Sales Presentation Kit

Off-highway Trucks

Off-highway Trucks

HD465-7 / HD605-7

Komatsu HD465-
HD465-7/HD605-
7/HD605-7
Off-
Off-highway Trucks
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 HD465-
HD465-7/HD605-
7/HD605-7
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Off-highway Trucks

HIGHLIGHTS AND TECHNICAL Page 2 -36

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SELLING POINTS [No.1]

z Komatsu is committed to building dump trucks that offer
maximum productivity, a comfortable ride, and hassle-free
operation and maintenance. This commitment, combined with
our many years of experience, has produced the HD465-
7/HD605-7 off-highway trucks. Harness the full capabilities of
the HD465-7/HD605-7 anywhere you use it.

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HIGHLIGHTS AND TECHNICAL Page 3 -36

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SELLING POINTS [No.2]

Productivity Features
z High Performance SAA6D170E-3
Komatsu Engine
z Automatic Idling Setting System (AISS)
z Mode-Changing System
z Hydraulically Controlled Wet Multiple-
Disc Brakes and Retarder
z Auto Retard Speed Control (ARSC)
z High Strength Body
z Small Turning Radius
z ABS (Anti-lock Braking System) (Option)
z ASR (Automatic Spin Regulator) (Option)
z PLM II (Memory Card Type Payload
Meter) (Option)

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HIGHLIGHTS AND TECHNICAL Page 4 -36

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SELLING POINTS [No.3]

Operator Environment
z Wide, Spacious Cab with Excellent Visibility
z Ergonomically Designed Cab
z Easy-to-See Instrument Panel
z Suspension Seat
z Tiltable, Telescoping Steering Wheel and
Low Effort Pedals
z Electric Body Dump Control Lever
z K-ATOMiCS with "Skip-Shift" Function
z Total Control System both Engine and
Transmission
z Hydropneumatic Suspension for All Terrains
z Viscous Cab Mounts
z Three-Mode Hydropneumatic Suspension
(Auto-Suspension) (Option)

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HIGHLIGHTS AND TECHNICAL Page 5 -36

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SELLING POINTS [No.4]

Safety Features
z Built-in ROPS/FOPS
z Supplementary Steering and Secondary
Brakes

Reliability Features
z Fully Hydraulic Braking System
z Reliable Komatsu Manufactured Major
Components
z High-Rigidity Frames
z Wet Multiple-Disc Brakes
z Flat Face-to-Face O-Ring Seals
z Sealed DT Connectors
z Highly Reliable Hydraulic System

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HIGHLIGHTS AND TECHNICAL Page 6 -36

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SELLING POINTS [No.5]

Easy Maintenance
z Extended Oil Change Interval
z Centralized Greasing Points
z Centralized Arrangement of Filters
z Flanged Type Rim
z Wet Multiple-Disc Parking Brake
z Vehicle Health Monitoring System
(VHMS) (Option)
Harmony with Environment
z Meets North American EPA Tier II
Emission
z Regulations for 2002 and Meets Stage II
z Directive 97/68/EC EU Emissions
z Low Operation Noise
z Low Fuel Consumption
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CONCEPT OF DEVELOPMENT Page 7 -36

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[No.1]
Main Improvements for Model Change
1. SAA6D170E-3 engine meets North American
EPA Tier II Emission regulations for 2002 and
Stage II Directive 97/68/EC EU Emissions.
2. Retarder absorbing capacity is increased
from 908 HP to 1,052 HP to shorten cycle
time.
3. ARSC (Auto Retard Speed Control) is
installed as standard equipment for easy
operation.
4. “Skip shift function” is utilized for comfortable
operation.
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CONCEPT OF DEVELOPMENT Page 8 -36

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[No.2]
5. Electric body dump control lever is utilized for
comfortable operation.
6. Cab mount is changed to viscous mount type
to reduce vibration [cab noise level: 80 dB(A)
77 dB(A)].
7. Brake control system is changed from air
over hydraulic type to fully hydraulic type for
high reliability and easy maintenance.
8. Parking brake is changed from dry disc type
to wet-multiple disc type for easy
maintenance.
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CONCEPT OF DEVELOPMENT Page 9 -36

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[No.3]
9. Engine oil and hydraulic oil change interval
are extended to reduce maintenance cost.
10. Dividable axle housing is utilized for easy
repair and overhaul of axle.
11. Rim is changed from wedge type to flange
type for easy removal/installation of tire.
12. Built-in ROPS/FOPS are installed as
standard equipment.

