DOWNLOAD PDF Komatsu HD465-7R Dump Truck Shop Manual SEN06285-07

SEN06285-07

DUMP TRUCK

HD465 -7R Extreme Cold Area Specification (-40 degree C) SERIAL NUMBERS

16132

and up

SEN06287-07

DUMP TRUCK 1SHOP MANUAL

HD465-7R

Machine model HD465-7R

Serial number 16132 and up

00 Index and foreword

1

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

HD465-7R

1

SEN06287-07

00 Index and foreword

Composition of shop manual

1

The contents of this shop manual are shown together with Form No. in a list. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN06285-07

00 Index and foreword Index Foreword and general information

SEN06286-07 SEN06287-07 SEN06288-01

01 Specification Specification and technical data

SEN06289-00 SEN06290-00

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 Electrical system, Part 5

SEN06291-04 SEN06292-00 SEN06293-00 SEN06294-00 SEN06295-01 SEN06296-00 SEN06297-01 SEN06298-00 SEN06299-01 SEN06300-01 SEN06301-00 SEN06302-01 SEN06303-00 SEN06304-02 SEN06918-00

20 Standard value table Standard service value table

SEN06305-00 SEN06306-00

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 Testing and adjusting, Part 6

SEN06307-06 SEN06308-03 SEN06309-04 SEN06310-02 SEN06311-00 SEN06312-01 SEN06919-01

40 Troubleshooting Failure code table and fuse locations General information on troubleshooting 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

SEN06313-04 SEN06314-01 SEN06315-01 SEN06316-01 SEN06317-01 SEN06318-01 SEN06319-01 SEN06320-01

2

HD465-7R

00 Index and foreword

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)

SEN06287-07

SEN06321-00 SEN06322-00 SEN06323-01 SEN06324-00 SEN06325-03 SEN06326-00 SEN06327-01

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, Part 1 Electrical system, Part 2

SEN06328-04 SEN06329-02 SEN06330-02 SEN06331-01 SEN06332-01 SEN06333-00 SEN06334-01 SEN06335-02 SEN06336-00 SEN06337-01 SEN06338-00 SEN06339-01 SEN06920-00

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

SEN06340-03 SEN06341-01 SEN06342-02

HD465-7R

3

SEN06287-07

00 Index and foreword

Table of contents

1

00 Index and foreword Index SEN06287-07 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN06288-01 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 SEN06290-00 Specification drawing................................................................................................................... 2 Specifications .............................................................................................................................. 3 Weight table ................................................................................................................................ 6 Fuel, coolant and lubricants ........................................................................................................ 7 10 Structure, function and maintenance standard Engine and cooling system SEN06292-00 Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler........... 2 Fuel system ................................................................................................................................. 4 Brake oil cooler............................................................................................................................ 5 Output shaft................................................................................................................................. 6 Power train, Part 1 SEN06293-00 Power train skeleton.................................................................................................................... 2 Drive shaft ................................................................................................................................... 4 Torque converter and transmission hydraulic piping ................................................................... 6 Torque converter ......................................................................................................................... 8 Torque converter valve ................................................................................................................ 15 Transmission ............................................................................................................................... 17 Transmission control valve .......................................................................................................... 33 ECMV .......................................................................................................................................... 34 Power train, Part 2 SEN06294-00 Axle ............................................................................................................................................. 2 Differential ................................................................................................................................... 4 Final drive.................................................................................................................................... 5 Wheels ........................................................................................................................................ 6 Steering system SEN06295-01 Steering column........................................................................................................................... 2 Steering linkage........................................................................................................................... 3 Brake system SEN06296-00 Brake piping ................................................................................................................................ 2 Brake valve.................................................................................................................................. 4 Secondary brake valve................................................................................................................ 7 Relay valve.................................................................................................................................. 8 Front brake off valve.................................................................................................................... 9

4

HD465-7R

00 Index and foreword

SEN06287-07

Accumulator charge valve........................................................................................................... 10 Accumulator ................................................................................................................................ 14 Slack adjuster.............................................................................................................................. 15 Brake........................................................................................................................................... 17 Parking brake solenoid valve ...................................................................................................... 21 Undercarriage and frame SEN06297-01 Suspension ................................................................................................................................. 2 Suspension cylinder .................................................................................................................... 4 Rear axle support........................................................................................................................ 10 Hydraulic system SEN06298-00 Steering and hoist hydraulic piping ............................................................................................. 2 Dump body control ...................................................................................................................... 4 Hydraulic tank ............................................................................................................................. 5 Steering valve.............................................................................................................................. 6 Crossover relief valve.................................................................................................................. 10 Steering cylinder.......................................................................................................................... 11 Steering control valve.................................................................................................................. 12 Hoist valve................................................................................................................................... 18 EPC valve ................................................................................................................................... 24 Hoist cylinder............................................................................................................................... 25 Hydraulic pump ........................................................................................................................... 26 Work equipment (Body) SEN06299-01 Auto greasing system.................................................................................................................. 2 Cab and its attachments SEN06300-01 Air conditioner ............................................................................................................................. 2 Rear view monitor ....................................................................................................................... 8 Electrical system, Part 1 SEN06301-00 Machine monitor system ............................................................................................................. 2 Electrical system, Part 2 SEN06302-01 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 disconnect switch............................................................................................................ 40 Dump control lever ...................................................................................................................... 44 Electrical system, Part 3 SEN06303-00 Payload meter (Card type) ...................................................................................................... 2 Electrical system, Part 4 SEN06304-02 VHMS controller related .............................................................................................................. 2 ASR system (If equipped) ........................................................................................................... 26 Sensors, switches ....................................................................................................................... 33 Electrical system, Part 5 SEN06918-00 Mobile communication terminal................................................................................................... 2 20 Standard value table Standard service value table SEN06306-00 Standard value table for engine .................................................................................................. 2 Standard value table for machine................................................................................................ 4 30 Testing and adjusting Testing and adjusting, Part 1 SEN06308-03 Tools for testing, adjusting, and troubleshooting ......................................................................... 3

HD465-7R

5

SEN06287-07

00 Index and foreword

Sketch of special tool .................................................................................................................. 6 Testing engine speed .................................................................................................................. 7 Testing air supply pressure (boost pressure) .............................................................................. 8 Testing exhaust temperature ....................................................................................................... 9 Testing exhaust gas color............................................................................................................ 11 Adjustment of valve clearance .................................................................................................... 13 Testing of compression pressure................................................................................................. 15 Testing blow-by pressure............................................................................................................. 18 Testing engine oil pressure.......................................................................................................... 19 Handling of fuel system devices.................................................................................................. 20 Releasing residual pressure from fuel system ............................................................................ 20 Testing of fuel pressure ............................................................................................................... 21 Cylinder cut-out mode operation ................................................................................................. 22 No-injection cranking................................................................................................................... 22 Testing of fuel return rate and fuel leakage ................................................................................. 23 Bleeding air from fuel circuit ........................................................................................................ 25 Testing the fuel circuit for leakage ............................................................................................... 26 Replacing and adjusting of fan belt ............................................................................................. 27 Replacing and adjusting of alternator and air conditioner compressor belt................................. 28 Testing and adjusting, Part 2 SEN06309-04 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 SEN06310-02 Setting and adjusting of devices.................................................................................................. 2 Special functions of machine monitor (EMMS)............................................................................ 15 Testing and adjusting, Part 4 SEN06311-00 Special functions of machine monitor (EMMS)............................................................................ 2 Testing and adjusting, Part 5 SEN06312-01 Request for opening ORBCOMM terminal .................................................................................. 2 VHMS controller initial setting procedure .................................................................................... 4

6

HD465-7R

00 Index and foreword

SEN06287-07

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 .................................................................................................... 36 Setting of payload meter built in VHMS ...................................................................................... 37 Setting of card-type payload meter (PLM- ) after installation or replacement ........................... 45 Testing and adjusting, Part 6 SEN06919-01 Setting of mobile communication terminal .................................................................................. 2 40 Troubleshooting Failure code table and fuse locations SEN06314-01 Failure codes table ...................................................................................................................... 2 Fuse locations ............................................................................................................................. 13 General information on troubleshooting SEN06315-01 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 Troubleshooting method for disconnecting wiring harness of pressure sensor system .............. 8 Connection table for connector pin numbers .............................................................................. 11 T- branch box and T- branch adapter table ................................................................................. 47 Troubleshooting by failure code, Part 1 SEN06316-01 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 SEN06317-01 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 HD465-7R

7

SEN06287-07

00 Index and foreword

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 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 SEN06318-01 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] Sensor power supply 1 low error .............................................................. 66 Failure code [CA386] Sensor power supply 1 high error............................................................. 68 Troubleshooting by failure code, Part 4 SEN06319-01 Failure code [CA431] Idle validation switch error ........................................................................ 3 Failure code [CA432] Idle validation action error ........................................................................ 6 Failure code [CA441] Battery voltage low error........................................................................... 9 Failure code [CA442] Battery voltage high error ......................................................................... 10 Failure code [CA449] Common rail pressure high error 2........................................................... 11 Failure code [CA451] Rail Press Sensor High Error ................................................................... 12

8

HD465-7R

00 Index and foreword

SEN06287-07

Failure code [CA452] Rail Press Sensor Low Error .................................................................... 14 Failure code [CA553] Common rail pressure high error 1........................................................... 16 Failure code [CA554] Common rail pressure sensor in range error............................................ 17 Failure code [CA559] Supply pump pressure very low error 1.................................................... 18 Failure code [CA689] Engine Ne speed sensor error ................................................................. 22 Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 24 Failure code [CA757] All continuous data lost error .................................................................... 25 Failure code [CA778] Engine Bkup speed sensor error.............................................................. 26 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 28 Failure code [CA2185] Throttle sensor power supply voltage high error .................................... 30 Failure code [CA2186] Throttle sensor power supply voltage low error...................................... 32 Failure code [CA2249] Supply pump pressure very low error 2.................................................. 34 Failure code [CA2555] Intake air heater relay open circuit error................................................. 36 Failure code [CA2556] Intake air heater relay short circuit error................................................. 38 Troubleshooting by failure code, Part 5 SEN06320-01 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............................................................................................. 21 Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low ............................................................................................ 23 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) ...................................................................................... 38 Failure code [DBB0KQ] or VHMS_LED display: "nF" o "11" VHMS controller: Disagreement of model selection signals .......................................................................... 40 Failure code [DBB3KK] or VHMS_LED display: "n9" o "05" VHMS controller battery power supply: Low power supply voltage (input) .................................................. 42 Failure code [DBB5KP] or VHMS_LED display: "n9" o "04" VHMS controller 5 V power supply output: Low output voltage .................................................................... 44 Failure code [DBB6KP] or VHMS_LED display: "n9" o "02" VHMS controller 24 V power supply output: Low output voltage .................................................................. 46 Failure code [DBB7KP] or VHMS_LED display: "n9" o "03" VHMS controller 12 V power supply output: Low output voltage .................................................................. 48 Failure code [DBQRKR] or VHMS_LED display: "n8" o "02" VHMS controller CAN communication: Defective communication (Abnormality in target component system) ........................................................................ 49 Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ....................................... 51 Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble .. 52 HD465-7R

9

SEN06287-07

00 Index and foreword

Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low ............................................................................................ 52 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.................................................................................................... 60 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.................................................................................................... 98 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 SEN06321-00 FFailure 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 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

10

HD465-7R

00 Index and foreword

SEN06287-07

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 [DJF1KA] Fuel level sensor: Disconnection ........................................................... 60 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)......................... 62 Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal............................................................................................ 63 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ........... 66 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal... 68 Failure code [DK54KX] Body positioner sensor: Out of input signal range................................. 70 Failure code [DKD0L6] Failure in steering speed sensor............................................................ 72 Failure code [DKH0KX] Clinometer sensor signal out of range .................................................. 74 Failure code [DKH1KX] or VHMS_LED display: "n4"o"33" Abnormality in clinometer sensor... 76 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection ......................... 78 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal...................................................................................................... 80 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............. 82 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal .......................................................................... 84 Troubleshooting by failure code, Part 7 SEN06322-00 Failure code [DLF8KA] (Wheel speed sensor: Disconnection (Right rear)) ................................ 4 Failure code [DLF8L3] (Wheel speed sensor: Disconnection (Right rear))................................. 6 Failure code [DLF8LC] (Wheel speed sensor: Trouble (Right rear))........................................... 8 Failure code [DLF8MA] (Wheel speed sensor: Disconnection (Right rear)) ............................... 9 Failure code [DLF9KA] (Wheel speed sensor: Disconnection (Left rear)) .................................. 10 Failure code [DLF9L3] (Wheel speed sensor: Trouble (Left rear)).............................................. 12 Failure code [DLF9LC] (Wheel speed sensor: Trouble (Left rear)) ............................................. 14 Failure code [DLF9MA] (Wheel speed sensor: Disconnection (Left rear)).................................. 15 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) .................... 16 Failure code [DLT3LC] (Transmission output shaft speed sensor: Disagreement of revolution speed signal) ......................................................................... 18 Failure code [DLT4KA] (Transmission output shaft speed sensor: Disconnection) .................... 20 Failure code [DLT4MA] (Transmission output shaft speed sensor: Malfunction) ........................ 22 Failure code [DV00KB] (Buzzer output: Short circuit) ................................................................. 24 Failure code [DW2AKA] (Main pressure variable valve output: Disconnection) ......................... 26 Failure code [DW2AKB] (Main pressure variable valve output circuit: Ground fault) .................. 28 Failure code [DW2AKY] (Main pressure variable valve output circuit: Hot short) ....................... 30 Failure code [DW2AL1] (Main pressure variable valve: Defective reset) .................................... 32 Failure code [DW2ALH] (Main pressure variable valve: Malfunction) ......................................... 34 Failure code [DW35KZ] (Failure in output system of auto suspension solenoid 1: Disconnection or short circuit) ........................................................................................... 36 Failure code [DW36KZ] (Failure in output system of auto suspension solenoid 2: Disconnection or short circuit) (If equipped) ...................................................................... 38 Failure code [DW72KZ] (Kick-out solenoid output system trouble: Disconnection or short circuit) ........................................................................................... 40 HD465-7R

