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KOMATSU GD655-6 GD675-6 MOTOR GRADER SHOP MANUAL SEN06523-14 – PDF DOWNLOAD
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KOMATSU GD655-6 GD675-6 MOTOR GRADER SHOP MANUAL SEN06523-14 – PDF DOWNLOAD
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KOMATSU GD655-6 GD675-6 MOTOR GRADER SHOP MANUAL SEN06523-14 – PDF DOWNLOAD
Language : English
Pages : 3248
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU GD655-6 GD675-6 MOTOR GRADER SHOP MANUAL SEN06523-14 – PDF DOWNLOAD
Cover................................................................................................................................. 1 00 Index and Foreword................................................................................................................ 3 Index............................................................................................................................ 4 Abbreviation List................................................................................................................ 23 Foreword, Safety, Basic Information.............................................................................................. 29 How to Read the Shop Manual.................................................................................................. 29 Safety Notice for Operation.................................................................................................. 31 Precautions to Prevent Fire.................................................................................................. 39 Procedures If Fire Occurs.................................................................................................... 41 Precautions When You Discard Waste Materials................................................................................. 42 Procedures for Exhaust Gas Regulations....................................................................................... 43 Precautions for DEF.......................................................................................................... 44 General Character and Precautions for Handling........................................................................... 44 Precautions When You Add................................................................................................. 44 Precautions for Storage.................................................................................................. 44 Precautions for Fire Hazard and Leakage.................................................................................. 44 Other Precautions........................................................................................................ 44 Store DEF.................................................................................................................... 45 Precautions When You Handle Hydraulic Equipment.............................................................................. 46 Precautions When You Disconnect and Connect Pipings.......................................................................... 49 Precautions When You Handle Electrical Equipment............................................................................. 56 Precautions When You Handle Fuel System Equipment............................................................................ 58 Precautions When You Handle Intake System Equipment.......................................................................... 59 Practical Use of KOMTRAX..................................................................................................... 60 Disconnect and Connect Push-Pull Type Coupler................................................................................ 61 How to Disconnect and Connect Type 1 Push-Pull Type Coupler.............................................................. 61 How to Disconnect and Connect Type 2 Push-Pull Type Coupler.............................................................. 62 How to Disconnect and Connect Type 3 Push-Pull Type Coupler.............................................................. 63 Precautions for Disconnection and Connection of Connectors................................................................... 65 Disconnect and Connect Deutsch Connector..................................................................................... 69 How to Disconnect and Connect Slide Lock Type Connector...................................................................... 70 Disconnect and Connect Connector with Lock to Pull........................................................................... 72 Disconnect and Connect Connector with Lock to Push........................................................................... 73 Disconnect and Connect Connector with Housing to Rotate...................................................................... 75 How to Read the Codes for Electric Cable..................................................................................... 76 Explanation of Terms for Maintenance Standard................................................................................ 80 Standard Tightening Torque Table............................................................................................. 83 Conversion Table............................................................................................................. 90 01 Specification..................................................................................................................... 95 Table of Contents................................................................................................................ 96 Abbreviation List................................................................................................................ 97 Specifications................................................................................................................... 103 Specification Drawing........................................................................................................ 103 Specification Drawing: GD655-6........................................................................................... 103 Specification Drawing: GD675-6........................................................................................... 105 Specifications............................................................................................................... 107 Specifications: GD655-6.................................................................................................. 107 Specifications: GD675-6.................................................................................................. 113 Weight Table................................................................................................................. 119 Weight Table: GD655-6.................................................................................................... 119 Weight Table: GD675-6.................................................................................................... 120 Table of Fuel, Coolant, and Lubricants....................................................................................... 121 10 Structure and Function............................................................................................................ 123 Table of Contents................................................................................................................ 124 Abbreviation List................................................................................................................ 128 Urea SCR System.................................................................................................................. 134 Layout Drawing of Urea SCR System............................................................................................ 134 Urea SCR System Diagram...................................................................................................... 137 Function of Urea SCR System.................................................................................................. 138 Function of DEF System (Machine Without DEF purge relay) (Applicable Machine: 60001 to 61072)............................ 138 Function of DEF System (Machine Without DEF purge relay) (Applicable Machine: 61073 and up).............................. 140 Function of DEF System (Machine with DEF purge relay) (Applicable Machine: 60001 to 61072)............................... 142 Function of DEF System (Machine with DEF purge relay) (Applicable Machine: 61073 and up)................................. 144 Inducement Strategy...................................................................................................... 147 Component Parts of Urea SCR System........................................................................................... 161 DEF Mixing Tube.......................................................................................................... 161 SCR Assembly............................................................................................................. 162 DEF Tank................................................................................................................. 164 DEF Pump................................................................................................................. 166 DEF Injector............................................................................................................. 168 DEF Hose................................................................................................................. 169 DEF Tank Heating Valve................................................................................................... 170 Boot-up System................................................................................................................... 171 Layout Drawing of Boot-up System............................................................................................. 171 System Operating Lamp System................................................................................................. 172 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal)........................................... 172 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)................................ 172 Function of System Operating Lamp System (Machine with KOMTRAX Terminal)................................................. 172 Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine Without DEF purge relay).... 173 Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine with DEF purge relay)....... 174 Battery Disconnect Switch.................................................................................................... 175 Layout Drawing of Battery Disconnect Switch.............................................................................. 175 Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal).................................................... 175 Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine Without DEF purge relay)....... 176 Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine with DEF purge relay).......... 177 Preheating System............................................................................................................ 178 System Diagram of Preheating System...................................................................................... 178 Function of Automatic Preheating System.................................................................................. 178 Operation of Automatic Preheating System................................................................................. 178 Engine System.................................................................................................................... 180 Layout Drawing of Engine System.............................................................................................. 180 Function of Engine System................................................................................................ 182 Engine Control System........................................................................................................ 183 System Diagram of Engine Control......................................................................................... 183 Function of Engine Control System........................................................................................ 183 Operation of Engine Control System....................................................................................... 184 Engine Power Mode Selector System............................................................................................ 186 Engine Power Mode Selector System Diagram................................................................................ 186 Function of Engine Power Mode Selector System............................................................................ 186 Operation of Engine Power Mode Selector System........................................................................... 186 Automatic Idle Stop System................................................................................................... 187 Function of Automatic Idle Stop System................................................................................... 187 Component Parts of Engine System............................................................................................. 188 VGT...................................................................................................................... 188 EGR System............................................................................................................... 193 EGR Valve................................................................................................................ 195 EGR Cooler............................................................................................................... 197 KCCV System.............................................................................................................. 199 KCCV Ventilator.......................................................................................................... 201 KDPF..................................................................................................................... 203 Cooling System................................................................................................................... 207 Layout Drawing of Cooling System............................................................................................. 207 Specifications of Cooling System......................................................................................... 209 Cooling Fan Control System................................................................................................... 210 System Diagram of Cooling Fan Control System............................................................................. 210 Function of Cooling Fan Control System................................................................................... 211 Component Parts of Cooling System............................................................................................ 213 Brake and Cooling Fan Pump............................................................................................... 213 Cooling Fan Motor........................................................................................................ 214 Control System................................................................................................................... 222 Layout Drawing of Control System............................................................................................. 222 Machine Monitor System....................................................................................................... 225 System Diagram of Machine Monitor System................................................................................. 225 Function of Machine Monitor System....................................................................................... 225 Rearview Monitor System...................................................................................................... 227 System Diagram of Rearview Monitor System................................................................................ 227 Function of Rearview Monitor System...................................................................................... 227 KOMTRAX System............................................................................................................... 228 KOMTRAX System Diagram (Machine with KOMTRAX Terminal)................................................................... 228 System Diagram of KOMTRAX System (Machine with Gateway Function Controller).............................................. 228 Function of KOMTRAX System............................................................................................... 229 Component Parts of Control System............................................................................................ 230 Machine Monitor.......................................................................................................... 230 Switch Panel............................................................................................................. 245 Rearview Monitor......................................................................................................... 246 Rearview Camera.......................................................................................................... 248 KOMTRAX Terminal......................................................................................................... 249 Gateway Function Controller.............................................................................................. 251 Communication Terminal................................................................................................... 254 Transmission Controller.................................................................................................. 256 Monitor Controller....................................................................................................... 260 CAN Terminating Resistor................................................................................................. 265 Engine Controller........................................................................................................ 266 Accelerator Pedal........................................................................................................ 278 Inching Pedal Potentiometer.............................................................................................. 280 Hydraulic System................................................................................................................. 283 Layout Drawing of Hydraulic System........................................................................................... 283 Hydraulic System Diagram..................................................................................................... 285 Function of Hydraulic System............................................................................................. 285 CLSS......................................................................................................................... 288 Structure of CLSS........................................................................................................ 288 Function of CLSS......................................................................................................... 289 Component Parts of Hydraulic System.......................................................................................... 