hd465 7 shop manual sn 7001 up

00-1

MACHINE MODEL SERIAL NUMBER

SEBM027612

2006All Rights ReservedPrinted in Japan 02-06(02) (12)

This shop manual may contain attachiments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you mayrequire.Materials and specifications are subject to change without notice.

HD465-7, HD605-7 mount the SAA6D170E-3 engine.For details of the engine, see the 170-3 Series Engine Shop Manual.

HD465-7 7001 and upHD605-7 7001 and up

00-2 HD465-7, HD605-7

CONTENTS

No. of page01 GENERAL ........................................................................................................................... 01-1

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

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

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

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

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HD465-7, HD605-7 00-2-1

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00-2-4 HD465-7, HD605-7(12)

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00-2-6 HD465-7, HD605-7(12)

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q 90-1 (12)90-2

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SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe 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 danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read

all the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing. Always wear safety glasses when hitting

parts with a hammer. Always wear safety glasses when grinding

parts with a grinder, etc.3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive () terminal first.

14.When raising heavy components, use a hoist orcrane.

Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts. When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

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

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

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.

NOTICE

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

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine seriesElectrical volume: Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. See the page number on the bottom of the page.

File the pages in correct order.2. Following examples show how to read the page

number.Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

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

REVISIONS

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

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

k Safety Special safety precautionsare necessary when per-forming the work.

a Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 WeightWeight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3 TighteningtorquePlaces that require specialattention for the tighteningtorque during assembly.

2 Coat Places to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.

} Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

k Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol

If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

! The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.k Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120 hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

4

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

k Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

lic tank. For detai ls, see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)! The adapter can be pushed in about 3.5

mm.! Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3)! Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4)! Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5)! When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3Di

sass

embl

y

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

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

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

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

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

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

Con

nec

tion

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

! The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.

! For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Qty Container Main applications, features

Adhesives

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B 790-129-9050 20 g (2 pcs.)Polyethylene

container

Used in places requiring an immediately effective, strong adhesive.Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

Features: Resistance to heat and chemicals

Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3790-129-9060

(Set of adhesive and hardening

agent)

Adhesive: 1 kg

Hardening agent: 500 g

Can

Used as adhesive or sealant for metal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylene container Used as sealant for machined holes.

Holtz MH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1735 790-129-9140 50 g

Polyethylene container

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha 201 790-129-9130 2 g


Quick hardening type adhesive Quick cure type

(max. strength after 30 minutes) Used mainly for adhesion of rubbers,

plastics and metals.

Loctite 648-50 79A-129-9110 50 cc


Resistance to heat, chemicals Used at joint portions subject to high

temperatures.

Gasket sealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5 790-129-9080 1 kg Can Used as sealant for various threads, pipe

joints, flanges. Used as sealant for tapered plugs,

elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive

case, etc.

LG-7 790-129-9070 1 kg Tube

Features: Silicon based, quick hardening type

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Three bond 1211 790-129-9090 100 g Tube

Used as heat-resisting sealant for repairing engine.

Three bond 1207B 419-15-18131 100 g Tube

Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material

Used as sealing material for transfer case

FOREWORD COATING MATERIALS

00-11

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube Used to prevent seizure or scuffling of the

thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings,

etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

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

Molybdenum disulphide greaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g 10400 g 20

16 kg

Bellows typeBellows type

Can

Used for heavy load portion

Hyper White Grease G2-TG0-T (*)*: For use in

cold district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

Seizure resistance and heat resistance higher than molybdenum disulfide grease

Since this grease is white, it does not stand out against machine body.

Biogrease G2BG2-BT (*)*: For high

temperature and large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.

Primer

SUNSTAR PAINT PRIMER 580 SUPER

417-926-391020 ml Glass container

Adhe

sive

fo

r ca

b gl

ass

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

SUNSTAR GLASS PRIMER 580 SUPER

20 ml Glass container Used as primer for glass side

(Using limit: 4 months)

SUNSTAR PAINT PRIMER 435-95

22M-54-27230 20 ml Glass container Used as primer for painted surface on

cab side (Using limit: 4 months)

SUNSTAR GLASS PRIMER 435-41

22M-54-27240 150 ml Can Used as primer for black ceramic-

coated surface on glass side and for hard polycarbonate-coated surface(Using limit: 4 months)

SUNSTAR SASH PRIMER GP-402

22M-54-27250 20 ml Glass container Used as primer for sash (Alumite).


Adhesive

SUNSTAR PENGUINE SUPER 560

22M-54-27210 320 mlEcocart (Special

container) Used as adhesive for glass.


SUNSTAR PENGUINE SEAL 580 SUPER S or W

417-926-3910 320 ml Polyethylene container

S is used for high-temperature season (April - October) and W for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months)

Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml


Used as adhesive for glass.(Using limit: 6 months)

Caulking material

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920 320 ml Polyethylene container Used to seal joints of glass parts.


SEKISUI SILICONE SEALANT

20Y-54-55130 333 ml Polyethylene container Used to seal front window.


GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220 333 ml Cartridge Used to seal joint of glasses.