11

SEN06287-07

00 Index and foreword

Failure code [DW73KZ] (Failure in hoist select valve output system: Disconnection or short circuit) ........................................................................................... 42 Failure code [DW78KZ] (Brake cooling valve (BCV) (rear wheel) output system trouble: Disconnection or short circuit) ........................................................................................... 44 Failure code [DWNBK4] (ASR shut-off valve: Trouble (Valve keeps operating)) ........................ 46 Failure code [DWNBKA] (ASR shut-off valve output circuit: Disconnection)............................... 48 Failure code [DWNBKB] (ASR shut-off valve output circuit: Ground fault) ................................. 50 Failure code [DWNBKY] (ASR shut-off valve output circuit: Short circuit) .................................. 52 Failure code [DWNBMA] (ASR shut-off valve: Trouble (Valve does not operate)) ...................... 53 Troubleshooting by failure code, Part 8 SEN06323-01 Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control ..................................................................................................................... 4 Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection .................................................................................................................... 6 Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit........................................................................................................................ 8 Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line....................................................................................... 9 Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction ........................................................................................................................ 10 Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection................................... 12 Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit ...................................... 14 Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line.. 16 Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve keeps operating) ........................................................................................ 18 Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit: Disconnection.............................................................................................. 20 Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit: Ground fault................................................................................................. 22 Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit: Short circuit ................................................................................................. 24 Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right): Trouble (Valve does not operate)....................................................................................... 25 Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve keeps operating) ........................................................................................ 26 Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit: Disconnection.............................................................................................. 28 Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit: Ground fault................................................................................................. 30 Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit: Short circuit ................................................................................................. 32 Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left): Trouble (Valve does not operate)....................................................................................... 33 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).............. 34 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)................. 35 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...................... 36 Failure code [DX21MA] Defective ABS control valve (Front right) .............................................. 38 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) ................ 40 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left) ................... 41 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) ........................ 42 Failure code [DX22MA] Defective ABS control valve (Front left) ................................................ 44 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) .............. 46 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................. 47 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ...................... 48 Failure code [DX23MA] Defective ABS control valve (Rear right)............................................... 50 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)................. 52 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ................... 53 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)......................... 54

12

HD465-7R

00 Index and foreword

SEN06287-07

Failure code [DX24MA] Defective ABS control valve (Rear left)................................................. 56 Failure code [DX25MA] Defective ABS front wheel system control valve................................... 58 Failure code [DX26MA] Defective ABS rear wheel system control valve ................................... 58 Troubleshooting by failure code, Part 9 SEN06324-00 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 HD465-7R

13

SEN06287-07

00 Index and foreword

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) SEN06325-03 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 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 ................................................................................ 47 E-16 Electric priming pump does not operate or does not stop automatically ............................ 49 E-17 Cannot access to the setting screen of the mobile communication terminal ...................... 51 E-18 Cannot log in to the setting screen of the mobile communication terminal because the log in password is unknown......................................................................................... 56 E-19 VHMS controller is not detected ......................................................................................... 58 E-20 VHMS controller does not become active........................................................................... 59 E-21 Communication between mobile communication terminal and KOMTRAX Plus server fails ......................................................................................................................... 60 E-22 Data is not sent to KOMTRAX Plus server ......................................................................... 63 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06326-00 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) SEN06327-01 4 Method of using troubleshooting chart ........................................................................................ S-1 Starting performance of engine is poor................................................................................. 8 S-2 Engine does not start............................................................................................................ 9 S-3 Engine does not pick up smoothly ........................................................................................ 12 S-4 Engine stops during operation .............................................................................................. 13

14

HD465-7R

00 Index and foreword

SEN06287-07

S-5 Engine does not rotate smoothly .......................................................................................... S-6 Engine lack output (or lacks power) ..................................................................................... S-7 Exhaust gas is black (incomplete combustion)..................................................................... S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... S-9 Oil becomes dirty quickly...................................................................................................... S-10 Fuel consumption is excessive........................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. S-12 Oil pressure drops .............................................................................................................. S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... S-14 Coolant temperature becomes too high (Overheating) ...................................................... S-15 Abnormal noise is made ..................................................................................................... S-16 Vibration is excessive .........................................................................................................

14 15 16 18 19 20 21 22 23 24 25 26

50 Disassembly and assembly General information on disassembly and assembly SEN06329-02 How to read this manual ............................................................................................................. 2 Coating materials list................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketches of special tools............................................................................................................. 11 Engine and cooling system SEN06330-02 Removal and installation of engine assembly ............................................................................. 2 Removal and installation of radiator assembly............................................................................ 9 Removal and installation of damper assembly............................................................................ 13 Disassembly and assembly of damper assembly ....................................................................... 14 Removal and installation of fuel supply pump assembly............................................................. 17 Removal and installation of fuel injector assembly ..................................................................... 20 Removal and installation of brake and power train oil cooler assembly...................................... 24 Power train, Part 1 SEN06331-01 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 SEN06332-01 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 SEN06333-00 Disassembly and assembly of steering cylinder assembly ......................................................... 2 Brake system SEN06334-01 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 SEN06335-02 Removal and installation of front wheel assembly ...................................................................... 2 Removal and installation of rear wheel assembly ....................................................................... 3 Removal and installation of front suspension cylinder assembly ................................................ 5 Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)... 7 Removal and installation of rear suspension cylinder assembly ................................................. 10 HD465-7R

15

SEN06287-07

00 Index and foreword

Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring) ... 11 Hydraulic system SEN06336-00 Disassembly and assembly of hoist cylinder assembly............................................................... 2 Body SEN06337-01 Removal and installation of body assembly ................................................................................ 2 Cab and its attachments SEN06338-00 Disassembly and assembly of operator's seat assembly ............................................................ 2 Removal and installation of air conditioner unit assembly........................................................... 11 Electrical system, Part 1 SEN06339-01 Removal and installation of engine controller assembly ............................................................. 2 Removal and installation of transmission controller assembly .................................................... 3 Removal and installation of retarder controller assembly............................................................ 4 Electrical system, Part 2 SEN06920-00 Removal and installation of mobile communication terminal....................................................... 2 Removal and installation of DC/DC converter ............................................................................. 4 Removal and installation of mobile communication terminal harness ......................................... 6 90 Diagrams and drawings Hydraulic diagrams and drawings SEN06341-01 Power train hydraulic circuit diagram .......................................................................................... 2 Steering and hoist hydraulic circuit diagram................................................................................ 3 Brake hydraulic circuit diagram ................................................................................................... 7 Electrical diagrams and drawings SEN06342-02 Electrical circuit diagram inside cab (1/3).................................................................................... 3 Electrical circuit diagram inside cab (2/3).................................................................................... 5 Electrical circuit diagram inside cab (3/3).................................................................................... 7 Electrical circuit diagram outside cab (1/3).................................................................................. 9 Electrical circuit diagram outside cab (2/3).................................................................................. 11 Electrical circuit diagram outside cab (3/3).................................................................................. 13 Electrical circuit diagram for VHMS............................................................................................. 15 Electrical circuit diagram for ASR (If equipped)........................................................................... 17 Air conditioner electrical circuit diagram...................................................................................... 19 Electrical circuit diagram of mobile communication terminal (if equipped).................................. 21 Connectors table and arrangement drawing ............................................................................... 23

16

HD465-7R

00 Index and foreword

HD465-7R

SEN06287-07

17

SEN06287-07

00 Index and foreword

HD465-7R DUMP TRUCK Form No. SEN06287-07

© 2023 KOMATSU All Rights Reserved Printed in Japan 03-23 (01)

18

HD465-7R

SEN06288-01

DUMP TRUCK 1SHOP MANUAL

HD465-7R

Machine model HD465-7R

Serial number 16132 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

HD465-7R

1

SEN06288-01

00 Index and foreword

Safety notice

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 w elding work, alw ays wear welding 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

HD465-7R

00 Index and foreword

2.

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.

3.

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.

HD465-7R

SEN06288-01

6)

When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) 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. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) 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. 11) 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. 12) 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 particularly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) 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. 16) 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

SEN06288-01

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.

HD465-7R

00 Index and foreword

SEN06288-01

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.

13) Remember the position of the main switch so that you can turn off the power immediately in an emergency. 14) 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. 15) If you find an obstacle around the hoist, stop the operation. 16) 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) Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes. 3) Observe the signs for sling work. 4) Operate the hoist at a safe place. 5) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 6) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 7) Do not raise or lower a load while the crane is moving longitudinally or laterally. 8) Do not drag a sling. 9) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 10) Consider the travel route in advance and lift up a load to a safe height. 11) Place the control switch on a position where it will not be an obstacle to work and passage. 12) After operating the hoist, do not swing the control switch.

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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

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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.

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00 Index and foreword

How to read the shop manual q q q

1.

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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.

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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

Special safety precautions are necessary when performing work.

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

Places that require special attention for tightening torque during assembly.

2

Coat

5

Oil, coolant

6

Drain

Remarks

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

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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 q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a 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. Example: Standard size 120

Tolerance –0.022 –0.126

a

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

q

Usually, the size of a hole and the size of the shaft to be fitted to that hole are 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

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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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2.

Standard clearance and standard value q 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.

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

00 Index and foreword

5.

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

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Handling of electric equipment and hydraulic component

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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.

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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 shortcircuited 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

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00 Index and foreword

3.

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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.

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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.

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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

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q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

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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 oil and water from the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. 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.

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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.

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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

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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.

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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

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3.

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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.

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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

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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

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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

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

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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

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

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

“f” of nominal No. denotes flexible”.

24

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3.

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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

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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

SEN06288-01

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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

HD465-7R

00 Index and foreword

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

a

a 3.

SEN06288-01

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.

HD465-7R

27

SEN06288-01

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”.

HD465-7R

00 Index and foreword

SEN06288-01

Method of disassembling and connecting push-pull type coupler

1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to

release the residual pressure from the hydraulic tank.

k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly, prepare an oil receiving container. Type 1 1.

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

2.

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

HD465-7R

29

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Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the 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)

2.

Connection q 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)

30

HD465-7R

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SEN06288-01

Type 3 1.

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)

2.

Connection q 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)

HD465-7R

31

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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

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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.

SEN06288-01

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

HD465-7R

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

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

SEN06288-01

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 —

HD465-7R

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.

SEN06288-01

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

HD465-7R

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

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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

HD465-7R

00 Index and foreword

SEN06288-01

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

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

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

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

HD465-7R

13.473 16.115 18.756 21.398 24.040

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

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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

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

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

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

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

419.5 491.8 564.2 636.5 708.8

1142.8 1215.1 1287.5 1359.8 1432.1

426.8 499.1 571.4 643.7 716.1

1150.0 1222.4 1294.7 1367.0 1439.4

HD465-7R

00 Index and foreword

SEN06288-01

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

HD465-7R

39

SEN06288-01

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

HD465-7R

00 Index and foreword

HD465-7R

SEN06288-01

41

SEN06288-01

00 Index and foreword

HD465-7R DUMP TRUCK Form No. SEN06288-01

© 2022 KOMATSU All Rights Reserved Printed in Japan 10-22 (01)

42

HD465-7R

SEN06290-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

01 Specification

1

Specification and technical data Specification drawing ...................................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................... 6 Fuel, coolant and lubricants ............................................................................................................................ 7

HD465-7R

1

SEN06290-00

Specification drawing

01 Specification

1

HD465-7R

2

HD465-7R

01 Specification

SEN06290-00

1 Machine model

HD465-7R

Serial No.

16132 and up

Empty

kg

43,100

Max. load

kg

55,000

Gross

kg

98,180

(front)

kg

20,260 (47%)

(rear)

kg

22,840 (53%)

(front)

kg

31,420 (32%)

(rear)

kg

66,760 (68%)

Struck

m

3

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

Empty

Weight distribution

Weight

Specifications

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

mm

6 – 170 x 170

Piston displacement

{cc}

23.15 {23,150}

kW{HP}/min-1{rpm}

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

Engine

Rated horsepower SAE J1995 (gross)

-1

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}

Max. torque

Nm/rpm{kgm/rpm}

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

Fuel consumption (Min.)

g/kWh {g/HPh}

196 {146}

Stating motor

24V, 7.5 kW x 2 units

Alternator

24V, 90A

Battery

12V, 200Ah x 2 units

HD465-7R

3

SEN06290-00

01 Specification

Machine model

HD465-7R

Serial No.

16132 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

Breke system

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

kPa {kg/cm2}

470 {4.75}

Front wheel

Single dry disc type, Hydraulically controlled

Rear axle

Oil cooled multiple disc brake, Hydraulically controlled

Service brake

Parking brake Retarder

4

4.737

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

HD465-7R

01 Specification

SEN06290-00

Machine model

HD465-7R

Serial No.

16132 and up

For both steering and work equipment Type

Hydraulic pump

Hydraulic system

Delivery (at engine rated speed 2,000 rpm)

Gear pump /min

348

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

Gear pump /min

228

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

Gear pump /min

456

Hoist cylinder

Cylinder

Type No. – bore (1st – 2nd) x stroke

2 – (170 mm – 150 mm) x 1,774 mm

Steering cylinder Type No. – bore x stroke

HD465-7R

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

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

5

SEN06290-00

01 Specification

Weight table

1

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

HD465-7R

Serial Number

16132 and up

Engine assembly

3,030

Output shaft assembly

123

Radiator assembly

405

Fuel tank

294

Torque converter assembly

430

Transmission assembly

1,266

Drive shaft assembly (front)

26

Drive shaft assembly (rear)

62

Rear axle assembly

6,293

• Differential

774

• Final drive (one-side)

1,421

• Rear brake (one-side)

721

Front axle (one-side)

330

Front brake (one-side)

142

Front suspension cylinder

460

Rear suspension cylinder

176

Frame

4,680

Cab (Platform)

1,104

Operator's seat

63

Steering cylinder

44

Hoist cylinder

206

Demand valve

26

Steering valve

20

Hoist valve

34

Hydraulic pump (SDR(30)–100+100)

40

Hydraulic pump (SDR(30)–80+80(1)6)

38

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

26

Dump body

10,730

1

6

HD465-7R

01 Specification

Fuel, coolant and lubricants

q

SEN06290-00

1

ASTM: America Society of Testing and Material

HD465-7R

7

SEN06290-00

01 Specification

Engine Oil Pan

Transmission Case

Brake control oil tank

Steering, Hoist Oil Tank

Front Suspension

Rear Suspension

Specified capacity (l)

76

253

65

180

16.5 each for right and left

11.3 each for right and left

Refill capacity (l)

70

170

45

122

—

—

Differential Case

Final drive case

Fuel tank

Cooling system

Specified oil level (l)

95

32 each for right and left

780

157

Refill capacity (l)

95

21 each for right and left

—

—

Notice Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. Note 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils. Note 3: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended. Note 4: Supercoolant (AF-NAC) 1) Coolant has the important function of anticorrosion as well as antifreeze. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling propertiesand can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant AF-NAC is strongly recommended wherever available. 2) For details of the ratio when diluting super coolant with water, see "Mixing rate of water and super coolant". Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never dilute with water) 3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%.