291 Hydraulic Tank........................................................................................................... 291 Steering and Work Equipment Pump......................................................................................... 294 Power Train Pump and Differential Lock Pump.............................................................................. 306 Control Valve............................................................................................................ 307 Power Train System............................................................................................................... 331 Layout Drawing of Power Train System......................................................................................... 331 Operation of Power Train System.............................................................................................. 333 Automatic Shift Control System............................................................................................... 334 Automatic Shift Control System Diagram................................................................................... 334 Function of Automatic Shift Control System............................................................................... 334 Transmission Control System.................................................................................................. 335 Transmission Control System Diagram...................................................................................... 335 Shift Lever Positions and Automatic Gear Shift Range..................................................................... 336 Transmission Gear Shift Control System....................................................................................... 339 Variable Horsepower Control (VHPC) Function.............................................................................. 339 Transmission Protection Function............................................................................................. 341 Engine Overrun Prevention Function....................................................................................... 341 Very Low Speed Travel Control Function................................................................................... 341 Component Parts of Power Train System........................................................................................ 342 Drive Shaft.............................................................................................................. 342 Torque Converter......................................................................................................... 343 Lockup Clutch ECMV....................................................................................................... 346 Transmission............................................................................................................. 349 Transmission Control Valve............................................................................................... 375 F, R, 1st, 2nd, 3rd, 4th Clutch ECMV..................................................................................... 378 Main Relief Valve and Torque Converter Relief Valve...................................................................... 383 Axle..................................................................................................................... 385 Differential............................................................................................................. 388 Final Drive.............................................................................................................. 391 Tandem Drive............................................................................................................. 392 Differential Lock Solenoid Valve......................................................................................... 394 Work Equipment System............................................................................................................ 395 Layout Drawing of Work Equipment System...................................................................................... 395 Function of Work Equipment System............................................................................................ 398 Component Parts of Work Equipment System..................................................................................... 399 Blade Lift Circuit Accumulator Solenoid Valve............................................................................ 399 Blade Lift Circuit Accumulator........................................................................................... 400 Scarifier Circuit Relief Valve........................................................................................... 402 Swivel Joint............................................................................................................. 403 Circle Rotation Motor.................................................................................................... 404 Circle Rotation Gear..................................................................................................... 406 Steering System.................................................................................................................. 408 Layout Drawing of Steering System............................................................................................ 408 Function of Steering System.................................................................................................. 411 Component Parts of Steering System........................................................................................... 412 Priority Valve........................................................................................................... 412 Orbitrol Valve........................................................................................................... 418 LS Pressure Reducing Valve............................................................................................... 425 Brake System..................................................................................................................... 427 Layout Drawing of Brake System............................................................................................... 427 Component Parts of Brake System.............................................................................................. 429 Brake Circuit Accumulator................................................................................................ 429 Brake Valve.............................................................................................................. 431 Slack Adjuster........................................................................................................... 435 Brake.................................................................................................................... 437 Parking Brake Solenoid Valve and Lifter Lock Pin Control Valve........................................................... 438 Parking Brake............................................................................................................ 439 Undercarriage and Frame.......................................................................................................... 440 Frame and Center Hinge Pin................................................................................................... 440 Structure of Frame and Center Hinge Pin.................................................................................. 440 Function of Frame and Center Hinge Pin................................................................................... 441 Tires........................................................................................................................ 442 Features of Radial Tire When Compared with Bias Tire..................................................................... 442 Structure of Radial Tire................................................................................................. 442 Function of Radial Tire.................................................................................................. 443 Structure of Bias Tire................................................................................................... 443 Function of Bias Tire.................................................................................................... 443 Work Equipment................................................................................................................... 444 Structure of Circle and Drawbar.............................................................................................. 444 Function of Circle and Drawbar............................................................................................... 445 Structure of Blade........................................................................................................... 446 Function of Blade............................................................................................................ 447 Structure of Lifter.......................................................................................................... 448 Function of Lifter........................................................................................................... 449 CAB Related Parts................................................................................................................ 450 ROPS CAB..................................................................................................................... 450 Structure of ROPS CAB.................................................................................................... 450 Function of ROPS CAB..................................................................................................... 450 20 Standard Value Table.............................................................................................................. 451 Table of Contents................................................................................................................ 452 Abbreviation List................................................................................................................ 453 Standard Value Table for Engine.................................................................................................. 459 Standard Value Table for Engine: GD655-6..................................................................................... 459 Standard Value Table for Engine: GD675-6..................................................................................... 463 Standard Value Table for Machine................................................................................................. 467 Standard Value Table for Machine: GD655-6.................................................................................... 467 Standard Value Table for Machine: GD675-6.................................................................................... 485 Machine Posture and Procedures to Measure Performance........................................................................ 503 Standard Value Table for Electricity............................................................................................. 504 Standard Value Table for Electricity......................................................................................... 504 30 Testing and Adjusting............................................................................................................. 515 Table of Contents................................................................................................................ 516 Precautions Before Work.......................................................................................................... 520 Abbreviation List................................................................................................................ 521 Related Information on Testing and Adjusting..................................................................................... 527 Tools for Testing and Adjusting.............................................................................................. 527 Sketch of Tools for Testing and Adjusting.................................................................................... 537 Engine and Cooling System........................................................................................................ 538 Examine Engine Speed......................................................................................................... 538 How to Examine Engine Speed.............................................................................................. 538 Examine Boost Pressure....................................................................................................... 543 How to Examine Boost Pressure............................................................................................ 543 Examine Exhaust Gas Temperature.............................................................................................. 546 How to Examine Exhaust Gas Temperature................................................................................... 546 Examine Exhaust Gas Color.................................................................................................... 549 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................ 549 How to Examine Exhaust Gas Color with Smoke Meter........................................................................ 551 Examine Mass Air Flow and Temperature Sensor................................................................................. 553 How to Examine Mass Air Flow and Temperature Sensor...................................................................... 553 Examine and Adjust Valve Clearance........................................................................................... 555 Check Valve Clearance.................................................................................................... 555 Adjust Valve Clearance................................................................................................... 556 Examine Compression Pressure................................................................................................. 557 How to Examine Compression Pressure...................................................................................... 557 Examine Blowby Pressure...................................................................................................... 562 How to Examine Blowby Pressure........................................................................................... 562 Examine Engine Oil Pressure.................................................................................................. 565 How to Examine Engine Oil Pressure....................................................................................... 565 Examine EGR Valve and VGT Oil Pressure....................................................................................... 567 How to Examine EGR Valve and VGT Oil Pressure............................................................................ 567 Examine Fuel Pressure........................................................................................................ 569 How to Examine Fuel Pressure............................................................................................. 570 Examine Fuel Discharge, Return and Leakage................................................................................... 575 How to Examine Fuel Discharge, Return, and Leakage....................................................................... 576 Bleed Air from Fuel System................................................................................................... 582 How to Bleed Air from Fuel System........................................................................................ 582 Examine Fuel Circuit for Leakage............................................................................................. 584 How to Examine Fuel System for Leakage................................................................................... 584 Handle Cylinder Cut-out Mode Operation....................................................................................... 586 Handle No-Injection Cranking Operation....................................................................................... 587 Examine KDPF, SCR and Muffler Stack for Looseness and Damage................................................................. 588 How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage...................................................... 588 Examine Installed Condition of Cylinder Heads and Manifolds.................................................................. 589 How to Examine Installed Condition of Cylinder Heads and Manifolds....................................................... 589 Examine Engine Piping for Damage and Looseness............................................................................... 590 How to Examine Engine Piping for Damage and Looseness.................................................................... 590 Examine and Adjust Air Conditioner Compressor Belt Tension................................................................... 591 How to Examine Air Conditioner Compressor Belt Tension................................................................... 591 How to Adjust Air Conditioner Compressor Belt Tension.................................................................... 591 Examine Alternator Belt...................................................................................................... 593 How to Examine Alternator Belt........................................................................................... 593 Examine Automatic Tensioner.................................................................................................. 595 How to Examine Automatic Tensioner....................................................................................... 595 Write Correction for Ash in Soot Accumulation to Engine Controller........................................................... 599 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................ 599 Examine SCR Related Functions................................................................................................ 600 Examine DEF Pump Raised Pressure......................................................................................... 604 Examine Injection Volume from DEF Injector............................................................................... 607 Examine DEF Line Heater Relay 1.......................................................................................... 612 Examine DEF Line Heater Relay 2.......................................................................................... 616 Examine DEF Pump Heater Relay............................................................................................ 620 Examine DEF Tank Heater Valve............................................................................................ 624 Examine SCR Denitration Efficiency....................................................................................... 628 Clean DEF Tank............................................................................................................... 632 How to Clean DEF Tank.................................................................................................... 632 Clean DEF Pump............................................................................................................... 637 How to Clean DEF Pump.................................................................................................... 637 Power Train...................................................................................................................... 