Translucent white seal.(Using limit: 12 months)

Category Komatsu code Part No. Qty Container Main applications, features

FOREWORD STANDARD TIGHTENING TORQUE

00-12

STANDARD TIGHTENING TORQUE

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

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS! In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

101214

1013171922

11.8 14.727 3459 7498 123

153 190

1.2 1.52.8 3.5

6 7.510 12.5

15.5 19.5

1618202224

2427303236

235 285320 400455 565610 765785 980

23.5 29.533 41

46.5 5862.5 7880 100

2730333639

4146505560

1150 14401520 19101960 24502450 30402890 3630

118 147155 195200 250250 310295 370

Thread diameter of bolt

Width across flats

Tightening torque

mm mm Nm kgm

68

1012

10131427

5.9 9.813.7 23.534.3 46.174.5 90.2

0.6 1.01.4 2.43.5 4.77.6 9.2

SAD00483

Sealing surface

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 4.949 19.6

78.5 19.6137.3 29.4176.5 29.4196.1 49245.2 49294.2 49

2.5 0.55 28 2

14 318 320 525 530 5


00-13

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

table below.

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

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

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

101216

141722

59 7498 123

235 285

6 7.5 10 12.5

23.5 29.5

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

0203, 0405, 0610, 12

14

1420243342

Varies depending on type of connector.

35 63 {3.5 6.5}84 132 {8.5 13.5}

128 186 {13.0 19.0}363 480 {37.0 49.0}

746 1010 {76.0 103}

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

Norminal No.Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

08101214161820243033364252

08101214161820243033364252

141719222427303232

36

5.88 8.82 {0.6 0.9}9.8 12.74 {1.0 1.3}14.7 19.6 {1.5 2.0}19.6 24.5 {2.0 2.5}24.5 34.3 {2.5 3.5}34.3 44.1 {3.5 4.5}44.1 53.9 {4.5 5.5}58.8 78.4 {6.0 8.0}

93.1 122.5 {9.5 12.5}107.8 147.0 {11.0 15.0}127.4 176.4 {13.0 18.0}181.3 240.1 {18.5 24.5}274.4 367.5 {28.0 37.5}

7.35 {0.75}11.27 {1.15}17.64 {1.8}22.54 {2.3}29.4 {3.0}39.2 {4.0}49.0 {5.0}68.6 {7.0}

107.8 {11.0}124.4 {13.0}151.9 {15.5}210.7 {21.5}323.4 {33.0}


00-14

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.

3) TAPERED SCREWSUse these torques for tapered screws (unit: inch) of Cummins Engine.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.! Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torquemm Nm kgm68

1012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22

Thread diameter Tightening torquemm Nm kgm68

101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51

Thread diameter Tightening torqueinch Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 212 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.202.45 0 0.413.67 0 0.516.12 0 0.92

Nominal size of hose

Width across flats

Tightening torque (Nm {kgm}) Taper seal type Face seal type

Range Target Thread size (mm)Nominal thread

size - Threads per inch, Thread series

Root diameter (mm) (Reference)

02 1934 54 {3.5 5.5} 44 {4.5}

18UN 14.3

34 63 {3.5 6.5} 44 {4.5} 14

0322 54 93 {5.5 9.5} 74 {7.5}

16UN 17.5

24 59 98 {6.0 10.0} 78 {8.0} 18

04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6

05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4

06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2

(10) 41 177 245 {18.0 25.0} 216 {22.0} 33 (12) 46 197 294 {20.0 30.0} 245 {25.0} 36 (14) 55 246 343 {25.0 35.0} 294 {30.0} 42

916

1116

1316

316

FOREWORD ELECTRIC WIRE CODE

00-15

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

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wireCable O.D.(mm)

Current rating(A) Applicable circuitNumber of

strandsDia. of strands(mm2)

Cross section(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-maryCode W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR BW RW YR GW LW

Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB BY RB YB GR LR

Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL BR RY YG GY LY

Color White & Blue Black & Red Red & Yellow Yellow & GreenGreen & Yellow Blue & Yellow

5Code WG RG YL GB LB

Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black

6Code RL YW GL

Color Red & Blue Yellow & White Green & Blue

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

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

EXAMPLE Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal linefrom (A).

(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line downfrom (B).

(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting frommillimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

(A)

(B)

(C)


