HD465-7E0, HD605-7E0



SEN01090-01



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Power train, Part 2 Axle ................................................................................................................................................................. 2 Differential ....................................................................................................................................................... 4 Final drive ....................................................................................................................................................... 5 Wheels ............................................................................................................................................................ 6



HD465-7E0, HD605-7E0



1



SEN01090-01



10 Structure, function and maintenance standard



Axle



1



Front



1.



Wheel hub Unit: mm



No. 2



2



Check item Wear of oil seal sliding surface



Criteria



Remedy



Standard size



Tolerance



Repair limit



280



–0.130 –0.130



—



Repair or replace



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01090-01



Rear



1. 2. 3. 4.



Differential Axle housing Brake Final drive



HD465-7E0, HD605-7E0



Specifications Reduction ratio Differential: 3.538 Final drive : 4.737 Oil Differential: T030-CD (95 liters) Final drive : T030-CD (32 liters each side) Tire size : 24.00-35 (HD465-7E0) 24.00R35 (HD605-7E0) Rim size: 17.00-35



3



SEN01090-01



10 Structure, function and maintenance standard



Differential



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



1



Coupling Cross shaft Bevel gear (No. of teeth: 46) Side gear (No. of teeth: 24) Pinion gear (No. of teeth: 17) Bevel pinion (No. of teeth: 13)



Specifications Type: Spiral bevel gear, splash-type lubrication Reduction ratio: 3.538 Differential: Straight bevel gear, splash-type lubrication Oil: T030-CD (95 liters) Unit: mm



No.



Check item



7



Wear of oil seal contact surface of coupling



8



Thickness of side gear thrust washer



9



Backlash between bevel gear and pinion



4



Criteria



Remedy



Standard size



Tolerance



Repair limit



150



–0.100 –0.100



—



Repair or replace



6



–0.100 –0.050



5.5



Replace



0.41 – 0.56



Adjust



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01090-01



Final drive



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



1



Sun gear (No. of teeth: 19) Planet gear (No. of teeth: 24) Planet gear shaft Ring gear (No. of teeth: 71) Inner hub Wheel hub Drive shaft



Specification Type: Planetary gear, splash-type lubrication Reduction ratio: 4.737 Oil: T030-CD (32 liters each side)



Unit: mm No.



Check item



8



Backlash between planet gear and sun gear



9



Backlash between planet gear and ring gear



Criteria Standard backlash



Repair limit



0.22 – 0.67



0.8



0.28 – 0.77



1.0



10 Curvature of drive shaft 11 Thickness of spacer



HD465-7E0, HD605-7E0



Remedy



Replace



Repair or replace



Repair limit: 1.5 TIR Standard size 51.5



Tolerance ±0.1



Repair limit 50



Replace



5



SEN01090-01



10 Structure, function and maintenance standard



Wheels Front wheel



1 1. 2. 3.



Tire Rim assembly Valve



Specifications Rim size: 17.00 x 35 Tire size : 24.00-35 (HD465-7E0) 24.00R35 (HD605-7E0)



Rear wheel 1. 2. 3.



Rim assembly Valve Extension



Specifications Rim size: 17.00 x 35 Tire size : 24.00-35 (HD465-7E0) 24.00R35 (HD605-7E0)



6



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01090-01



7



SEN01090-01



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01090-01



© 2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)



8



HD465-7E0, HD605-7E0



SEN01091-01



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Steering system Steering column .............................................................................................................................................. 2 Steering linkage .............................................................................................................................................. 3



HD465-7E0, HD605-7E0



1



SEN01091-01



Steering column



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



2



10 Structure, function and maintenance standard



1



Steering shaft Steering column Lock lever Yoke Joint shaft Steering valve



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Steering linkage



1. 2. 3. 4.



SEN01091-01



1



Center lever Tie rod Arm (A-frame) Knuckle arm



HD465-7E0, HD605-7E0



3



SEN01091-01



4



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01091-01



Unit: mm No.



5



Check item Clearance between inner and outer for knuckle arm bushing



Criteria Standard size



Tolerance Shaft



Hole



165



Remedy Standard clearance



Clearance limit



0.150 – 0.300



0.7



6



Clearance between bushing and pin



85



–0.035 –0.035



+0.054 +0.054



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



Clearance between inner and outer bushing



80



0.120 – 0.250



0.4



9



Clearance between tie rod mounting pin and bushing



40



0.055 – 0.133



0.3



10



Clearance between inner and outer bushing



110



0.120 – 0.250



0.4



11



Clearance between arm mounting pin and bushing



55



0.060 – 0.152



0.3



12



Clearance between inner and outer bushing



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



Clearance between center 14 lever mounting pin and bushing



55



–0.030 –0.076



+0.197 +0.137



0.167 – 0.273



1.0



15



Clearance between inner and outer bushing



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



Clearance between suspen17 sion cylinder mounting pin and bushing



60



–0.030 –0.076



+0.046 +0.054



0.030 – 0.122



0.3



HD465-7E0, HD605-7E0



–0.025 –0.064



–0.030 –0.076



+0.069 +0.030



+0.076 +0.030



0.089



0.3



Replace



5



SEN01091-01



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01091-01



© 2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)



6



HD465-7E0, HD605-7E0



SEN01092-02



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Brake system Brake piping .................................................................................................................................................... 2 Brake valve ..................................................................................................................................................... 4 Secondary brake valve ................................................................................................................................... 7 Relay valve ..................................................................................................................................................... 8 Front brake off valve ....................................................................................................................................... 9 Accumulator charge valve............................................................................................................................. 10 Accumulator .................................................................................................................................................. 14 Slack adjuster ............................................................................................................................................... 15 Brake............................................................................................................................................................. 17 Parking brake solenoid valve ........................................................................................................................ 21



HD465-7E0, HD605-7E0



1



SEN01092-02



Brake piping



2



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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



Front brake OFF valve Relay valve Slack adjuster Secondary brake valve Brake valve Parking brake valve



HD465-7E0, HD605-7E0



SEN01092-02



7. 8. 9. 10. 11. 12.



Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder) Brake system tank



3



SEN01092-02



10 Structure, function and maintenance standard



Brake valve



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



4



Pilot piston Rod Lower cylinder Spool Upper cylinder Spool



1



A: B: C: D: E:



To rear brake To front brake To brake system tank From front accumulator From rear accumulator



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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.



SEN01092-02



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 valve 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 pr e s s ur e b et we en p or t ( A ) an d po r t ( C ) becomes high, the oil entering port (H) from 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.



HD465-7E0, HD605-7E0



5



SEN01092-02



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.



6



10 Structure, function and maintenance standard



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 brake system tank 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 brake system tank return circuit to release the front brake.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Secondary brake valve



1. 2. 3.



Rod Spool Cylinder



A: P: T:



To parking brake valve From accumulator To brake system tank



HD465-7E0, HD605-7E0



SEN01092-02



1



Function q This valve operates the brake depending on the parking brake release pressure controlled by the secondary brake pedal.



7



SEN01092-02



Relay valve



1. 2. 3. 4.



Spool Upper cylinder Lower cylinder Spool



A: P: Pp: T:



To front brake From accumulator From secondary brake valve To brake system tank



8



10 Structure, function and maintenance standard



1



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Front brake off valve



1. 2.



Connector Solenoid



A: P: T:



To front brake From brake valve To brake system tank



HD465-7E0, HD605-7E0



SEN01092-02



1



Function q 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.



9



SEN01092-02



10 Structure, function and maintenance standard



Accumulator charge valve



ACC:To accumulator P: From hydraulic pump PP: From accumulator T: To brake system tank H1: Relief valve R1: Relief valve R3: Main relief valve



10



1



Specification q q



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. q When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load of the pump. q



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



1. 2. 3.



Main relief valve (R3) Valve body Relief valve (R1)



HD465-7E0, HD605-7E0



SEN01092-02



4. 5. 6.



Relief valve (H1) Filter Filter



11



SEN01092-02



Operation 1. When no oil is being supplied to accumulator (cut-out condition) q 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. q The spring chamber at the right end of spool (15) is connected to port (C) of the relief valve (R1), so the pressure becomes the brake oil tank pressure. 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). q It also passes through orifices (17), (18) and (16), and flows to the brake oil tank.



12



10 Structure, function and maintenance standard



2.



When oil supplied to accumulator 1) Cut-in condition q 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). q Valve seat (7) and poppet (6) are brought into tight contact, and port (C) and port (T) are shut off. q 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. q When the pressure at port (P) goes above the pressure at port (B) (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. (A) fixed amount is supplied regardless of the engine speed.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



2) q



q



q



q



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.



HD465-7E0, HD605-7E0



SEN01092-02



3. q



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.



13



SEN01092-02



Accumulator



1. 2. 3. 4.



10 Structure, function and maintenance standard



1



Valve Top cover Cylinder Piston



Function q 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}



14



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01092-02



Slack adjuster



1. 2. 3.



Cylinder Check valve Piston



A: B:



Inlet port Outlet port



1



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



No.



4



Check item Clearance between body and piston



Criteria Tolerance



Standard size 55



Shaft



Hole



Standard clearance



–0.030 –0.076



+0.074 +0.074



0.030 – 0.150



Standard size 5



Slack adjuster spring



HD465-7E0, HD605-7E0



Remedy Clearance limit 0.25



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}



—



—



Replace



15



SEN01092-02



Function q 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.



10 Structure, function and maintenance standard



q



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.



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.



Operation 1. When brake pedal is depressed q Before the brake is depressed, piston (4) is returned by the distance of stoke (S) (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port (P) of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke (S) to the left and right.



q



q



16



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.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01092-02



Brake



1



Front



1. 2. 3.



Piston Pad Disc



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 Correct or 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.



HD465-7E0, HD605-7E0



17



SEN01092-02



10 Structure, function and maintenance standard



Rear



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



18



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01092-02



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



Standard distortion



Repair limit



Max. 0.45



0.7



Max. 0.50



0.7



Standard size



Repair limit



97.9



90.9



17



Distortion of disc friction surface



18



Distortion of plate and damper friction surface



19



Assemble thickness of plate and disc



HD465-7E0, HD605-7E0



Replace



19



SEN01092-02



Function q The rear brake is of an oil cooled multiple disc type, and it operates as a parking brake by use of spring. Operation of brake When the brake pedal is depressed, oil pressure 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.



q



q



20



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.



10 Structure, function and maintenance standard



Operation of parking brake q 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. q The parking releasing hydraulic pressure acts on the parking brake piston (10) from the accumulator through the brake valve and parking brake solenoid. q 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).



q



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.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Parking brake solenoid valve



1. 2.



Connector Solenoid



B: P: T:



To parking brake From secondary brake valve To brake system tank



HD465-7E0, HD605-7E0



SEN01092-02



1



Function q The parking brake solenoid is installed in the brake oil circuit between the secondary 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.



21



SEN01092-02



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01092-02



© 2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (02)



22



HD465-7E0, HD605-7E0



SEN01093-03



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Undercarriage and frame Suspension ..................................................................................................................................................... 2 Suspension cylinder........................................................................................................................................ 4 Rear axle support.......................................................................................................................................... 12



HD465-7E0, HD605-7E0



1



SEN01093-03



10 Structure, function and maintenance standard



Suspension



1. 2. 3. 4. 5.



Front suspension cylinder Radius rod (Upper rod) Rear suspension cylinder Radius rod (Lower rod) Arm (A-frame)



Outline q 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. q Hydropneumatic cylinders are used for the suspension cylinders to reduce the shock. With hydropneumatic cylinders, the suspension cylinder is charged (sealed) with oil and nitrogen



2



1



q



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.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01093-03



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 (Aframe) 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.



HD465-7E0, HD605-7E0



3



SEN01093-03



10 Structure, function and maintenance standard



Suspension cylinder



1



Front



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



4



Feed valve Cylinder Rod Valve (for bleeding air) Air bleeding valve Tube



A: B:



Port Port



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01093-03



Unit: mm No.



8



Check item



Clearance between piston rod and bushing



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



160



–0.043 –0.106



+0.240 +0.006



0.103 – 0.346



Clearance limit Replace bushing 0.4



9



Clearance between piston rod and bushing



160



–0.043 –0.106



+0.540 +0.360



0.403 – 0.646



0.7



Replace bushing



10



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



11 Elasticity of leaf spring



Max. 0.3 mm



Replace Measuring method: Measure protrusion and elongation of stopper. All the conditions below must be fulfilled.



12 Deformation of stopper



HD465-7E0, HD605-7E0



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



5



SEN01093-03



10 Structure, function and maintenance standard



Auto suspension specification



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



6



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



7. 8. 9. 10.



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



A: B:



Port Port



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01093-03



Unit: mm No.



Check item



Clearance between piston rod 11 and bushing



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



160



–0.043 –0.106



+0.240 +0.006



0.103 – 0.346



Clearance limit Replace bushing 0.4



12



Clearance between piston rod and bushing



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



HD465-7E0, HD605-7E0



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



7



SEN01093-03



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). 1. Nitrogen gas While 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 gas 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.



8



10 Structure, function and maintenance standard



2.