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PRODUCT LINE COMPARISON Page 10 -36

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HIGH PERFORMANCE KOMATSU Off-

Off-highway Trucks

Page 11 -36
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SAA6D170E-3 ENGINE [NO.1]

z This engine delivers faster acceleration and higher travel speeds with
high horsepower per ton. Advanced technology, such as High Pressure
Injection system (HPI), air to air aftercooler, and an efficient
turbocharger enables the engine to meet the North American EPA Tier II
emission regulations and to meet Stage II Directive 97/68/EC EU
Emissions. High torque at low speed, impressive acceleration, and low
fuel consumption ensures maximum productivity.
Model KOMATSU CAT HITACHI
Item HD465-7/HD605-7 HD465-5/HD605-5 773E/775E 773D/775D EH1000 EH1100
Komatsu Komatsu CAT CAT Cummins Detroit Diesel
Engine model -
SAA6D170E-3 SAA6D170E-2 3412E 3412E QSK19-C700 12V-2000
(A）Flywheel horsepower (Gross) HP 739 739 710/760 682/725 700/760
(B)Gross vehicle weight ton 98.8/109.9 96.2/104.3 99.3/108.4 92.5/106.6 101.6/108.4
(A)/(B) HP/ton 7.5/6.7 7.7/7.1 7.2/7.0 7.4/6.8 6.9/7.0
Fuel consumption (at rated rpm) g/HP.h 154 157 INA 169 INA
Conformance to emission regulations - Tier II Tier I Tier II / Tier I Tier I Tier II / Tier I
F1 11.5 (7.1) 11.5 (7.1) 10.0 (6.2) 10.2 (6.3)
F2 16.0 (9.9) 16.0 (9.9) 13.9 (8.6) 13.8 (8.6) 15.2 (9.4)
F3 21.5 (13.4) 21.5 (13.4) 18.7 (11.6) 20.2 (12.6)
F4 29.5 (18.3) 29.5 (18.3) 25.1 (15.6) 30.1 (18.7)
km/h
Travel speed F5 39.0 (24.2) 39.0 (24.2) 34.0 (21.1) 40.6 (25.3)
(MPH)
F6 52.5 (32.6) 52.5 (32.6) 45.9 (28.5) 61.3 (38.1)
F7 70.0 (43.5) 70.0 (43.5) 65.8 (40.9) -
R1 12.0 (7.5) 12.0 (7.5) 12.0 (7.5) 8.0 (5.0)
R2 - - - 11.9 (7.4)

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HIGH PERFORMANCE KOMATSU Off-

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Page 12 -36
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SAA6D170E-3 ENGINE [NO.2]

zProductivity comparison

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HYDRAULICALLY CONTROLLED WET Off-

Off-highway Trucks

Page 13 -36
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MULTIPLE-DISC BRAKES AND RETARDER

z Wet multiple-disc brakes and large

capacity brake oil cooler ensure highly
reliable and stable brake performance.
The large-capacity, continuously
cooled, wet-multiple disc brakes also
function as a highly responsive
retarder which gives the operator
greater confidence at higher speeds
when traveling downhill.

Model KOMATSU CAT HITACHI

Item HD465-7/HD605-7 HD465-5/HD605-5 773E/775E 773D/775D EH1000/EH1100
Service brake (rear) - Wet multiple disc Wet multiple disc Wet multiple disc Wet multiple disc Wet multiple disc
Retarder absorbing capacity Kw 785 677 526 526 597 (800) /
(continuous descent) (HP) (1052) (908) (705) (705) 656 (800)
2 2
Brake surface (rear) cm (in ) 64230 (9956) 58880 (9126) 61264 (9496) 61264 (9496) 59616 (9240)
Speed at 8% total resistance km/h 39.5 (24.5) / 39.5 (24.5) / 18.6 (11.6) /
25.4 / (15.8) 25.4 / (15.8)
(loaded,continuous descent) (MPH) 40.0 (24.9) 40.0 (24.9) 18.8 (11.7)

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WIDE AND SPACIOUS CAB Page 14 -36

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z The wide and spacious cab provides a comfortable

working environment. The large-sized windshield
greatly improves the front visibility. A full-size
passenger seat is useful for on-board training.