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

022.0544.0966.1488.18

110.23132.28154.32176.37198.42

2.2024.2546.3068.3490.39

112.44134.48156.53178.57200.62

4.4126.4648.5070.5592.59

114.64136.69158.73180.78202.83

6.6128.6650.7172.7594.80

116.85138.89160.94182.98205.03

8.8230.8651.9174.9697.00

119.05141.10163.14185.19207.24

11.0233.0755.1277.1699.21

121.25143.30165.35187.39209.44

13.23 35.27 57.32 79.37101.41

123.46145.51167.55189.60211.64

15.43 37.48 59.53 81.57103.62

125.66147.71169.76191.80213.85

17.64 39.68 61.73 83.78105.82

127.87149.91171.96194.01216.05

19.84 41.89 63.93 85.98108.03

130.07152.12174.17196.21218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

0 2.642 5.283 7.92510.567

13.20915.85018.49221.13423.775

0.264 2.906 5.548 8.18910.831

13.47316.11518.75621.39824.040

0.528 3.170 5.812 8.45411.095

13.73716.37919.02021.66224.304

0.793 3.434 6.076 8.71811.359

14.00116.64319.28521.92624.568

1.057 3.698 6.340 8.98211.624

14.26516.90719.54922.19024.832

1.321 3.963 6.604 9.24611.888

14.52917.17119.81322.45525.096

1.585 4.227 6.869 9.51012.152

14.79517.43520.07722.71925.361

1.849 4.491 7.133 9.77412.416

15.05817.70020.34122.98325.625

2.113 4.755 7.39710.03912.680

15.32217.96420.60523.24725.889

2.378 5.019 7.66110.30312.944

15.58618.22820.87023.51126.153

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

0 2.200 4.399 6.599 8.799

10.99813.19815.39817.59819.797

0.220 2.420 4.619 6.819 9.019

11.28113.41815.61817.81820.017

0.440 2.640 4.839 7.039 9.239

11.43813.63815.83818.03720.237

0.660 2.860 5.059 7.259 9.459

11.65813.85816.05818.25720.457

0.880 3.080 5.279 7.479 9.679

11.87814.07816.27818.47720.677

1.100 3.300 5.499 7.969 9.899

12.09814.29816.49818.69720.897

1.320 3.520 5.719 7.91910.119

12.31814.51816.71818.91721.117

1.540 3.740 5.939 8.13910.339

12.52814.73816.93819.13721.337

1.760 3.950 6.159 8.35910.559

12.75814.95817.15819.35721.557

1.980 4.179 6.379 8.57910.778

12.97815.17817.37819.57721.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

0 72.3144.7217.0289.3

361.7434.0506.3578.6651.0

723.3795.6868.0940.31012.6

1084.91157.31129.61301.91374.3

7.2 79.6151.9224.2296.6

368.9441.2513.5585.9658.2

730.5802.9875.2947.51019.9

1092.21164.51236.81309.21381.5

14.5 86.8159.1231.5303.8

376.1448.5520.8593.1665.4

737.8810.1882.4954.8

1027.1

1099.41171.71244.11316.41388.7

21.7 94.0166.4238.7311.0

383.4455.7528.0600.3672.7

745.0817.3889.7962.01034.3

1106.61179.01251.31323.61396.0

28.9101.3173.6245.9318.3

390.6462.9535.2607.6679.9

752.2824.6896.9969.21041.5

1113.91186.21258.51330.91403.2

36.2108.5180.8253.2325.5

397.8470.2542.5614.8687.1

759.5831.8904.1976.5

1048.8

1121.11193.41265.81338.11410.4

43.4115.7188.1260.4332.7

405.1477.4549.7622.0694.4

766.7839.0911.4983.71056.0

1128.31200.71273.01345.31417.7

50.6123.0195.3267.6340.0

412.3484.6556.9629.3701.6

773.9846.3918.6990.91063.2

1135.61207.91280.11352.61424.9

57.9130.2202.5274.9347.2

419.5491.8564.2636.5708.8

781.2853.5925.8998.2

1070.5

1142.81215.11287.51359.81432.1

65.1137.4209.8282.1354.4

426.8499.1571.4643.7716.1

788.4860.7933.11005.41077.7

1150.01222.41294.71367.01439.4


00-20

kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

100110120130140

150160170180190

200210220230240

0 142.2 284.5 426.7 568.9

711.2 853.4 995.6

11381280

14221565170718491991

21342276241825602702

28452987312932713414

14.2 156.5 298.7 440.9 583.2

725.4 867.6

101011521294

14371579172118632005

21482290243225742717

28593001314332863428

28.4 170.7 312.9 455.1 597.4

739.6 881.8

102411661309

14511593173518772020

21622304244625892731

28733015315833003442

42.7 184.9 327.1 469.4 611.6

753.8 896.1

103811811323

14651607174918922034

21762318246026032745

28873030317233143456

56.9 199.1 341.4 483.6 625.8

768.1 910.3

105311951337

14791621176419062048

21902333247526172759

29013044318633283470

71.1 213.4 355.6 497.8 640.1

782.3 924.5

106712091351

14931636177819202062

22052347248926312773

29163058320033433485

85.3 227.6 369.8 512.0 654.3

796.5 938.7

108112231365

15081650179219342077

22192361250326462788

29303072321433573499

99.6 241.8 384.0 526.3 668.5

810.7 953.0

109512371380

15221664180619492091

22332375251826602802

29443086322933713513

113.8 256.0 398.3 540.5 682.7

825.0 967.2

110912521394

15361678182119632105

22472389253226742816

29583101324333853527

128.0 270.2 412.5 554.7 696.9

839.2 981.4

112412661408

15501693183519772119

22622404254626882830

29733115325733993542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F

C F C F C F C F

40.437.234.431.728.9

28.327.827.226.726.1

25.625.024.423.923.3

22.822.221.721.120.6

20.019.418.918.317.8

17.216.716.115.615.0

14.413.913.312.812.2

4035302520

1918171615

1413121110

9 8 7 6 5

4 3 2 1 0

1 2 3 4 5

6 7 8 9 10

40.031.022.013.0 4.0

2.2 0.4 1.4 3.2 5.0

6.8 8.6 10.4 12.2 14.0

15.8 17.6 19.4 21.2 23.0

24.8 26.6 28.4 30.2 32.0

33.8 35.6 37.4 39.2 41.0

42.8 44.6 46.4 48.2 50.0

11.711.110.610.0 9.4

8.9 8.3 7.8 7.2 6.7

6.1 5.6 5.0 4.4 3.9

3.3 2.8 2.2 1.7 1.1

0.6 0

0.6 1.1 1.7

2.2 2.8 3.3 3.9 4.4

5.0 5.6 6.1 6.7 7.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.8 53.6 55.4 57.2 59.0