Principle of generation of damping force Inside of 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. 1) 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 (Y) to orifice plate (8a) is throttled by orifices in four places to generate a damping force. 2) 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 (Z) and passes through two orifices from orifice plate (8a) to generate a damping force.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



3.



SEN01093-03



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 hydraulic 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.



HD465-7E0, HD605-7E0



9



SEN01093-03



10 Structure, function and maintenance standard



Rear



1. 2. 3. 4. 5.



10



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01093-03



Unit: mm No.



Check item



Criteria Tolerance Shaft



Hole



Standard clearance



Clearance limit



180



–0.043 –0.106



+0.306 +0.060



0.103 – 0.412



0.5



7



Clearance between piston rod and bushing



180



–0.043 –0.106



+0.246 +0.246



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



6



Clearance between piston rod and bushing



Standard size



Remedy



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. 1)



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.



2)



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.



HD465-7E0, HD605-7E0



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



11



SEN01093-03



Rear axle support



1. 2. 3. 4.



12



10 Structure, function and maintenance standard



1



Rod Rod Axle Suspension cylinder



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01093-03



Unit: mm No.



Check item



Clearance between rod mount5 ing pin and bushing



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



Clearance limit



70



–0.030 –0.076



+0.046 +0.046



0.030 – 0.122



0.1



6



Clearance between inner and outer bushing



100



—



—



0.110 – 0.180



0.5



7



Clearance between suspension cylinder mounting pin and frame or axle



70



–0.030 –0.076



+0.046 +0.046



0.030 – 0.122



0.3



8



Clearance between inner and outer bushing



100



—



—



0.110 – 0.180



0.5



HD465-7E0, HD605-7E0



Replace



13



SEN01093-03



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01093-03



© 2008 KOMATSU All Rights Reserved Printed in Japan 01-08 (02)



14



HD465-7E0, HD605-7E0



SEN01094-03



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Hydraulic system Steering and hoist hydraulic piping ................................................................................................................. 2 Dump body control.......................................................................................................................................... 4 Hydraulic tank ................................................................................................................................................. 5 Steering valve ................................................................................................................................................. 6 Crossover relief valve ................................................................................................................................... 10 Steering cylinder ............................................................................................................................................11 Steering control valve.................................................................................................................................... 12 Hoist valve .................................................................................................................................................... 18 Dump control valve (EPC valve) ................................................................................................................... 24 Hoist cylinder ................................................................................................................................................ 28 Hydraulic pump ............................................................................................................................................. 29



HD465-7E0, HD605-7E0



1



SEN01094-03



Steering and hoist hydraulic piping



2



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



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



SEN01094-03



Cross-over relief valve Steering cylinder Hydraulic pump (SDR(30)80+80+(1)6) Steering control valve Hoist valve Hoist cylinder Hydraulic tank Steering hoist filter Steering valve



HD465-7E0, HD605-7E0



3



SEN01094-03



Dump body control



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



4



Dump control lever Hydraulic pump (SDR(30)80+80+SB(1)6) Hoist valve Dump control valve (EPC valve) Body positioner sensor Hoist cylinder Manual body lowering valve Serial No.: q and up



10 Structure, function and maintenance standard



1



Function q The positioner sensor senses the body control operation, and from this data the retarder controller controls output to the dump control valve (EPC valve). q The signal from the dump lever is controlled by the retarder controller, and actuates the dump control valve (EPC valve). The pilot pressure generated by the dump control valve (EPC valve) moves the spool of the hoist valve and controls the hoist cylinder. q If the body does not lower because of a trouble in the controller or electrical equipment, open manual body lowering valve (7) and drain the body holding oil in hoist cylinder (6) to the tank to lower the body. (For the operating procedure, see Testing and adjusting.) HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Hydraulic tank



1. 2. 3.



SEN01094-03



1



Breather Drain Oil level gauge



Capacity: 97 l



HD465-7E0, HD605-7E0



5



SEN01094-03



10 Structure, function and maintenance standard



Steering valve



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



6



Input shaft Upper cover Valve spool Housing Ball Stator Lower cover



1



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



Ball Torsion bar Link Sleeve Rotor Manifold Commutator



a: b: c: d: e:



From steering control valve (P port) To tank (R port) To steering cylinder (RT port) To steering control valve (LS port) To steering cylinder (LT port)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



Operation 1.



When steering is at neutral



q



The oil from the pump passes through the steering control valve and enters port (P) of the steering valve Valve spool (3) is at the neutral position, so port (P) and the port (RT and LT) to cylinder are closed. No oil flows to the cylinder, so the cylinder does not move. At the same times, port (LS) is connected trough port (R) to the tank. As a result, there is no oil pressure at port (LS), so all the oil from the pump at the steering control valve flows to the hoist valve.



q



q



HD465-7E0, HD605-7E0



7



SEN01094-03



2.



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



q



When the steering wheel is turned (to the right), input shaft (1) rotates. When this happens, valve spool (3) moves down. (Input shaft (1) has a spiral groove in which ball (8) moves, so when input shaft (1) rotates, torsion bar (9) is twisted, and all (8) moves up or down to move valve spool (3).) The oil from the steering control valve flows from port (P) through port (A) and port (G) and goes to port (F). The oil at port (F) then passes between stator (6) and rotor (12) in the metering position. After the amount of oil flowing to steering cylinder is measured here, it enters the inside of valve spool (3), passes through hole (a) in the valve spool through port (RT) and flows to the steering cylinder. In this way, the two cylinders are actuated and the wheels turn to the right.



q



q



q



8



10 Structure, function and maintenance standard



q



q



q



The oil returning from the steering cylinder flows from port (LT) trough port (E) and port (R) and goes back to the tank. At the same time, the oil pressure at port (P) is restricted by valve spool (3), and passes trough port (A), so a lower oil pressure (the drop in pressure (pressure difference) differs to according to the area of the opening of the spool) than the pressure at port (P) is applied to port (LS). The steering control valve spool is actuated by the difference in pressure between the oil pressure at port (P) end and the oil pressure at the port (LS) end. As a result, only the necessary amount of oil flows to the steering circuit, and remaining oil flows from the steering control valve to the hoist valve.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



3.



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



q



When steering wheel is turned (to the left), input shaft (1) rotates. When this happens, valve spool (3) moves up. The oil from the steering control valve flows from port (P) enters port (B) passes trough hole (a) in valve spool (3), and enters the inside of the valve spool. The oil inside valve spool (3) passes between stator (6) and rotor (12) in metering portion. After the amount of oil flowing to the steering cylinder is measured here, it flows to port (F). The oil at port (F) passes trough port (LT) and flows to steering cylinder. In this way, the two cylinders are actuated and the wheels turn to the left. The oil returning from the steering cylinder flows from port (RT) trough port (D) and port (R) and goes back to the tank.



q



q



q q q



HD465-7E0, HD605-7E0



SEN01094-03



q



q



At the same time, the oil pressure at port (P) is restricted by valve spool (3), so a lower oil pressure than the pressure at port (P) is applied to port (LS). The steering control valve spool is actuated by the difference in pressure between the oil pressure at port (P) end and the oil pressure at the port (LS) end. As a result, only the necessary amount of oil flows to steering circuit, and remaining oil flows from the steering control valve to the hoist circuit.



9



SEN01094-03



10 Structure, function and maintenance standard



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



1



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



Valve body Valve seat Relief valve Valve spring Sleeve Adjustment screw Lock nut



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



Steering cylinder



1



Unit: mm No.



1



Check item Clearance between piston rod and bushing



2



Clearance between piston rod supports shaft and bushing



3



Clearance between cylinder bottom support shaft and bushing



HD465-7E0, HD605-7E0



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



55



–0.030 –0.104



+0.163 +0.006



0.036 – 0.267



45



—



+0.039 +0.039



—



—



+0.039 +0.039



45



Clearance limit Replace bushing 0.567 1.0 Replace



—



1.0



11



SEN01094-03



Steering control valve



12



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



P1: P2: PH: PE: PT: PST: LS: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.



SEN01094-03



From hydraulic pump From hydraulic pump To hoist control valve From emergency steering pump To tank To steering valve From steering valve



Spool return spring Steering control valve 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 Standard size



12 Spool return spring



13 Check valve spring



HD465-7E0, HD605-7E0



Remedy Repair limit



Free length x O.D



Installed length



Installed load



Free length



Installed load



213.6 x 32.5



140



363.6 N {37.1 kg}



—



342.0 N {34.9 kg}



42.2 x 17



33.5



3.4 N {0.345 kg}



—



3.1 N {0.315 kg}



Replace



13



SEN01094-03



10 Structure, function and maintenance standard



Function q The steering control valve acts to divide the oil sent from the steering pump and the hoist pump for the work equipment, and sends it to the steering circuit and hoist circuit according to the pressure signal from the steering valve. q Steering control valve is a load sensing type and is controlled the steering control valve spool according to the operation of steering. In other words, if the steering is not being operated (when no oil is needed in the steering circuit), the steering control valve sends all the oil from the pump to the hoist valve. When the steering circuit is operated the amount of oil needed for steering is sent to the steering circuit, and the rest is sent to the hoist valve. In this way, the hydraulic power loss in the steering circuit is reduced. Operation 1. When steering valve is at neutral. The oil from the steering pump enters port (A). At the same times, the oil from the hoist pump enters port (B). When the steering valve is at neutral, port (P) of the steering valve is closed, so the pressure at port (P) rises. The pressure from port (P) passes through orifice (a), enters the chamber (C), and moves spool (2) to the right. Port (LS) and chamber (D) are connected to the tank, and the force moving spool (2) to the left is only the force of spool return spring (1). The pressure in chamber (C) rises until it overcomes the set pressure of spool return spring (1). As a result , spool (2) stops in the position shown in diagram on the right, and all the oil from the steering pump and hoist pump flows to the hoist valve.



14



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



2.



SEN01094-03



When steering valve is operated. When the steering is operated, port (P) and port (LS) are connected, and the circuit between the tank and port (LS) is shut off. The hydraulic pressure before entering the orifice of the steering control valve acts on chamber (C) of spool (2), and the hydraulic pressure coming out from the orifice acts on chamber (D). There is a difference in the area of the opening of the steering control valve orifice when the steering is turned quickly and when it is turned slowly. Therefore, the hydraulic pressure on both sides of the orifice also changes and a pressure difference is created. In this way, spool (2) is actuated by the balance of the force of return spring (1) and the differential pressure between both sides of the orifice. In other words, it moves according to the balance of the oil in chamber (C) pushing to the right, and the force of the oil in chamber (D) pushing to left + return spring (1). The larger the difference in pressure at the orifice is, the more spool (2) moves to the right. (1) When steering wheel is operated quickly The area of opening of the steering control valve orifice is large, so the difference in pressure between the two sides of the orifice is small. As a result, spool (2) only moves a short distance to the right, and all the oil from the steering pump together with some of the oil from the hoist pump passes through check valve (3) and flows to steeri ng valv e to prov ide a lar ge amount of oil to the steering valve.



HD465-7E0, HD605-7E0



15



SEN01094-03



10 Structure, function and maintenance standard



(2) When steering wheel is operated slowly The area of opening of the steering control valve orifice is small, so the difference in pressure between the two sides of the orifice is large. As a result, the movement to the right increases, and all some of oil from the steering pump flows to the steering valve. The remaining oil from the steering pump and all the oil from the hoist pump flows to the hoist valve.



16



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



Steering relief valve



q



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



1. 2. 3. 4. 5.



q



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 q This valve is located in the steering control 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 q Port (A) is connected to the pump circuit, and port (C) is connected to the tank drain circuit. q Oil flows through the orifice of the main valve (1), and port (B) is filled with oil. q Also, the pilot poppet (3) is seated to the valve seat (2).



HD465-7E0, HD605-7E0



17



SEN01094-03



Hoist valve



18



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



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 Standard size



Remedy Repair limit



Free length x O.D.



Installed length



Installed load



Free length



Installed load



49.3 x 12.8



41.9



259 N {26.4 kg}



—



233 N {23.8 kg}



13 Check valve spring



32.6 x 10.9



24.5



44 N {4.5 kg}



—



40 N {4.1 kg}



14 Spool return spring (lifting)



51.3 x 34.5



50



156 N {15.9 kg}



—



140 N {14.3 kg}



15 Spool return spring (lowering)



34.2 x 28.7



32



124 N {12.7 kg}



—



112 N {11.4 kg}



16 Spool return spring (floating)



74.0 x 36.0



55.5



927 N {94.5 kg}



—



849 N {85.1 kg}



12 Relief valve poppet spring



HD465-7E0, HD605-7E0



If damaged or deformated, replace the spring



19



SEN01094-03



10 Structure, function and maintenance standard



Operation 1. Hoist valve HOLD position



q



20



Oil from the steering control 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.



q



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.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



2.



Hoist valve at LIFT position



q



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).



q



HD465-7E0, HD605-7E0



SEN01094-03



q



q



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.



21



SEN01094-03



3.



Hoist valve at FLOAT position



q



When the hoist lever in the cab is set to the FLOAT position, pressurized oil from the solenoid valve pushes the hoist spool (2) to the right. Then, chambers (C), (D), (B), (H) and (D) are all connected. Oil from the steering control valve flows from chamber (C) through chamber (B) to the host cylinder and from chamber (C) through chamber (D) to the oil cooler circuit.



q



22



10 Structure, function and maintenance standard



q



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.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



4.