8

HD465-7R

01 Specification

SEN06290-00

Mixing rate of water and super coolant Min. atmospheric temperature

°C

-10

-15

-20

-25

-30

-35

-40

-45

-50

°F

14

5

-4

-13

-22

-31

-40

-49

-58

Liters

47.1

55.0

62.8

70.7

78.5

84.8

91.1

95.8

100.5

US gal

12.45

14.54

16.60

18.70

20.75

22.4

24.1

25.3

26.6

Liters

109.9

102.0

94.2

86.3

78.5

72.2

65.9

61.2

56.5

US gal

29.05

26.96

24.90

22.80

20.75

19.1

17.4

16.2

14.9

%

30

35

40

45

50

54

58

61

64

Amount of antifreeze

Amount of water Volume ratio

HD465-7R

9

SEN06290-00

01 Specification

HD465-7R DUMP TRUCK Form No. SEN06290-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

10

HD465-7R

SEN06292-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

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

HD465-7R

1

SEN06292-00

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

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06292-00

3

SEN06292-00

Fuel system

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

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 Water separator

HD465-7R

10 Structure, function and maintenance standard

Brake oil cooler

1.

Cooler element

A: B: C: D:

Oil inlet Oil outlet Coolant inlet Coolant outlet

HD465-7R

SEN06292-00

1

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

5

SEN06292-00

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.

HD465-7R

10 Structure, function and maintenance standard

SEN06292-00

Unit: mm No.

1

Check item Clearance between flywheel and bearing

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

100

–0.015 –0.015

–0.010 –0.045

–0.045 – 0.005

0.02

Standard size

Clearance limit

2

Clearance between shaft and bearing

55

–0.010 –0.040

–0.015 –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

External

HD465-7R

Replace

Repair or replace

Standard backlash (Dimension at smallest width: L) Replace

90

81

75

67 No cracks

7

SEN06292-00

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06292-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

8

HD465-7R

SEN06293-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 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 Torque converter ............................................................................................................................................. 8 Torque converter valve.................................................................................................................................. 15 Transmission................................................................................................................................................. 17 Transmission control valve............................................................................................................................ 33 ECMV............................................................................................................................................................ 34

HD465-7R

1

SEN06293-00

Power train skeleton

2

10 Structure, function and maintenance standard

1

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

1. 2. 3. 4.

Engine Output shaft Front drive shaft Brake cooling pump (SDR(30)100+100) 5. Torque converter transmission charge pump and brake cooling brake control pump (SDR(30)100+SA(1)25) 6. PTO 7. Torque converter 8. Transmission 9. Rear drive shaft 10. Differential gear 11. Drive shaft 12. Brake 13. Tire 14. Final drive 15. Parking brake 16. Steering, hoist and hoist control pump (SDR(30)80+80+SB(1)6)

HD465-7R

3

SEN06293-00

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).

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06293-00

5

SEN06293-00

10 Structure, function and maintenance standard

Torque converter and transmission hydraulic piping

6

1

HD465-7R

10 Structure, function and maintenance standard

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

SEN06293-00

Torque converter Transmission Oil filler tube Hydraulic pump (SDR(30)100+25) Torque converter valve Transmission oil filter Transmission oil filter relief valve

HD465-7R

7

SEN06293-00

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.

8

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

HD465-7R

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

HD465-7R

SEN06293-00

10. Stator shaft 11. Sleeve 12. Inner race 13. Free wheel 14. Stator 15. Lockup clutch disc 16. Lockup clutch piston 17. Lockup clutch housing 18. Retainer

9

SEN06293-00

10 Structure, function and maintenance standard

Unit: mm

10

HD465-7R

10 Structure, function and maintenance standard

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)

SEN06293-00

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 13

Backlash between input shaft and PTO gear

Clearance between PTO gear 14 and bearing

15

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“

HD465-7R

11

SEN06293-00

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).

12

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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 turbine boss (7) O Transmission input shaft (8)

HD465-7R

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)

13

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10 Structure, function and maintenance standard

Oil flow

q

q

q

14

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.

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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}

HD465-7R

Replace

Installation Installation Free length load load

15

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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

16

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".

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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

HD465-7R

1

1. 2. 3. 4. 5.

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

17

SEN06293-00

18

10 Structure, function and maintenance standard

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

1. Transmission input shaft 2. H sun gear (number of teeth: 34) 3. H ring gear (hub) 4. H clutch 5. H planetary pinion (number of teeth: 32) 6. H Carrier 7. L ring gear (hub) 8. L clutch 9. H ring gear (number of teeth: 98) 10. L clutch housing 11. 4th clutch housing 12. 4th clutch drum 13. 4th clutch 14. 4th ring gear (hub) 15. 3rd planetary pinion (number of teeth: 21) 16. 3rd clutch 17. 3rd ring gear (number of teeth: 93) 18. 3rd sun gear (number of teeth: 51) 19. R clutch 20. R planetary pinion (number of teeth: 21) 21. R sun gear (number of teeth: 41) 22. R ring gear (number of teeth: 93) 23. 2nd clutch 24. 2nd ring gear (number of teeth: 105) 25. 2nd planetary pinion (number of teeth: 30) 26. 2nd sun gear (number of teeth: 45) 27. 2nd and 1st carrier 28. 1st clutch 29. 1st ring gear (number of teeth: 104) 30. Transmission output shaft 31. 1st planetary pinion (number of teeth: 38) 32. 1st clutch piston 33. 2nd clutch piston 34. Intermediate shaft (1st sun gear number of teeth: 28) 35. R clutch piston 36. R planetary pinion (number of teeth: 21) 37. 3rd and R carrier 38. 4th clutch piston 39. L clutch piston 40. H clutch piston 41. 3rd clutch piston

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.

HD465-7R

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

19

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20

10 Structure, function and maintenance standard

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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

Standard size

Tolerance

Repair limit

27.8

±0.22

25.8

7

Total thickness of 5 discs and 4 plates for L clutch

45.0

±0.30

42.0

8

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

HD465-7R

Replace

21

SEN06293-00

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

Replace

Unit: mm

22

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

No.

Check item

Criteria

35

Deterioration of disc internal teeth

Repair limit: 0.3

36

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

37

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

Side clearance 38 of planetary pinion

39

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

Stepped-type wear of seal ring mating surface

Contact surface of 40 output shaft oil seal

41

Remedy

Replacement of thrust washer or carrier

Standard size

Amount of wear

—

Max 0.05

Standard size

Amount of wear

120

119.8

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

HD465-7R

Clutch No.

Standard size

H (outside)

Tolerance

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.

23

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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

24

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.

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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)

HD465-7R

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

25

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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)

26

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

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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)

HD465-7R

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

27

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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)

28

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 O O O O O 2nd sun gear (20) O i––

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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)

HD465-7R

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 O O O O O 2nd sun gear (20) O i––

29

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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)

30

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 O O O O O O O 2nd sun gear (20) O i––

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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)

HD465-7R

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 O O O O O O O 2nd sun gear (20) O i––

31

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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)

32

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

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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. H clutch ECMV 2. Lockup clutch ECMV 3. L clutch ECMV 4. 4th clutch ECMV 5. 3rd clutch ECMV 6. R clutch ECMV 7. 2nd clutch ECMV 8. 1st clutch ECMV 9. Last chance filter 10. Valve seat

HD465-7R

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.

33

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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: To clutch P: From pump T: Drain Dr: Drain P1: Clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7.

34

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

*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*******

HD465-7R

10 Structure, function and maintenance standard

SEN06293-00

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.

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).

HD465-7R

35

SEN06293-00

10 Structure, function and maintenance standard

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.

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

36

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

HD465-7R

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).

HD465-7R

SEN06293-00

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.

37

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

A: To clutch P: From pump T: Drain Dr: Drain P1: Clutch oil pressure pickup port 1. 2. 3. 4. 5.

38

*1: Operated clutches

Stamp of the nameplates

Lockup

K*******

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

HD465-7R

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.

SEN06293-00

Operation When traveling in torque converter range

When changing from torque converter travel to direct travel

At gear shift (in direct travel)

HD465-7R

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).

39

SEN06293-00

10 Structure, function and maintenance standard

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

q

q

40

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.

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06293-00

41

SEN06293-00

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06293-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

42

HD465-7R

SEN06294-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

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

HD465-7R

1

SEN06294-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06294-00

Rear

1. 2. 3. 4.

Differential Axle housing Brake Final drive

HD465-7R

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 Rim size: 17.00-35

3

SEN06294-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06294-00

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

HD465-7R

Remedy

Replace

Repair or replace

Repair limit: 1.5 TIR Standard size 51.5

Tolerance ±0.1

Repair limit 50

Replace

5

SEN06294-00

10 Structure, function and maintenance standard

Wheels

1

Front wheel 1. 2. 3.

Tire Rim assembly Valve

Specifications Rim size: 17.00 x 35 Tire size : 24.00-35

Rear wheel 1. 2. 3.

Rim assembly Valve Extension

Specifications Rim size: 17.00 x 35 Tire size : 24.00-35

6

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06294-00

7

SEN06294-00

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06294-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

8

HD465-7R

SEN06295-01

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

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

HD465-7R

1

SEN06295-01

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

HD465-7R

10 Structure, function and maintenance standard

Steering linkage

1. 2. 3. 4.

SEN06295-01

1

Center lever Tie rod A-arm Knuckle arm

HD465-7R

3

SEN06295-01

4

10 Structure, function and maintenance standard

HD465-7R

10 Structure, function and maintenance standard

SEN06295-01

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

HD465-7R

–0.025 –0.064

–0.030 –0.076

+0.069 +0.030

+0.076 +0.030

0.089

0.3

Replace

5

SEN06295-01

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06295-01

© 2023 KOMATSU All Rights Reserved Printed in Japan 03-23 (01)

6

HD465-7R

SEN06296-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 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

HD465-7R

1

SEN06296-00

Brake piping

10 Structure, function and maintenance standard

1

The upper figure shows HD465-7R.

2

HD465-7R

10 Structure, function and maintenance standard

SEN06296-00

1: -40 degree C 1. 2. 3. 4. 5. 6.

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

HD465-7R

7. Accumulator charge valve 8. Accumulator (parking brake) 9. Accumulator (rear brake) 10. Accumulator (front brake) 11. Proportional reducing valve (for retarder) 12. Brake system tank

3

SEN06296-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06296-00

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.

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.

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

Applying brake when lower valve fails • Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.

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

HD465-7R

5

SEN06296-00

10 Structure, function and maintenance standard

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

Brake released Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port (a) is opened and the oil from the brake cylinder flows to the brake system tank return circuit to release the rear brakes.

6

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.

HD465-7R

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

HD465-7R

SEN06296-00

1

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

7

SEN06296-00

Relay valve

1. 2. 3. 4.

Spool Upper cylinder Lower cylinder Spool

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.

A: To front brake P: From accumulator Pp: From secondary brake valve T: To brake system tank

8

HD465-7R

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

HD465-7R

SEN06296-00

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

SEN06296-00

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

HD465-7R

10 Structure, function and maintenance standard

1. 2. 3.

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

HD465-7R

SEN06296-00

4. 5. 6.

Relief valve (H1) Filter Filter

11

SEN06296-00

10 Structure, function and maintenance standard

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.

2.

12

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.

HD465-7R

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.

HD465-7R

SEN06296-00

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

SEN06296-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06296-00

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

HD465-7R

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

SEN06296-00

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.

HD465-7R

10 Structure, function and maintenance standard

SEN06296-00

Brake

1

Front

1. 2. 3.

Piston Pad Disc

Unit: mm No.

Check item

4

Wear of pad (remaining thickness of wear material)

5

Criteria

Remedy

Standard size

Repair limit

19.5

3.0

Missing portion of pad

—

Ratio of surface: 10%

6

Face runout of disc (Note 1)

0.15

0.50

7

Wear of disc (thickness of disc)

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.

HD465-7R

17

SEN06296-00

10 Structure, function and maintenance standard

Rear

1. Inner gear 2. Retainer 3. Outer gear 4. Plate 5. Disc 6. Damper 7. Piston 8. Spring (for parking brake) 9. Cylinder 10. Piston (for parking brake)

18

HD465-7R

10 Structure, function and maintenance standard

SEN06296-00

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

HD465-7R

Replace

19

SEN06296-00

10 Structure, function and maintenance standard

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 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).

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.

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.

HD465-7R

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

HD465-7R

SEN06296-00

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

SEN06296-00

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06296-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

22

HD465-7R

SEN06297-01

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

Undercarriage and frame Suspension ..................................................................................................................................................... 2 Suspension cylinder........................................................................................................................................ 4 Rear axle support.......................................................................................................................................... 10

HD465-7R

1

SEN06297-01

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) A-arm

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.

HD465-7R

10 Structure, function and maintenance standard

SEN06297-01

Function 1. Front suspension The front suspension cylinder functions as a shock absorber and spring, and is connected by spherical bearings to the lower arm (A-arm) 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.

HD465-7R

3

SEN06297-01

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 and mounting pressure sensor) Air bleeding valve Tube

7. Hydraulic cylinder 8. Valve assembly 9. Damping force selector valve 10. Damping force selector valve lever A: B:

Port Port

HD465-7R

10 Structure, function and maintenance standard

SEN06297-01

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 +0.115

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

HD465-7R

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

5

SEN06297-01

10 Structure, function and maintenance standard

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

6

HD465-7R

10 Structure, function and maintenance standard

c.

SEN06297-01

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

HD465-7R

7

SEN06297-01

10 Structure, function and maintenance standard

Rear

1. 2. 3. 4. 5.