643 Examine Power Train Oil Pressure............................................................................................. 643 How to Examine Power Train Oil Pressure.................................................................................. 646 Adjust Transmission Input Shaft Speed Sensor................................................................................. 660 How to Adjust Transmission Input Shaft Speed Sensor...................................................................... 660 Adjust Transmission Intermediate Shaft Speed Sensor.......................................................................... 661 How to Adjust Transmission Intermediate Shaft Speed Sensor............................................................... 661 Adjust Transmission Output Shaft Speed Sensor................................................................................ 662 How to Adjust Transmission Output Shaft Speed Sensor..................................................................... 662 Examine After You Adjust Transmission Speed Sensor........................................................................... 663 Examine After Adjustment of Transmission Speed Sensor.................................................................... 663 Flush Torque Converter and Transmission Hydraulic Circuit.................................................................... 664 How to Flush Torque Converter and Transmission Hydraulic Circuit......................................................... 664 Move Disabled Machine Due to Transmission Valve Failure...................................................................... 667 How to Move Disabled Machine Due to Transmission Valve Failure........................................................... 667 Examine Drive Shaft for Looseness, Backlash, and Damage...................................................................... 670 How to Examine Drive Shaft for Looseness, Backlash, and Damage........................................................... 670 Examine and Adjust Differential Lock Hydraulic Oil Pressure.................................................................. 671 Examine Differential Lock Oil Pressure................................................................................... 671 Adjust Differential Lock Oil Pressure.................................................................................... 674 Steering System.................................................................................................................. 675 Examine and Adjust Steering Circuit Oil Pressure............................................................................. 675 Examine Steering Circuit Oil Pressure.................................................................................... 675 Adjust Steering Circuit Oil Pressure..................................................................................... 676 Examine Internal Oil Leakage of Steering Cylinder............................................................................ 677 Examine Oil Leakage from Steering Cylinder............................................................................... 677 Bleed Air from Steering Circuit.............................................................................................. 678 How to Bleed Air from Steering Circuit................................................................................... 678 Examine and Adjust Toe-in.................................................................................................... 679 Examine Toe-in........................................................................................................... 679 Adjust Toe-in............................................................................................................ 680 Adjust Bearing Preload....................................................................................................... 681 How to Adjust Bearing Preload............................................................................................ 681 Brake System..................................................................................................................... 682 Release Remained Pressure from Brake Circuit................................................................................. 682 How to Release Remained Pressure from Brake Circuit...................................................................... 682 Examine Wheel Brake Oil Pressure............................................................................................. 683 How to Examine Wheel Brake Oil Pressure.................................................................................. 683 Examine and Adjust Accumulator Charge Pressure............................................................................... 685 How to Examine Accumulator Charge Pressure............................................................................... 685 Adjust Accumulator Charge Pressure....................................................................................... 686 Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas............................................................ 688 How to Examine Accumulator Nitrogen Gas Pressure for Brake............................................................... 688 How to Charge Accumulator Nitrogen Gas Pressure for Brake................................................................ 690 Bleed Air from Brake Circuit................................................................................................. 693 How to Bleed Air from Brake Circuit...................................................................................... 693 Examine Pressure Decrease of Wheel Brake..................................................................................... 695 How to Examine Pressure Decrease of Wheel Brake.......................................................................... 695 Examine Wear of Wheel Brake Disc............................................................................................. 696 How to Examine Wear of Wheel Brake Disc.................................................................................. 696 Examine Parking Brake Oil Pressure........................................................................................... 697 How to Examine Parking Brake Oil Pressure................................................................................ 697 Release Parking Brake Manually............................................................................................... 699 How to Release Parking Brake Manually.................................................................................... 699 Examine and Adjust Parking Brake Pad......................................................................................... 700 How to Examine Wear of Parking Brake Pad................................................................................. 700 How to Adjust Clearance of Parking Brake Pad............................................................................. 701 Hydraulic System................................................................................................................. 703 Examine and Adjust Work Equipment Oil Pressure............................................................................... 703 How to Examine Work Equipment Oil Pressure............................................................................... 703 Adjust Work Equipment Oil Pressure....................................................................................... 707 Examine and adjust oil pressure in pump PC control circuit................................................................... 708 How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................... 708 How to Adjust Oil Pressure in Pump PC Control Circuit.................................................................... 710 Examine and Adjust Oil Pressure in Pump LS Control Circuit................................................................... 712 Examine LS Differential Pressure......................................................................................... 712 Adjust LS Valve.......................................................................................................... 714 Examine Oil Pressure of Lifter Lock Pin Circuit.............................................................................. 715 How to Examine Oil Pressure of Lifter Lock Pin Circuit................................................................... 715 Bleed Air from Work Equipment Circuit........................................................................................ 717 How to Bleed Air from Work Equipment Circuit............................................................................. 717 Examine Cooling Fan Speed.................................................................................................... 719 How to Examine Cooling Fan Speed......................................................................................... 719 Examine Cooling Fan Circuit Oil Pressure..................................................................................... 721 How to Examine Cooling Fan Circuit Oil Pressure.......................................................................... 721 Examine Oil Leakage from Work Equipment Cylinder............................................................................. 723 How to Examine Oil Leakage from Blade Lift Cylinder...................................................................... 723 How to Examine Oil Leakage from Blade Side-Shift Cylinder................................................................ 724 Examine Oil Leakage from Drawbar Side-Shift Cylinder..................................................................... 725 Examine Oil Leakage from Power Tilt Cylinder............................................................................. 725 How to Examine Oil Leakage from Articulate Cylinder...................................................................... 726 How to Examine Oil Leakage from Leaning Cylinder......................................................................... 727 Work Equipment................................................................................................................... 729 Adjust Clearance in Drawbar Joint............................................................................................ 729 How to Adjust Clearance in Drawbar Joint................................................................................. 729 Examine and Adjust Clearance in Circle Guide................................................................................. 730 How to Examine Clearance in Circle Guide................................................................................. 731 Adjust Clearance in Circle Guide......................................................................................... 731 Examine and Adjust Circle Rotation Gear...................................................................................... 735 Examine Circle Rotation Gear............................................................................................. 735 Adjust Circle Rotation Gear.............................................................................................. 736 Charge Blade Accumulator Nitrogen Gas Pressure............................................................................... 739 How to Charge Blade Accumulator Nitrogen Gas Pressure.................................................................... 739 Electrical System................................................................................................................ 743 Set and Adjust Each Equipment................................................................................................ 743 Set and Operate Machine Monitor.............................................................................................. 745 Operator Mode............................................................................................................ 749 Function to Show Technician Identification Status Screen................................................................. 749 Function to Show Operator Identification Input Screen.................................................................... 749 Examine Function by LCD (Liquid Crystal Display)......................................................................... 750 Examine Function of Service Meter and Odometer........................................................................... 751 Usage Limitation and Change Maintenance Password......................................................................... 751 Service Mode............................................................................................................. 755 How to Operate Service Mode.............................................................................................. 755 How to See Pre-defined Monitoring Information............................................................................ 757 How to Examine Self-Define Monitor Information........................................................................... 764 Abnormality Record Menu.................................................................................................. 776 How to See Maintenance Record............................................................................................ 781 Maintenance Mode Setting................................................................................................. 783 Set Phone Number Entry................................................................................................... 788 Default Menu............................................................................................................. 790 Diagnostic Tests Menu.................................................................................................... 804 Adjustment Menu.......................................................................................................... 815 No-Injection Cranking Operation.......................................................................................... 833 KOMTRAX Settings Menu.................................................................................................... 835 Show Service Message..................................................................................................... 840 Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal).................................................................... 842 Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)................................................................. 846 Start Up KOMTRAX System (Machine with Gateway Function Controller)........................................................... 848 Stop Use of KOMTRAX System (Machine with Gateway Function Controller)........................................................ 854 Adjust Rearview Camera Angle................................................................................................. 856 How to Adjust Rearview Camera Angle...................................................................................... 856 Set Region of Bluetooth(R) Compatible Radio.................................................................................. 858 Set Region of Bluetooth(R) Compatible Radio.............................................................................. 858 Handle Voltage Circuit of Engine Controller.................................................................................. 860 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)............................................................. 861 Handle Battery Disconnect Switch (Machine with Gateway Function Controller).................................................. 862 Examine Diodes............................................................................................................... 863 Examine Diodes by Digital Tester......................................................................................... 863 How to Examine Diodes by Analog Tester................................................................................... 863 Pm Clinic........................................................................................................................ 864 Pm Clinic Service............................................................................................................ 864 Pm Clinic Check Sheet: GD655-6........................................................................................... 866 Pm Clinic Check Sheet: GD675-6........................................................................................... 876 40 Troubleshooting................................................................................................................... 887 Table of Contents................................................................................................................ 888 Precautions Before Work.......................................................................................................... 899 Abbreviation List................................................................................................................ 900 Related Information to Troubleshooting........................................................................................... 906 General Troubleshooting Points............................................................................................... 906 Troubleshooting Points for Urea SCR System................................................................................... 907 Sequence of Events in Troubleshooting........................................................................................ 921 Checks Before Troubleshooting................................................................................................ 923 Inspection Procedure Before Troubleshooting.................................................................................. 925 Walk-Around Check........................................................................................................ 925 Test in Accordance with Testing Procedure.................................................................................... 927 Examine Fuel Level and Type.............................................................................................. 927 Examine for Impure Ingredient in Fuel.................................................................................... 927 Examine DEF Level and Type............................................................................................... 928 Examine Fuel Prefilter................................................................................................... 928 Examine Fuel Main Filter................................................................................................. 930 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type.............................................................. 930 Examine Coolant Level (Reservoir Tank)................................................................................... 931 Examine Air Cleaner Clogging............................................................................................. 932 Clean Outer Element...................................................................................................... 933 Replace Element.......................................................................................................... 936 Examine Hydraulic Oil Level.............................................................................................. 936 Examine Hydraulic Oil Strainer........................................................................................... 937 Examine Hydraulic Oil Filter............................................................................................. 