Hoist valve at LOWER position



q



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.



q



HD465-7E0, HD605-7E0



SEN01094-03



q



q



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.



23



SEN01094-03



10 Structure, function and maintenance standard



Dump control valve (EPC valve)



1



HD465-7E0 Serial No.: 10001 – 10037, 10101 – 10612 HD605-7E0 Serial No.: 8001 – 8032, 10101 – 10612



1. 2. 3. 4.



Manual operation button Solenoid assembly (Solenoid a) Relief valve (R) Solenoid assembly (Solenoid b)



A: B: P1: P2: T1: T2:



To hoist valve (RAISE side) To hoist valve (LOWER side) From hydraulic pump Pick up port To hydraulic tank To hydraulic tank



24



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



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01094-03



25



SEN01094-03



10 Structure, function and maintenance standard



HD465-7E0 Serial No.: 10614 and up HD605-7E0 Serial No.: 10613 and up



26



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



1. 2. 3. 4. 5.



Manual operation button Solenoid assembly (Solenoid a) Relief valve (R) Solenoid assembly (Solenoid b) Strainer



A: B: P1: P2: T1: T2:



To hoist valve (RAISE side) To hoist valve (LOWER side) From hydraulic tank Pick up port To hydraulic tank To hydraulic tank



SEN01094-03



Function q The EPC valve sends the oil from the hydraulic pump to the hoist valve spool to change the pilot pressure and control the hoist valve.



HD465-7E0, HD605-7E0



27



SEN01094-03



10 Structure, function and maintenance standard



Hoist cylinder



1



Unit: mm No.



1



Check item Clearance between cylinder and bushing



Criteria Standard size



Tolerance



Remedy



Shaft



Hole



Standard clearance



Clearance limit



170



–0.043 –0.143



+0.264 +0.046



0.089 – 0.407



0.707



2



Clearance between piston rod and bushing



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



28



Replace



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



Hydraulic pump



1



Steering, hoist and hoist control pump SDR(30)80+80+SB(1)6



Unit: mm No.



Check item



Criteria Model



1



Side clearance



Standard clearance



Clearance limit



0.16 – 0.20



0.24



0.10 – 0.15



0.19



0.06 – 0.131



0.20



SDR(30)-80 SDR(30)-80 SBR(1)-6



2



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



SDR(30)-80 SDR(30)-80 SBR(1)-6 Model



3



Depth to knock in pin



4



Rotating torque of spline shaft



SDR(30)-80 SDR(30)-80 SBR(1)-6



0.20



Standard size



Tolerance



Repair limit



10



–0.5 –0.5



—



9.1



± 0.3



Standard Delivery Delivery Rotating delivery pressure amount limit speed amount (rpm) MPa {kg/cm2} ( /min) ( /min)



SDR(30)-80 SDR(30)-80 SBR(1)-6



HD465-7E0, HD605-7E0



0.06 – 0.119



Replace



15.8 – 28.5 Nm {1.6 – 2.9 kgm} Model



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



Remedy



2,500



20.6 {210}



184.5



170.4



13.8



12.6



—



29



SEN01094-03



10 Structure, function and maintenance standard



Retarder cooling pump SDR(30)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



3



Depth to knock in pin



4



Rotating torque of splined shaft



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



Criteria Model



Standard clearance



Clearance limit



SDR(30)-100



0.16 – 0.20



0.24



SDR(30)-100



0.06 – 0.131



0.20 Replace



Model



Standard size



Tolerance



Repair limit



SDR(30)-100



10



–0.5 –0.5



—



13.7 – 23.5 Nm {1.4 – 2.4 kgm} Model



SDR(30)-100



30



Remedy



Rotating speed (rpm)



Delivery pressure



Standard delivery amount ( /min.)



Delivery amount limit ( /min.)



2,500



20.6 MPa {210 kg/cm2}



230.9



213.4



—



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01094-03



Torque converter, transmission, retarder cooling and brake pump SDR(30)100+SA(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



0.16 – 0.20



0.24



SAR(1)-25



0.10 – 0.15



0.20



SDR(30)-100



0.06 – 0.131



SAR(1)-25



0.06 – 0.119 Tolerance



10



–0.5 –0.5



SDR(30)-100



Rotating torque of spline shaft



Replace



—



8.9 – 16.7 Nm {0.9 – 1.7 kgm} Model SDR(30)-100 SAR(1)-25



HD465-7E0, HD605-7E0



0.20



Standard size



SAR(1)-25



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



Remedy



SDR(30)-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}



230.9



213.4



24.5 {250}



56.5



50.8



—



31



SEN01094-03



10 Structure, function and maintenance standard



Emergency steering pump SBL(1)-014



Unit: mm No.



Check item



Criteria



Remedy



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



Replace Model



3



Depth to knock in pin



4



Rotating torque of splined shaft



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



Tolerance



Repair limit



10



–0.5 –0.5



—



SBL(1)-014



2.0 – 4.9 Nm {0.2 – 0.5 kgm} Model



SBL(1)-014



32



Standard size



Rotating speed (rpm)



Delivery pressure



Standard delivery amount ( /min.)



Delivery amount limit ( /min.)



3,500



20.6 MPa {210 kg/cm2}



45.7



42.4



—



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01094-03



33



SEN01094-03



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01094-03



© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (02)



34



HD465-7E0, HD605-7E0



SEN04679-00



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Work equipment (Body) Auto greasing system ..................................................................................................................................... 2



HD465-7E0, HD605-7E0



1



SEN04679-00



Auto greasing system



2



10 Structure, function and maintenance standard



1



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN04679-00



3



SEN04679-00



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



Flow divider valve (1) Flow divider valve (2) Flow divider valve (3) Flow divider valve (4) Flow divider valve (5) Flow divider valve (6) Flow divider valve (7) Flow divider valve (8) Flow divider valve (9) Branch block Electric grease pump Controller



10 Structure, function and maintenance standard



Automatic greasing point



q



No.



Greasing point



Flow divider valve No.



1



Front suspension upper pin (left)



(1)



2



Tie rod center lever pin (right)



(2)



3



Tie rod end pin (left)



4



Steering cylinder end pin (left)



5



King pin (left)



6



Center lever pin



7



Steering cylinder frame pin (right)



8



Steering cylinder frame pin (left)



9



Tie rod center lever pin (left)



10 A-frame front pin (left)



(1)



(4)



(2)



11 A-frame rear pin (left) 12 A-frame front pin (right)



(4)



13 A-frame rear pin (right) 14 Tie rod end pin (right) 15 King pin (right) 16 Steering cylinder end pin (right)



(3)



17 Front suspension upper pin (right)



4



18 Hoist cylinder upper pin (right)



(5)



19 Hoist cylinder lower pin (right)



(6)



20 Lower rod frame pin (right)



(5)



21 Lower rod frame pin (left)



(7)



22 Hoist cylinder lower pin (left)



(6)



23 Hoist cylinder upper pin (left)



(7)



24 Body hinge pin (right)



(5)



25 Rear suspension lower pin (right)



(8)



26 Rear suspension upper pin (right)



(5)



27 Upper rod axle pin (right)



(8)



28 Upper rod frame pin (right)



(5)



29 Lower rod axle pin (right)



(8)



30 Lower rod axle pin (left)



(9)



31 Upper rod frame pin (left)



(7)



32 Upper rod axle pin (left)



(9)



33 Rear suspension upper pin (left)



(7)



34 Rear suspension lower pin (left)



(9)



35 Body hinge pin (left)



(7)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



System diagram



HD465-7E0, HD605-7E0



5



SEN04679-00



10 Structure, function and maintenance standard



Operation q The automatic greasing system adds the hours of operation of the equipment, and every time the total reaches 2 hours, it carries out greasing. q Operation is sensed by checking the controller power ON signal output when the starting switch is turned ON. q The amount of grease for each work equipment pin is set according to the load on the pin.



Automatic greasing controller



Electric grease pump



Item



Unit



Specification value



Greasing interval



Hour (H)



2



Greasing time



Minutes (min)



15



Method of Start of calculation calculating greasing End of calculation interval (See figure below) Greasing timing



When starting switch is turned off and controller power source is turned off When total calculation for greasing interval (hatched area) Reaches 2 hours



Max. pressure



kg/cm2



245



Discharge amount



cc/min



12



Tank capacity



cc



Grease used



6



When starting switch is turned on and controller power source is turned on



–



1,600 G2-L1 (For standard specification, when machine is shipped) *G0-L1(For cold areas, available for supply)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



No.



Flow divider valve



Amount of grease



HD465-7E0, HD605-7E0



cc each time



SEN04679-00



Greasing point



Flow divider valve No.



Amount of grease



1



Front suspension upper pin (left)



(1)



0.15



2



Tie rod center lever pin (right)



(2)



0.65



3



Tie rod end pin (left)



4



Steering cylinder end pin (left)



5



King pin (left)



6



Center lever pin



7



Steering cylinder frame pin (right)



8



Steering cylinder frame pin (left)



9



Tie rod center lever pin (left)



10



A-frame front pin (left)



0.65 (1)



0.65 0.65



(4)



0.65 0.65 0.65



(2)



0.65 0.65



11



A-frame rear pin (left)



0.65



12



A-frame front pin (right)



0.65



13



A-frame rear pin (right)



14



Tie rod end pin (right)



15



King pin (right)



16



Steering cylinder end pin (right)



17



Front suspension upper pin (right)



18



Hoist cylinder upper pin (right)



19



Hoist cylinder lower pin (right)



(6)



0.25



20



Lower rod frame pin (right)



(5)



0.65



21



Lower rod frame pin (left)



(7)



0.65



22



Hoist cylinder lower pin (left)



(6)



0.25



23



Hoist cylinder upper pin (left)



(7)



0.25



24



Body hinge pin (right)



(5)



0.55



25



Rear suspension lower pin (right)



(8)



0.65



26



Rear suspension upper pin (right)



(5)



0.25



27



Upper rod axle pin (right)



(8)



0.65



28



Upper rod frame pin (right)



(5)



0.65



29



Lower rod axle pin (right)



(8)



0.65



30



Lower rod axle pin (left)



(9)



0.65



(4)



0.65 0.65



(3)



0.65 0.65 0.15



(5)



0.25



31



Upper rod frame pin (left)



(7)



0.65



32



Upper rod axle pin (left)



(9)



0.65



33



Rear suspension upper pin (left)



(7)



0.25



34



Rear suspension lower pin (left)



(9)



0.65



35



Body hinge pin (left)



(7)



0.55



7



SEN04679-00



10 Structure, function and maintenance standard



Components of system Controller



1. 2. 3. 4.



Connector (CN1) Connector (CN2) Controller Fuse



Specification Model: LC2MP



CN1 No.



Name of signal



Input/output signal



1



–



–



2



–



–



3



–



–



4



Battery 24V



Input



5



Earth



Output



6



ACC



Input



Name of signal



Input/output signal



CN2 No.



8



1



Motor



Input



2



Pressure pickup switch



Input



3



Motor



Output



4



Pressure pickup switch



Output



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



Electric grease pump



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



Motor Tank Air bleed plug Pump Pressure switch Connector



HD465-7E0, HD605-7E0



Specification Model: LD10FP



9



SEN04679-00



Operation 1) q



q



q



10



Greasing, pressurizing When motor (1) rotates in the normal direction, eccentric shaft (2) rotates counterclockwise and pump piston (4) is operated in a reciprocal movement by link plate (3). During the return stroke (i) of pump pump piston (4), the grease inside tank (5) is sucked in, and on the discharge stroke (o), check valve (6) is pushed open and the grease is pushed out to discharge port (P). Pressure release spool (7) is moves to the right by pin (8) of eccentric shaft (2) and pressure release hook (9). This shuts off discharge port (P) and return passage (T), so the pressurized condition is maintained.



10 Structure, function and maintenance standard



q



q



When the pressure inside the pump rises and goes above the set pressure, indicator (10) is pushed to the left, pressure switch (11) is switched ON, and motor (1) stops. When the pressure goes down again and pressure switch (11) is turned OFF, motor (1) starts again and the pressurized condition is maintained.



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



q



If abnormal pressure is generated in the circuit at discharge port (P) end, safety valve (12) opens and releases the pressure to return circuit (T) to protect the equipment from damage.



SEN04679-00



2) q



q



q



q



q



HD465-7E0, HD605-7E0



Release of pressure, waiting for work When the greasing is completed, motor (1) rotates in reverse, and eccentric shaft (2) rotates clockwise. Pressure release spool (7) is moved to the left by pin (8) of eccentric shaft (2) and pressure release hook (9). As a result, discharge port (P) and return circuit (T) are interconnected, and the pressure in the circuit is released to tank (5). When this happens, pump piston (4) moves in a reciprocal motion, but the discharged grease flows to return circuit (T), so the pressure does not rise. When the pressure in the circuit drops, indicator (10) is pushed back, and pressure switch (11) is turned OFF motor (1) stops. If pressure switch (11) is not turned off, the controller automatically rotates motor (1) in the opposite direction to release the pressure.