8

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

HD465-7R

10 Structure, function and maintenance standard

SEN06297-01

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. a)

Retracting action When the machine is traveling and it hits a bump or object on the road, the wheels are pushed up, and the cylinder rod is pushed inside the cylinder. When this happens, the nitrogen gas inside chamber (7) is compressed, the oil in chamber (6) is sent through both orifices (4) and (5) to cavity (2), and cavity (2) is filled more quickly than when extending.

b)

Extending action When the machine has passed any bump or object on the road surface, the cylinder rod is pushed up by the weight of the wheels and axle and the pressure of the nitrogen inside chamber (7). As a result, the amount of oil in cavity (2) is reduced, and pressure is applied to the oil remaining in cavity (2). This pressurized oil closes orifice (4) with check ball (3), and is sent to chamber (6) through only orifice (5), so the flow of oil passing through the orifice is controlled so that it is less than during retraction. In this way, the amount of oil returning to chamber (6) is restricted to provide a shock absorbing effect.

HD465-7R

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

7. Nitrogen gas chamber 8. Cylinder rod 9. Cylinder 10. Feed valve a: When extending b: When retracting

9

SEN06297-01

Rear axle support

1. 2. 3. 4.

10

10 Structure, function and maintenance standard

1

Rod Rod Axle Suspension cylinder

HD465-7R

10 Structure, function and maintenance standard

SEN06297-01

Unit: mm No.

Check item

Clearance between rod mount5 ing pin and bushing

Criteria Standard size 70

6

Clearance between inner and outer bushing

100

7

Clearance between suspension cylinder mounting pin and frame or axle

70

8

Clearance between inner and outer bushing

100

HD465-7R

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

–0.030 –0.076

+0.046 +0.046

0.030 – 0.122

1.0

0.110 – 0.180

0.5

0.030 – 0.122

0.3

0.110 – 0.180

0.5

–0.030 –0.076

+0.046 +0.046

Replace

11

SEN06297-01

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06297-01

© 2023 KOMATSU All Rights Reserved Printed in Japan 03-23 (01)

12

HD465-7R

SEN06298-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 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 EPC valve ..................................................................................................................................................... 24 Hoist cylinder ................................................................................................................................................ 25 Hydraulic pump ............................................................................................................................................. 26

HD465-7R

1

SEN06298-00

Steering and hoist hydraulic piping

2

10 Structure, function and maintenance standard

1

HD465-7R

10 Structure, function and maintenance standard

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

SEN06298-00

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

HD465-7R

3

SEN06298-00

Dump body control

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

4

Dump lever Hydraulic pump (SDR(30)80+80+(1)6) Hoist valve EPC valve Body positioner sensor Hoist cylinder

10 Structure, function and maintenance standard

1

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

HD465-7R

10 Structure, function and maintenance standard

Hydraulic tank

1. 2. 3.

SEN06298-00

1

Breather Drain Oil level gauge

Capacity: 97 l

HD465-7R

5

SEN06298-00

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. Ball 9. Torsion bar 10. Link 11. Sleeve 12. Rotor 13. Manifold 14. 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)

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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

HD465-7R

7

SEN06298-00

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.

HD465-7R

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

HD465-7R

SEN06298-00

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

SEN06298-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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

HD465-7R

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

SEN06298-00

Steering control valve

12

10 Structure, function and maintenance standard

1

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

P1: From hydraulic pump P2: From hydraulic pump PH: To hoist control valve PE: From emergency steering pump PT: To tank PST: To steering valve LS: From steering valve 1. Spool return spring 2. Steering control valve spool 3. Check valve 4. Check valve spring 5. Valve body 6. Main relief valve 7. Main relief valve spring 8. Pilot poppet 9. Pilot poppet spring 10. Lock nut 11. Adjustment screw

Unit: mm No.

Check item

Criteria Standard size

12 Spool return spring

13 Check valve spring

HD465-7R

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

SEN06298-00

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

HD465-7R

10 Structure, function and maintenance standard

2.

SEN06298-00

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 steering valve to provide a large amount of oil to the steering valve.

HD465-7R

15

SEN06298-00

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

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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).

HD465-7R

17

SEN06298-00

Hoist valve

18

10 Structure, function and maintenance standard

1

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

T: To tank P: From flow amplifier A1: To hoist cylinder bottom B1: To hoist cylinder head PA: From EPC valve (pressurized side in lowering or floating operation) PB: From EPC valve (pressurized side in lifting operation) 1. Body 2. Spool 3. Retainer 4. Spring (lifting) 5. Relief valve 6. Spring (floating) 7. Spring (lowering) 8. Retainer 9. Retainer 10. Retainer 11. Check valve

Unit: mm 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

HD465-7R

If damaged or deformated, replace the spring

19

SEN06298-00

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.

HD465-7R

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

HD465-7R

SEN06298-00

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

SEN06298-00

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.

HD465-7R

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

HD465-7R

SEN06298-00

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

SEN06298-00

10 Structure, function and maintenance standard

EPC valve

1

1. 2. 3.

Manual operation button Solenoid assembly Solenoid assembly

A: To hoist valve B: From hoist valve P1: From hydraulic pump T1: To hydraulic tank T2: 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.

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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

HD465-7R

Replace

25

SEN06298-00

10 Structure, function and maintenance standard

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

26

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

—

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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

HD465-7R

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

—

27

SEN06298-00

10 Structure, function and maintenance standard

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

10

–0.5 –0.5

Replace

—

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

28

Tolerance

SDR(30)-100

Rotating torque of spline shaft

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

—

HD465-7R

10 Structure, function and maintenance standard

SEN06298-00

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

HD465-7R

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

—

29

SEN06298-00

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06298-00

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13 (01)

30

HD465-7R

SEN06299-01

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

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

HD465-7R

1

SEN06299-01

Auto greasing system

2

10 Structure, function and maintenance standard

1

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06299-01

3

SEN06299-01

1. Flow divider valve (1) 2. Flow divider valve (2) 3. Flow divider valve (3) 4. Flow divider valve (4) 5. Flow divider valve (5) 6. Flow divider valve (6) 7. Flow divider valve (7) 8. Flow divider valve (8) 9. Flow divider valve (9) 10. Branch block 11. Electric grease pump 12. 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-arm front pin (left)

(1)

(4)

(2)

11 A-arm rear pin (left) 12 A-arm front pin (right) 13 A-arm rear pin (right)

(4)

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

System diagram

HD465-7R

5

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

No.

Flow divider valve

HD465-7R

Amount of grease

cc each time

SEN06299-01

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

(1)

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-arm front pin (left)

0.65 0.65 (4)

0.65 0.65 0.65

(2)

0.65 0.65

11

A-arm rear pin (left)

12

A-arm front pin (right)

0.65

13

A-arm 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)

(5)

0.25

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

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

(4)

0.65 0.65 0.65

(3)

0.65 0.65 0.15

7

SEN06299-01

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

1

Motor

Input

2

Pressure pickup switch

Input

3

Motor

Output

4

Pressure pickup switch

Output

CN2 No.

8

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

Electric grease pump

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

Motor Tank Air bleed plug Pump Pressure switch Connector

HD465-7R

Specification Model: LD10FP

9

SEN06299-01

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.

HD465-7R

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.

SEN06299-01

2) q

q

q

q

q

HD465-7R

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

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

(2) Left front side

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

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

HD465-7R

13

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

(4) Right front side

A: B: C: D: E:

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

HD465-7R

15

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

(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)

HD465-7R

17

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

(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

HD465-7R

19

SEN06299-01

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)

HD465-7R

10 Structure, function and maintenance standard

SEN06299-01

Structure

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

Measurement piston Head Body Spring Spring retainer Pilot piston

HD465-7R

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

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

21

SEN06299-01

Operation 1) q

q

Supply When grease from the pump is supplied to supply port (F), the pressure at supply port (F) rises and pilot piston (6) is pushed up. As a result, oil passage (E) opens and the grease enters piston chamber (D) of measurement piston (1) from oil passage (E)

10 Structure, function and maintenance standard

q

q

q

22

Measurement piston (1) is pushed down by the grease in piston chamber (D), and the grease in measurement chamber (C) is discharged to the work equipment pins from discharge ports (A) and (B). At the end of this stroke, pilot piston (6) is pushed back down by measurement piston (1), and supply port (F) and oil passage (E) are closed. In this way, the measurement and discharge process for one cycle is completed.

HD465-7R

10 Structure, function and maintenance standard

2) q

q

SEN06299-01

Resetting When the pump enters the pressure release mode, measurement piston (1) is pushed back up by spring (4). When this happens, the grease in piston chamber (D) passes from oil passage (E) through the inside of pilot piston (6), and enters measurement chamber (C) to reset the system to the initial stage in preparation for the next time of actuation.

HD465-7R

23

SEN06299-01

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06299-01

© 2023 KOMATSU All Rights Reserved Printed in Japan 03-23 (01)

24

HD465-7R

SEN06300-01

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

Cab and its attachments Air conditioner ................................................................................................................................................. 2 Rear view monitor ........................................................................................................................................... 8

HD465-7R

1

SEN06300-01

10 Structure, function and maintenance standard

Air conditioner

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

1

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

Specifications Refrigerant used Refrigerant refilling level (g)

HFC134a (R134a) 850 ± 50

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

2

Heating q Heating is carried out using the coolant from the engine. High-temperature coolant from the hot water take-off port flows to the air conditioner unit, and hot air is blown out by a fan. When the temperature of the coolant drops, it is returned to the hot water return port and flows as coolant for the engine. Cooling The refrigerant gas compressed and pressurized by the air conditioner compressor enters the air conditioner condenser where it is cooled by dissipating the heat It then enters the air conditioner unit and cold air is blown out by the fan. When the temperature of the refrigerant gas rises, it is returned to the compressor.

q

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

Refrigerant flow system

HD465-7R

3

SEN06300-01

10 Structure, function and maintenance standard

Air conditioner unit

1. 2. 3. 4.

4

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

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

Receiver dryer

1.

Sight glass

A: B:

Refrigerant gas inlet port Refrigerant gas outlet port

HD465-7R

5

SEN06300-01

10 Structure, function and maintenance standard

Condenser

1. 2.

Fin Tube

A: B:

Refrigerant gas inlet port Refrigerant gas outlet port

6

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

Compressor

1. 2.

Case Clutch

A: B:

Suction service valve Discharge service valve

HD465-7R

7

SEN06300-01

Rear view monitor

10 Structure, function and maintenance standard

1

(If equipped) Serial number HD465-7R: 15001 - 16344

1. 2. 3.

8

Monitor Camera Cable

HD465-7R

10 Structure, function and maintenance standard

Rear view monitor

SEN06300-01

1

(If equipped) Serial number HD465-7R: 16345 and up

1. 2. 3.

Rear view monitor Rear view camera Cable

HD465-7R

9

SEN06300-01

10 Structure, function and maintenance standard

Serial number HD465-7R: 16345 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.

10

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

Serial number HD465-7R: 15001 - 16344

Monitor

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

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

HD465-7R

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

11

SEN06300-01

10 Structure, function and maintenance standard

Serial number HD465-7R: 16345 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)

2

Power supply return GND

Input -

3

External starting signal

Input

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

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

12

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

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

Input

3

(*1)

-

4

(*1)

-

5

GND (rear view camera power supply)

-

6

(*1)

-

7

(*1)

-

8

GND (rear view camera shield)

-

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

HD465-7R

13

SEN06300-01

10 Structure, function and maintenance standard

Serial number HD465-7R: 15001 - 16344

Camera

1. 2.

14

Camera Connector

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

HD465-7R

10 Structure, function and maintenance standard

SEN06300-01

Serial number HD465-7R: 16345 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.

HD465-7R

15

SEN06300-01

10 Structure, function and maintenance standard

HD465-7R DUMP TRUCK Form No. SEN06300-01

© 2019 KOMATSU All Rights Reserved Printed in Japan 03-19 (01)

16

HD465-7R

SEN06301-00

DUMP TRUCK HD465-7R

Machine model HD465-7R

Serial number 16132 and up

10 Structure, function and maintenance standard

1

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

HD465-7R

1

SEN06301-00

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

HD465-7R

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

HD465-7R

SEN06301-00

2.

Displaying trouble history data for machine Displays machine failure occurrence data from each controller that is saved in machine monitor. 3. Real-time monitor Takes input, output signal, and calculation values recognized by each controller on network and displays them in real time. 4. 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. 5. No injection cranking This function is used to lubricate an engine without starting the engine to drive a vehicle after a long-term storage. 6. 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. 7. Maintenance monitor This function is used to change filter oil replacement interval and stop the function. 8. Operation information display function This function is used to display fuel consumption amount per operation hour. 9. Engine mode fixing function This function is used to check the performance. 10. Snapshot function For details of this function, see "Structure, function and maintenance standard" of "Manual snapshot". 11. 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)". 12. Option selection function This function is used to select controller information and optional equipment to be operated. 13. Model selection function Input model information to be mounted. 14. Initialize This function is used to set the machine monitor when the machine is shipped from the factory.

3

SEN06301-00

10 Structure, function and maintenance standard

Machine monitor

1. Speedometer 2. Engine tachometer 3. Retarder oil temperature gauge 4. Torque converter oil temperature gauge 5. Coolant temperature gauge 6. Fuel gauge 7. Character display 8. Centralized warning lamp 9. Retarder oil temperature caution lamp 10. Torque converter oil temperature caution lamp 11. Coolant temperature caution lamp 12. Fuel level caution lamp 13. Maintenance caution lamp 14. Battery charging circuit caution lamp 15. Steering oil temperature caution lamp 16. Engine oil pressure caution lamp 17. Retarder oil pressure caution lamp 18. Parking brake caution lamp 19. Machine monitor option system caution lamp 20. Engine system caution lamp 21. Transmission system caution lamp 22. Retarder system caution lamp 23. Inclination caution lamp 24. Seat belt caution lamp 25. Body caution lamp

4

26. Emergency steering pilot lamp 27. Turn signal pilot lamp (right) 28. Turn signal pilot lamp (left) 29. Head lamp high beam pilot lamp 30. Shift lever position pilot lamp 31. Shift indicator 32. Retarder pilot lamp 33. Lockup pilot lamp 34. Output mode pilot lamp (power mode) 35. Output mode pilot lamp (economy mode) 36. Suspension mode pilot lamp (hard) (if equipped) 37. Suspension mode pilot lamp (medium) (if equipped) 38. Suspension mode pilot lamp (soft) (if equipped) 39. ABS pilot lamp (if equipped) 40. ASR pilot lamp (if equipped) 41. Preheater pilot lamp 42 Automatic retarder READY pilot lamp (if equipped) 43. Automatic retarder set speed indicator (if equipped) 44. Automatic retarder set speed unit indicator (km/ h) (if equipped) 45. Automatic retarder set speed unit indicator (MPH) (if equipped)

HD465-7R

10 Structure, function and maintenance standard

46. Rotary switch [SW1] 47. Rotary switch [SW2] 48. Rotary switch [SW3] 49. Dipswitch [SW5-4] 50. Dipswitch [SW5-3] 51. Dipswitch [SW5-2] 52. SI Spec, Non-SI Spec selection switch [SW5-1] 53. Dipswitch [SW6-4] 54. Dipswitch [SW6-3] 55. Dipswitch [SW6-2] 56. Dipswitch [SW6-1]

HD465-7R

SEN06301-00

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

SEN06301-00

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. Display item

1

2

3 9

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

Gauge

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

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.