[Cab features]
ySuspension seat yAshtray
yPassenger seat ySun visor
yTiltable, telescoping yLarge storage under
steering wheel passenger seat
yPower windows yLarge glove box
yCup holder yLarge mirrors

Model HD465-7/ HD465-5/

Item HD605-7 HD605-5
Cab volume(outside) m 3 (cu.yd) 4.25 (5.55) 3.47 (4.54)
Windshield area m 2 (sq.ft) 1.30 (14.0) 1.05 (11.3)

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INSTRUMENT PANEL Page 15 -36

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z Various meters and caution lamps are arranged on

the instrument panel so that the operator can read
them easily. Accordingly, the operator can grasp the
condition of the dump truck at a glance.

„ Troubleshooting function of
instruments panel
If any abnormality occurs in the dump
truck, a message is displayed on the
character display to notify the operator
of what action to take. Accordingly, Character display
the operator can take that action
immediately. The abnormality is Monitoring system
displayed as a fault code on the
Engine controller
character display and stored so that it
will be available for quick Transmission controller
troubleshooting to shorten downtime.
Retarder controller

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SUSPENSION SEAT Page 16 -36

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z A comfortable suspension seat

with retractable seat belt is
standard. Since its headrest,
front, back and lateral
positions, reclining angle,
cushion, etc. are adjustable, it
can comfortably accommodate
a person of any size.

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HIGH STEERING PERFORMANCE Page 17 -36

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AND CONTROL
z The steering wheel feels
HD465-7/HD605-7
comfortable in the operator’s
hands. The tiltable, telescoping
steering wheel can be set to the
best position for the operator and
provides light steering effort.
Accordingly, the operator can
steer the HD465-7/HD605-7
easily. CAT 773E/775E
The gearshift lever is similar to
that found on a car.
Since the throttle requires light
effort, the operator is less
fatigued even after long hours of
operation.

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ELECTRIC BODY DUMP CONTROL Page 18 -36

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LEVER
z An electric body dump control
lever is used. The operating
effort of this lever is light so the
operator can control dumping
with minimal effort. A positioning
sensor is installed for dump body
control which significantly
reduces the shock made by the
lowering of the dump body.
Model KOMATSU CAT HITACHI
HD465-7/ HD465-5/ 773E/ 773D/ EH1000/
Item HD605-7 HD605-5 775E 775D EH1100
Mechanical
Body dump control lever Electric type Electric type Electric type Electric type
(cable) type

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K-ATOMICS WITH “SKIP-SHIFT” Page 19 -36

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FUNCTION

z The K-ATOMiCS (Komatsu Advanced Transmission

with Optimum Modulation Control System) with “skip-
shift” function ensures proper clutch modulation
pressure when the clutch is engaged. A newly
equipped total control system controls both the
engine and transmission by monitoring the vehicle
conditions. This system and newly added “skip-shift”
function ensure smooth shifting and responsive
acceleration.

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“SKIP-SHIFT” FUNCTION [NO.1] Page 20 -36

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z When the vehicle speed is reduced while driving up a

slope, if its control system determines (from information
of the accelerator pedal angle, change of the travel
speed, etc.) that downshifting one gear at a time is not
required, it automatically skips unnecessary gear
speed(s) to the best gear speed. This function is called
the skip shift control.
Example:
While the vehicle is driving at F4, if
the control system judges that the
best gear speed is F1, it goes to F1
automatically, skipping F3 and F2.
As the number of gear shifting times
is reduced, the riding feel is
improved, spilling is prevented and
the durability of the power train is
increased.
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“SKIP-SHIFT” FUNCTION [NO.2] Page 21 -36

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New
The objective gear speed is set
according to the lowering rate of the
travel speed (deceleration rate).
The current gear speed is held until
the travel speed is lowered to a
level at which skip shift is possible,
then one or more gear speeds are
skipped. Even while the current
gear speed is held for skip shift, if
the deceleration rate changes
because of a change of the grade of
the ground, etc. and the control
system judges that skip shift is not
proper, it downshifts one gear at a
time.

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VISCOUS CAB MOUNTS Page 22 -36

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z Since the cab is supported on

viscous mounts consisting of
“rubber” and “silicone oil” cushions,
less mechanical vibration and noise
are transferred to it from the
chassis. The average noise at
operator's ears is only 77 dB(A), the
operator is less fatigued and
working efficiency is increased.