11



SEN04679-00



10 Structure, function and maintenance standard



Flow divider valve (1) Left front side



A: B: C: D: E:



12



From electric grease pump Front suspension upper pin (left) Tie rod end pin (left) Steering cylinder end pin (left) King pin (left)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



(2) Left front side



A: B: C: D: E: F:



From electric grease pump A-frame front pin (left) A-frame rear pin (left) Steering cylinder frame pin (left) Tie rod center lever pin (left) Tie rod center lever pin (right)



HD465-7E0, HD605-7E0



13



SEN04679-00



10 Structure, function and maintenance standard



(3) Right front side



A: B: C: D: E:



14



From electric grease pump King pin (right) Steering cylinder end pin (right) Tie rod end pin (right) Front suspension upper pin (right)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



(4) Right front side



A: B: C: D: E:



From electric grease pump Center lever pin A-frame front pin (right) A-frame rear pin (right) Steering cylinder frame pin (right)



HD465-7E0, HD605-7E0



15



SEN04679-00



10 Structure, function and maintenance standard



(5) Right rear side



A: B: C: D: E: F:



16



From electric grease pump Lower rod frame pin (right) Upper rod frame pin (right) Body hinge pin (right) Hoist cylinder upper pin (right) Rear suspension upper pin (right)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



(6) Center rear side



A: B: C: D:



From electric grease pump Hosit cylinder lower pin (right) Hosit cylinder lower pin (left) To flow divider valve (9)



HD465-7E0, HD605-7E0



17



SEN04679-00



10 Structure, function and maintenance standard



(7) Left rear side



A: B: C: D: E: F:



18



From electric grease pump Rear suspension upper pin (left) Hoist cylinder upper pin (left) Body hinge pin (left) Upper rod frame pin (left) Lower rod frame pin (left)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



(8) Right rear side



A: B: C: D: E:



To flow divider valve (5) Rear suspension lower pin (right) Lower rod axle pin (right) Upper rod axle pin (right) From electric grease pump



HD465-7E0, HD605-7E0



19



SEN04679-00



10 Structure, function and maintenance standard



(9) Right rear side



A: B: C: D:



20



From electric grease pump Upper rod axle pin (left) Lower rod axle pin (left) Rear suspension lower pin (left)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN04679-00



Structure



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



Measurement piston Head Body Spring Spring retainer Pilot piston



HD465-7E0, HD605-7E0



A: B: C: D: E: F:



Discharge port Discharge port Measurement chamber Piston chamber Oil passage Supply port



21



SEN04679-00



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN04679-00



© 2008 KOMATSU All Rights Reserved Printed in Japan 07-08 (02)



24



HD465-7E0, HD605-7E0



SEN01095-03



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Cab and its attachments ROPS cab ....................................................................................................................................................... 2 Air conditioner ................................................................................................................................................. 3 Rear view monitor ........................................................................................................................................... 9



HD465-7E0, HD605-7E0



1



SEN01095-03



ROPS cab



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



2



10 Structure, function and maintenance standard



1



Front wiper Front glass Air conditioner fresh filer Door (Left) Rear glass Door (Right) Washer tank



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Air conditioner



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



SEN01095-03



1



Receiver dryer Air conditioner unit Compressor Condenser Hot water return port Hot water take-off port



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



HD465-7E0, HD605-7E0



3



SEN01095-03



10 Structure, function and maintenance standard



Refrigerant flow system



4



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01095-03



Air conditioner unit



A. B. C. D.



Hot water outlet port Hot water inlet port Refrigerant gas inlet side Refrigerant gas outlet side



Outline q The vertical air conditioner unit on which evaporator and heater core is synchronized with the blower and intake unit to generate cool and hot air. q The temperature adjusting switch on the air conditioner panel controls air mix dampers to adjust the spurting out temperature. Cooler The cooler circulates refrigerant through evaporator to cause heat exchange (dehumidification and cooling). q Air taken in by the blower and intake unit is cooled with evaporator and then blown out from the grill through the duct. q



Heater q The heater circulates engine coolant in heater core to cause heat exchange (heating). q Air taken in by the blower and intake unit is heated with heater core and then blown out from the grill through the duct.



HD465-7E0, HD605-7E0



5



SEN01095-03



10 Structure, function and maintenance standard



Receiver dryer



1.



Sight glass



A: B:



From condenser To air conditioner unit



Function q It is used to store liquefied high-pressure, hightemperature refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation circuit and water content in the refrigerant by use of the built-in filter and desiccating agent. q Sight glass (1) allows inspecting flow of the refrigerant. Specifications



6



Effective cubic capacity (cm3)



578



Mass of desiccating agent (g)



300



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01095-03



Condenser



1. 2.



Fin Tube



A: B:



Refrigerant gas inlet port Refrigerant gas outlet port



Function q It cools and liquefies the high-pressure and high-temperature gas which compressed by compressor. a If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection. Specifications Fin pitch (mm)



1.5



Total heat dissipation surface (m2)



6.55



Max. pressure used (MPa {kg/cm2})



HD465-7E0, HD605-7E0



3.6 {3.6}



7



SEN01095-03



10 Structure, function and maintenance standard



Compressor



1. 2.



Case Clutch



A: B:



Suction service valve Discharge service valve



Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator to high-pressure, high-temperature gas so that it may be easily regenerated (liquefied) at normal temperature. q Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure. Specifications Number of cylinder – Bore x Stroke (mm) Piston capacity (cc/rev)



129.2



Allowable maximum speed (rpm)



4,000



Refrigerant oil used



Sanden: SP-10



Refrigerant oil refilling volume (cc)



8



7 – 29.3 x 27.4



135



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Rear view monitor



SEN01095-03



1



(If equipped) Serial number HD465-7E0: 10001 - 10037, 10101 - 11382 HD605-7E0: 8001 - 8032, 10101 - 11371



1. 2. 3.



Monitor Camera Cable



HD465-7E0, HD605-7E0



9



SEN01095-03



Rear view monitor



10 Structure, function and maintenance standard



1



(If equipped) Serial number HD465-7E0: 11383 and up HD605-7E0: 11372 and up



1. 2. 3.



10



Rear view monitor Rear view camera Cable



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01095-03



Serial number HD465-7E0: 11383 and up HD605-7E0: 11372 and up



Rear view monitor system 4. 5. 6.



Rear view monitor Brightness adjustment switch Reverse-interlock mode switch



Outline When the machine travels in reverse, the camera installed to the rear of the machine is operated to display the screen of rear view monitor (1) to check the rear for safety



Switches Brightness adjustment switch This switch (2) is used for adjusting the brightness (luminance) of the rear view monitor. (A): Increases brightness. (B): Decreases brightness.



Reverse-interlock mode switch This switch (3) is used for changing the display method of the rear view monitor. (A): Always displays images on rear view monitor. (B): Displays images on rear view monitor only when traveling in reverse.



HD465-7E0, HD605-7E0



11



SEN01095-03



10 Structure, function and maintenance standard



Serial number HD465-7E0: 10001 - 10037, 10101 - 11382 HD605-7E0: 8001 - 8032, 10101 - 11371



Monitor



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



12



Auto switch Manual switch Zoom/Iris switch (Reverse light compensation switch) Bright/Dim light selector switch Mark switch Contrast adjustment knob Brightness adjustment knob



Specifications TV signal method: As per Japanese standard TV method Scanning method: 2:1 Interlace method CRT: 4.5 inch, black and white, 90-deg. deflection Resolution: Horizontal 400 lines and vertical 300 lines Power supply voltage: DC 24/12 V



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01095-03



Serial number HD465-7E0: 11383 and up HD605-7E0: 11372 and up



Rear view monitor



Rear view monitor input/output signals AMP-12P [CN-RMN1] Pin No.



Signal name



Input/output signal



1



Continuous power supply (24 V)



Input



2



Power supply return GND



3



External starting signal



4



(*1)



5



Rear view monitor brightness adjustment switch +



Input



6



Rear view monitor brightness adjustment switch -



Input



7



Shift lever R signal



Input



8



Monitor brightness selector switch (night mode signal)



Input



9



LIN



Input/Output



10



(*1)



-



11



(*1)



12



Key switch ACC signal



Input -



Input



*1: Never connect these pins. Malfunctions or failures may occur.



HD465-7E0, HD605-7E0



13



SEN01095-03



10 Structure, function and maintenance standard



AMP-8P [CN-RMN2] Pin No.



Signal name



Input/output signal



1



Rear view camera power supply output



Output



2



Rear view camera NTSC signal



3



(*1)



-



4



(*1)



-



5



GND (rear view camera power supply)



-



6



(*1)



-



7



(*1)



-



8



GND (rear view camera shield)



-



Input



*1: Never connect these pins. Malfunctions or failures may occur.



14



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01095-03



Serial number HD465-7E0: 10001 - 10037, 10101 - 11382 HD605-7E0: 8001 - 8032, 10101 - 11371



Camera



1. 2.



Camera Connector



HD465-7E0, HD605-7E0



Specifications TV signal method: As per Japanese standard TV method Scanning method: 2:1 Interlace method Image sensor: 1/4 inch color CCD with 250,000 pixels Lens: 1.7 mm, 1:2.8 Angle of view: Horizontal; Approx. 118 deg., Vertical; Approx. 97.6 deg. Electronic zoom: Approx. 1.4 power Using luminance range: Min. luminance of object; 3 lux Power supply voltage: DC 5.5 V – 99.5 V for main unit (supplied by monitor) Power consumption: Max. 120 mA



15



SEN01095-03



10 Structure, function and maintenance standard



Serial number HD465-7E0: 11383 and up HD605-7E0: 11372 and up



Rear view camera



Rear view camera input/output signals CN1 [CN-BMN] Pin No.



Signal name



Input/output signal



1



Rear view camera power supply



Input



2



Rear view camera NTSC signal



Output



3



(*1)



-



4



GND (rear view camera power supply)



-



*1: Never connect these pins. Malfunctions or failures may occur.



16



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0



SEN01095-03



17



SEN01095-03



10 Structure, function and maintenance standard



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01095-03



© 2016 KOMATSU All Rights Reserved Printed in Japan 10-16 (01)



18



HD465-7E0, HD605-7E0



SEN01096-05



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



10 Structure, function and maintenance standard



1



Electrical system, Part 1 Machine monitor system ................................................................................................................................. 2



HD465-7E0, HD605-7E0



1



SEN01096-05



Machine monitor system



10 Structure, function and maintenance standard



1



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



2



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



Outline The machine monitor system is comprised of controllers and a machine monitor. 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 vehicle and transmit those data as network data to the machine monitor. The machine monitor, in return, displays these data and inform the operator of the condition of the machine. q There are two types of display on the machine monitor: the normal mode and the service mode. q The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items q Meters (speedometer, tachometer) q Gauges (engine coolant temperature, torque converter oil temperature, retarder oil temperature, fuel level) q Pilot display q Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (while an action code is being displayed, press machine monitor mode selector switch (>). A failure code (6-digit) is then displayed.) 3. Maintenance monitor function When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Others In combination with the character display and the machine monitor mode selector switch, which is used to operate the character display, the following items can be displayed, set, and adjusted. 1) Dozing counter (option) 2) Display reverse travel distance measurement value 3) Reset filter oil replacement interval 4) Input telephone number 5) Select language 6) Payload meter calibration ID setting (if equipped) q To make it easier to carry out troubleshooting of the controllers on the network (including the monitor panel itself), a service mode function is provided. Its main content is as follows. 1. Displaying trouble history data for electrical components q Displays electrical component failure occurrence data from each controller that is saved in machine monitor. q Deletes data from memory



HD465-7E0, HD605-7E0



SEN01096-05



2.



3.



4.



5.



6.



7.



8.



9.



10.



11.



12.



13. 14.



Displaying trouble history data for machine Displays machine failure occurrence data from each controller that is saved in machine monitor. Real-time monitor Takes input, output signal, and calculation values recognized by each controller on network and displays them in real time. Reduced cylinder mode This function is used to stop the supply of fuel sprayed from the fuel injector to each of the cylinders. This function is used for the purpose of, for example, determining the cylinder where there is defective combustion. No injection cranking This function is used to lubricate an engine without starting the engine to drive a vehicle after a long-term storage. Adjusting function This function is used to correct installation errors of sensors, solenoid valves, and compensate production tolerances of parts and components. This function is also used to change control characteristic data in response to user's request. Maintenance monitor This function is used to change filter oil replacement interval and stop the function. Operation information display function This function is used to display fuel consumption amount per operation hour. Engine mode fixing function This function is used to check the performance. Snapshot function For details of this function, see "Structure, function and maintenance standard" of "Manual snapshot". Payload meter function (if equipped) This function is used to setting and adjusting of payload meter. For details of this function, see "Operation and maintenance manual" or "Structure, function and maintenance standard" of "Payload meter (having VHMS)". Option selection function This function is used to select controller information and optional equipment to be operated. Model selection function Input model information to be mounted. Initialize This function is used to set the machine monitor when the machine is shipped from the factory.



3



SEN01096-05



10 Structure, function and maintenance standard



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. 24. 25.