938 Examine Oil Level in Transmission Case................................................................................... 939 Examine Transmission Case Strainer....................................................................................... 940 Replace Transmission Oil Filter Cartridge................................................................................ 941 Examine Oil Level in Final Drive Case.................................................................................... 942 Bleed Air from Fuel System............................................................................................... 942 Bleed Air from Hydraulic System.......................................................................................... 942 How to Examine Electric Equipment........................................................................................ 943 Preparation for Troubleshooting of Electrical System......................................................................... 952 Procedure for Troubleshooting................................................................................................ 961 Symptom and Troubleshooting Numbers.......................................................................................... 963 Information Shown in Troubleshooting Table................................................................................... 967 Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness..................................................... 969 Connector List and Layout (Machine with KOMTRAX Terminal).................................................................... 972 Connector List and Layout (Machine with Gateway Function Controller)......................................................... 989 Connector Contact Connection Table...........................................................................................1006 T-Branch Box and T-Branch Adapter Table......................................................................................1046 Fuse Location Table (Machine with KOMTRAX Terminal)..........................................................................1052 Fuse Location Table (Machine with Gateway Function Controller)...............................................................1055 Precautions When You Clean and Replace KDPF (KCSF and KDOC)..................................................................1058 Prepare Troubleshoot Machine Monitor.........................................................................................1062 Procedure to Make Harness Checker on Machine Monitor LCD Unit................................................................1064 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]).........................................1070 Failure Code Table...........................................................................................................1072 Troubleshooting by Failure Code (Display of Code)................................................................................1091 Failure Code [1500L0]........................................................................................................1091 Failure Code [15G0MW]........................................................................................................1092 Failure Code [15H0MW]........................................................................................................1093 Failure Code [15J0MW]........................................................................................................1094 Failure Code [15K0MW]........................................................................................................1095 Failure Code [15L0MW]........................................................................................................1097 Failure Code [15M0MW]........................................................................................................1099 Failure Code [15N0MW]........................................................................................................1101 Failure Code [15SBL1]........................................................................................................1103 Failure Code [15SBMA]........................................................................................................1105 Failure Code [15SCL1]........................................................................................................1107 Failure Code [15SCMA]........................................................................................................1109 Failure Code [15SDL1]........................................................................................................1111 Failure Code [15SDMA]........................................................................................................1113 Failure Code [15SEL1]........................................................................................................1115 Failure Code [15SEMA]........................................................................................................1117 Failure Code [15SFL1]........................................................................................................1119 Failure Code [15SFMA]........................................................................................................1121 Failure Code [15SGL1]........................................................................................................1123 Failure Code [15SGMA]........................................................................................................1125 Failure Code [15SHL1]........................................................................................................1127 Failure Code [15SHMA]........................................................................................................1129 Failure Code [15SJMA]........................................................................................................1131 Failure Code [15U0NT]........................................................................................................1132 Failure Code [2F00MA]........................................................................................................1133 Failure Code [2F00MB]........................................................................................................1135 Failure Code [2G42ZG]........................................................................................................1137 Failure Code [2G43ZG]........................................................................................................1139 Failure Code [989L00]........................................................................................................1141 Failure Code [989M00]........................................................................................................1142 Failure Code [989N00]........................................................................................................1143 Failure Code [A1U0N3]........................................................................................................1144 Failure Code [A1U0N4]........................................................................................................1146 Failure Code [AA10NX]........................................................................................................1148 Failure Code [AB00KE]........................................................................................................1150 Failure Code [AB00KY]........................................................................................................1152 Failure Code [AQ10N3]........................................................................................................1154 Failure Code [AS00N3]........................................................................................................1156 Failure Code [AS00R2]........................................................................................................1158 Failure Code [AS00R3]........................................................................................................1159 Failure Code [AS00R4]........................................................................................................1160 Failure Code [AS00R5]........................................................................................................1161 Failure Code [AS00R6]........................................................................................................1162 Failure Code [AS00ZK]........................................................................................................1163 Failure Code [AS10KM]........................................................................................................1164 Failure Code [AS10NR]........................................................................................................1165 Failure Code [AS10NT]........................................................................................................1166 Failure Code [B@BAZG]........................................................................................................1167 Failure Code [B@BCNS]........................................................................................................1168 Failure Code [B@BCQA]........................................................................................................1169 Failure Code [B@BCZK]........................................................................................................1171 Failure Code [B@CENS]........................................................................................................1173 Failure Code [B@CKNS]........................................................................................................1174 Failure Code [B@HANS]........................................................................................................1176 Failure Code [CA115].........................................................................................................1178 Failure Code [CA122].........................................................................................................1179 Failure Code [CA123].........................................................................................................1181 Failure Code [CA131].........................................................................................................1183 Failure Code [CA132].........................................................................................................1185 Failure Code [CA144].........................................................................................................1188 Failure Code [CA145].........................................................................................................1190 Failure Code [CA153].........................................................................................................1192 Failure Code [CA154].........................................................................................................1195 Failure Code [CA187].........................................................................................................1197 Failure Code [CA221].........................................................................................................1199 Failure Code [CA222].........................................................................................................1201 Failure Code [CA227].........................................................................................................1203 Failure Code [CA234].........................................................................................................1204 Failure Code [CA238].........................................................................................................1205 Failure Code [CA239].........................................................................................................1207 Failure Code [CA249].........................................................................................................1209 Failure Code [CA256].........................................................................................................1211 Failure Code [CA271].........................................................................................................1213 Failure Code [CA272].........................................................................................................1215 Failure Code [CA322].........................................................................................................1217 Failure Code [CA323].........................................................................................................1219 Failure Code [CA324].........................................................................................................1221 Failure Code [CA325].........................................................................................................1223 Failure Code [CA331].........................................................................................................1225 Failure Code [CA332].........................................................................................................1227 Failure Code [CA343].........................................................................................................1229 Failure Code [CA351].........................................................................................................1230 Failure Code [CA352].........................................................................................................1231 Failure Code [CA356].........................................................................................................1234 Failure Code [CA357].........................................................................................................1236 Failure Code [CA386].........................................................................................................1239 Failure Code [CA428].........................................................................................................1240 Failure Code [CA429].........................................................................................................1242 Failure Code [CA431].........................................................................................................1244 Failure Code [CA432].........................................................................................................1247 Failure Code [CA435].........................................................................................................1251 Failure Code [CA441].........................................................................................................1253 Failure Code [CA442].........................................................................................................1255 Failure Code [CA449].........................................................................................................1256 Failure Code [CA451].........................................................................................................1257 Failure Code [CA452].........................................................................................................1259 Failure Code [CA488].........................................................................................................1261 Failure Code [CA515].........................................................................................................1262 Failure Code [CA516].........................................................................................................1264 Failure Code [CA553].........................................................................................................1266 Failure Code [CA555].........................................................................................................1267 Failure Code [CA556].........................................................................................................1268 Failure Code [CA559].........................................................................................................1269 Failure Code [CA595].........................................................................................................1272 Failure Code [CA687].........................................................................................................1273 Failure Code [CA689].........................................................................................................1275 Failure Code [CA691].........................................................................................................1278 Failure Code [CA692].........................................................................................................1280 Failure Code [CA697].........................................................................................................1282 Failure Code [CA698].........................................................................................................1283 Failure Code [CA731].........................................................................................................1284 Failure Code [CA778].........................................................................................................1286 Failure Code [CA1117]........................................................................................................1291 Failure Code [CA1664]........................................................................................................1292 Failure Code [CA1669]........................................................................................................1295 Failure Code [CA1673]........................................................................................................1296 Failure Code [CA1677]........................................................................................................1297 Failure Code [CA1678]........................................................................................................1298 Failure Code [CA1682]........................................................................................................1299 Failure Code [CA1683]........................................................................................................1304 Failure Code [CA1684]........................................................................................................1306 Failure Code [CA1686]........................................................................................................1308 Failure Code [CA1691]........................................................................................................1309 Failure Code [CA1694]........................................................................................................1312 Failure Code [CA1695]........................................................................................................1315 Failure Code [CA1696]........................................................................................................1316 Failure Code [CA1712]........................................................................................................1318 Failure Code [CA1713]........................................................................................................1321 Failure Code [CA1714]........................................................................................................1323 Failure Code [CA1715]........................................................................................................1324 Failure Code [CA1776]........................................................................................................1325 Failure Code [CA1777]........................................................................................................1328 Failure Code [CA1843]........................................................................................................1331 Failure Code [CA1844]........................................................................................................1333 Failure Code [CA1879]........................................................................................................1336 Failure Code [CA1881]........................................................................................................1339 Failure Code [CA1883]........................................................................................................1341 Failure Code [CA1885]........................................................................................................1345 Failure Code [CA1887]........................................................................................................1347 Failure Code [CA1921]........................................................................................................1349 Failure Code [CA1922]........................................................................................................1352 Failure Code [CA1942]........................................................................................................1357 Failure Code [CA1993]........................................................................................................1358 Failure Code [CA2185]........................................................................................................1361 Failure Code [CA2186]........................................................................................................1363 Failure Code [CA2249]........................................................................................................1365 Failure Code [CA2271]........................................................................................................1366 Failure Code [CA2272]........................................................................................................1369 Failure Code [CA2288]........................................................................................................1372 Failure Code [CA2311]........................................................................................................1373 Failure Code [CA2349]........................................................................................................1374 Failure Code [CA2353]........................................................................................................1377 Failure Code [CA2357]........................................................................................................1379 Failure Code [CA2381]........................................................................................................1380 Failure Code [CA2382]........................................................................................................1383 Failure Code [CA2383]........................................................................................................1386 Failure Code [CA2386]........................................................................................................1389 Failure Code [CA2387]........................................................................................................1391 Troubleshooting Flowchart................................................................................................1395 Failure Code [CA2555]........................................................................................................1396 Failure Code [CA2556]........................................................................................................1399 Failure Code [CA2637]........................................................................................................1401 Failure Code [CA2639]........................................................................................................1403 Failure Code [CA2771]........................................................................................................1406 Failure Code [CA2777]........................................................................................................1412 Failure Code [CA2976]........................................................................................................1415 Failure Code [CA3133]........................................................................................................1417 Failure Code [CA3134]........................................................................................................1420 Failure Code [CA3135]........................................................................................................1422 Failure Code [CA3142]........................................................................................................1426 Failure Code [CA3143]........................................................................................................1427 Failure Code [CA3144]........................................................................................................1428 Failure Code [CA3146]........................................................................................................1430 Failure Code [CA3147]........................................................................................................1431 Failure Code [CA3148]........................................................................................................1432 Failure Code [CA3151]........................................................................................................1434 Failure Code [CA3165]........................................................................................................1440 Failure Code [CA3229]........................................................................................................1442 Failure Code [CA3231]........................................................................................................1444 Failure Code [CA3232]........................................................................................................1446 Failure Code [CA3235]........................................................................................................1450 Failure Code [CA3239]........................................................................................................1452 Failure Code [CA3241]........................................................................................................1455 Failure Code [CA3242]........................................................................................................1458 Failure Code [CA3251]........................................................................................................1461 Failure Code [CA3253]........................................................................................................1463 Failure Code [CA3254]........................................................................................................1466 Failure Code [CA3255]........................................................................................................1469 Failure Code [CA3256]........................................................................................................1473 Failure Code [CA3311]........................................................................................................1475 Failure Code [CA3312]........................................................................................................1477 Failure Code [CA3313]........................................................................................................1480 Failure Code [CA3314]........................................................................................................1481 Failure Code [CA3315]........................................................................................................1482 Failure Code [CA3316]........................................................................................................1485 Failure Code [CA3317]........................................................................................................1486 Failure Code [CA3318]........................................................................................................1487 Failure Code [CA3319]........................................................................................................1490 Failure Code [CA3321]........................................................................................................1491 Failure Code [CA3322]........................................................................................................1493 Failure Code [CA3419]........................................................................................................1496 Failure Code [CA3421]........................................................................................................1498 Failure Code [CA3497]........................................................................................................1500 Failure Code [CA3498]........................................................................................................1501 Failure Code [CA3543]........................................................................................................1502 Failure Code [CA3545]........................................................................................................1509 Failure Code [CA3547]........................................................................................................1511 Failure Code [CA3558]........................................................................................................1512 Failure Code [CA3559]........................................................................................................1514 Failure Code [CA3562]........................................................................................................1516 Failure Code [CA3563]........................................................................................................1518 Failure Code [CA3567]........................................................................................................1521 Failure Code [CA3568]........................................................................................................1524 Failure Code [CA3571]........................................................................................................1530 Failure Code [CA3572]........................................................................................................1532 Failure Code [CA3574]........................................................................................................1534 Failure Code [CA3575]........................................................................................................1536 Failure Code [CA3577]........................................................................................................1538 Failure Code [CA3578]........................................................................................................1540 Failure Code [CA3582]........................................................................................................1542 Failure Code [CA3583]........................................................................................................1550 Failure Code [CA3596]........................................................................................................1552 Failure Code [CA3649]........................................................................................................1555 Failure Code [CA3681]........................................................................................................1557 Failure Code [CA3682]........................................................................................................1562 Failure Code [CA3713]........................................................................................................1567 Failure Code [CA3717]........................................................................................................1570 Failure Code [CA3718]........................................................................................................1571 Failure Code [CA3725]........................................................................................................1572 Failure Code [CA3741]........................................................................................................1575 Failure Code [CA3748]........................................................................................................1576 Failure Code [CA3751]........................................................................................................1579 Failure Code [CA3755]........................................................................................................1581 Failure Code [CA3866]........................................................................................................1583 Failure Code [CA3867]........................................................................................................1587 Failure Code [CA3868]........................................................................................................1590 Failure Code [CA3899]........................................................................................................1594 Failure Code [CA3911]........................................................................................................1596 Failure Code [CA3912]........................................................................................................1600 Failure Code [CA3932]........................................................................................................1602 Failure Code [CA3933]........................................................................................................1604 Failure Code [CA3934]........................................................................................................1606 Failure Code [CA3935]........................................................................................................1609 Failure Code [CA3936]........................................................................................................1611 Failure Code [CA4151]........................................................................................................1613 Failure Code [CA4152]........................................................................................................1617 Failure Code [CA4155]........................................................................................................1621 Failure Code [CA4156]........................................................................................................1623 Failure Code [CA4157]........................................................................................................1626 Failure Code [CA4158]........................................................................................................1628 Failure Code [CA4159]........................................................................................................1629 Failure Code [CA4161]........................................................................................................1630 Failure Code [CA4162]........................................................................................................1633 Failure Code [CA4163]........................................................................................................1636 Failure Code [CA4164]........................................................................................................1638 Failure Code [CA4165]........................................................................................................1640 Failure Code [CA4166]........................................................................................................1642 Failure Code [CA4168]........................................................................................................1644 Failure Code [CA4169]........................................................................................................1647 Failure Code [CA4171]........................................................................................................1649 Failure Code [CA4249]........................................................................................................1652 Failure Code [CA4251]........................................................................................................1654 Failure Code [CA4259]........................................................................................................1656 Failure Code [CA4261]........................................................................................................1659 Failure Code [CA4277]........................................................................................................1661 Failure Code [CA4281]........................................................................................................1665 Failure Code [CA4459]........................................................................................................1668 Failure Code [CA4461]........................................................................................................1670 Failure Code [CA4658]........................................................................................................1673 Failure Code [CA4731]........................................................................................................1677 Failure Code [CA4732]........................................................................................................1678 Failure Code [CA4739]........................................................................................................1679 Failure Code [CA4768]........................................................................................................1680 Failure Code [CA4769]........................................................................................................1682 Failure Code [CA4842]........................................................................................................1685 Failure Code [CA4952] (Machine with KOMTRAX Terminal)........................................................................1689 Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1691 Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1693 Failure Code [CA5115]........................................................................................................1695 Failure Code [CA5179]........................................................................................................1698 Failure Code [CA5181]........................................................................................................1700 Failure Code [CA5383]........................................................................................................1702 Failure Code [D160KA]........................................................................................................1704 Failure Code [D160KB]........................................................................................................1706 Failure Code [D160KY]........................................................................................................1708 Failure Code [D19JKZ]........................................................................................................1710 Failure Code [D19KKZ]........................................................................................................1712 