Engine speed

Oil temperature of retarder

Gauge Oil tem4 perature of torque 10 converter

6

Color

Scale: white, red 50 – 135°C BackMove- ground (120°C or 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)

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

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

Caution

LED

Red

At 102°C or higher

Lit up during warning

Backlight

LED

Amber

When the small lamp is lit up.

Lit up during operation.

Gauge

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

Caution

LED

Red

Backlight

LED

Amber

Service meter

Action code

Failure code

HD465-7R

Action code

Failure code

Analog display

—

—

—

(Note)

—

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.

—

—

Specified level or less (At 76 z or higher)

Lit up during operation

—

—

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.

—

Note 1:"KOMATSU" is displayed in the upper column. Note 2 Note 2:"Program No." is displayed in the lower column.

the "upper column" on the character display

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

LCD

—

Remarks

Analog display

* Displayed in

Odometer (Regu- Odometer lar display item)

7

Display method

Gauge

Fuel level

Service meter (Regular display item)

Display range/ conditions

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

Coolant 5 temperature 11

6 12

Color

When any problem or When any prob- failure occurs, the action Display lem or failure code is discharacoccurs on the played in the ter: machine, * Disupper colblack played in the umn and remBackupper and lower edies or ground columns on the color: character display. description of problem in green the lower column. The failure Press machine code monitor mode (6 digits) and selector switch > detection during the occur- controller are rence of the displayed in problem or the upper colfailure on the umn and the machine. faulty system * Appears in the or descripupper and lower tion of problem in the columns on the lower character display. column.

—

—

—

(Note)

Note 1

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

7

SEN06301-00

10 Structure, function and maintenance standard

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

No. Display item

7

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

Display range/ conditions

Display method

LCD

Display character: black Background color: green

Press machine monitor mode selector switch " "

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

LED

Green

When the small lamp is lit up.

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

LED

Red

During system is abnormal

Lit up when abnormal.

Red

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

Lit up or flashed

LED

Red

During battery charging circuit being abnormal

Lit up when abnormal.

LED

Red

When the steering oil temperature rises.

Lit up when abnormal.

13

Maintenance caution

LED

14

Battery charging circuit caution

Steering oil 15 temperature caution

Caution

Remarks

For details, see the Operation & Maintenance Manual.

—

—

—

—

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

16

Engine oil pressure caution

LED

Red

When the engine oil pressure drops.

Lit up when abnormal.

17

Retarder oil pressure caution

LED

Red

When the retarder oil pressure drops.

Lit up when abnormal.

18

Parking brake caution

Red

When the parking brake is operated.

Lit up during operation. (Note) (Note)

Operates when the parking brake is operated and the shift lever is in other than the "N" position.

Lit up when abnormal.

Under present conditions, used in the event of failure of the machine monitor.

Lit up when abnormal.

LED

Machine monitor or 19 optional system caution

LED

Red

During being abnormal in machine monitor or optional controller system

Engine system caution

LED

Red

During being abnormal in engine control system.

20

8

(Note) (Note)

Operates when the alternator R terminal is ON.

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

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

No. Display item

Display category

Device

Color

Display range/ conditions

Display method

21

Transmission system caution

LED

Red

When transmission control system is abnormal

Lit up when abnormal.

22

Retarder system caution

LED

Red

When retarder control system is abnormal

Lit up when abnormal.

23

Inclination caution

LED

Red

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

Lit up when abnormal.

Red

When the seatbelt is not fastened.

During operation: lit up During nonoperation: turned OFF.

Red

See the instruction manual

During operation: lit up During nonoperation: turned OFF.

Red

When the emergency steering is operated.

During operation: lit up During nonoperation: turned OFF.

—

—

During operation

During operation: lit up During nonoperation: turned OFF.

—

—

During operation

During operation: lit up During nonoperation: turned OFF.

—

—

—

—

Caution 24

25

Seatbelt caution

LED

Body caution

LED

Emer26 gency steering

27

Turn signal, right

28

Turn signal, left

29

Headlight, high beam

LED

LED

LED

Green

Green

—

Remarks

—

(Note) (Note)

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

LED

Blue

During operation

During operation: lit up During nonoperation: turned OFF.

Shift 30 lever (R) position R

LED

Green

When the shift lever is in the "R" position

Lit up (*)

—

—

Shift 30 lever (N) position N

LED

Orange

When the shift lever is in the "N" position

Lit up

—

—

Shift 30 lever (D) position D

LED

Green

When the shift lever is in the "D" position

Lit up (*)

—

—

* Blinks when the neu-

Shift 30 lever (6) position 6

LED

Green

When the shift lever is in the "6" position

Lit up (*)

—

—

* Blinks when the neu-

Shift 30 lever (5) position 5

LED

Green

When the shift lever is in the "5" position

Lit up (*)

—

—

* Blinks when the neu-

HD465-7R

Pilot

* Blinks when the neutral safety is operated.

tral safety is operated.

tral safety is operated.

tral safety is operated.

9

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No. Display item

10 Structure, function and maintenance standard

Display category

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

Device

Color

Display range/ conditions

Display method

Shift 30 lever (4) position 4

LED

Green

When the shift lever is in the "4" position

Lit up (*)

—

—

Shift 30 lever (3) position 3

LED

Green

When the shift lever is in the "3" position

Lit up (*)

—

—

Shift 30 lever (2) position 2

LED

Green

When the shift lever is in the "2" position

Lit up (*)

—

—

Shift 30 lever (L) position L

LED

Green

When the shift lever is in the "L" position

Lit up (*)

—

—

LCD

Background color: gray

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

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

—

—

LED

Amber

When the small lamp is lighted up.

During operation: lit up

—

—

Orange

When the retarder brake is operated.

During operation: lit up During nonoperation: turned OFF

—

—

Green

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

During operation: lit up During nonoperation: turned OFF

—

—

At high-power mode

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

—

—

—

—

—

—

Pilot

Shift indicator 31

Night lighting

Backlight

32 Retarder

LED

33

Lockup

34

Output mode (power mode)

35

Output mode (economy mode)

LED

Green

At economy mode

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

36

Suspension mode (hard) (if equipped)

LED

Green

At suspension "hard" mode

Lit up in "hard" mode

10

LED

Pilot

LED

Green

Remarks

* Blinks when the neutral safety is operated.

* Blinks when the neutral safety is operated.

* Blinks when the neutral safety is operated.

* Blinks when the neutral safety is operated.

All lit up.

All lit up.

HD465-7R

10 Structure, function and maintenance standard

No. Display item

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

Device

Color

Display range/ conditions

Display method

Suspension mode 37 (medium) (if equipped)

LED

Green

In suspension "medium" mode

Lit up in "medium" mode

—

—

Suspension 38 mode (soft) (if equipped)

LED

Green

In suspension "soft" mode

Lit up in "soft" mode

—

—

During operation: lit up During nonoperation: turned OFF

—

—

During operation: lit up During nonoperation: turned OFF

—

—

39

40

Display category

SEN06301-00

ABS (if equipped)

LED

ASR (if equipped)

LED

Orange

When ABS is operated.

Orange

When ASR is operated.

During operation: lit up During nonoperation: turned OFF

LED

Red

When electric intake air heater for preheating engine is operated.

Automatic retarder 42 being ready (if equipped)

LED

Green

When autoWhen ready matic retarder is to be ready to be operoperated: ated. lit up

—

—

Automatic retarder 43 set speed (if equipped)

LCD

Background color: gray

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

—

—

Green

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

During operation: lit up During nonoperation: turned OFF

—

—

Green

When automatic retarder switch is turned on and the unit MPH is selected.

During operation: lit up During nonoperation: turned OFF

—

—

41

Preheating Pilot

Automatic retarder unit 44 display (km/h) (if equipped) automatic retarder 45 display unit (MPH) (if equipped)

HD465-7R

LED

LED

Remarks

* Zero is displayed when the set speed is cancelled.

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10 Structure, function and maintenance standard

Self-diagnostic function when starting switch is operated 1.

2.

When the starting switch is turned to the ON position before starting the engine, the system check is carried out for 3 seconds. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch at the ON position, everything will go to the normal operating condition. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have passed after the starting switch is turned to the ON position.

Check function of central warning lamp, alarm buzzer, monitor lamps, and meters To check the normal display function of the machine monitor, press the machine monitor check switch to check the actuation. For details of the actuation, see "Machine monitor normal display functions when machine monitor check switch is operated".

12

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10 Structure, function and maintenance standard

HD465-7R

SEN06301-00

13

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Service mode functions Outline 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. To initialize sensors, operation settings, and the like, enter into the service mode of the machine monitor. How to operate the machine monitor 1. Enter into the service mode 1) Operation method (1) Turn on the start switch of the vehicle to power ON the machine monitor. (2) While service meter screen or alert screen is being displayed on the character display of the machine monitor, press machine monitor mode selector switch 1 (t) and machine monitor mode selector switch 2 (<) at the same time for more than five seconds continuously, to enter into service ID input screen. The service ID input screen is then displayed. Machine monitor mode selector switches 1, 2

10 Structure, function and maintenance standard

2)

ID input procedure (1) Press switches </> to increase or decrees the value at the cursor position. Use these switches to select a desired value and the press switch U. (2) Repeat the above operation (1) for four digits. The electrical equipment system failure history screen is displayed. a When an incorrect value is entered, press the t switch and then enter the correct data starting from the highest digit. a You can return to the service meter screen or alert screen by pressing the t switch when the cursor is located at the highest digit. a If any switch operation is not done for 60 seconds or more during input of an ID. The screen will be returned to the service meter screen or alert screen. To enter into the service mode, input "6491" as ID. Supplementary explanation: You can return to the service meter screen or alert screen by turning OFF the starting switch on the service mode and then turn ON the starting switch.

Service ID input screen

14

HD465-7R

10 Structure, function and maintenance standard

2.

SEN06301-00

Service Mode Menu

(*1) If equipped the "Payload meter (having VHMS)". (*2) If equipped the VHMS. a

a

a

On the service menu mode, the screen can be changed by pressing switches </>. Use these switches to select the desired operation menu screen. While the following display screen (selection screen) is being displayed, the screen can be changed to the menu screen/operation screen of each function by pressing switch U. While the following display screen (selection screen) is being displayed, the screen can be changed to the service meter screen of each function by pressing switch t.

HD465-7R

15

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10 Structure, function and maintenance standard

Operation menu screen (character display) 1) Electrical equipment system failure history screen

3)

**

indicates the number of currently memorized failure histories. (Up to max. 20 failure histories can be memorized.)

Real-time monitor screen

Outline Use this function to check the inputting and outputting signals being recognized by respective controllers on the network.

Outline Use this function to check the electric system failure history of respective controllers being memorized by the machine monitor. Regarding the error code being used in the electric equipment system failure history, refer to the Chapter "Troubleshooting". When the fault is repaired and after checking and confirming that normal operation has been restored, delete the fault history. 2)

Vehicle system failure history screen

4)

**

indicates the number of currently memorized failure histories. (Up to max. 20 failure histories can be memorized.)

Outline Use this function to cut off the supply of fuel sprayed from the fuel injector to each of the cylinders in order to determine the cylinder where there is defective combustion. Regarding the inspection method using this function, refer to the Section "Reduced cylinder mode operation of engine" in the chapter "Inspection and Adjustment"

Outline Use this function to check the machine system failure history of respective controllers being memorized by the machine monitor. Regarding the error code being used in the machine system failure history, refer to the Chapter "Troubleshooting".

16

Engine reduced cylinder function screen

HD465-7R

10 Structure, function and maintenance standard

5)

No injection cranking function screen

SEN06301-00

7)

Maintenance monitor function screen

Outline Use this function to lubricate an engine without starting the engine to drive a vehicle after a longterm storage. Regarding the engine start method using this function, refer to the Section "No injection cranking operation of engine" in the chapter "Inspection and Adjustment"

Outline This function is being explained in the section "Filter and oil changing time indication on the character display" in the Chapter "Handling" in the Operation and Maintenance Manual. Use this function to change filter oil replacement interval and stop function.

6)

8)

Adjusting function screen

Outline Use this function to correct installation errors of sensors, solenoid valves, and compensate production tolerances of parts and components. Use this function to change control characteristic data in response to user's request. Regarding the adjusting method using this function, refer to the Section "Adjustment using monitor" in the chapter "Inspection and Adjustment"

HD465-7R

Operation information display function screen

Outline Use this function to display fuel consumption amount per operation hour.

17

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10 Structure, function and maintenance standard

9)

11) Payload meter screen

Engine mode fixing function screen

Outline The engine mode controlled automatically according to the load on the machine, etc. is fixed forcibly. This function is used to check the performance in each engine mode.

Outline For details of this function, see "Related to VHMS controller" of "Payload meter (having VHMS)".

10) Manual snapshot screen

12) Option selection function screen

Outline Use this function to order the snapshot data taking in, this function is used only having VHMS. When do the inspection used this function, see "Inspection and Adjustment" of "Inspection using VHMS".

Outline Use this function to indicate the installation status of the optional equipment and to change the settings. Use this function when optional equipment is installed or removed. Regarding the setting change method using this function, refer to the Section "Adjustment using monitor" in the chapter "Inspection and Adjustment"

18

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

13) Model selection function screen

a Indicates the currently selected model. Outline Use this function to input and select machine model.

14) Initialize function screen

Outline This function operates on factory setting mode. Since this function is for factory use only, do not touch it.