4



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 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 Seat belt caution lamp Body caution lamp



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



Emergency steering pilot lamp Turn signal pilot lamp (right) Turn signal pilot lamp (left) Head lamp high beam 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 (if equipped) Automatic retarder set speed indicator (if equipped) Automatic retarder set speed unit indicator (km/ h) (if equipped) Automatic retarder set speed unit indicator (MPH) (if equipped)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.



Rotary switch [SW1] Rotary switch [SW2] Rotary switch [SW3] Dipswitch [SW5-4] Dipswitch [SW5-3] Dipswitch [SW5-2] SI Spec, Non-SI Spec selection switch [SW5-1] Dipswitch [SW6-4] Dipswitch [SW6-3] Dipswitch [SW6-2] Dipswitch [SW6-1]



HD465-7E0, HD605-7E0



SEN01096-05



a a a a a



Do not change setting. When moving the switches, use a precision screwdriver and turn slowly. Be careful not to touch anything except the switches inside the grommet. Be careful not to let any dirt or dust get in. After completing the setting, return the grommet securely to its original position.



5



SEN01096-05



10 Structure, function and maintenance standard



Machine monitor normal display functions : Lighted up : Discontinuous sounds A1: The mark shows that the light is lit up while the machine monitor check switch is ON. A2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second. A1 When A2 machine Immedimonitor ately Central after warn- Alarm check ing buzzer switch is turning oper- key ON. lamp ated. Related operation



No.



1



2



3 9



Display item



Display category Device



Display range/ conditions



Display method



Meter



Movement



Scale: white Background color: black



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



Analog display



—



—



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation



—



—



Machine speed



Meter



Movement



Scale: white, red Background color: black



0 – 3,400 rpm



Analog display * When the overrun prevention brake is operated, the buzzer and central warning lamp are turned ON.



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation



Engine speed



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



Gauge



Movement



Caution



LED



Red



At 120°C or higher



Lit up during warning



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation.



Oil temperature of retarder



Gauge Oil tem4 perature of torque 10 converter



6



Color



Scale: white, red 50 – 135°C BackMove(120°C or ground ment higher in the red color: zone) black



Analog display



Analog display



Caution



LED



Red



At 120°C or higher



Lit up during warning



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation.



(Note)



(Note)



—



Remarks



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



—



—



—



—



—



—



—



—



—



(Note)



(Note)



HD465-7E0, HD605-7E0



10 Structure, function and maintenance standard



SEN01096-05



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



No.



Display item



Display category Device



Gauge Coolant 5 temperature 11



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



Action code



Failure code



Analog display



Red



At 102°C or higher



Lit up during warning



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation.



Scale: white, red MoveBackEMPTY – FULL ment ground color: black



—



—



—



—



Analog display



—



—



(Note)



(Note)



Remarks



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



—



Note: When machine monitor check switch is operated, pointer starts at current position and moves around indication range and then returns to starting point.



Caution



LED



Red



Specified level or less (At 76 z or higher)



Lit up during operation



—



—



Backlight



LED



Amber



When the small lamp is lit up.



Lit up during operation.



—



—



0 – 65535.0h



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



—



—



When 65535.0h is exceeded, fixed at 65535.0h.



—



—



When 999999.9 km is exceeded, fixed at 999999.9 km.



* Displayed in



Service meter



the "upper column" on the character display



Odometer (Regu- Odometer lar display item)



7



Display method



LED



Fuel level



Service meter (Regular display item)



Display range/ conditions



Caution



Gauge 6 12



Color



Action code



0 – 999999.9 km * Displayed in Operates durthe "lower coling traveling. umn" on the character display



LCD



Failure code



HD465-7E0, HD605-7E0



When any probDisplay lem or failure characoccurs on the ter: machine, * Disblack played in the Backupper and lower ground columns on the color: character display. green



When any problem or failure occurs, the action code is displayed in the upper column and remedies or description of problem in 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:"KOMATSU" is displayed in the upper column. Note 2 Note 2:"Program No." is displayed in the lower column.



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



7



SEN01096-05



10 Structure, function and maintenance standard



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



No.



7



Display item



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



8



Display category



Backlight



Central warning lamp



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 "] switch: Number at cursor moves forward. q [], [] switch: Number at cursor moves forward. [] switch: Select "YES". [], [] switch: Number at cursor moves forward. q [] switch: Number at cursor moves forward. q [] switch: Number at cursor moves forward. q [] switch: Number at cursor moves forward. q [] switch: Number at cursor moves forward. q [], [] switch or []: To proceed to next monitoring system and function q [ ]: Select NO (move cursor). q [t]: Execute YES or NO a After initializing, confirm that the display on the lower line indicates that initialization is completed. q Initialization is done: INITIAL STATUS



HD465-7E0, HD605-7E0



30 Testing and adjusting



10) With 2 items simultaneous monitoring selected, press the [U] switch and display the monitoring code input screen. q [U]: Execute monitoring system and function. 11) In the monitoring code input screen, operate each of the switches [>], [ ]: Number at the cursor increases. q [ < ]: Number at the cursor decreases q [U]: Number at the cursor is determined q [ t]: Cursor moves to the left end / To return to the monitoring system and function selection screen. q Monitoring code: 32500 and 38920 a Indicate the transmission oil temperature in the upper row (32500) and study condition of clutch trigger in the lower row (38920) (0: not learned yet, 1: already learned).



12) Set AISS LOW switch to LOW. 13) Start the engine, keep the gear shift lever at N position for 10 seconds at the low idle, then operate the gear shift lever as follows. a Gear shift lever operation: NoRoN 14) Confirm the trigger learning display of R clutch in the monitoring display. a Proceed to the next step if the display is "1". a If the display is "0", repeat procedure 13) until it becomes "1". a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV. a The * marked clutch display can be either "0" or "1".



HD465-7E0, HD605-7E0



SEN01653-02



15) Set the gearshift lever in the 6 position and press the accelerator pedal fully to run the truck and shift up the gear to F6. a Shifting up: F1 o F2 o F3 o F4 o F5 o F6 16) After the gear is shifted up to F6, release the accelerator pedal and shift down the gear to F1 by coasting run. a Shift down: F6 o F5 o F4 o F3 o F2 o F1 a Do not apply the brake during coasting run. 17) Check that the trigger learning of the 4th clutch is displayed on the monitor. a If "1" is displayed, go to the next step. a If the display is "0", repeat procedure 15) – 16) until it becomes "1". a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV. a The * marked clutch display can be either "0" or "1".



29



SEN01653-02



18) Set the gearshift lever in the 4 position and press the accelerator pedal fully to run the truck and shift up the gear to F4. a Shifting up: F1 o F2 o F3 o F4 19) After running the machine at F4 for 10 seconds, release the accelerator pedal and shift down the gear to F1 by coasting run. a Shifting down: F4 o F3 o F2 o F1 a Do not apply the brake during coasting run. 20) Check that the trigger learning of the 2nd clutch is displayed on the monitor. a If "1" is displayed, go to the next step. a If "0" is displayed, repeat steps 18) – 20) until "1" is displayed. a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV. a The * marked clutch display can be either "0" or "1".



21) Set the gearshift lever in the 3 position and press the accelerator pedal fully to run the truck and shift up the gear to F3. a Shifting up: F1 o F2 o F3 22) After running the machine at F3 for 10 seconds, release the accelerator pedal and shift down the gear to F1 by coasting run. a Shifting down: F3 o F2 o F1 a Do not apply the brake during coasting run.



30



30 Testing and adjusting



23) Check that the trigger learning of the Hi clutch is displayed on the monitor. a If "1" is displayed, go to the next step. a If "0" is displayed, repeat steps 21) – 23) until "1" is displayed. a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV. a The * marked clutch display can be either "0" or "1".



24) Set the gearshift lever in position 4 and press the accelerator pedal fully to shift up the gear to F3 and then continue travel at F3, adjusting the accelerator pedal. a Shifting up: F1 o F2 o F3 25) After running the machine at F3 for 10 seconds, press the accelerator pedal fully to shift up the gear to F4. a Shifting up: F3 o F4 26) Stop the machine and check that the trigger learning of the low clutch and 3rd clutch is displayed on the monitor. a If "1" is displayed, go to the next step. a If "0" is displayed, repeat steps 24) – 26) until "1" is displayed. a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV. a The * marked clutch display can be either "0" or "1".



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01653-02



27) Set the gearshift lever in the 2 position and press the accelerator pedal fully to run the truck and shift up the gear to F2. a Shifting up: F1 o F2 28) After running the machine at F2 for 10 seconds, release the accelerator pedal and shift down the gear to F1 by coasting run. a Shifting down: F2 o F1 29) Check that the trigger learning of the 1st clutch is displayed on the monitor. a If "1" is displayed the initial learning has completed finally. a If "0" is displayed, repeat steps 27) – 29) until "1" is displayed. a If "1" is not displayed after repeating the steps 4 times, the ECMV may be defective. In this case, replace the ECMV.



30) In the monitiring display, confirm finally the trigger learning display of lower line. a If displayed as drawing, the initial learning has completed normally.



31) Press [t] switch sereral times and complete service menu. q [t]: To return to the previous screen.



HD465-7E0, HD605-7E0



31



SEN01653-02



[16] Filter and oil replacement time setting function (MAINTENANCE MONITOR) Machine monitor can set the maintenance intervals for various filters and oil which become the base of replacement time display for filter and oil. Also the machine monitor can activate or deactivate the display function. 1. Selection of the service menu Select the filter and oil replacement time setting function (MAINTENANCE MONITOR) in the service menu selection screen.



30 Testing and adjusting a



No.



Displayed function:



Display



Displaying and selecting the maintenance item and function 1) With the service menu selected, press the [U] switch to display the maintenance item and function selection screen. q [U]: Conduct the service menu.



32



and



Maintenance items and functions



41:FUEL P FILT



Fuel pre filter



2



01:ENG OIL



Engine oil



3



02:ENG FILT



Engine oil filter



4



13:TM FILT



Transmission oil filter



5



03:FUEL FILT



Fuel main filter



6



06:CORR RES



Corrosion resistor



7



17:TC/TM/ BK OIL



Torque convertery/ Transmission/Brake oil



8



14:BK OIL FILT



Brake oil filter



9



16:BK C FILT



Brake cooling oil filter Hydraulic oil filter



11 11:DIFF OIL



Differential oil



12 08:FNL OIL



Final drive oil



13 10:HYD OIL



Hydraulic oil



14 INITIALIZE



Setting default value for all items



15 ALL ITEMS



Setting validity or invalidity for all items



a



a



2)



item



1



10 04:HYD FILT



2.



maintenance



No.1 – 14 are the maintenance items where the setting is changed by item, and No.15 – 16 are the functions which allows to change the setting of all items simultaneously. Display the item and function in the [*] section.



If [>] switch or []: To proceed to next maintenance item and function. q [] switch or the [], [ ]: Number at the cursor increases. q [ < ]: Number at the cursor decreases. q [U]: Number at the cursor is determined. q [ t]: To return to the service menu selection screen. a The time must always be input with 4 digits. For the time with less than 4 digits, input 0s in place of the vacant number.



HD465-7E0, HD605-7E0



5.



When the interval time is completely determined, the screen to confirm the changes is displayed. Then, operate each of the switches [] and [t]. q [ ]: Select NO (move cursor) q [t]: Execute YES or NO



Set the function activation or deactivation by maintenance item (items No.1 – 14). 1) With the item selected on the maintenance item and function selection screen (ex: FUEL P FILT) to change the activation or deactivation of the function, press the [U]switch to display the interval input screen. q [U]: Implement the function to change maintenance item.



33



SEN01653-02



2)



3)



After displaying the screen to input intervals, press the [>] switch or the []: Switch the setting screen. q [ ]: Select NO (move cursor) q [t]: Execute YES or NO



Display the all item default value setting screen and operate each [] and [t] switches. q [ ]: Select NO (move cursor) q [t]: Execute YES or NO



a



a



34



If the timer which has been OFF is turned ON, the interval is set to the value before it was turned OFF and the rest of set time of the timer is reset. The number of resetting times is set to the value before it was turned OFF.



If the intervals for all the items are changed in an item, all the items are set to their respective default values, regardless of the ON or OFF state of each item. The rest of the set time of the timer is set to the [default value/elapsed time after the previous replacement].



HD465-7E0, HD605-7E0



30 Testing and adjusting a a 7.



SEN01653-02 a



The number of resetting times is kept at the value before the default was set. Each item is set turned ON.



Setting the function activation or deactivation for all the items (function No.16) 1) With the activation or deactivation setting for all items selected (ALL ITEMS) on the maintenance item and function selection screen, press the [U] switch to display the all items activation or deactivation setting screen. q [U]: Implement the function to set activation or deactivation of all the items.



a



4)



2)



3)



After the all items activation or deactivation setting screen is displayed, press the [>] switch or the []: Switch the setting screen. q [] switch or the []: To display the next information screen. q [] switch or the [] switch or the []: Switch the displayed screen q [], [ ]: To switch the cursor symbol (+/-) / Number increases. q [ < ]: To switch the cursor symbol (+/-) / Number decreases. q [U]: Sign/number at the cursor is determined. q [ t]: Return to the fuel correction screen a The correction value at the plant before shipment is [+/-00.0%] (In case of inputting 00.0, +/- does not matter.) a The compensation value can be input within the range of [-50.0% – +50.0%].