Failure Code [D1EHKA]........................................................................................................1715 Failure Code [D1EHKB]........................................................................................................1716 Failure Code [D1EHKY]........................................................................................................1717 Failure Code [D1FBKB]........................................................................................................1718 Failure Code [D5ZHL6]........................................................................................................1720 Failure Code [D811MC]........................................................................................................1722 Failure Code [D862KA]........................................................................................................1723 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)........................................................................1724 Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1726 Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1728 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)........................................................................1730 Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1732 Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1734 Failure Code [D8AQK4]........................................................................................................1736 Failure Code [D8AQKR]........................................................................................................1737 Failure Code [D8G1KT]........................................................................................................1739 Failure Code [D8G6KT]........................................................................................................1740 Failure Code [DAF0KT]........................................................................................................1741 Failure Code [DAF0MB]........................................................................................................1742 Failure Code [DAF0MC]........................................................................................................1743 Failure Code [DAF3KK]........................................................................................................1744 Failure Code [DAF8KB]........................................................................................................1746 Failure Code [DAFDKB]........................................................................................................1748 Failure Code [DAFGMC]........................................................................................................1750 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)........................................................................1751 Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1753 Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1755 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)........................................................................1757 Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1759 Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1761 Failure Code [DAFQKR]........................................................................................................1763 Failure Code [DAQ0KK]........................................................................................................1768 Failure Code [DAQ0KT]........................................................................................................1770 Failure Code [DAQ0MC]........................................................................................................1771 Failure Code [DAQ1KA]........................................................................................................1772 Failure Code [DAQ2KK]........................................................................................................1774 Failure Code [DAQ9KQ]........................................................................................................1776 Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)........................................................................1777 Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1779 Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1781 Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)........................................................................1783 Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)........................1785 Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)..........................1787 Failure Code [DAQQKR]........................................................................................................1789 Failure Code [DAQRKR]........................................................................................................1790 Failure Code [DAQRMA]........................................................................................................1791 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)........................................................................1792 Failure Code [DB2QKR] (Machine with Gateway Function Controller).............................................................1797 Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)........................................................................1802 Failure Code [DB2RKR] (Machine with Gateway Function Controller).............................................................1807 Failure Code [DD1PKB]........................................................................................................1812 Failure Code [DD1QKB]........................................................................................................1814 Failure Code [DDAAL6]........................................................................................................1816 Failure Code [DDB6L4]........................................................................................................1818 Failure Code [DDTHKA]........................................................................................................1822 Failure Code [DDTJKA]........................................................................................................1823 Failure Code [DDTKKA]........................................................................................................1824 Failure Code [DDTLKA]........................................................................................................1825 Failure Code [DDTMKA]........................................................................................................1826 Failure Code [DDTNKA]........................................................................................................1827 Failure Code [DDTPKA]........................................................................................................1828 Failure Code [DF10KA]........................................................................................................1829 Failure Code [DF10L4]........................................................................................................1833 Failure Code [DGF1KX]........................................................................................................1837 Failure Code [DGH2KB]........................................................................................................1839 Failure Code [DGT1KX]........................................................................................................1841 Failure Code [DGT7KB]........................................................................................................1843 Failure Code [DHA4KA]........................................................................................................1845 Failure Code [DHAAMA]........................................................................................................1847 Failure Code [DHACMA]........................................................................................................1849 Failure Code [DHT8KA]........................................................................................................1851 Failure Code [DHT8KB]........................................................................................................1853 Failure Code [DHT8ZG]........................................................................................................1855 Failure Code [DJF1KA]........................................................................................................1856 Failure Code [DK70KX]........................................................................................................1858 Failure Code [DKD0KX]........................................................................................................1860 Failure Code [DLF1KA]........................................................................................................1862 Failure Code [DLF1LC]........................................................................................................1864 Failure Code [DLF2KA]........................................................................................................1866 Failure Code [DLF2LC]........................................................................................................1868 Failure Code [DLM3KA]........................................................................................................1870 Failure Code [DLM3LC]........................................................................................................1872 Failure Code [DLM3MB]........................................................................................................1873 Failure Code [DLT3KA]........................................................................................................1874 Failure Code [DPQ1KR]........................................................................................................1876 Failure Code [DPQ2KR]........................................................................................................1878 Failure Code [DPQ3KR]........................................................................................................1881 Failure Code [DV00KB]........................................................................................................1884 Failure Code [DW4BKA]........................................................................................................1886 Failure Code [DW4BKB]........................................................................................................1888 Failure Code [DW4BKY]........................................................................................................1890 Failure Code [DW7BKA]........................................................................................................1892 Failure Code [DW7BKB]........................................................................................................1894 Failure Code [DW7BKY]........................................................................................................1896 Failure Code [DX16KA]........................................................................................................1898 Failure Code [DX16KB]........................................................................................................1900 Failure Code [DX16KY]........................................................................................................1902 Failure Code [DXH1KA]........................................................................................................1904 Failure Code [DXH1KB]........................................................................................................1906 Failure Code [DXH1KY]........................................................................................................1908 Failure Code [DXH2KA]........................................................................................................1910 Failure Code [DXH2KB]........................................................................................................1912 Failure Code [DXH2KY]........................................................................................................1914 Failure Code [DXH3KA]........................................................................................................1916 Failure Code [DXH3KB]........................................................................................................1918 Failure Code [DXH3KY]........................................................................................................1920 Failure Code [DXH4KA]........................................................................................................1922 Failure Code [DXH4KB]........................................................................................................1924 Failure Code [DXH4KY]........................................................................................................1926 Failure Code [DXH5KA]........................................................................................................1928 Failure Code [DXH5KB]........................................................................................................1930 Failure Code [DXH5KY]........................................................................................................1932 Failure Code [DXH6KA]........................................................................................................1934 Failure Code [DXH6KB]........................................................................................................1936 Failure Code [DXH6KY]........................................................................................................1938 Failure Code [DXH7KA]........................................................................................................1940 Failure Code [DXH7KB]........................................................................................................1942 Failure Code [DXH7KY]........................................................................................................1944 Failure Code [DXHHKA]........................................................................................................1946 Failure Code [DXHHKB]........................................................................................................1948 Failure Code [DXHHKY]........................................................................................................1950 Failure Code [F313KA]........................................................................................................1952 Failure Code [F313KB]........................................................................................................1954 Failure Code [F314KA]........................................................................................................1955 Failure Code [F314KB]........................................................................................................1957 Failure Code [F315KB]........................................................................................................1959 Failure Code [F315KY]........................................................................................................1961 Failure Code [F316KB]........................................................................................................1963 Failure Code [F316KY]........................................................................................................1965 Failure Code [F318KB]........................................................................................................1967 Failure Code [F318KY]........................................................................................................1969 Failure Code [F31AKB]........................................................................................................1970 Failure Code [F31AKY]........................................................................................................1972 Failure Code [F31BKB]........................................................................................................1974 Failure Code [F31BKY]........................................................................................................1976 Failure Code [F31CKB]........................................................................................................1978 Failure Code [F31CKY]........................................................................................................1980 Failure Code [F31DKB]........................................................................................................1982 Failure Code [F31DKY]........................................................................................................1984 Failure Code [F31EKB]........................................................................................................1986 Failure Code [F31EKY]........................................................................................................1988 Failure Code [FS10ZE]........................................................................................................1990 Troubleshooting of Electrical System (E-Mode)....................................................................................1991 Engine Does Not Start (Engine Does Not Crank)................................................................................1991 Manual Preheating System Does Not Operate....................................................................................1999 Automatic Preheating System Does Not Operate.................................................................................2002 While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On.....................................................2005 Engine Coolant Temperature Gauge Does Not Show Correct Temperature...........................................................2007 LCD Unit and LED Unit on Machine Monitor Do Not Show Anything................................................................2009 LCD Unit on Machine Monitor Shows Nothing....................................................................................2012 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)........................................2015 LCD Screen on Machine Monitor Does Not Show Correctly........................................................................2018 LED Unit Lamp on Machine Monitor is Abnormal.................................................................................2021 Switch of Switch Panel on Machine Monitor Does Not Operate...................................................................2023 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate...................................................2026 Switch Panel Buzzer of Machine Monitor is Abnormal...........................................................................2029 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally.............................................2032 DEF Level is Not Shown Correctly.............................................................................................2033 Rearview Monitor Does Not Come On or Backlight Flickers......................................................................2036 Rearview Monitor Images are Not Shown Clearly................................................................................2038 Rearview Monitor Brightness Cannot be Adjusted...............................................................................2041 Night Mode Lamp of