HD465-7R

19

SEN06301-00

10 Structure, function and maintenance standard

Items related to the fault history of electric system

20

1)

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

2)

Selection of displaying the fault history of electric system (first layer) Pressing the > switch changes the screen to the [Select the initializing function] screen. Pressing the < switch changes the screen to the [Select displaying the fault history of vehicle system] screen. Pressing the t switch changes the screen to the ordinary or alert screen. Pressing the U switch changes the screen to the [Display abnormalities in electric system] screen.

HD465-7R

10 Structure, function and maintenance standard

3)

*

4)

SEN06301-00

Selection of displaying the fault history of electric system and clearing the entire fault history of electric system (second layer) A current fault is displayed prior to the restored ones. Pressing the > switch displays the next newer fault. Pressing the < switch displays the next older fault. After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the entire fault history of electric system of the relevant controller. Pressing the t switch changes the screen to the [Select displaying abnormalities in electric system] screen on the first layer. Pressing the U switch changes the screen to the [Clear individually the fault history of electric system] or [Clear the fault history of electric system] screen. If the history consisted of one fault, pressing the switch does not change the screen to that for allout clearing (but change the screen to that for individual clearing).

Clearing individually the fault history of electric system, and clearing the entire fault history of electric system (the third layer) Select YES or NO with the < or > switch. Cursor (_) blinks on the selected item. Pressing the t switch changes the display as follows, with the history reset if YES was selected, or not if NO was selected: i) If No (cancel) was selected, the display returns to the [Display the fault history of electric system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually (entirely) the fault history of electric system] screen). ii) If YES (clear ) was selected, the display returns to the [Display the fault history of electric system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the screen returns to the [Select displaying the fault history of electric system] screen. By default, the cursor is on NO (no reset) to prevent resetting by error. A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the operation is cancelled.

HD465-7R

21

SEN06301-00

10 Structure, function and maintenance standard

Items related to the fault history of machine system

22

1)

Display of the fault history of vehicle system A current fault is displayed prior to the restored ones. Pressing the > switch displays the next newer fault. Pressing the < switch displays the next older fault. After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the entire fault history of electric system of the relevant controller. Pressing the t switch changes the screen to the [Select displaying abnormalities in machine system] screen on the first layer.

2)

Selection of displaying the fault history of machine system (first layer) Pressing the > switch changes the screen to the [Select the real-time monitor functions] screen. Pressing the < switch changes the screen to the [Select displaying the fault history of machine system] screen. Pressing the t switch changes the screen to the ordinary or alert screen. Pressing the U switch changes the screen to the [Display abnormalities in electric system] screen.

HD465-7R

10 Structure, function and maintenance standard

3)

SEN06301-00

Display of the fault history of vehicle system (second layer) The fault history is displayed in the order of occurrence with the newest fault first. A current fault is displayed prior to the restored ones. The fault history is displayed in the order of occurrence with the newest fault first. Pressing the > switch displays the next newer fault. Pressing the < switch displays the next older fault. Pressing the t switch changes the screen to the [Select displaying abnormalities in vehicle system] screen.

HD465-7R

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10 Structure, function and maintenance standard

Real-time monitoring function The real-time monitor shows real-time the information which the controller mounted on the vehicle has. This function is used for checking and adjustment, diagnosis of faults of the vehicle and other purposes. The real-time monitor shows the items and their data, classified by the controllers which have information. It shows them in two ways: the ordinary display, and the 2-item display where two data items are shown simultaneously. Operation 1. Press the t switch and < switch for more than five seconds to go to the [ID Entry] screen.

2.

Enter ID with the < and > switch, and press the U switch to go to the screen for service persons.

3.

Press the < and > switch to display the [Select the real-time monitor] screen, then press the U switch to fix the screen.

24

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10 Structure, function and maintenance standard

SEN06301-00

4.

Press the switch U, and the [Monitor information display/selection] screen appears. Press the switch < and the switch > to display the [Transmission controller information display/selection] screen, [Engine controller information display/selection] screen, [Retarder controller information display/selection] screen, [ABS controller information display/selection] screen (if equipped) and [2 item display function selection] screen in order.

5.

Pressing the U switch, while each selection screen is shown, displays the [One-item display] screen or the [Select information on 2-item display] screen.

***: Shows items. %%%%%: Shows data and unit (SI system) $$$$: Shows ID. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the information each controller has.

HD465-7R

25

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10 Structure, function and maintenance standard

How to Enter an ID After the screen was changed from another, “00000” is shown. Enter a number 0-9 in the cursor position. The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1 within a range 0-9. If the desired number was entered, press the U switch. The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last number is filled in the lowest digit. If the lowest digit was entered, press the U switch, and the screen changes to that for displaying/selecting the second item. Alternately, pressing the t switch returns the screen to that for displaying/selecting two items.

In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown simultaneously. The IDs shown are the same as those on the 1-item display screen. 6.

26

In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the information each controller has.

HD465-7R

10 Structure, function and maintenance standard

HD465-7R

SEN06301-00

27

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10 Structure, function and maintenance standard

List of real-time monitoring display contents The conditions of the input and output signals of the controller can be checked with the real-time monitoring function of the monitor. The following table shows the items related to the machine monitor and displayed with the real-time monitoring function in the normal state. No.

Item

ID No.

Display of item

Displayed data

1

Software No.

20020

VERSION

2

Application ver. No.

20021

VERSION (APP)

Application ver. No. is displayed.

3

Data ver. No.

20222

VERSION (DATA)

Data ver. No. is displayed.

4

Rheostat

30300

RHEOSTAT

5

Rotary switch 1 – 3

30800

SW1, SW2, SW3

–

6

DIP switch 5-1, 2

30900

SW5-1, SW5-2

SW5-1: Selection of SI or non-SI specification SW5-2: Unused

7

DIP switch 5-3, 4

30901

SW5-3, SW5-4

–

8

DIP switch 6-1, 2

30202

SW6-1, SW6-2

–

9

DIP switch 6-3, 4

30903

SW6-3, SW6-4

–

10

D-IN--0------7

40900

D-IN--0------7

Input signal is displayed.

11

D-IN--8------15

40901

D-IN--8------15

Input signal is displayed.

28

Software No. is displayed.

Rheostat voltage is displayed.

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Contents of display in normal state

Remarks

As per software No. As per application version No. As per data version No. 0 – 30 V –

Unused

SW5-1: For 7831-46-7000*, normally OFF For 7831-46-8000*, normally ON SW5-2: Unused –

Unused

–

Unused

–

Unused

1 0000000 (Headlight = ON)

D-IN-0:

High beam

0 1 000000 (Switch = ON)

D-IN-1:

Machine monitor check switch

00 1 00000 (AISS switch = ON)

D-IN-2:

AISS switch

00000 1 00 (Switch = ON)

D-IN-5:

ABS system switch (if equipped) If not equipped: 0

000000 1 0 (Switch = ON)

D-IN-6:

Passing switch

0000000 1 (Switch = Economy)

D-IN-7:

Engine mode switch

1 0000000 (Normally 1)

D-IN-8:

Connector check

0 0 000000 (Monitor mode switch (t) = ON)

D-IN-9:

Machine monitor mode switch (t)

00 1 00000 (Monitor mode switch (>) = ON)

D-IN-10: Machine monitor mode switch (>)

000 1 0000 (Monitor mode switch (<) = ON)

D-IN-11: Machine monitor mode switch (<)

0000 1 000 (Winker (Right) = ON)

D-IN-12: Winker (Right)

00000 1 00 (Winker (Left) = ON)

D-IN-13: Winker (Left)

000000 1 0 (Monitor mode switch (U) = ON)

D-IN-14: Machine monitor mode switch (U)

0000000 0 (Unused)

D-IN-15: Unused

HD465-7R

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No.

10 Structure, function and maintenance standard

Item

ID No.

Display of item

Displayed data

12

D-IN-16-----23

40902

D-IN-16-----23

State of input signal is displayed.

13

D-IN-24-----31

40903

D-IN-24-----31

State of input signal is displayed.

14

D-IN-32-----39

40904

15

D-OUT-0--3

40925

30

D-IN-32-----39

D-OUT-0--3

State of input signal is displayed.

State of output signal is displayed.

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Contents of display in normal state

Remarks

0 0000000 (Switch = ON)

D-IN-16: ARSC system switch (Upper) (If equipped) If not equipped: 0

0 1 000000 (Switch = ON)

D-IN-17: ARSC system switch (Lower) (If equipped) If not equipped: 0

00 1 00000 (Switch = ON)

D-IN-18: ABS system switch (Upper) (If equipped) If not equipped: 0

000 1 0000 (Switch = ON)

D-IN-19: ABS system switch (Lower) (If equipped) If not equipped: 0

0000 1 000 (Switch = ON)

D-IN-20: ASR system switch (Upper) (If equipped) If not equipped: 0

00000 0 00 (Unused)

D-IN-21: ASR system switch (Lower) (If equipped) If not equipped: 0

000000 1 0 (Switch = ON)

D-IN-22: Front brake cut-off switch If not equipped: 0

0000000 0 (Unused)

D-IN-23: Unused

1 0000000 (Headlight = ON)

D-IN-24: Night lighting recognition

0 1 000000 (Seat belt = Installed)

D-IN-25: Seat belt

00 1 00000 (Unused)

D-IN-26: Unused

000 0 0000 (Unused)

D-IN-27: Unused

0000 1 000 (Unused)

D-IN-28: Unused

00000 0 00 (Unused)

D-IN-29: Unused

000000 1 0 (Unused)

D-IN-30: Unused

0000000 1 (Unused)

D-IN-31: Unused

0 0000000 (Unused)

D-IN-32: Unused

0 0 000000 (Unused)

D-IN-33: Unused

00 0 00000 (Normally 0)

D-IN-34: Connector check

000 0 0000 (Unused)

D-IN-35: Unused

0000 0 000 (Unused)

D-IN-36: Unused

00000 0 00 (Unused)

D-IN-37: Unused

000000 0 0 (Unused)

D-IN-38: Unused

0000000 0 (Reservation for service, OP7 = OPEN)

D-IN-39: Reservation for service

1 000 (Headlight Hi/Lo selector switch = ON)

D-OUT-0: Headlight Hi/Lo selector switch

0 1 00 (Buzzer = ON)

D-OUT-1: Buzzer

00 0 0 (Unused)

D-OUT-2: Unused

000 0 (Unused)

D-OUT-3: Unused

HD465-7R

31

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VHMS real monitor display table (if equipped) No.

Item

ID No.

Display of item

1

Air temperature

37501

AIR TEMP

Display air temperature

2

Air temperature

37504

AIR TEMP

Display air temperature

3

Blow-by pressure

42801

BLOWBY PRESS

Display blow-by pressure

4

Blow-by pressure

42802

BLOWBY PRESS

Display blow-by pressure

5

Exhaust temperature (FRONT)

42610

EXHAUST TMP F

Display exhaust temperature (FRONT)

6

Exhaust temperature (FRONT)

42612

EXHAUST TMP F

Display exhaust temperature (FRONT)

7

Exhaust temperature (REAR)

42611

EXHAUST TMP R

Display exhaust temperature (REAR)

8

Exhaust temperature (REAR)

42613

EXHAUST TMP R

Display exhaust temperature (REAR)

9

Inclinometer (pitch angle)

32901

INCLINOMETER

Display inclination angle

10

Inclinometer (pitch angle)

32902

INCLINOMETER

Display inclination angle

11

Payload

42200

PAYLOAD

12

Rated payload

42201

RATE WEIGHT

Display rated weight

13

Shift lever N signal

42500

SHIFT LEVER N

Display shift lever N position

14

Stop run flag

45000

STOP RUN FLAG

Display discrination the STOP or RUN

15

Suspension pressure (F.L.)

32805

SUS PRESS (FL)

Display suspension pressure (F.L.)

16

Suspension pressure (F.L.)

32811

SUS PRESS (FL)

Display suspension pressure (F.L.)

17

Suspension pressure (F.R.)

32804

SUS PRESS (FR)

Display suspension pressure (F.R.)

18

Suspension pressure (F.R.)

32810

SUS PRESS (FR)

Display suspension pressure (F.R.)

32

Displayed data

Display payload

HD465-7R

10 Structure, function and maintenance standard

Contents of display in normal state

SEN06301-00

Remarks

–30 to +100 [°C], It depends on air temperature. 0.0 to 20.0 [kPa], Refer Pm clinic inspection table. 0.0 to 20.0 [kPa], Refer Pm clinic inspection table. 0.5 [V] at 0 [kPa] 3.5 [V] at 15 [kPa] Check after engine warm-up. 200 – 950 [°C] Refer Pm clinic inspection table. Check after engine warm-up. 0 to 5 [V] 2.2 [V] at 300 [°C] 3.9 [V] at 700 [°C] Check after engine warm-up. 200 – 950 [°C] Refer Pm clinic inspection table. Check after engine warm-up. 0 to 5 [V] 2.2 [V] at 300 [°C] 3.9 [V] at 700 [°C] Flat ground: 0.0 [° ] (When Front up: plus, Measurement range: +/–15°)

When PLM (having VHMS) is setted up.

Flat ground: 2.6 [V] 4.15 [V] at +15° 1.06 [V] at –15°

When PLM (having VHMS) is setted up.

Payload [t] (Always, Metric ton)

When PLM (having VHMS) is setted up.

Rated payload [t] (Always, Metric ton)

When PLM (having VHMS) is setted up.

When shift lever is N position: ON

When PLM (having VHMS) is setted up.

When stoped: ON

When PLM (having VHMS) is setted up.

0.00 – 20.0 [MPa]

When PLM (having VHMS) is setted up.

1.0 [V] at 0 [Mpa] 2.0 [V] at 4.9 [Mpa]

When PLM (having VHMS) is setted up.

0.00 – 20.0 [MPa]

When PLM (having VHMS) is setted up.

1.0 [V] at 0 [Mpa] 2.0 [V] at 4.9 [Mpa]

When PLM (having VHMS) is setted up.

HD465-7R

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10 Structure, function and maintenance standard

No.

Item

ID No.

Display of item

19

Suspension pressure (R.L.)

32807

SUS PRESS (RL)

Display suspension pressure (R.L.)

20

Suspension pressure (R.L.)

32813

SUS PRESS (RL)

Display suspension pressure (R.L.)

21

Suspension pressure (R.R)

32806

SUS PRESS (RR)

Display suspension pressure (R.R.)

22

Suspension pressure (R.R)

32812

SUS PRESS (RR)

Display suspension pressure (R.R.)