[18] Engine mode fixing function (FIX POWER MODE) While the screen is displayed, the operator can measure the high idle speed and torque converter stall speed to check the engine performance. q Engine high idle speed q Torque converter stall speed If a mode is selected by the following operation, it is sent to the transmission controller, which sends it to the engine controller. 1. Advance check Before the operation, check the following items. q Parking brake: ON (Parking) q Failure code: Not displayed a Refer to "Standard valve table" about mode and spec. 2.



SEN01653-02



3.



Selection of mode While the service menu is selected, press the [U] switch to display the engine mode fixing screen. q [U]: Execute service menu



4.



Selection of displayed information While the engine mode fixing screen is displayed, select the information screen to be displayed with the [>] or [ ] switch: Select setting screen q [ < ] switch: Select setting screen q [t] switch: Engine mode fixing function a The mode is four kind of A – D.



5.



Finishing of display Press the [t} switch to return to the engine mode fixing function screen. q Fixing of the engine mode is reset.



Selection of service menu While the service menu selection screen is displayed, select the engine mode fixing function (FIX POWER MODE).



HD465-7E0, HD605-7E0



39



SEN01653-02



[19] Manual snapshot function (Snapshot) q This function is applicable to only machines equipped with VHMS. q The manual snapshot function stores 7 minutes and 30 seconds worth data to be used for Pm clinic or testing/adjustment to VHMS controller. q When collecting data at a regular interval for Pm clinic, it is required to observe the machine operating procedure specified for the quick Pm. As for the data collection for the testing or adjustment purpose, however, no specified machine operating procedure is stipulated. q When using the data being stored with the manual snapshot function, a PC must be connected. For the connecting as well as operating procedure, refer to VHMS controller initial setting procedure. (Connection of a PC may be done before or after the snapshot.) a For detail of operation of the snapshot function, see the Quick Pm implementation procedure. 1. Display the SNAPSHOT screen from the menu screen of Service mode.



2.



40



Pressing [U] switch to turn on the ready (READY) screen. a The lower column displays 15 pieces of [–] sign.



30 Testing and adjusting



3.



Press [U] switch to start the snapshot. a The upper column displays the elapsed time. a [–] sign in the leftmost position of the lower column is replaced with [*] and it starts flashing. a For every 30 seconds, [–] is replaced with [*] starting with the leftmost one. When two or more [*] signs are displayed, the rightmost one flashes. a Pressing [t] switch while the snapshot is taking place stops the snapshot.



4.



Refer to the Pm clinic implementation procedure for the machine operation. a After 10th [*] is displayed (5 minutes elapsed from the start), [#] will be displayed for 11th through 15th positions. q *: Indicates the data sampling interval is once every 10 seconds. q #: Data sampling interval is once every 1 second.



5.



As 7 minutes and 30 seconds elapsed from start of the snapshot, following screen appears and then the initial screen is restored in 5 seconds later. (End of snapshot)



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01653-02



[20] PLM setting function (PLM) q This function is applicable when the PLM in VHMS is installed. Set various items of the payload meter (PLM) with the machine monitor. The details refer to "Setting of payload meter built in VHMS".



[23] Initializing function (INITIALIZE) a This function is exclusive for the plant, and is not used for service.



[21] Option selection function (OPTIONAL SELECTION) Machine monitor can set and adjust various optional devices which have been installed or removed. a The operating method of this function refers to the item of "Setting and adjusting various equipment".



[22] Model selection function (MACHINE) Machine monitor is common among many models, and if the machine monitor is replaced, select the same model as the one currently installed. a The operating method of this function refers to the item of "Setting and adjusting various equipment".



HD465-7E0, HD605-7E0



41



SEN01653-02



30 Testing and adjusting



HD465-7E0, HD605-7E0 Dump truck Form No. SEN01653-02



© 2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (02)



42



HD465-7E0, HD605-7E0



SEN01654-04



DUMP TRUCK HD465-7E0 HD605-7E0



Machine model



Serial number



HD465-7E0 HD465-7E0 HD605-7E0 HD605-7E0



10001 10101 8001 10101



– 10037 and up – 8032 and up



30 Testing and adjusting



1



Testing and adjusting, Part 5 Request for opening ORBCOMM terminal...................................................................................................... 2 VHMS controller initial setting procedure........................................................................................................ 4 Using method of KOMTRAX functions of ORBCOMM terminal.................................................................... 24 Precautions for replacing VHMS controller ................................................................................................... 27 Pm Clinic check sheet................................................................................................................................... 33 Initial setting of payload meter ...................................................................................................................... 37 Setting of payload meter built in VHMS ........................................................................................................ 38 Setting of card-type payload meter (PLM- ) after installation or replacement............................................. 46



HD465-7E0, HD605-7E0



1



SEN01654-04



30 Testing and adjusting



Request for opening ORBCOMM terminal 1 a



a a



2



If the machine is equipped with ORBCOMM, fill in the "Request for opening VHMS ORBCOMM terminal" and send it by fax or mail to "KOMATSU KOMTRAX SUPPORT CENTER" before initializing the VHMS controller. Initialize the VHMS controller after the opening notification is received from "KOMATSU KOMTRAX SUPPORT CENTER". If the ORBCOMM antenna is installed and the starting switch is turned to the ON position before the opening notification is received, the ORBCOMM terminal transmits radio waves and ORBCOMM CO. LTD. sends out the stop signal automatically. In this case, complicated procedures and some time are required to open the ORBCOMM terminal service again.



HD465-7E0, HD605-7E0



30 Testing and adjusting



HD465-7E0, HD605-7E0



SEN01654-04



3



SEN01654-04



30 Testing and adjusting



VHMS controller initial setting procedure a



1.



1



Testing instrument



Symbol



Part No.



Part name



1



799-608-3211 Diskette



2



799-608-3220 Wiring harness



3



Note type PC Commercially (Windows 98/2000/Me/XP/ available VISTA(*) and terminal "RS232C" is with it)



N



No.



* : VHMS setting tool Ver.3.06.00.03 or later, VHMS analysis tool Ver.3.05.00.00 or later. a



a



a



a



a



a a a



4



Initial setting of VHMS controller shall be done according to the following procedure. This operation is needed prior to a full-scale operation of a machine being delivered and assembled in the field, or prior to resumption of its operation after a long time of storage. Machine data collected with VHMS controller are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be provided among the settings done on VHMS controller. Inconsistencies in the settings obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. The initial setting, therefore, is a must. For the method of installing the VHMS Initialization Program to the personal computer, refer to the Operation and Maintenance Manual contained in the package of diskette N1. Since the service menu of the machine monitor will be used in the following procedure, read " Sp e c i a l f u n c t i o n s o f m a c h i n e m o n i t o r (EMMS)" and understand the operating procedure in advance. The initial setting procedure is described in the ORBCOMM installation specification and the ORBCOMM-less specification. When using the ORBCOMM installation specification, implement the procedures needed for VHMS alone, bypassing those prepared only for ORBCOMM installation specification. Check each step of the setting work referencing the VHMS initial setting work check sheet. Information such as models shown in the figures may not be identical with actual ones. During the initialization work, confirm each work according to the "VHMS Initialization Work Checklist".



Confirmation of machine information, engine information, transmission controller information and controller information a This confirmation procedure is targeted at the entire machine. Confirm and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information.



2.



Information to be confirmed



1



Model name



2



Machine serial No.



3



Current service meter hour



4



Engine serial No.



5



Transmission serial No.



6



VHMS controller serial No.



7



ORBCOMM terminal serial No. [Only for machines equipped with ORBCOMM]



Connecting a PC a This work is done inside the cab. 1) Make sure the starting switch is at OFF position. k Before connecting or disconnecting a PC, be sure to turn off the starting switch. 2) Using harness N2, connect the PC N3 and download connector DPC7. a Then connect the PC to RS232C terminal.



HD465-7E0, HD605-7E0



30 Testing and adjusting a



SEN01654-04



Download connector DPC7 is installed to box (1) in the cover at the rear of the operator's seat.



3)



3.



Confirming VHMS controller operation and confirming satellite capturing state a This work is done inside the cab. a Confirmation of capturing of the satellite is done for [ORBCOMM installation specification]. 1) Turn the starting switch ON. 2) Check the controller for normal operation referencing 7-segment LED of VHMS controller. a The VHMS controller is powered with the accessory power supply. Accordingly, when the starting switch is turned ON, the 7-segment LED must blink to display rotation and then count up in hexadecimal notation. If the LED operates in this way, the VHMS controller is operating normally.



HD465-7E0, HD605-7E0



Among the 7-segment LED situated in the right side of VHMS controller, refer to the one that represents the decimal point to check whether or not ORBCOMM controller has captured the communication satellite. [ORBCOMM installation specification] a Check whether or not ORBCOMM terminal is capturing the communication satellite from VHMS controller. a Perform this check within 3 minutes after the VHMS starts. a If the decimal point LED of the righthand 7-segment LED blinks, the ORBCOMM controller is capturing the communication satellite normally. a The ORBCOMM terminal may take time to capture the satellite, depending on the strength of the signals from the satellite.



– States of decimal point LED – q OFF: The terminals cannot communicate with the ORBCOMM terminal. q ON: Communication between VHMS controller and ORBCOMM terminal is normal. The terminals have not captured the satellite. q Quick blink: Communication between VHMS controller and ORBCOMM terminal is normal. The ORBCOMM terminal does not have any data to transmit. It has captured the satellite.



5



SEN01654-04



q



4.



Starting the VHMS initial setting tool a This work is done inside the cab (from PC). 1) Turn on the PC power and start the OS. 2) Operating [VHMS initial setting tool] icon on the PC, start up the VHMS initial setting tool.



3) 4) 5)



6



Slow blink: Communication between VHMS controller and ORBCOMM terminal is normal. The ORBCOMM terminal has data to transmit and it has captured the satellite.



Important a Appearance of the setup screen of the VHMS setting tool depends its tool. a When using Ver.3.5.2.1 or older version (CD-ROM), the setting procedure shall conform to that described in Section 5. a When using an update version (Ver.3.5.2.1 or after), the procedure in Section 6 shall be used. a It is recommended to download the latest VHMS version from WebCARE to update the currently used version. (Related material: SERVICE MATE SMP-623) Enter the 10-digit service ID to [Service ID]. a Service ID: 7826142000 Select [Data clear and Set up] from [Select Function] item. Click [OK] button to proceed to the setup screen.



30 Testing and adjusting



5.



Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or older version) a This work is done inside the cab (from PC). a It is prohibited in the initial setting to modify the data of service meter [SMR]. [Machine Information] 1) Open [Machine Information] tab. a [Data clear and Set up] menu displays [Machine Information] tab first. 2) Check every data for correctness. a The figure shows the display of another model as an example.



a 3)



Select a [Variation Code] from the following table. When [Date/Time] information is not appropriate, correct it in the following manner. 1] Press [Edit] button in the lower right side of [Date/Time] box to display the correction screen. 2] After correcting it to the correct information, press [OK] button.



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01654-04



Setting with VHMS initial setting manual (tool) (*1) VHMS controller



PLM function in VHMS controller



Card-type payload meter (PLM- )



Not installed



—



Not installed



Not installed



Not installed



—



Installed



Installed



Installed



Not installed



Not installed



Not installed



Payload meter (PLM) function



Model



Installed



Not installed



Installed



Installed



Installed



Installed



Not installed



Installed



Type



Variation code



Date Time Time difference (GMT) Summer time



—



—



—



—



—



—



—



—



ST HD465 HD605



– 7E0



P2



Set properly



PV



(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool) a A variation code is an item among the model, date, etc. that are set with the personal computer software when the VHMS is initialized. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV), whether PLM II 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.



HD465-7E0, HD605-7E0



7



SEN01654-04



8



4)



When [Machine Information] information is not appropriate, correct it in the following manner. 1] Press [Edit] button in the lower right side of [Machine Information] dialog box to display the correction screen. 2] After correcting it to the correct information, press [OK] button.



5)



As every data in [Machine Information] has been checked and corrected, press [Apply] button to settle the setting. a As [Apply] button is pressed, a message confirming above setting will appear on the screen. Check the setting again and, if the setting is correct, press [OK] button. a ORBCOMM installation specification requires the settlement operation after [Communication Setting] is completed.



30 Testing and adjusting



[Communication Setting] [ORBCOMM installation specification only] a This setting shall be implemented after the request for station opening has been made and station of ORBCOMM has been opened. 6) Open [Communication Setting] tab. 7) Check every data for correctness.



8)



When modifying the setting of [SHORT FAULT HISTRY], employ the following procedure. 1] Select [SHORT FAULT HISTRY] from the screen and then press [Edit] button in the lower left side of [File Transfer Setting] block to display the setup screen. 2] Correct the setting and, as it is completed, press [OK] button. a In the initial setting, select [Occurrence] from [Timing] item and then set the function to ON.