Model
HD465-7/HD605-7 HD465-5/HD605-5
Item
Cab mount - Viscous mount Rubber mount
Noise level at Average of left and right side dB(A) 77 80
operator's ear Maximum dB(A) 79 83

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BUILT-IN ROPS/FOPS Page 23 -36

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z The cab with built-in

ROPS/FOPS is installed
as standard. This cab
certified for ISO 03471
and SAE J1040.

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WET MULTIPLE-DISC BRAKES Page 24 -36

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z Wet disc brakes are fully sealed.

Contaminants are kept out, reducing
wear and maintenance. Brakes
require no adjustments for wear,
meaning even lower maintenance.
The new parking brake is
incorporated with rear brake. It's also
adjustment-free, wet multiple-disc for
high reliability and long life.
Added reliability is designed into the
braking system by the use of three
independent hydraulic circuits. This
provides hydraulic backup should one
of the circuits fail.
Model KOMATSU CAT HITACHI
HD465-7/ HD465-5/ 773E/ 773D/ EH1000/
Item HD605-7 HD605-5 775E 775D EH1100
Wet Wet Wet
Parking brake Dry disc Dry disc
multiple disc multiple disc multiple disc
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FULLY HYDRAULIC BRAKING Page 25 -36

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SYSTEM [No.1]
z Fully hydraulic brake system means no air
system to bleed, or condensation of water
that can lead to contamination, corrosion, and
freezing.
- There is no need to drain the brake air circuit after
completing operations every day.
- No rust is formed in the air circuit piping, so there is
high reliability.
- There is no problem of defective braking caused by
freezing of the air circuit in cold weather.

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FULLY HYDRAULIC BRAKING Page 26 -36

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SYSTEM [No.2]

Model KOMATSU CAT HITACHI

HD465-7/ HD465-5/ 773E/ 773D/ EH1000/
Item HD605-7 HD605-5 775E 775D EH1100
Fully Air over Air over Air over Fully
Brake control system
hydraulic hydraulic hydraulic hydraulic hydraulic

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FLAT FACE-TO-FACE O-RING SEALS Off-

Off-highway Trucks

Page 27 -36
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z While the tapered metal sealing has been used for

the former model, the flat face-to-face O-ring seals
are utilized for the new models. Its O-ring seals
securely and the reliability in preventing oil leakage is
improved greatly.
Nipple Hose
O-ring

O-ring

KOMATSU CAT HITACHI

Model HD465-7/ HD465-5/ EH1000/
773E/775E 773D/775D
HD605-7 HD605-5 EH1100
Sealing for Flat face-to-face Tapered metal Flat face-to-face Flat face-to-face
INA
hydraulic piping O-ring type type O-ring type O-ring type

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DT CONNECTORS Page 28 -36

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z DT connectors having high

reliability for construction
machines are used to connect
the main wiring harnesses.
They are also used for the
controller to attain high water
resistance and dust resistance.

Model KOMATSU CAT HITACHI

HD465-7/ HD465-5/ EH1000/
773E/775E 773D/775D
Item HD605-7 HD605-5 EH1100
Connector for Conventional
DT type DT type DT type INA
main wiring harness type

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EXTENDED OIL CHANGE Page 29 -36

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INTERVAL

z A hybrid filter is utilized to extend engine oil

and hydraulic oil change intervals in order to
minimize operating costs.

Model KOMATSU CAT HITACHI

HD465-7/ HD465-5/ 773E/ 773D/ EH1000/
Item HD605-7 HD605-5 775E 775D EH1100
Engine oil
h 500 250 250 250 INA
change interval
Hydraulic oil
h 4000 2000 500 500 INA
change interval

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FLANGE TYPE RIM Page 30 -36

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z Flange type rims provide easy

removal/installation for the tires.

New: Flange type Current: Wedge type

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DIVIDABLE AXLE HOUSING Page 31 -36

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z The rear axle housing becomes dividable into three

pieces to provide easy repair and overhaul of axle.