23

Machin status

42400

TRUCK STATUS

Display machine status

24

Input signal D_IN_0–7

40944

D-IN--0------7

Display input signal condition

25

Input signal D_IN_8–15

40945

D-IN--8-----15

Display input signal condition

26

Out put signal D_OUT_0–7

40946

D-OUT-0--3

Display input signal condition

27

SEL signal 0–3

40947

D-SEL--0--3

Display SEL signal condition

34

Displayed data

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Contents of display in normal state

Remarks

0.00 – 20.0 [MPa]

When PLM (having VHMS) is setted up.

1.0 [V] at 0 [Mpa] 2.0 [V] at 4.9 [Mpa]

When PLM (having VHMS) is setted up.

0.00 – 20.0 [MPa]

When PLM (having VHMS) is setted up.

1.0 [V] at 0 [Mpa] 2.0 [V] at 4.9 [Mpa]

When PLM (having VHMS) is setted up.

Empty Stooped: 1 Empty Traveling: 2 During loading: 3 Loaded Traveling: 4 Losded Stopped: 5 During Unloading: 6

When PLM (having VHMS) is setted up.

0 0000000 (Unused) 0 1 000000 (OBCOM connection = ON) 00 0 00000 (Unused) 000 0 0000 (Unused) 0000 1 000 (PLM2 connection = ON) 00000 0 00 (Unused) 000000 1 0 (Cab under download SW = ON) 0000000 1 (Body float condition = ON)

D-IN-0: Unused D-IN-1: OBCOM connection D-IN-2: Unused D-IN-3: Unused D-IN-4: PLM2 conection D-IN-5: Unused D-IN-6: Cab under download SW D-IN-7: Body float

1 0000000 (Protocol cange connector: automatic transmit = ON) 0 1 000000 (Protocol cange connector: MMS communication = ON) 00 0 00000 (Unused) 000 0 0000 (Unused) 0000 0 000 (Unused) 00000 0 00 (Unused) 000000 0 0 (Unused) 0000000 0 (Unused)

D-IN-0: Protocol cange connector

0 000 (External display lamp: Green= light ON) 0 0 00 (External display lamp: Yellow = light ON) 00 0 0 (External display lamp: Red = light ON) 000 1 (VHMS is in action)

D-OUT-0: External display lamp Green D-OUT-1: External display lamp Yellow D-OUT-2: External display lamp Red D-OUT-3: VHMS is in action

0 000 (Always 0) 0 1 00 (Always 1) 00 1 0 (Always 1) 000 0 (Always 0)

SEL-0: Always 0 SEL-1: Always 1 SEL-2: Always 1 SEL-3: Always 0

HD465-7R

D-IN-1: Protocol cange connector D-IN-2: Unused D-IN-3: Unused D-IN-4: Unused D-IN-5: Unused D-IN-6: Unused D-IN-7: Unused

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10 Structure, function and maintenance standard

Engine cylinders cut-out function Regarding the inspection method using this function, refer to the Section "Reduced cylinder mode operation of engine" in the chapter "Inspection and Adjustment" This section will describe the operation method only. 1.

Press the t switch and < switch for more than five seconds to go to the [ID Entry] screen.

2.

Enter ID with the < and > switch, and press the U switch to go to the screen for service persons.

3.

Press the < and > switch to display the [Select the cylinder cut-out mode] screen, then press the U switch to fix the screen.

36

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10 Structure, function and maintenance standard

4.

SEN06301-00

How to operate the cylinder cut-out function Each time the > switch is pressed (to select the cylinder to be cut-out with a command), the cursor moves one step to the right. Each time the < switch is pressed (to select the cylinder to be cut-out with a command), the cursor moves one step to the left. Pressing the U switch issues the command to cut-out the cylinder selected. Each time it is pressed, the command toggles between cut-out and cancel. Pressing the t switch returns the screen to that of [Select the cylinder cut-out mode], and any cut-out command which has been issued from monitor is cancelled. Example of operation: The command is issued to stop the third cylinder.

HD465-7R

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10 Structure, function and maintenance standard

No injection cranking function screen Regarding the engine start method using this function, refer to the Section "No injection cranking operation of engine" in the chapter "Inspection and Adjustment" This section will describe the operation method only.

38

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10 Structure, function and maintenance standard

SEN06301-00

Adjusting function Regarding the adjusting method using this function, refer to the Section "Adjustment using monitor" in the chapter "Inspection and Adjustment" This section will describe the operation method only.

01: TM TRIGGER Transmission Initial learning reset a Refer to "Rest of Initial learning for Transmission and Learning Operation" in the chapter "Adjustment" 02: ECMV TUNING ECMV compensation a Refer to "Transmission ECMV Current Adjustment" in the chapter "Adjustment".

HD465-7R

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10 Structure, function and maintenance standard

Maintenance monitor function 1.

Maintenance monitor selection display (first layer) Regarding the screen, which the current screen turns to when the <, >, or t switch is pressed, refer to "Second Layer Transition Diagram" in the Section "Service Person Function". When the U switch is pressed, the current screen turns to the [Maintenance item No. 1] screen.

40

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10 Structure, function and maintenance standard

2.

a.

SEN06301-00

Maintenance item selection 1) Each time the > switch is pressed, the item No. of the displayed screen changes from No. 1 in the ascending order. a When the item No. of the displayed screen is the largest, pressing the > switch changes the screen to the "Default value is set" screen.

Maintenance interval time change

2) a

(4) The cursor moves to the second highest digit. Repeat the procedures mentioned in (2) and (3) until the last number is filled in the lowest digit. (5) After the lowest digit is entered, press the U switch. a If the entered value represents the interval time which can be set, the screen changes to the confirmation screen. a If the entered value represents the interval time which cannot be set, the time doe not change. (6) The cursor is returned to the highest digit. a The interval time can be set up to 50 h. (7) If a wrong number is entered, unless the cursor is positioned at the highest digit, press the t switch to bring the cursor to the highest digit, and do the procedures from the beginning again. a At this time, the entered values remain unchanged. (8) When the cursor is positioned at the highest digit, pressing the t switch changes the screen to the higher layer. q q

How to enter interval time (1) Enter a number from 0 to 9 in the cursor position. (2) The cursor is positioned at the highest digit first. Each time the > or < switch is pressed, the number is changed in the INC/DEC order by 1 within a range 0 to 9. (3) If the desired number is entered, press the U switch to apply it. HD465-7R

Each time the < switch is pressed, the item No. of the displayed screen changes from the largest number in the descending order. When the item No. of the displayed screen is No. 1, pressing the < switch changes the screen to the "All timer stop/all item valid" screen.

a

Press the <> switch to select YES/NO. The cursor (_) blinks on the selected item When YES is selected, pressing the t switch accepts the change. When NO is selected, pressing the t switch cancels the change, and goes to the "maintenance item selection" screen. The cursor is positioned at NO by default to prevent from mistakenly carrying out the reset operation.

When the interval time is changed, the remaining time on the timer is as follows. [Set interval time – time elapsed from the previous operation]

q

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10 Structure, function and maintenance standard

b.

3. Default individual setting

Item specific timer stop/item specific valid selection

q

When "item specific timer" is currently operating, "ON o OFF" is displayed on the lower panel. q When "item specific timer" is currently stopping, "OFF o ON" is displayed on the lower panel. a The timer function should be valid by default with [ON] displayed. q Setting "Item specific timer" to stop state, [OFF] is displayed on the higher panel. q Setting "Item specific timer" to operation state, [ON] is displayed on the higher panel. q Press the <> switch to select YES/NO. q The cursor (_) blinks on the selected item. When YES is selected, pressing the t switch accepts the change. When NO is selected, pressing the t switch cancels the change, and goes to the "maintenance item selection" screen. a The cursor is positioned at NO by default to prevent from mistakenly carrying out the reset operation. q Set the timer to stop/ release from stop for each of the maintenance items. q When the timer is made enabled after it was stopped, the interval time set to the timer before the timer was disabled is restored. q The remaining time on the timer is reset. a The number of reset times is not incremented but remains the same. q

42

q

a

q q q

a a

Press the <> switch to select YES/NO. The cursor (_) blinks on the selected item. When YES is selected, pressing the t switch accepts the change. When NO is selected, pressing the t switch cancels the change, and goes to the "maintenance item selection" screen. The cursor is positioned at NO by default to prevent from mistakenly carrying out the reset operation. For each maintenance item, the timer should be set to stop/stop release. Set the timer to stop/ release from stop for each of the maintenance items. When the timer is made enables after it was stopped, the interval time set to the timer before the timer was disabled is restored. The remaining time on the timer is reset. The number of reset times is not incremented but remains the same.

HD465-7R

10 Structure, function and maintenance standard

4.

SEN06301-00

"All item timer stop/all item valid selection"

*1. Press the U switch to change the screen to the "All item timer stop" screen. *2. In the case that "All item timer stop" is selected *3. When all item stop is carried out: The timer functions for all items are disabled, and the screen returns to the "Maintenance monitor selection" screen. When the specific item is carried out, the setting is made to disable the function. When cancel is carried out: The operation is cancelled and the screen returns to the "maintenance selection" screen. *4. When "All item valid" is selected *5. Press the <> switch to select YES/NO. The cursor (_) blinks on the selected item a The cursor is positioned at NO (not change) by default to prevent from mistakenly carrying out the reset operation. *6. When all item valid is carried out: Regardless of whether specific item is valid or invalid, the interval time set to the timer before the timer was disabled is effective for all items. The remaining time on the timer is reset. Meanwhile, the number of reset times is not incremented but remains the same. The screen returns to the "maintenance monitor selection" screen. Setting is made valid for each item. When cancel is carried out: The operation is cancelled and the screen returns to the "maintenance selection" screen.

HD465-7R

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5.

10 Structure, function and maintenance standard

Maintenance monitor item

No.

Item

Interval [h]

English message [11 one-byte characters]

ID number

1

Pre fuel filter

500

P FUEL FILT

41

2

Engine oil

500

ENG OIL

01

3

Engine oil filter

500

ENG FILT

02

4

Transmission oil filter

500

TM FILT

13

5

Fuel filter

1,000

FUEL FILT

03

6

Corrosion resistor

1,000

CORR RES

06

7

Torque converter, transmission and rear brake cooling oil

1,000

TC/TM/BK OIL

24

8

Brake oil filter

1,000

BK OIL FILT

14

9

Brake cooling oil filter

1,000

BK C FILT

16

10

Hydraulic oil filter

2,000

HYD FILT

04

11

Differential case oil

2,000

DIFF OIL

11

12

Final drive oil

2,000

FNL OIL

08

13

Steering hoist oil

4,000

HYD OIL

10

44

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10 Structure, function and maintenance standard

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Operation information display function Outline q The fuel consumption value is calculated based on the target injection quantity information supplied from the engine controller. q The fuel consumption value can be used merely as a reference value because the actual fuel consumption is not measured.

*1 Upper column q Displays fuel consumption (L/km or L/mile) for every 1 km (or mile) since the previous reset q Calculation is made based on the above fuel consumption and the travel distance q Counting will stop when the upper limit 99999.9 is reached. Lower column q Displays average fuel consumption (L/h) since the previous reset q Counting will stop when the upper limit 9999.9 is reached. *2 Upper column q Displays accumulated fuel consumption (L) since the previous reset q Counting will stop when the upper limit 9999999.9 is reached.

HD465-7R

Lower column q Displays travel distance (km or mile) since the previous reset q Counting will stop when the upper limit 9999999.9 is reached. *3 Upper column q Displays accumulated fuel consumption (L) since the previous reset q Counting will stop when the upper limit 9999999.9 is reached. Lower column q Displays elapsed time (h) since the previous reset q Counting will stop when the upper limit 9999999.9 is reached.

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*4 (if equipped the VHMS) q Display loaded quantity {ton} from the last reset on the upper line. q Stop at the upper limit of 999999999.9. q Whether short ton or metric ton is used depends on option settings. q Display the number of loadings from the last reset on the upper line. q Stop at the upper limit of 999999999.9. a The above data should be obtained from the value calculated by VHMS when PLM built into VHMS is enabled. a VHMS sends load capacity to a monitor panel at the time of determination of 1 cycle. a When load capacity at the time of determination of 1 cycle is received, the monitor panel adds the loaded quantity to the last value and add 1 to the number of loadings. *1 – *4 q Calculation is made only when engine is operating and optional equipment is provided. *5 q Press the U switch to delete data in the screen (*1), (*2), (*3) and return to the screen of the previous layer. q Press the t switch to return to the screen of the previous layer without resetting the current screen. a Reset the data when "initializing the monitor panel" and when "turning the optional functions OFF", in addition to the above resetting operation.

*6 Setting of gain compensation value 1) In order to change the screen, display the current setting value and place the cursor on the symbol (+/–). 2) While the cursor is being positioned at the symbol, repeat '+', '<–>', '–', each time the >, /, or < switch is pressed. 3) Press the U switch to confirm the symbol. o The cursor moves to the highest digit. 4) The cursor is positioned at the highest digit first. Each time the >, /, or < switch is pressed, the number is changed in the INC/DEC order by 1 within a range 0 to 9 (the highest digit is 0 to 2). 5) If the desired number is entered, press the U switch to apply it. 6) The cursor moves to the lower digit. Repeat the procedure mentioned in 4). 7) The cursor moves to the lowest digit. Press the U switch. (When the number is confirmed, the screen returns to that of the previous layer.) 8) While the number is being entered, pressing the t switch makes the number remain unchanged and the cursor returns to the position of the symbol. Pressing the t switch again change the screen to the previous screen. 9) When the number is not within the range from – 50.0 to + 50.0 while the lowest digit is confirmed, the number remains unchanged and the cursor returns to the position of the symbol, as is the case for pressing the t switch.

Obtaining fuel consumption level [L] The monitor panel calculates the accumulated fuel consumption (L) based on the instantaneous fuel consumption [L/h] supplied from the engine controller. q The accumulated fuel consumption (L) is compensated using the fuel adjusting function [FUEL ADJUST] on the service mode. q The instantaneous fuel consumption [L/h] supplied from the engine controller is compensated in accordance with the table shown below. q

Procedures with the monitor panel: q Default value: 0.0% q Specify the setting value to compensate the accumulated fuel consumption (L) in the range of [– 50.0 to + 50.0]

[Compensated value in accordance with the table] = [Instantaneous fuel consumption supplied from engine controller] x [compensation value (a)] Model

Compensation value (a)

HD325-7, HD405-7

1

HD465-7E0, HD605-7E0

1

HD465-7R, HD605-7R

1

HD785-7

1

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RDT snapshot (having VHMS) For information about this function, see the section "Implementation of PM Clinic Using Manual Snapshot".