HD465-7E0, HD605-7E0



30 Testing and adjusting



9)



When modifying the setting of [SHORT TREND ANALYSIS], employ the following procedure. 1] Select [SHORT TREND ANALYSIS] from the screen and then press [Edit] button in the lower left side of [File Transfer Setting] block to display the setup screen. 2] Correct the setting and, as it is completed, press [OK] button. a In the initial setting, enter [20h] to [SMR] and then set the function to ON.



SEN01654-04



GCC Code



Area



Remarks



N.America (*1) *1: Except U.S. Territories in C.S.Americas Micronesia and Midway Faroe Islands Island



1



120



Europe (*2) Middle East Asia (*3) Africa Oceania CIS



130



Japan



*2: Except Faroe Islands *3: Except Japan



a



If the combination of the country name and code in the list box displayed by the setting tool is different from the above table, select the GCC code in the table or input the value through the keyboard. 11) As every data in [Communication Setting] has been checked and corrected, press [Apply] button to settle the setting. a As [Apply] button is pressed, a message confirming above setting will appear on the screen. Check the setting again and, if the setting is correct, press [OK] button.



10) When modifying the setting of [Satellite Setting], employ the following procedure. 1] Press [Edit] button in the [Satellite Setting] block to display the correction screen. 2] Set the GCC code to the region applied and, as setting is completed, press [OK] button.



HD465-7E0, HD605-7E0



9



SEN01654-04



12) As every data in [Machine Information] and [Communication Setting] has been checked and corrected, press [Exit] button to end [VHMS initial setting tool].



6.



30 Testing and adjusting



2)



Select [Set up & All clear] and press [Next] button.



3)



Confirm the machine information and, if they are correct, press [Next] button.



Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or later version) a This work is done inside the cab (from PC). a It is prohibited in the initial setting to modify the data of service meter [SMR]. 1) Select [VHMS Setting] and then press [Next] button.



a



10



When VHMS has been installed later, it is required to enter the information such as [Serial No.].



HD465-7E0, HD605-7E0



30 Testing and adjusting



4) 5) 6)



7)



Select the time zone. Enter the local time. When DST (Daylight Saving Time) (or summer time) is currently used, press [Next] button. a Selecting DST advances the clock by an hour. Thus, correction of the time is needed again.



8)



If there is no problem in the setting displayed last, press [Apply] button.



9)



A screen message will confirm whether or not the data before the setting is to be saved. If the data is not necessary, select [NO].



Set the GCC code to the target region of application and, as setting is completed, press [Next] button.



GCC Code 1



SEN01654-04



Area



Remarks



N.America (*1) *1: Except U.S. Territories in C.S.Americas Micronesia and Midway Faroe Islands Island



120



Europe (*2) Middle East Asia (*3) Africa Oceania CIS



130



Japan



a



*2: Except Faroe Islands *3: Except Japan



If the combination of the country name and code in the list box displayed by the setting tool is different from the above table, select the GCC code in the table or input the value through the keyboard.



HD465-7E0, HD605-7E0



11



SEN01654-04



10) As correction of the first setting is completed, press [OK] button to end the program.



30 Testing and adjusting



4) 5)



Press the buzzer cancel switch [U]. [READY] will be displayed on the screen, turning on the standby mode. a The lower column displays 15 pieces of [–] sign.



6)



Press the buzzer cancel switch [U] to start the snapshot. a As the snapshot is started, the upper column starts displaying the elapsed time. a [–] in the leftmost position of the lower column is replaced with [*] for every 30 seconds. When two or more [*] signs are displayed, the rightmost one flashes. a When stopping the snapshot currently taking place, press the buzzer cancel switch [t].



7)



After the snapshot is started, operate the machine according to the following table. a Make sure the engine coolant temperature and torque converter oil temperature are within the operating range. a After 10th [*] is displayed (5 minutes elapsed from the start), [#] will be displayed for 11th through 15th positions. q *: Indicates the data sampling interval is once every 10 seconds.



11) Turn the starting switch OFF. Check that the 7-segment LED of the VHMS controller keeps displaying for several seconds and then goes off securely.



7.



Executing quick Pm a Quick Pm denotes the Pm click done by use of the manual snapshot function of the machine monitor. a It stores 7 minutes and 30 seconds worth of data to VHMS controller. k Park the machine in a flat place. 1) 2)



3)



12



Start the engine. Switch the machine monitor to Service menu. a For the procedure of opening Service menu, see "Special functions of machine monitor". Display the manual snapshot function screen from the menu screen of Service mode.



HD465-7E0, HD605-7E0



30 Testing and adjusting



q



SEN01654-04



#: Indicates the data sampling interval is once every 1 second.



HD465-7E0, HD605-7E0



13



SEN01654-04 a



30 Testing and adjusting



Machine operation for snapshot 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



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



AISS switch



Power mode Shift lever setting



Parking brake



Retarder



Dump lever



ON



ON



Hold



OFF



OFF



Hold



ON



Float



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)



14



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).



HD465-7E0, HD605-7E0



30 Testing and adjusting



8)



As 7 minutes and 30 seconds elapsed from start of the snapshot, following screen appears and then the initial screen is restored in 5 seconds. (End of snapshot)



Important Data of quick Pm are recorded only once. Thus, if another quick PM is repeated, the current data will be overwritten with the last one. In order to avoid above trouble, be sure to download data of every completed quick Pm shall to PC. For the procedure, see 8. Download of setting data. 9)



Read the quick PM data by use of the analysis tool. a For detailed usage of the analysis tool, see the operation and maintenance manual.



HD465-7E0, HD605-7E0



SEN01654-04



10) Open the quick Pm data to draw a graph. a Set the Time to the X-axis and set the following to the Y-axis. q Engine Speed (Engine speed) q Fuel Inject (Fuel injection rate) q Blowby Press (Blow-by pressure) q F Exhaust Temp (Exhaust temperature of No. 1, 2, 3 cylinders) q R Exhaust Temp (Exhaust temperature of No. 4, 5, 6 cylinders) q Engine Oil Press (Engine oil pressure) q Engine Oil Temp (Engine oil temperature) q Coolant Temp (Engine coolant temperature) q Ambient Temp (Ambient temperature) q Boost Press (Boost pressure) q Accelerator Pos (Accelerator position) q Hoist Lev Pos (Dump lever position) q T/C Oil Temp (Torque converter oil temperature) q T/M Out speed (Transmission output speed) q Shift Indicator (Gearshift position) q Lock Up Signal (Lockup signal) q Retarder Temp (Retarder oil temperature) q F Brake Press (Front brake oil pressure) q R Brake Press (Rear brake oil pressure) q Retarder Position (Retarder position) q Foot Brake Position (Foot brake position)



15



SEN01654-04



30 Testing and adjusting



11) Apply a check mark to the Display graph value at clicked position.



16



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30 Testing and adjusting



SEN01654-04



12) Clicking the graph shows, below the graph, the X-axis value of respective measurement items. (An example of a graph displayed – Not an actual one)



HD465-7E0, HD605-7E0



17



SEN01654-04



8.



30 Testing and adjusting



Download of setting data 1) Using harness N2, connect PC N3 to download connector DPC7 in the cab or download connector VDL on the ground.



a



Download connector DPC7 in the cab is installed to box (1) in the cover at the rear of the operator's seat.



2) 3)



4)



a



18



When using download connector DPC7 in the cab, set the starting switch to ON position. When using download connector VDL on the ground, set switch (3) to ON position. a The green LED will come on. Operating [VHMS analysis tool] on PC, start up the VHMS analysis tool.



Ground download connector VDL is installed in box (2) at the rear of the f r on t t ir e on t he l eft si d e o f th e machine.



HD465-7E0, HD605-7E0



30 Testing and adjusting a a



5)



Enter [User Name] and [Password]. For the operating procedure, see the VHMS analysis tool operation and maintenance manual.



Using [Download] function, download the data currently recorded on VHMS to PC. a For the operating procedure, see the VHMS analysis tool operation and maintenance manual. a After making sure the download is complete, proceed to the next step.



HD465-7E0, HD605-7E0



SEN01654-04



9.



Confirmation of download data 1) Check the setting data using [View] function. a For the operating procedure, see the VHMS analysis tool operation and maintenance manual. a Make sure that [MFA0] code, which was used in the quick snapshot, is indicated in [Fault History]. a Make sure the snap shot data are recorded.



2)



As check of the setting data is finished, end [VHMS analysis tool].



19



SEN01654-04



30 Testing and adjusting



10. Disconnecting the PC 1) Make sure the starting switch is at OFF position. k Before connecting or disconnecting a PC, be sure to turn off the starting switch. 2) End the OS of PC N3 and then turn off the PC power.



3)



When the data was download into the cab, disconnect harness N2 from download connector DPC7.



11. Report to Komatsu As steps 1 – 10 are completed, send VHMS/ WebCARE setting report to VHMS/WebCARE Support Center in Komatsu Headquarters. a This report is a must since setting on the receiving end in the satellite communication must be done by Komatsu. a In this case, send VHMS data via Notes (LAN) or E-mail (WAN). a When using the KOMTRAX functions on the machine equipped with the ORBCOMM, complete the sign-up test on the machine side and enter the use of the KOMTRAX functions in the "VHMS/WebCARE setting notification form". Komatsu VHMS/WebCARE Support Center



2-3-6, Akasaka Minato-Ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user) E-mail: [email protected]



4)



20



When the data was download to the ground, disconnect N2 from download connector VDL.



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01654-04



[For storage] VHMS Initial Setting Work Check Sheet



Date of setting: DB/branch office name Data entered by:



Setup step



Check item



Result



Model name Confirmation of machine body and 1 component nameplates



Serial No. Engine serial No. Transmission controller serial No. VHMS controller serial No.



2



Connection between PC and VHMS controller



Is the connection secure?



yes



no



3



VHMS controller check for normal operation



Is it operating normally? (Displays counting in ascending-order succeeding to rotation)



yes



no



Is "Data Clear and Set up" selected for the setting tool mode?



yes



no



Is model name identical with machine body?



yes



no



4 Starting of VHMS initial setting tool



Initial setting of VHMS controller



Is machine body serial No. correctly entered?



yes



no



(Setting of machine body informa5 tion) In this step, basic machine body information are set on VHMS controller



Is engine serial No. correctly entered?



yes



no



Is today's date entered?



yes



no



Is current time entered?



yes



no



Is SMR correctly entered?



yes



no



6 Saving of settings



Is LED (7-segment) turned off?



yes



no



7 Confirmation of VHMS function



Is LED operation normal?



yes



no



8 Execution of quick Pm



Is service mode "SNAPSHOT" turned on and is the switch hit?



yes



no



9 Data storing operation on VHMS



Is LED (7-segment) turned off?



yes



no



10 Download



Is LED operation normal?



yes



no



Are all files downloaded?



yes



no



The time downloaded (Reference wrist watch) 11 Confirmation of download data



12 Data storing operation on VHMS



HD465-7E0, HD605-7E0



Hour, minute:



[Confirmation of data] Is [MFA0] error present in Fault History?



yes



no



Are SMR and time in Fault History consistent with settings?



yes



no



Is any data missing in Snap Shot?



yes



no



Is LED (7-segment) turned off?



yes



no



21



SEN01654-04



30 Testing and adjusting



[For storage] ORBCOMM Station Opening Work Check Sheet Setup step



Date of setting: DB/branch office name Data entered by: Check item



Result



Model name Serial No. 1



Confirmation of machine body and component nameplates



Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM terminal serial No.



2



Connection between PC and VHMS controller



Is the connection secure?



yes



no



3



VHMS controller check for normal operation



Is it operating normally? (Displays counting in ascending-order succeeding to rotation)



yes



no



Is "Set up" selected for the setting tool mode?



yes



no



On



Off



On



Off



On



Off



4 Starting of VHMS initial setting tool



Entry of setting to S.Fault History Initial setting of VHMS controller 1. Setting of communication (Setting of machine body information and PLM are completed)



Presence/absence of communication Number of cases (Default is 8 cases) Entry of setting of S.Trend Analysis setting Presence/absence of communication Interval (Default is 20H)



5



Entry of setting of S.Payload data Presence/absence of communication Tabulation start time Interval of tabulation (in days) 2. Setting for start of communication



6 Saving of settings 7



22



ORBCOMM controller performance check



day



Is GCC code set? (130 for Japan)



yes



no



Is LED (7-segment) turned off after data was stored?



yes



no



How is decimal point display in VHMS monitor (7-segment)? (OFF, ON, long/short flashing)



yes



no



HD465-7E0, HD605-7E0



30 Testing and adjusting



HD465-7E0, HD605-7E0



SEN01654-04



23



SEN01654-04



30 Testing and adjusting



Using method of KOMTRAX functions of ORBCOMM terminal1 a



a



a



The ORBCOMM terminal equipped with the KOMTRAX function can display the machine on the control screen of the KOMTRAX system. Whether the ORBCOMM terminal has the KOMTRAX functions can be checked by the part No. of the ORBCOMM terminal. q KOMTRAX functions provided: No. 7826-12-2500 q KOMTRAX functions not provided: No. 7826-12-2302 When using the KOMTRAX functions, perform the following procedure.



1.



Make the request for opening the ORBCOMM terminal and receive the opening notification. a See "Request for opening ORBCOMM terminal".



2.



Initialize the VHMS controller and set the GCC code of the machine location. a See "Initialization procedure for VHMS controller".