60.8 62.6 64.4 66.2 68.0

69.8 71.6 73.4 75.2 77.0

78.8 80.6 82.4 84.2 86.0

87.8 89.6 91.4 93.2 95.0

96.8 98.6100.4102.2104.0

105.8107.6109.4111.2113.0

7.8 8.3 8.9 9.410.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859 0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

81 82 83 84 85

86 87 88 89 90

91 92 93 94 95

96 97 98 99100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22 04-05

UNITS

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

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

HD465-7, HD605-7 01-1

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

01 GENERAL

01-2 HD465-7, HD605-7

GENERAL

SPECIFICATION DRAWINGS

HD465-7

HD605-7

SPECIFICATION DRAWINGS

HD465-7, HD605-7 01-3

GENERAL

SPECIFICATIONS

Machine model HD465-7

Serial No. 7001 and up

Wei

ght

Empty

Max. load

Gross

kg

kg

kg

42,800

55,000

97,875

Wei

ght

dist

ribut

ion Empty

Gross

(front)(rear)(front)(rear)

kg

kg

kg

kg

20,120 (47%)22,680 (53%)31,320 (32%)66,555 (68%)

Perfo

rma

nce

Dump body capacityStruck

Heaped (2 :1)m3

m3

25

34.2

Max. travel speed

Gradeability (sin )Min. turning radius

Dumping angle

km/h

%

m

70

37

8.5

48

Dim

en

sion

s

Overall length

Overall width

Overall height

Wheel base

mm

mm

mm

mm

9,355

4,595

4,400

4,300

TreadFront wheel

Rear wheel

mm

mm

3,515

3,080

Ground clearance mm 645

Engi

ne

Model

Type

No. of cylinders Bore x stroke

Piston displacement

Rated output

Max. torque

Fuel consumption (Min.)Stating motor

Alternator

Battery

mm

{cc}kW/rpm{HP/rpm}Nm/rpm{kgm/rpm}g/kWh {g/HPh}

KOMATSU SAA6D170E-3

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

6 170 x 170

23.15 {23,150}533/2,000 {715/2,000}

3,256/1,400 {332/1,400}207 {154}

24V, 7.5 kW x 2 units

24V, 50A

12V, 200Ah x 2 units

SPECIFICATIONS

(10)

01-4 HD465-7, HD605-7

GENERAL



Pow

er tr

ain

Torque converterStructure

Lock- up clutch

3-element, 1-stage, 2-phase

Hydraulically actuated, wet-type, multiple-disk clutch

TransmissionType

No. of speeds

TORQFLOW planetary gearFully automatic, electrically-hydraulically

actuated, force-feed type pump

F7, R1

Reduction gear

Type

Reduction ratio

Differential type

Spiral bevel gear, splash lubrication

3.538

Straight bevel gear, splash lubrication

Final driveType

Reduction ratio

Planetary gear, splash lubrication

4.737

Ste

erin

g sy

ste

m

Type Fully hydraulic steering system

Susp

ensi

on Axle type

Suspension method

Front axle

Rear axle

Front axle

Rear axle

Independent suspension (Mac Pherson type)Full floating

Hydropneumatic(Automatic damping force selection type)

Hydropneumatic

Tire

s Size and No.

Tire pressure

Front tire

Rear tire

Front and rear tire kPa {kg/cm2}

24.00 35 36PR x 2

24.00 35 36PR x 4

470 {4.75}

Brek

e sy

ste

m

Service brakeFront wheel

Rear axle

Single dry disc type, Hydraulically controlled

Oil cooled multiple disc brake, Hydraulically controlled

Parking brake Multiple disc wet type disc brake, Hydraulically released spring type

Retarder Oil cooled multiple disc type, Hydraulically controlled

SPECIFICATIONS

(10)

HD465-7, HD605-7 01-5

GENERAL



Hyd

rau

lic sy

ste

m

Hyd

raul

ic pu

mp

For both steering and work equipment

Type

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

Type

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

Type

Delivery (at engine rated speed 2,000 rpm)

/min

/min

/min

Gear pump

348

Gear pump

228

Gear pump

456

Cylin

der

Hoist cylinder

Type

No. bore (1st 2nd) x strokeSteering cylinder

Type

No. bore x stroke

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

2 (170 mm 150 mm) x 1,774 mm

Piston type, double acting

2 85 mm x 410 mm

SPECIFICATIONS

01-6 HD465-7, HD605-7

GENERAL



Wei

ght

Empty

Max. load

Gross

kg

kg

kg

45,900

63,000

108,975

Wei

ght

dist

ribut

ion Empty

Gross

(front)(rear)(front)(rear)

kg

kg

kg

kg

21,575 (47%)24,325 (53%)34,870 (32%)74,105 (68%)