(*1) Start the snapshot and exit it during recording. After 7 minutes 30 seconds have elapsed, a move to "READY" takes place when U is pressed on the "SNAPSHOT" screen. When 7 minutes 30 seconds have not elapsed, a move to the "EXECUTING" screen takes place.

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

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

Option selecting function a Regarding the setting method using this function, refer to the Section "Adjustment using monitor" in the chapter "Inspection and Adjustment".

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

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Table of signals for each monitor connector Machine monitor No.

Specification CN

PIN

I/0

A/D

1

CN1

1

–

–

–

2

CN1

2

–

–

–

3

CN1

3

–

–

–

4

CN1

4

–

–

NSW power supply (+24 V)

5

CN1

5

–

–

NSW power supply (+24 V)

6

CN1

6

–

–

SW power supply (+24 V)

7

CN1

7

–

–

SW power supply (+24 V)

8

CN1

8

–

–

–

9

CN1

9

–

–

GND

10

CN1

10

–

–

GND

11

CN1

11

0

D

D_OUT_3, (Sync 200 mA)

12

CN1

12

0

D

D_OUT_2, (Sync 200 mA)

13

CN1

13

0

D

D_OUT_1, (Sync 200 mA)

14

CN1

14

0

D

D_OUT_0, (Sync 200 mA)

15

CN1

15

–

–

Sensor power output (+24 V, 100 mA)

16

CN1

16

–

–

Sensor power output (+5 V, 100 mA)

17

CN1

17

–

–

GND

18

CN1

18

–

–

GND

19

CN1

19

–

–

GND

20

CN1

20

–

–

GND

21

CN2A

1

I

D

D_IN_0, (+24 V, 5 mA, PULL DOWN)

22

CN2A

2

I

D

D_IN_2, (+24 V, 5 mA, PULL DOWN)

23

CN2A

3

I

D

D_IN_4, (+24 V, 5 mA, PULL DOWN)

24

CN2A

4

I

D

D_IN_6, (+24 V, 5 mA, PULL DOWN)

25

CN2A

5

I

D

D_IN_8, (+24 V, 5 mA, PULL DOWN)

26

CN2A

6

I

D

D_IN_10, (+24 V, 5 mA, PULL DOWN)

27 *1

CN2A

7

I

D

D_IN_12, (NSW+24 V, 5 mA, PULL DOWN)

28 *1

CN2A

8

I

D

D_IN_14, (NSW+24 V, 5 mA, PULL DOWN)

*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly from battery.

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Signal and model Model name

Remarks

Signal name

HD325-7 HD405-7

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

OPEN (RESERVED)

–

–

–

–

–

OPEN (RESERVED)

BAT DIRECT +24 V

Q

Q

Q

Q

Directly from battery +24 V

BAT DIRECT +24 V

Q

Q

Q

Q

Directly from battery +24 V

POWER SUPPLY +24 V

Q

Q

Q

Q

Key switch +24 V (ACC)

POWER SUPPLY +24 V

Q

Q

Q

Q

Key switch +24 V (ACC)

–

–

–

–

(–) : NON CONNECT

GND (for power supply)

Q

Q

Q

Q

+24 V POWER CONNECT

GND (for power supply)

Q

Q

Q

Q

+24 V POWER CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

BUZZER OUTPUT

Q

Q

Q

Q

Warning buzzer (Max. 200 mA sync)

HEAD LIGHT H/L SWITCHING

Q

Q

Q

Q

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

HI BEAM

Q

Q

Q

Q

AISS SW

Q

Q

Q

Q

EXHAUST SW2

–

–

–

Q

PASSING SW

Q

Q

Q

Q

CONNECTER CHECK

Q

Q

Q

Q

Used to detect improper connector, connection

MODE SW2-1 >

Q

Q

Q

Q

Mode SW2 upper side

RIGHT TURN

Q

Q

Q

Q

MODE SW1-1 U

Q

Q

Q

Q

–

HD465-7R

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

HD785-7

Exhaust brake switch lower side

Mode SW1 upper side

51

SEN06301-00

10 Structure, function and maintenance standard

Machine monitor No.

Specification CN

PIN

I/0

A/D

29

CN2A

9

–

–

GND

30

CN2A

10

I

D

D_IN_1 (+24 V, 5 mA, PULL DOWN)

31

CN2A

11

I

D

D_IN_3 (+24 V, 5 MA, PULL DOWN)

32

CN2A

12

I

D

D_IN_5 (+24 V, 5 MA, PULL DOWN)

33

CN2A

13

I

D

D_IN_7 (+24 V, 5 MA, PULL DOWN)

34

CN2A

14

I

D

D_IN_9 (+24 V, 5 MA, PULL DOWN)

35

CN2A

15

I

D

D_IN_11 (+24 V, 5 MA, PULL DOWN)

36 *1

CN2A

16

I

D

D_IN_13 (NSW+24 V, 5 MA, PULL DOWN)

37 *1

CN2A

17

I

D

D_IN_15 (NSW+24 V, 5 MA, PULL DOWN)

38

CN2A

18

I

A

D_IN_0 (0 – 30 V)

39

CN2B

1

I

D

D_IN_16 (+24 V, 5 MA, PULL UP)

40

CN2B

2

I

D

D_IN_18 (+24 V, 5 MA, PULL UP)

41

CN2B

3

I

D

D_IN_20 (+24 V, 5 MA, PULL UP)

42

CN2B

4

I

D

D_IN_22 (+24 V, 5 MA, PULL UP)

43

CN2B

5

I

D

D_IN_24 (+24 V, 5 MA, PULL DOWN)

44

CN2B

6

–

–

GND

45

CN2B

7

I

D

D_IN_17 (+24 V, 5 MA, PULL UP)

46

CN2B

8

I

D

D_IN_19 (+24 V, 5 MA, PULL UP)

47

CN2B

9

I

D

D_IN_21 (+24 V, 5 MA, PULL UP)

48

CN2B

10

I

D

D_IN_23 (+24 V, 5 MA, PULL UP)

49

CN2B

11

I

D

D_IN_25 (+24 V, 5 MA, PULL DOWN)

50

CN2B

12

I

A

A_IN_1 (0 – 30 V)

51

CN3A

1

I

D

D_IN_26 (+24 V, 5 MA, PULL DOWN)

52

CN3A

2

I

D

D_IN_28 (+24 V, 5 MA, PULL DOWN)

53

CN3A

3

I

D

D_IN_30 (+24 V, 5 MA, PULL DOWN)

54 *2

CN3A

4

I

D

D_IN_32 (GND, 5 MA, PULL UP)

55 *2

CN3A

5

I

D

D_IN_34 (GND, 5 MA, PULL UP)

56 *2

CN3A

6

I

D

D_IN_36 (GND, 5 MA, PULL UP)

*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly from battery. *2: Setting is made to PULL UP.

52

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Signal and model Model name Signal name

HD325-7 HD405-7

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

Remarks HD785-7

SENSOR GND

Q

Q

Q

Q

CHECK SW

Q

Q

Q

Q

EXHAUST BRAKE SW1

–

–

–

Q

ABS CHECK SW

Q

Q

Q

Q

ENGINE MODE SW

Q

Q

Q

Q

MODE SW1-2 t

Q

Q

Q

Q

Mode SW1 lower side

MODE SW1-2 <

Q

Q

Q

Q

Mode SW1 lower side

LEFT TURN

Q

Q

Q

Q

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

ARSC SYSTEM SW1

Q

Q

Q

Q

ARSC system switch (upper)

ABS SYSTEM SW1

Q

Q

Q

Q

ABS system switch (upper)

ASR SYSTEM SW1

Q

Q

Q

Q

ASR system switch (upper)

FRONT BRAKE CUT OFF

Q

Q

Q

–

(–) : NON CONNECT

NIGHT LIGHTING SW +24 V

Q

Q

Q

Q

Head Light SW recognition for Night Lighting function

SENSOR GND

Q

Q

Q

Q

ARSC SYSTEM SW2

Q

Q

Q

Q

ARSC system switch (lower)

ABS SYSTEM SW2

Q

Q

Q

Q

ABS system switch (lower)

ASR SYSTEM SW2

Q

Q

Q

Q

ASR system switch (lower)

–

–

–

–

(–) : NON CONNECT

SEAT BELT

Q

Q

Q

Q

PANEL DIMMER SWITCH

Q

Q

Q

Q

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

Q

Q

Q

Q

(–) : NON CONNECT, Used to detect improper connector connection

–

–

–

–

(–) : NON CONNECT

–

CONNECTOR CHECK 2 (OPEN) –

HD465-7R

Exhaust brake switch upper side

53

SEN06301-00

10 Structure, function and maintenance standard

Machine monitor No.

Specification CN

PIN

I/0

A/D

57 *2

CN3A

7

I

D

D_IN_38 (GND, 5 mA, PULL UP)

58

CN3A

8

I

P

P_IN_0 (0.5 Vp-p)

59

CN3A

9

–

–

GND

60

CN3A

10

I

D

D_IN_27 (+24 V, 5 mA, PULL DOWN)

61

CN3A

11

I

D

D_IN_29 (+24 V, 5 mA, PULL DOWN)

62

CN3A

12

I

D

–

63 *2

CN3A

13

I

D

D_IN_33 (GND, 5 mA, PULL UP)

64 *2

CN3A

14

I

D

D_IN_35 (GND, 5 mA, PULL UP)

65 *2

CN3A

15

I

D

D_IN_37 (GND, 5 mA, PULL UP)

66 *2

CN3A

16

I

D

D_IN_39 (GND, 5 mA, PULL UP)

67

CN3A

17

I

P

P_IN_0 (0.5 Vp-p)

68

CN3A

18

–

–

NC

69

CN3B

1

I

A

A_IN_2 (High resistance input)

70

CN3B

2

I

A

A_IN_4 (High resistance input)

71

CN3B

3

I

A

A_IN_6 (Low resistance input)

72

CN3B

4

I

A

A_IN_8 (0 – 5 V)

73

CN3B

5

I

A

A_IN_10 (0 – 5 V)

74

CN3B

6

–

–

GND

75

CN3B

7

I

A

A_IN_3 (High resistance input)

76

CN3B

8

I

A

A_IN_5 (High resistance input)

77

CN3B

9

I

A

A_IN_7 (0 – 5 V)

78

CN3B

10

I

A

A_IN_9 (0 – 5 V)

79

CN3B

11

–

–

GND

80

CN3B

12

–

–

NC

81

CN4

1

–

–

S_NET (+)

82

CN4

2

–

–

S_NET (+)

83

CN4

3

–

–

CAN (+)

84

CN4

4

–

–

S_NET (–)

*2: Setting is made to PULL UP.

54

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Signal and model Model name

Remarks

Signal name

HD325-7 HD405-7

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

Q

Q

Q

Q

For service mode

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

–

–

–

–

–

(–) : NON CONNECT

Q

Q

Q

Q

–

–

–

–

OP7

CAN (+) –

HD465-7R

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

HD785-7

(–) : NON CONNECT

55

SEN06301-00

10 Structure, function and maintenance standard

Machine monitor No.

Specification CN

PIN

I/0

A/D

85

CN4

5

–

–

S_NET (–)

86

CN4

6

–

–

GND

87

CN4

7

–

–

GND

88

CN4

8

–

–

CAN (–)

89

CN4

9

–

–

NC

90

CN4

10

–

–

NC

91

CN4

11

–

–

NC

92

CN4

12

–

–

NC

93

CN5

1

–

–

NC

94

CN5

2

–

–

RA232C_1_RTS

95

CN5

3

–

–

RA232C_1_RD

96

CN5

4

–

–

RA232C_2_RD

97

CN5

5

–

–

RA232C_2_RTS

98

CN5

6

–

–

NC

99

CN5

7

–

–

NC

100

CN5

8

–

–

RA232C_1_CTS

101

CN5

9

–

–

RA232C_1_TX

102

CN5

10

–

–

RA232C_1_SG

103

CN5

11

–

–

RA232C_2_SG

104

CN5

12

–

–

RA232C_2_TX

105

CN5

13

–

–

RA232C_2_CTS

106

CN5

14

–

–

NC

107

CN6

1

–

–

–

108

CN6

2

–

–

–

109

CN6

3

–

–

–

110

CN6

1

–

–

NC

111

CN6

5

–

–

–

112

CN6

6

–

–

NC

113

CN6

7

–

–

–

114

CN6

8

–

–

GND

56

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Signal and model Model name

Remarks

Signal name

HD325-7 HD405-7

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

CAN SHIELD GND

Q

Q

Q

Q

CAN (–)

Q

Q

Q

Q

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

–

Q

Q

Q

Q

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

(–) : NON CONNECT

–

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

(–) : NON CONNECT

Q

Q

Q

Q

(–) : NON CONNECT

Q

Q

Q

Q

CAN (+) –

HD465-7R

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

HD785-7

57

SEN06301-00 a

10 Structure, function and maintenance standard

Switch input on monitor panel board No.

SW

Position

I/0

A/D

1

SW1

0

I

D

2

SW1

1

I

D

3

SW1

2

I

D

4

SW1

3

I

D

5

SW1

4

I

D

6

SW1

5

I

D

7

SW1

6

I

D

8

SW1

7

I

D

9

SW1

8

I

D

10

SW1

9

I

D

11

SW1

A

I

D

12

SW1

B

I

D

13

SW1

C

I

D

14

SW1

D

I

D

15

SW1

E

I

D

16

SW1

F

I

D

17

SW2

0

I

D

18

SW2

1

I

D

19

SW2

2

I

D

20

SW2

3

I

D

21

SW2

4

I

D

22

SW2

5

I

D

23

SW2

6

I

D

24

SW2

7

I

D

25

SW2

8

I

D

26

SW2

9

I

D

27

SW2

A

I

D

28

SW2

B

I

D

29

SW2

C

I

D

30

SW2

D

I

D

31

SW2

E

I

D

32

SW2

F

I

D

Specification

Rotary switch (16 pousitions)

Rotary switch (16 positions)

58

HD465-7R

10 Structure, function and maintenance standard

SEN06301-00

Model name Signal name

HD325-7 HD405-7

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–