Rearview Monitor is Abnormal..............................................................................2044 Air Cleaner Clogging Caution Lamp Does Not Come On...........................................................................2046 Radiator Coolant Level Caution Lamp Does Not Come On.........................................................................2047 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low............................2049 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low.............................2050 Speedometer Does Not Show Normally...........................................................................................2051 Engine Tachometer Does Not Show Normally.....................................................................................2053 Fuel Gauge Does Not Show Normally............................................................................................2055 Torque Converter Oil Temperature Gauge Does Not Show Normally................................................................2057 Articulation Indicator Does Not Show Actual Articulated Angle................................................................2059 Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On.....................2062 Seatbelt Caution Lamp Does Not Show Normally.................................................................................2064 Alarm Buzzer Does Not Operate................................................................................................2065 Alarm Buzzer Does Not Stop...................................................................................................2067 Engine Mode Selector Function Does Not Operate Correctly.....................................................................2068 Transmission Selector Function Does Not Operate Normally.....................................................................2070 Differential Lock Function Does Not Operate or Cannot be Cancelled...........................................................2072 Lock by Lifter Lock Pin Cannot be Done or Cannot be Cancelled................................................................2075 Lifter Lock Pin Pilot Lamp Does Not Show Correctly...........................................................................2077 Blade Accumulator Function Does Not Operate or Cannot be Cancelled...........................................................2078 Blade Accumulator Pilot Lamp Does Not Show Correctly.........................................................................2081 Horn Does Not Sound..........................................................................................................2083 Horn Does Not Stop...........................................................................................................2085 Backup Alarm Does Not Sound..................................................................................................2087 Backup Alarm Continues to Sound and Backup Lamp Keeps Lit....................................................................2088 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On.......................................................................2089 Headlamp Does Not Come On or Go Out..........................................................................................2091 Headlamp Selection (Low or High Beam) Cannot be Done.........................................................................2094 Headlamp (High Beam) Does Not Come On........................................................................................2098 Front Working Lamp Does Not Come On or Go Out................................................................................2099 Working Lamp Pilot Lamp Does Not Come On or Go Out...........................................................................2103 Rear Working Lamp Does Not Come On or Go Out.................................................................................2105 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out....................................................................2109 Turn Signal Lamp Does Not Come On or Go Out..................................................................................2114 Hazard Lamp Does Not Come On or Go Out.......................................................................................2117 Turn Signal Lamp Does Not Come On or Go Off..................................................................................2121 Brake Lamp Does Not Come On or Stays Lit.....................................................................................2122 Backup Lamp Does Not Come On.................................................................................................2125 No Wiper Operates............................................................................................................2129 Front Wiper Does Not Operate.................................................................................................2131 Rear Wiper Does Not Operate..................................................................................................2135 Right and Left Door Wipers Do Not Operate....................................................................................2139 Left Door Wiper Does Not Operate.............................................................................................2142 Right Door Wiper Does Not Operate............................................................................................2145 Front or Door Washer Does Not Operate........................................................................................2148 Rear Washer Does Not Operate.................................................................................................2151 KOMTRAX System Does Not Operate Correctly....................................................................................2153 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)....................................................................2154 Information Shown in Troubleshooting Table (H-Mode)..........................................................................2154 Failure Mode and Cause Table.................................................................................................2155 Machine Does Not Start.......................................................................................................2164 Lockup is Not Released.......................................................................................................2165 Torque Converter Lockup Clutch Does Not Engage...............................................................................2166 Machine Does Not Upshift or Downshift from Neutral...........................................................................2167 Machine Does Not Upshift or Downshift........................................................................................2168 Travel Speed or Power is Low.................................................................................................2170 Travel Speed or Power is Low in Specified Gear...............................................................................2172 Time Lag is Large When You Start Machine or Shift Gears......................................................................2174 Torque Converter Oil Temperature is High.....................................................................................2176 Differential Lock Function Does Not Operate or Cannot be Cancelled...........................................................2178 Unusual Noise is Heard from Around Hydraulic Pump............................................................................2179 Engine Speed Drops Largely or Engine Stops...................................................................................2180 Steering Wheel is Disabled...................................................................................................2181 Steering Speed or Power is Not Sufficient....................................................................................2182 Steering Wheel Does Not Move or is Heavy to Operate..........................................................................2183 Wheel Brakes Do Not Operate or are Weak......................................................................................2184 Wheel Brakes are Not Released or Drag........................................................................................2185 Parking Brake Does Not Operate or is Weak....................................................................................2186 Parking Brake is Not Released or Drags.......................................................................................2187 Lifter Lock Pin is Not Locked or Not Cancelled...............................................................................2188 All Work Equipment Operate Slowly............................................................................................2189 All Work Equipment Do Not Operate............................................................................................2191 Blade Lift Speed or Power is Low.............................................................................................2192 Drawbar Side-Shift Speed or Power is Low.....................................................................................2193 Blade Side-Shift Speed or Power is Low.......................................................................................2194 Power Tilt Speed or Power is Low.............................................................................................2195 Articulate Speed or Power is Low.............................................................................................2196 Leaning Speed or Power is Low................................................................................................2197 Hydraulic Drift of Blade Lift is Large.......................................................................................2198 Hydraulic Drift of Leaning is Large..........................................................................................2199 Blade Does Not Rotate........................................................................................................2200 Blade Accumulator Function Does Not Operate or Cannot be Cancelled...........................................................2201 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)..................................................................2202 Unusual Noise is Heard from Around Fan.......................................................................................2203 Troubleshooting of Engine (S-Mode)...............................................................................................2204 Information Shown in Troubleshooting Table (S-Mode)..........................................................................2204 Engine Does Not Crank When Starting Switch is Turned to Start Position.......................................................2205 Engine Cranks but No Exhaust Smoke Comes Out.................................................................................2206 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)......................................2207 Engine Startability is Unsatisfactory........................................................................................2209 Engine Does Not Pick Up Smoothly.............................................................................................2211 Engine Stops During Operation................................................................................................2213 Engine Does Not Rotate Smoothly..............................................................................................2215 Engine Lacks Output (or Lacks Power).........................................................................................2216 KDPF Becomes Clogged in a Short Time.........................................................................................2218 Engine Oil Consumption is Excessive..........................................................................................2220 Engine Oil Becomes Dirty Quickly.............................................................................................2221 Fuel Consumption is Excessive................................................................................................2222 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)........................................................2223 Engine Oil Pressure Drops....................................................................................................2224 Fuel Mixes Into Engine Oil...................................................................................................2226 Water Mixes Into Engine Oil (Milky)..........................................................................................2227 Coolant Temperature Increases Too High (Overheat)............................................................................2228 Unusual Noise is Heard.......................................................................................................2229 Vibration is Excessive.......................................................................................................2230 Air Cannot be Bled from Fuel Circuit.........................................................................................2231 Active Regeneration is Done Frequently.......................................................................................2232 Active Regeneration Continues Long...........................................................................................2234 White Smoke is Exhausted During Active Regeneration..........................................................................2235 DEF Consumption is Excessive.................................................................................................2236 There is an Unusual Smell (Irritating Odor)..................................................................................2238 Foreign Materials Enter DEF (DEF Increases)..................................................................................2239 50 Disassembly and Assembly..........................................................................................................2241 Table of Contents................................................................................................................2242 Precautions Before Work..........................................................................................................2247 Abbreviation List................................................................................................................2248 Related Information on Disassembly and Assembly..................................................................................2254 How to Read This Manual......................................................................................................2254 Coating Materials List.......................................................................................................2255 Special Tool List............................................................................................................2260 Sketches of Special Tools....................................................................................................2279 Engine and Cooling System........................................................................................................2312 Remove and Install Supply Pump Assembly......................................................................................2312 Remove Supply Pump Assembly..............................................................................................2312 Install Supply Pump Assembly.............................................................................................2315 Remove and Install Injector Assembly.........................................................................................2319 How to Remove Injector Assembly..........................................................................................2319 How to Install Injector Assembly.........................................................................................2323 Remove and Install Cylinder Head Assembly....................................................................................2330 How to Remove Cylinder Head Assembly.....................................................................................2330 How to Install Cylinder Head Assembly....................................................................................2339 Remove and Install EGR Valve Assembly........................................................................................2353 Remove EGR Valve Assembly................................................................................................2353 Install EGR Valve Assembly...............................................................................................2354 Remove and Install EGR Cooler Assembly.......................................................................................2357 How to Remove EGR Cooler Assembly........................................................................................2357 How to Install EGR Cooler Assembly.......................................................................................2360 Remove and Install Starter Assembly..........................................................................................2363 Remove Starting Motor Assembly...........................................................................................2363 Install Starting Motor Assembly..........................................................................................2365 Remove and Install Alternator Belt...........................................................................................2368 Remove Alternator Belt...................................................................................................2368 Install Alternator Belt..................................................................................................2371 Remove and Install Automatic Tensioner.......................................................................................2375 Remove Automatic Tensioner...............................................................................................2375 Install Automatic Tensioner..............................................................................................2375 Remove and Install Radiator Assembly.........................................................................................2376 How to Remove Radiator Assembly..........................................................................................2376 How to Install Radiator Assembly.........................................................................................2382 Remove and Install Aftercooler Assembly......................................................................................2388 Remove Aftercooler Assembly..............................................................................................2388 Install Aftercooler Assembly.............................................................................................2391 Remove and Install Power Train Oil Cooler Assembly...........................................................................2395 How to Remove Power Train Oil Cooler Assembly............................................................................2395 How to Install Power Train Oil Cooler Assembly...........................................................................2399 Remove and Install Cooling Fan Motor Assembly................................................................................2403 Remove Cooling Fan Motor Assembly........................................................................................2403 