3.



Perform the sign-up test on the machine side. a Perform the sign-up test in an open outdoor place. a If the sign-up test is performed in an indoor place where the satellite radio waves are blocked, it may not be completed. a It may take time to complete the sign-up test, depending on the condition of receiving signals from the ORBCOMM communication satellite and GPS satellite. 1) Check that the VHMS controller, ORBCOMM terminal, ORBCOMM antenna and GPS antenna are connected to the wiring harness of the machine. 2) Turn the starting switch to the ON position. 3) Wait until LED1 lights up. a LED1 keeps flashing until the sign-up test is completed. a The ORBCOMM terminal executes the sign-up test and judges the result by itself. The criterion is as follows. q The starting switch is in the ON position. q The VHMS controller can communicate with the ORBCOMM terminal (They are connected normally). q A valid GCC code is set to the VHMS controller.



24



The ORBCOMM terminal is receiving the signals from the ORBCOMM communication satellite. (The ORBCOMM antenna is connected.) q Positioning of the machine with the is completed (The GPS antenna is connected.) Check that LED1 is lighting. a At this time, the sign-up test is completed. a Once the sign-up test is completed, the ORBCOMM terminal cannot be returned to the original state. q



4)



HD465-7E0, HD605-7E0



30 Testing and adjusting



[LED display] (1) LED-green



SEN01654-04



[State] Waiting for server trigger: Lighting Normal operating state: Turning off (2) LED-green ORBCOMM satellite capture Satellite not captured: Lighting Satellite captured (No transmission data): Quick flashing Satellite captured (There is transmission data): Slow flashing Power OFF: Turning off (3) LED-yellow VHMS start recognition VHMS start recognized: Lighting VHMS stop recognized: Turning off (4) LED-green ORBCOMM MODEM power ON: Lighting OFF: Turning off (5) LED-red Unused Kept Turning off (6) LED-red Unused Kept Turning off (7) 7-segment LED Number of mails waiting to be sent (Max. of 9) (8) Dot GPS satellite capture state Satellite not captured: Turning off Satellite captured: Lighting * Flashing interval Quick flashing: Period of 1 sec (Lighting for 0.5 sec and Turning off for 0.5 sec repeatedly) Slow flashing: Cycle of 4 sec (Lighting for 2 sec and Turning off for 2 sec repeatedly) KOMTRAX state



HD465-7E0, HD605-7E0



25



SEN01654-04



4.



30 Testing and adjusting



Apply for starting to use. 1) Notify the VHMS/WebCARE operations administrator of the following information of the machine which has completed the station set-up check. q Model, model No. and serial No. of machine q Part No. and serial No. of ORBCOMM terminal q Reading of service meter when signup test was completed (0.1 h unit) 2) Fill in the "VHMS/WebCARE setting notification form" and enter "Use" in the column of "Use of KOMTRAX Service". 3) Send the "VHMS/WebCARE setting notification form" to VHMS/WebCARE Support Center in Komatsu Head Office. Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) E-mail: [email protected]



4)



26



The KOMTRAX operations administrator registers the machine using the KOMTRAX client personal computer. a For the registration procedure, see the "Global KOMTRAX Web Reference Manual (For Key Person)".



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01654-04



Precautions for replacing VHMS controller 1 a



Testing instrument



Symbol



Part No.



Part name



1



799-608-3211 Diskette



2



799-608-3220 Wiring harness



3



Note type PC Commercially (Windows 98/2000/Me/XP/ available VISTA(*) and terminal "RS232C" is with it)



N



* : VHMS setting tool Ver.3.06.00.03 or later, VHMS analysis tool Ver.3.05.00.00 or later. a



a



a a



When it is required to replace a VHMS controller, setup of the replacing VHMS controller shall be conducted before and after the replacement according to the following procedure. Machine data collected with VHMS controller are stored and managed on WebCARE database. In order to endure smooth data processing on WebCARE , consistency must be provided among the settings done on VHMS controller. Inconsistencies in the settings obstruct loading of data to WebCARE, hampering appropriate use of VHMS data. Setting work after replacement, therefore, is a must. Check each step of the setting work referencing the "VHMS initial setting work check sheet". Information such as models shown in the figures may not be identical with actual ones.



[Operations needed prior to replacement of VHMS controller] 1. Download of the remaining data a This work is done inside the cab (from PC). a Using [Download] function, download the currently recorded and remained data on VHMS to PC. a For the operating procedure, refer to "8. Download of setting data" in "VHMS controller initial setting procedure".



HD465-7E0, HD605-7E0



2.



Confirmation, saving and loading of VHMS controller setting information (Ver. 3. 5. 2. 1 or older version) a This work is done inside the cab (from PC). a Setting information is saved from the VHMS controller to be replaced to the PC and the saved information is loaded to the new VHMS controller after the replacement. 2-1. Confirmation and saving of VHMS controller setting information prior to replacement 1) Connect the PC and start the VHMS initial setting tool. a See the "VHMS controller initial setting procedure" for this operation. 2) Select [Save/Load] and press [OK] button.



3) 4)



Confirm every information before the replacement. Select [Save] from [File] of the menu.



27



SEN01654-04



30 Testing and adjusting



2-2. Loading the setting information to the replacing VHMS controller 1) Connect the PC again and start the VHMS initial setting tool. a See the "VHMS controller initial setting procedure" for this operation. 2) Select [Save/Load] and press [OK] button.



5)



Reconfirm the information and then press [OK] button to save the information.



3)



6) 7)



8) 9)



28



Select [Load] from [File] of the menu.



Select [Exit] from [File] of the menu to end the VHMS setting tool. Disconnect the PC. a Refer to "10. Disconnecting the PC" in "VHMS controller initial setting procedure". Turns the PC power off. Proceed to replacement of VHMS controllers.



HD465-7E0, HD605-7E0



30 Testing and adjusting



4)



5) 6)



Currently saved information will be displayed. Press [OK] button.



SEN01654-04



7)



After adjusting time, press [OK] button.



8)



Press [Apply] button to display contents of the setting. Check the setting again and, if it is acceptable, press [OK] button.



Display the saved information on another screen. Press [Edit] button and adjust the time.



HD465-7E0, HD605-7E0



29



SEN01654-04



9) a



The confirmation screen will ask whether or not the data before the above setup is to be saved. Press [NO] button. It is not necessary to save the data before the setting.



30 Testing and adjusting



3.



Confirmation, saving and loading of VHMS controller setting information (Ver. 3. 5. 2. 1 or later version) a This work is done inside the cab (from PC). a Setting information is saved from the VHMS controller to be replaced to the PC and the saved information is loaded to the new VHMS controller after the replacement.



3-1. Confirmation of VHMS controller setting information prior to replacement 1) Connect the PC and start the VHMS initial setting tool. a See the "VHMS controller initial setting procedure" for this operation. 2) Select [When VHMS needs to be replaced] and then press [Next] button.



10) The setup result is displayed. Confirm the contents and press [Close] button.



3)



Select [Save current setting before replacement of VHMS controller] and press [Next] button.



11) Select [Exit] from [File] of the menu to end the VHMS initial setting tool.



30



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01654-04



4)



Confirm every information before the replacement and then press [Save] button.



3)



Select [Use previous setting after replacement of VHMS controller] and press [Next] button.



5)



Select [Exit] from [File] of the menu to end the VHMS initial setting tool. Disconnect the PC. a Refer to "10. Disconnecting the PC" in "VHMS controller initial setting procedure". Turns the PC power off. Proceed to replacement of VHMS controllers.



4)



Currently saved information will be displayed. Press [Next] button.



5)



Adjust the time and press [Apply] button.



6)



7) 8)



3-2. Loading the setting information to the replacing VHMS controller 1) Connect the PC again and start the VHMS initial setting tool. a See the "VHMS controller initial setting procedure" for this operation. 2) Select [When VHMS needs to be replaced] and then press [Next] button.



HD465-7E0, HD605-7E0



31



SEN01654-04



6)



The confirmation screen will ask whether or not the data before the above setup is to be saved. Press [NO] button. a It is not necessary to save the data before the setting.



30 Testing and adjusting



[Operations needed after replacement of VHMS controller] a Execute the quick Pm referring "7. Executing quick Pm" in "VHMS controller initial setting procedure". a Download the data referring "8. Download of setting data" in "VHMS controller initial setting procedure". a After the replacement, send VHMS/WebCARE setting report sheet to VHMS/WebCARE Support Center in Komatsu Headquarters. a Also send two sets of data, the downloaded before and after the VHMS replacement, via Notes (LAN) or E-mail (WAN). Komatsu VHMS/WebCARE Support Center



2-3-6, Akasaka Minato-Ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user)



7)



32



The above completes modification of the setting. Press [OK] button to end the VHMS initial setting tool.



E-mail: [email protected]



HD465-7E0, HD605-7E0



30 Testing and adjusting



Pm Clinic check sheet



HD465-7E0, HD605-7E0



SEN01654-04



1



33



SEN01654-04



34



30 Testing and adjusting



HD465-7E0, HD605-7E0



30 Testing and adjusting



HD465-7E0, HD605-7E0



SEN01654-04



35



SEN01654-04



36



30 Testing and adjusting



HD465-7E0, HD605-7E0



30 Testing and adjusting



SEN01654-04



Initial setting of payload meter



1



In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time 2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed 3. When the VHMS controller or transmission controller is replaced 4. When setting of VHMS controller (PLM ) is changed Table 1 Setting with VHMS initial setting manual (tool) (*1) VHMS controller



PLM function in VHMS controller



Card-type payload meter (PLM- )



Payload meter (PLM) function



Model



Not installed



—



Not installed



Not installed



Not installed



—



Installed



Installed



Installed



Not installed



Not installed



Not installed



Installed



Not installed



Installed



Installed



Installed



Installed



Not installed



Installed



Type



Variation code



Date Time Time difference (GMT) Summer time



—



—



—



—



—



—



—



—



ST HD465 HD605



– 7E0



P2



Set properly



PV



(*1) 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 In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 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 In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initialization manual (tool)" according to Table 1. 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.



HD465-7E0, HD605-7E0



37



SEN01654-04



Setting of payload meter built in VHMS



30 Testing and adjusting



1



Outline of procedure



38



HD465-7E0, HD605-7E0



30 Testing and adjusting



Set various items of the payload meter (PLM) with the machine monitor. 1. Selection of service menu While the service menu selection screen is displayed, select the PLM setting function (PLM).



2.



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). q [ > ] button: Number at cursor moves forward q [ < ] button: Number at cursor moves backward q [U] button: Enter number at cursor q [ t ] button: Stop inputting number a If the set value is too small, the system may recognize that loading is completed while the machine is still being loaded.



HD465-7E0, HD605-7E0



SEN01654-04



3.



Correction of calculation of load weight a Since this function affects the accuracy directly, execute the following procedure securely. a Be sure to measure the weight of the empty machine and that of the fully loaded machine as a set in order according to the following procedure. a The machine must travel for about 3 minutes each after its empty weight and its fully loaded weight are measured. Accordingly, secure a road for this purpose. a The relationship between the suspension pressure and load weight corrected with this function cannot be returned to the condition at the time of shipment. Accordingly, perform the following procedure very carefully. 1) Measure the weight of the empty machine with the load meter and record it (Write it on a sheet of paper, etc.) 2) Input the measured weight of the empty machine and drive the machine for about 3 minutes. 1] Select "EMPTY WEIGHT".



[>], [ ] button: Select "YES" [< ] button: Select "NO" q [t] button: Enter Move the machine to a place where you can drive it for about 3 minutes. q q



[U] button: Check that measurement has been completed and go to the next step q [t] button: Return to the previous screen Input the measured weight of the empty machine. q



3]



5]



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



[>] button: Number at cursor moves forward q [], [] button: Number at cursor moves forward q [] button: Number at cursor moves forward q [ ] button: Number at cursor moves forward q [ < ] button: Number at cursor moves backward q [U] button: Enter number at cursor q [ t] button: Stop inputting number The setting range is 6 – 25.5% of the rated load weight. (Default: 15%) a This function does not assure the operation because of the contrary phenomena shown below. q If the value is reduced, start of loading may be recognized wrongly. q 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.



Setting of criterion of maximum travel speed



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



Setting of load weight to recognize start of loading



7.



Setting of indication range of outside indicator lamps



Input an indication range of the outside indicator lamps by pressing the following buttons. q [ > ] button: Number at cursor moves forward



44



HD465-7E0, HD605-7E0



30 Testing and adjusting



q q q



a



8.



SEN01654-04



[ < ] button: Number at cursor moves backward [U] button: Enter number at cursor [t] button: Stop inputting number % The setting range is 0 - 130% of the rated load weight. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp), however.



Setting of OFFSET range



2)



Input an offset range by pressing the following buttons. q [ > ] button: Number at cursor moves forward q [ < ] button: Number at cursor moves backward q [U] button: Enter number at cursor q [t] button: Stop inputting number a The setting range is -5.0 – +5.0 [t]. Check the unit of the input value by the previous menu screen. a The unit is indicated in the ( ) on the right side of the input value [t]. (METRIC): metric ton (SHORT): short ton 9.



[>], [