Dividable

Model KOMATSU CAT HITACHI

HD465-7/ HD465-5/ EH1000/
773E/775E 773D/775D
Item HD605-7 HD605-5 EH1100
Rear axle housing Dividable Not dividable Dividable Dividable Not dividable

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VHMS (VEHICLE HEALTH Off-

Off-highway Trucks

Page 32 -36
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MONITORING SYSTEM) (OPTION)

z VHMS controller monitors the health conditions of
major components, and enables remote analysis of the
machine and its operation. This process is supported
by Komatsu distributors, factory and design team. This
contributes to reduced repair costs and to maintaining
maximum availability.
Vehicle equipped with
the VHMS can
indicate payload in the
character display,
which is useful in
preventing overload.

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INTERCHANGEABILITY [NO.1] Page 33 -36

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Interchangeability from Dash 7 to Dash 5 Interchangeability : Interchangeable

Interchangeability from Dash 5 to Dash 7 : Not Interchangeable
Name Interchangeability Remarks
Engine SAA6D170E-3 New Current
Built-in torque converter cooler is discontinued. Fuel
Radiator New Current
cooler is utilized.
Torque converter New Current Characteristic is changed.
Transmission New Current Large-sized oil pan is utilized.
Output shaft damper New Current
Front drive shaft New Current Length is changed.
Rear drive shaft New Current Durability is increased.
Gear ratio is changed. Coupling size is increased
Differential New Current
(#10 #12).
Final drive New Current Gear ratio is changed. Flange type rim is utilized.
Front axle New Current Flange type rim is utilized.
Front brake New Current Diameter of brake disc is changed.
Rear Brake New Current Built-in parking brake is utilized.
Parking brake New Current Changed to built-in type.
Rim New Current Changed to flange type.
Foot brake valve New Current Fully hydraulic braking system is utilized.
Hand brake valve New Current Fully hydraulic braking system is utilized.
Discontinued because fully hydraulic braking
Brake chamber -
system is utilized.
Slack adjuster New Current Control pressure is changed.
Transmission controller New Current Skip shift function is added.
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INTERCHANGEABILITY [NO.2] Page 34 -36

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Interchangeability from Dash 7 to Dash 5 Interchangeability : Interchangeable

Interchangeability from Dash 5 to Dash 7 : Not Interchangeable
Name Interchangeability Remarks
Main frame New Current Rear support is changed.
Front suspension New Current Fully hydraulic braking system is utilized.
Rear suspension New Current Only color is different (yellow black gray)
Hydraulic tank New Current Capacity is changed.
Cab New Current Changed to built-in ROPS/FOPS type.
Operator's seat New Current Installation dimension is changed.
Hydraulic pump New Current Two independent hydraulic circuits are utilized.
Demand valve New Current Vibration is reduced.
Steering valve New Current
Hoist valve New Current Changed to hydraulic pilot control type.
Steering cylinder New Current Port for hydraulic piping is changed.
Hoist cylinder New Current Only color is different (yellow black gray)
Dump body New Current Dimensions are changed.
Full-flow filter New Current
Bypass filter - Discontinued.
Engine Large-sized filter is utilized. Filter change interval
Fuel filter New Current
is extended.
Corrosion resistor New Current
Transmission filter
New Current
(high pressure)
Transmission filter Hybrid filter is utilized.
New Current
(low pressure)
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INTERCHANGEABILITY [NO.3] Page 35 -36

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Interchangeability from
Dash 7 to Dash 5 Interchangeability : Interchangeable
Interchangeability from
Dash 5 to Dash 7 : Not Interchangeable
Name Interchangeability Remarks
Hydraulic filter (high pressure)New Current Prevention of oil-spilling when changing filter
Hydraulic oil change interval is changed from 2000h
Hydraulic filter (low pressure) New Current
to 4000h.
Air cleaner New Current FTG15S FRG15S
Air conditioner filter New Current Filter is common to HM articulated dump truck.
Tire New Current
Transmission clutch disc New Current
Torque converter lockup clutch New Current
Rear brake disc New Current Prevention from concentration of stress
Front brake pad New Current
Discontinued because fully hydraulic braking
Parking brake lining -
system is utilized.
Fan drive belt New Current Engine is changed.
Air conditioner compressor Engine is changed.
New Current
drive belt
Discontinued because built-in ROPS/FOPS cab is
ROPS guard -
utilized.
Passenger seat New Current Mounting method is changed.
Secondary steering motor New Current
Supplementary steering Pump type is changed (SAL14 SBL14)
New Current
hydraulic pump

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EXTERNAL APPEARANCE AND Off-

Off-highway Trucks

Page 36 -36
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DIMENSIONS

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