Perfo

rma

nce

Dump body capacityStruck

Heaped (2 :1)m3

m3

29

40

Max. travel speed

Gradeability (sin )Min. turning radius

Dumping angle

km/h

%

m

70

37

8.5

48

Dim

en

sion

s

Overall length

Overall width

Overall height

Wheel base

mm

mm

mm

mm

9,355

4,595

4,400

4,300

TreadFront wheel

Rear wheel

mm

mm

3,515

3,080

Ground clearance mm 645

Engi

ne

Model

Type

No. of cylinders Bore x stroke

Piston displacement

Rated output

Max. torque

Fuel consumption (Min.)Stating motor

Alternator

Battery

mm

{cc}kW/rpm{HP/rpm}Nm/rpm{kgm/rpm}g/kWh {g/HPh}

KOMATSU SAA6D170E-3

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

6 170 x 170

23.15 {23,150}533/2,000 {715/2,000}

3,256/1,400 {332/1,400}207 {154}

24V, 7.5 kW x 2 units

24V, 50A

12V, 200Ah x 2 units

SPECIFICATIONS

(10)

HD465-7, HD605-7 01-7

GENERAL



Pow

er tr

ain

Torque converterStructure

Lock- up clutch

3-element, 1-stage, 2-phase

Hydraulically actuated, wet-type, multiple-disk clutch

TransmissionType

No. of speeds

TORQFLOW planetary gearFully automatic, electrically-hydraulically

actuated, force-feed type pump

F7, R1

Reduction gear

Type

Reduction ratio

Differential type

Spiral bevel gear, splash lubrication

3.538

Straight bevel gear, splash lubrication

Final driveType

Reduction ratio

Planetary gear, splash lubrication

4.737

Ste

erin

g sy

ste

m

Type Fully hydraulic steering system

Susp

ensi

on Axle type

Suspension method

Front axle

Rear axle

Front axle

Rear axle

Independent suspension (Mac Pherson type)Full floating

Hydropneumatic(Automatic damping force selection type)

Hydropneumatic

Tire

s Size and No.

Tire pressure

Front tire

Rear tire

Front and rear tire kPa {kg/cm2}

24.00 R35 aa x 2

24.00 R35 aa x 4

686 {7.0}

Brek

e sy

ste

m

Service brakeFront wheel

Rear axle

Single dry disc type, Hydraulically controlled

Oil cooled multiple disc brake, Hydraulically controlled

Parking brake Multiple disc wet type disc brake, Hydraulically released spring type

Retarder Oil cooled multiple disc type, Hydraulically controlled

SPECIFICATIONS

(10)

01-8 HD465-7, HD605-7

GENERAL



Hyd

rau

lic sy

ste

m

Hyd

raul

ic pu

mp

For both steering and work equipment

Type

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

Type

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

Type

Delivery (at engine rated speed 2,000 rpm)

/min

/min

/min

Gear pump

348

Gear pump

228

Gear pump

456

Cylin

der

Hoist cylinder

Type

No. bore (1st 2nd) x strokeSteering cylinder

Type

No. bore x stroke

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

2 (170 mm 150 mm) x 1,774 mm

Piston type, double acting

2 85 mm x 410 mm

SPECIFICATIONS

HD465-7, HD605-7 01-9

GENERAL

WEIGHT TABLE This weight table is a guide for use when transporting or handling component.

Unit: kg

Machine model HD465-7 HD605-7

Serial Number 7001 and up 7001 and up

Engine assembly

Output shaft assembly

Radiator assembly

Fuel tank

Torque converter assembly

Transmission assembly

Drive shaft assembly (front)Drive shaft assembly (rear)Rear axle assembly

Differential

Final drive (one-side) Rear brake (one-side)

Front axle (one-side)Front brake (one-side)Front suspension cylinder

Rear suspension cylinder

Frame

Cab (Platform)Operator's seat

Steering cylinder

Hoist cylinder

Demand valve

Steering valve

Hoist valve

Hydraulic pump (SAR(3)100+100)Hydraulic pump (SAR(3)80+80)Hydraulic pump (SAR(3)100+(1)25)Dump body

2,740

123

304

276

403

1,184

28

62

6,355

822

1,502

646

330

142

460

172

4,698

920

63

44

206

26

20

34

28

33

23

10,730

2,740

123

304

276

403

1,184

28

62

6,355

822

1,502

646

330

142

460

172

4,698

920

63

44

206

26

20

34

28

33

23

13,418

WEIGHT TABLE

(10)

01-10 HD465-7, HD605-7

GENERAL

FUEL, COOLANT AND LUBRICANTS


(10)

HD465-7, HD605-7 01-11

GENERAL

Fuel and oil Select fuel and oil according to the above table.

CoolantSince Komatsu genuine Supercoolant (AF-ACL) isadded to the cooling water, the latter does not needto be replaced while the atmospheric temperature isabove 10C. If the atmospheric temperature dropsbelow 10C, adjust the concentration of AF-ACLaccording to the operation and meintenance manual.

a The specified capacity means the total amount ofoil including oil for components and oil in piping.The refill capacity means the amount of oilneeded to refill the system during normal inspec-tion and maintenance.

a When starting the engine in an atmospheric tem-perature of lower than 0C, be sure to useeng ine o i l o f SAE10W, SAE 10W-30 o rSAE15W-40, even through the atmospheric tem-perature goes up to 10C or above during theday.

Engine Oil Pan

Transmission Case

Steering, Hoist Oil Tank

Front Suspension

Rear Suspension

Differential Case

Specified capacity ( ) 67 285 180

17 each for right and left

11.3 each for right and left 95

Refill capacity ( ) 57 190 122 95

Final drive case

Fuel tank Cooling system

Specified oil level ( )

32 each for right and left 780 154

Refill capacity ( )

21 each for right and left


(10)

HD465-7, HD605-7 10-1

10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD

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

Steering and hoist hydraulic system diagram...................................................... 10-88Dump body control ...................................... 10-90HYdraulic tank ............................................. 10-91Steering control valve .................................. 10-92Crossover relief valve .................................. 10-96Steering cylinder .......................................... 10-97Demand valve.............................................. 10-98Hoist valve ................................................. 10-102EPC valve.................................................. 10-108Hoist cylinder ............................................. 10-109Hydraulic pump.......................................... 10-110Air conditioner............................................ 10-114Machine monitor system............................ 10-119Engine control system ............................... 10-134Automatic shift control system................... 10-136Payload meter (card type)...................... 10-151Automatic emergency steering system...... 10-184Automatic suspension system ................... 10-188Retarder control system ............................ 10-192Sensors, switches...................................... 10-204Dump lever ................................................ 10-212

[Related to VHMS controller]VHMS controller ........................................ 10-216BLOW-BY pressure sensor ....................... 10-216Engine oil temperature sensor................... 10-217Exhaust temperature sensor/amp ............. 10-218Ambient temperature sensor...................... 10-218Communications (orborbcomm) controller/antenna.................................... 10-219Payload meter (Having VHMS) ................. 10-220

For details of VHMS, see TESTING AND ADJUSTING.

(10)

HD465-7, HD605-7 10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

RADIATOR, TORQUE CONVERTEROIL COOLER, AFTER COOLER, WORK

EQUIPMENT OIL COOLER, FUEL COOLER

1. Pick-up for radiator coolant level sensor2. Upper tank 3. Lower tank 4. Core5. Work equipment oil cooler6. After cooler7. Fuel cooler

A : Coolant inlet port B : Coolant outlet port

SpecificationsRadiator

Core type: CF4-5Total radiation surface: 130.6 m2

Work equipment oil cooler Core type: CF40-1Radiation surface: 2.90 m2

Fuel coolerCore type: FC1-3Heat radiation area: 6.75 m2

(10)

10-4 HD465-7, HD605-7


BRAKE OIL COOLER

BRAKE OIL COOLER

1. Cooler element

A : Oil inletB : Oil outletC : Coolant inletD : Coolant outlet

Oil cooler specificationsElement type : Multiple plateRadiation surface: 8.13 m2Pressure resistance (oil side): 2.9 MPa {30 kg/cm2}

(10)

HD465-7, HD605-7 10-5


POWER TRAIN SKELETON

POWER TRAIN SKELETON

1. Engine 2. Output shaft 3. Front drive shaft 4. Brake cooling pump

(SAR(3)100+100) 5. Torque converter

transmission charge pump and brake cooling brake control pump (SAR(3)100+25)

6. PTO 7. Torque converter 8. Transmission 9. Rear drive shaft10. Differential gear11. Drive shaft12. Brake13. Tire14. Final drive15. Parking brake16. Steering, hoist and hoist

control pump (SAR(3)80+80+(1)6)

10-6 HD465-7, HD605-7


OUTPUT SHAFT

OUTPUT SHAFT

1. Rubber cushion2. Outer body3. Flange4. Shaft5. Coupling6. Inner body7. Cover

FunctionThe output shaft is installed to the engine flywheel,and absorbs the twisting vibration caused bychanges in the engine torque.

HD465-7, HD605-7 10-7


Unit: mm

No. Check item Criteria Remedy

1 Clearance between flywheel and bearing

Standard sizeTolerance Standard

clearance Clearance limit

Replace

Shaft Hole

100 00.015

0.0100.045

0.045 0.005 0.02

2 Clearance between shaft and bearing 550.0100.040

00.015

0.005 0.040 0.10

3 Clearance between bearing and cover 150

+0.0060.024

0.0080.033

0.039 0.016 0.06

4 Clearance between bearing and shaft 85

+0.025+0.003

+0.0050.025

0.050 0.002 0.013

5 Wear of oil seal contact sur-face of coupling

Standard size Repair limitRepair or replace110 0

0.1

6 Backlash at splineStandard backlash Backlash limit

Replace

0.080 0.231 0.4

7Defomation of rubber cushion

Original dimension: Lo Standard backlash (Dimension at smallest width: L)90 81

75 67

External No cracks

OUTPUT SHAFT

(10)

10-7-1 HD465-7, HD605-7


DRIVE SHAFT

DRIVE SHAFT

(6)

1. Front drive shaft2. Rear drive shaft

Outline The power from the engine is transmitted

through the output shaft, the front drive shaft (1)and the transmission, to the rear drive shaft (2).

10-8 HD465-7, HD605-7


TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING

TORQUE CONVERTER ANDTRANSMISSION HYDRAULIC PIPING

HD465-7, HD605-7 10-9

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER AND

TRANSMISSION HYDRAULIC PIPING

1. Torque converter2. Transmission 3. Oil filler tube 4. Hydraulic pump (SAR(3)100+(1)25)5. Torque converter valve6. Transmission oil filter

10-10 HD465-7, HD605-7


TORQUE CONVERTER

TORQUE CONVERTER

1. PTO Gear (Number of teeth : 91)

A : Main oil pressure detection portB : Torque converter oil inletC : Torque converter oil inlet pressure detection portD : Torque converter oil outletE : To transmission control valveF : To lock-up clutchG: Torque converter oil outlet pressure detection portH : To transmission lubrication

SpecificationType : 3-element, 1-stage, 2-phase

With modulation With lock-up clutch

Lock-up clutch : Wet type double plate clutch Hydraulic control (with modulation mechanism)

Stall torque ratio: 2.32

(10)

HD465-7, HD605-7 10-11

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER

1. Coupling 2. Input shaft (Number of teeth : 108) 3. Front housing 4. Drive case 5. Turbine 6. Race 7. Torque converter valve 8. Pump 9. Rear housing

10. Stator shaft11. One-way clutch12. Stator13. Disc14. Piston15. Clutch housing16. Retainer

10-12 HD465-7, HD605-7


HD465-7, HD605-7 10-13


Unit: mm


1 Coupling oil seal sliding por-tion outside diameter

Standard size Tolerance Repair limit

Correction by chrome plating or replace-ment

110 00.087 109.8

2 Input shaft seal ring sliding portion inside diameter 35+0.025

0 35.1

3 Pump housing seal ring slid-ing portion inside diameter 135+0.040

0 135.5

4 Input shaft seal ring sliding portion inside diameter 75+0.030

0 75.1

5 Stator shaft seal ring wear

Width 3.95 00.1 3.55

Replace

Thickness 5.1 0.1 4.59

6Outer race one-way clutch transmission face inside diameter

127.844 0.013 127.874

7Inner race one-way clutch transmission face outside diameter

108.883 0.013 108.853

8 Bushing sliding portion inside diameter 108.96+0.040+0.018 109.04

9 Bushing sliding portion thick-ness 50

0.1 4.5

10 Clutch disc thickness 5.4 0.1 4.8

11 Clearance between clutch housing and piston (outside)


clearance Clearance limitShaft Hole

420 0.50.7+0.097

0 0.5 0.797 0.88

12 Clearance between clutch housing and piston (inside) 2950.1100.191

+0.0810 0.11 0.272 0.30

TORQUE CONVERTER

10-14 HD465-7, HD605-7


POWER TRAINWhen the lock-up clutch is [RELEASED]

When the lock-up clutch is [RELEASED], thedrive case (1) is separated from the turbine (2)and the torque converter functions as a normaltorque converter.

The power generated with the engine is transmit-ted to the coupling (3), the input shaft (4) and theclutch housing (5) through the drive shaft and thedamper and rotates the drive case (1) and thepump (6) as one part.

Power of the pump (6) rotates the turbine (2)using oil as the medium and is transmitted fromthe turbine (2) to the transmission input shaft (7).

When the lock-up clutch is [IN]

When the lock-up clutch is [IN], the drive case (1)and the turbine (2) are connected and integrated,and the stator (8) rotates with the pump (6) andthe turbine (2).

The power generated with the engine is transmit-ted to the coupling (3), the input shaft (4) and theclutch housing (5) through the propeller shaftfrom the damper and rotates the drive case (5)and the pump (6) as one part.

Since the drive case (1) and the turbine (2) wereconnected, the power is transmitted directly tothe transmission input shaft (7) from the turbine(2) not using oil as the medium.

(9)

HD465-7, HD605-7 10-15


OIL FLOW

After the oil passed through the main relief valve,the torque converter relief valve adjusts the oilpressure below the set pressure. Then, the oilenters the input port A, passes through the oilroute of the stator shaft (1) and flows to thepump (2) from between the pump (2) and thestator (3). The oil enters the turbine (4) aftergetting centrifugal force from the pump (2) andtransmits its energy to the turbine (4).The oil from the turbine is forced to flow to thestator (3) and enters the pump again. But partof the oil passes through between the turbine (4)and the stator (3), flows to the oil cooler for cool-ing from the outlet port B and is used for lubricat-ing the transmission.

(9)

10-16 HD465-7, HD605-7


TORQUE CONVERTER VALVE

Unit: mm


1 Clearance between torque converter spool and body


clearance Clearance limit

Replace

Shaft Hole

32 0.0350.045

+0.0160

0.035 0.061 0.081

2 Clearance between main relief spoon and body 32

0.0350.045

+0.0160

0.035 0.061 0.081

3 Main relief valve spring

Standard size Repair limit

Free length Installed length Installed load Free length Installed load

118 94.5 1213.2 N{123.8 kg} 114.51153.8 N{117.6 kg}

4 Torque converter relief valve spring 137 93.5

331.2 N{33.8 kg} 132.9

315.0 N{32.1 kg}

5 Poppet spring (touque con-verter relief, main relief) 26 17

32.0 N{3.3 kg} 25.2

30.8 N{3.1 kg}

TORQUE CONVERTER

(10)

10-18 HD465-7, HD605-7


TRANSMISSION

TRANSMISSION

HD465-7, HD605-7 10-19

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION

1. Input shaft2. Transmission valve3. Coupling4. Strainer5. Drain valve

A : Speed sensor (for input shaft)B : Speed sensor (for intermediate shaft)C : Speed sensor (for output shaft)D : Lubricating oil pressure detection portE : To pump (suction)F : To lock upG: From torque converter (main circuit)J : From oil coolerH : From torque converter (lubrication circuit)K : From torque converter (drain circuit)L : Brake cooling relief valveM: Lubrication relief valveN : To breather

10-20 HD465-7, HD605-7


HD465-7, HD605-7 10-21


1. Input shaft 2. No. 1 sun gear (Number of teeth : 34) 3. No. 1 clutch hub 4. No. 1 clutch (High) 5. No. 1 planetary pinion (Number of teeth : 32) 6. No. 1 planetary carrier 7. No. 2 clutch hub 8. No. 2 clutch (Low) 9. No. 1 ring gear (Number of teeth : 98)10. No. 2 clutch housing11. No. 3 clutch housing12. No. 3 clutch drum13. No. 3 clutch (4th)14. No. 3 clutch hub15. No. 4 planetary pinion (Number of teeth : 21)16. No. 4 clutch (3rd)17. No. 4 ring gear (Number of teeth : 93)18. No. 4 sun gear (Number of teeth : 51)19. No. 5 clutch (R)20. No. 5 planetary pinion (Number of teeth : 21)21. No. 5 sun gear (Number of teeth : 41)22. No. 5 ring gear (Number of teeth : 93)23. No. 6 clutch (2nd)24. No. 6 ring gear (Number of teeth : 105)25. No. 6 planetary pinion (Number of teeth : 30)26. No. 6 sun gear (Number of teeth : 45)27. No. 6, 7 planetary carrier28. No. 7 clutch (1st)29. No. 7 ring gear (Number of teeth : 104)30. Output shaft31. No. 7 planetary pinion (Number of teeth : 38)32. No. 7 clutch piston33. No. 6 clutch piston34. Intermediate shaft (No. 7 sun gear : Number of

teeth 28)35. No. 5 clutch piston36. No. 5 planetary pinion (Number of teeth : 21)37. No. 4, 5 planetary carrier38. No. 3 clutch piston39. No. 2 clutch piston40. No. 1 clutch piston41. No. 4 clutch piston

10-22 HD465-7, HD605-7


HD465-7, HD605-7 10-23


Unit: mm


1 No. 1 clutch spring

Standard size Repair limit

Replace

Free length Installed length Installed load Free length Installed load

42.0 32.0 74.5 N{7.6 kg} 39.563.7 N{6.5 kg}

2 No. 4 clutch spring 52.0 49.1 49.1 N{5.0 kg} 48.942.2 N{4.3 kg}




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


27.8 0.22 25.8

7 Total thickness of 5 discs and 4 plates for No. 2 clutch 45.0 0.30 42

8 Total thickness of 4 discs and 3 plates for No. 3 clutch 35.0 0.26 32.3


10 Total thickness of 5 discs and 4 plates for No. 5 clutch 47 0.30 43.7



13 Thickness of 1 disc

No. 1,4,5,6,7 5.4 0.10 4.8

No. 2,3 5.0 0.10 4.4

14 Thickness of 1 plate

No. 1,6,7 5.8 0.10 5.6

No. 2,3,4,5 5.0 0.10 4.8

15Wear of transmis-sion input shaft seal ring (small)

Width 2.56 0.010.03 2.30

Thickness 1.7 0.10 1.55

16Wear of transmis-sion input shaft seal ring (large)

Width 3.0 0.010.03 2.70

Thickness 3.1 0.10 2.95

17

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

Width 4.0 0.010.03 3.6

Thickness 4.6 0.12 4.45

TRANSMISSION

10-24 HD465-7, HD605-7


Unit: mm


18Wear of No. 2 and 3 clutch collar seal rings

Width


Replace

4.0 0.010.03 3.6

Thickness 5.1 0.12 4.85

19Wear of No. 4 and 5 carrier seal rings

Width 4.0 0.010.04 3.6

Thickness 6.3 0.15 6.15


Width 4.0 0.010.04 3.6

Thickness 4.0 0.15 3.85


Width 3.95 00.1 3.56

Thickness 5.25 0.1 4.73


Width 4.0 0.010.04 3.6

Thickness 4.0 0.15 3.85

23 Backlash between No. 1 sun gear and planetary gear 0.13 0.36

24 Backlash between No. 1 plan-etary gear and ring gear 0.16 0.41

25 Backlash between No. 4 sun gear and planetary gear 0.14 0.36

26 Backlash between

hd465 7 shop manual sn 7001 up

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