Install Cooling Fan Motor Assembly.......................................................................................2407 Remove and Install Engine, Torque Converter, and Transmission Assembly.......................................................2411 Remove Engine, Torque Converter, and Transmission Assembly...............................................................2411 Install Engine, Torque Converter, and Transmission Assembly..............................................................2420 Disconnect and Connect Engine, Torque Converter, and Transmission Assembly...................................................2429 Disconnect Engine, Torque Converter, and Transmission Assembly...........................................................2429 Connect Engine, Torque Converter, and Transmission Assembly..............................................................2430 Remove and Install Engine Front Oil Seal.....................................................................................2432 How to Remove Engine Front Oil Seal......................................................................................2432 How to Install Engine Front Oil Seal.....................................................................................2434 Remove and Install Engine Rear Oil Seal......................................................................................2436 How to Remove Engine Rear Oil Seal.......................................................................................2436 How to Install Engine Rear Oil Seal......................................................................................2437 Remove and Install Engine Hood Assembly......................................................................................2441 How to Remove Engine Hood Assembly.......................................................................................2441 How to Install Engine Hood Assembly......................................................................................2445 Remove and Install Fuel Tank Assembly........................................................................................2449 Remove Fuel Tank Assembly................................................................................................2449 Install Fuel Tank Assembly...............................................................................................2455 Remove and Install DEF Tank Assembly.........................................................................................2461 How to Remove DEF Tank Assembly..........................................................................................2461 How to Install DEF Tank Assembly.........................................................................................2467 Remove and Install DEF Tank Sensor Flange Assembly...........................................................................2473 How to Remove DEF Tank Sensor Flange Assembly............................................................................2473 How to Install DEF Tank Sensor Flange Assembly...........................................................................2478 Remove and Install DEF Tank Sensor...........................................................................................2483 Remove DEF Tank Sensor...................................................................................................2483 Install DEF Tank Sensor..................................................................................................2484 Remove and Install DEF Tank Strainer.........................................................................................2491 Remove DEF Tank Strainer.................................................................................................2491 Install DEF Tank Strainer................................................................................................2491 Remove and Install KDPF Assembly.............................................................................................2492 How to Remove KDPF Assembly..............................................................................................2493 How to Install KDPF Assembly.............................................................................................2500 Disassemble and Assemble KDPF Assembly.......................................................................................2511 Disassemble KDPF Assembly................................................................................................2511 Assemble KDPF Assembly...................................................................................................2515 Remove and Install SCR Assembly..............................................................................................2520 How to Remove SCR Assembly...............................................................................................2520 How to Install SCR Assembly..............................................................................................2524 Remove and Install KDPF and SCR Assembly.....................................................................................2531 How to Remove KDPF and SCR Assembly......................................................................................2531 Install KDPF and SCR Assembly............................................................................................2539 Remove and Install KCCV Assembly.............................................................................................2549 Remove KCCV Assembly.....................................................................................................2549 Install KCCV Assembly....................................................................................................2551 Remove and Install DEF Mixing Tube...........................................................................................2553 Remove DEF Mixing Tube...................................................................................................2553 Install DEF Mixing Tube..................................................................................................2556 Remove and Install DEF Injector..............................................................................................2560 Remove DEF Injector......................................................................................................2560 Install DEF Injector.....................................................................................................2564 Remove and Install DEF Pump..................................................................................................2568 Remove DEF Pump..........................................................................................................2568 Install DEF Pump.........................................................................................................2571 Remove and Install DEF Hose..................................................................................................2574 Remove DEF Hose..........................................................................................................2574 Install DEF Hose.........................................................................................................2582 Remove and Install Air Cleaner Assembly......................................................................................2590 Remove Air Cleaner Assembly..............................................................................................2590 Install Air Cleaner Assembly.............................................................................................2590 Remove and Install Air Conditioner Compressor Assembly.......................................................................2592 Remove Air Conditioner Compressor Assembly...............................................................................2592 How to Install Air Conditioner Compressor Assembly.......................................................................2594 Remove and Install Air Conditioner Condenser Assembly........................................................................2597 How to Remove Air Conditioner Condenser Assembly.........................................................................2597 How to Install Air Conditioner Condenser Assembly........................................................................2598 Power Train......................................................................................................................2600 Disassemble and Assemble Torque Converter Assembly...........................................................................2600 How to Disassemble Torque Converter Assembly.............................................................................2601 How to Assemble Torque Converter Assembly................................................................................2605 Disassemble and Assemble Transmission Assembly...............................................................................2612 How to Disassemble Transmission Assembly.................................................................................2614 How to Assemble Transmission Assembly....................................................................................2632 Remove and Install Tandem Drive and Final Drive Assembly.....................................................................2657 How to Remove Tandem Drive and Final Drive Assembly......................................................................2658 How to Install Tandem Drive and Final Drive Assembly.....................................................................2662 Disassemble and Assemble Tandem Drive Assembly...............................................................................2667 How to Disassemble Tandem Drive Assembly.................................................................................2667 How to Assemble Tandem Drive Assembly....................................................................................2671 Disassemble and Assemble Differential Assembly...............................................................................2678 How to Disassemble Differential Assembly.................................................................................2679 How to Assemble Differential Assembly....................................................................................2684 Disassemble and Assemble Final Drive Assembly................................................................................2694 How to Disassemble Final Drive Assembly..................................................................................2695 How to Assemble Final Drive Assembly.....................................................................................2700 Steering System..................................................................................................................2709 Remove and Install Steering Valve Assembly...................................................................................2709 Remove Steering Valve Assembly...........................................................................................2709 Install Steering Valve Assembly..........................................................................................2715 Brake System.....................................................................................................................2721 Disassemble and Assemble Wheel Brake Assembly................................................................................2721 How to Disassemble Wheel Brake Assembly..................................................................................2722 How to Assemble Wheel Brake Assembly.....................................................................................2725 Undercarriage and Frame..........................................................................................................2734 Remove and Install Center Hinge Pin..........................................................................................2734 Remove Center Hinge Pin..................................................................................................2734 Install Center Hinge Pin.................................................................................................2744 Hydraulic System.................................................................................................................2755 Remove and Install Hydraulic Tank, Battery and Frame Assembly................................................................2755 How to Remove Hydraulic Tank, Battery and Frame Assembly.................................................................2755 How to Install Hydraulic Tank, Battery and Frame Assembly................................................................2763 Remove and Install Hydraulic Tank Assembly...................................................................................2772 Remove Hydraulic Tank Assembly...........................................................................................2772 How to Install Hydraulic Tank Assembly...................................................................................2779 Remove and Install Cooling Fan Pump Assembly.................................................................................2787 Remove Cooling Fan Pump Assembly.........................................................................................2787 Install Cooling Fan Pump Assembly........................................................................................2788 Remove and Install Control Valve Assembly....................................................................................2790 How to Remove Control Valve Assembly.....................................................................................2790 How to Install Control Valve Assembly....................................................................................2793 Work Equipment...................................................................................................................2797 Remove and Install Ripper Assembly...........................................................................................2797 Remove Ripper Assembly...................................................................................................2798 Install Ripper Assembly..................................................................................................2800 Remove and Install Blade Assembly............................................................................................2804 Remove Blade Assembly....................................................................................................2804 Install Blade Assembly...................................................................................................2805 Remove and Install Circle and Drawbar Assembly...............................................................................2807 How to Remove Circle and Drawbar Assembly................................................................................2807 How to Install Circle and Drawbar Assembly...............................................................................2809 Remove and Install Circle Rotation Gear Assembly.............................................................................2812 How to Remove Circle Rotation Gear Assembly..............................................................................2812 How to Install Circle Rotation Gear Assembly.............................................................................2814 Disassemble and Assemble Circle Rotation Gear Assembly.......................................................................2816 How to Disassemble Circle Rotation Gear Assembly.........................................................................2816 How to Assemble Circle Rotation Gear Assembly............................................................................2818 Disassemble and Assemble Work Equipment Cylinder Assembly....................................................................2823 How to Disassemble Work Equipment Cylinder Assembly......................................................................2824 How to Assemble Work Equipment Cylinder Assembly.........................................................................2827 CAB Related Parts................................................................................................................2832 Remove and Install Operator Cab Assembly.....................................................................................2832 How to Remove Operator Cab Assembly......................................................................................2832 Install Operator CAB Assembly............................................................................................2841 Remove and Install Operator Cab Door.........................................................................................2851 Remove Operator Cab Door.................................................................................................2851 Install Operator Cab Door................................................................................................2852 Remove and Install Operator Cab Glass (Adhered Glass)........................................................................2857 Remove Operator CAB Glass (Adhered Glass)................................................................................2861 Install Operator CAB Glass (Adhered Glass)...............................................................................2861 Remove and Install Floor Frame Assembly......................................................................................2871 How to Remove Floor Frame Assembly.......................................................................................2871 How to Install Floor Frame Assembly......................................................................................2875 Remove and Install Air Conditioner Unit Assembly.............................................................................2880 Remove Air Conditioner Unit Assembly.....................................................................................2880 Install Air Conditioner Unit Assembly....................................................................................2885 Remove and Install Operator Seat.............................................................................................2891 Remove Operator's Seat...................................................................................................2891 Install Operator's Seat..................................................................................................2892 How to Remove and Install Seat Belt..........................................................................................2894 How to Remove Seat Belt..................................................................................................2894 How to Install Seatbelt..................................................................................................2895 Electrical System................................................................................................................2896 Remove and Install Engine Controller Assembly................................................................................2896 How to Remove Engine Controller Assembly.................................................................................2896 How to Install Engine Controller Assembly................................................................................2899 Remove and Install Transmission Controller Assembly..........................................................................2902 Remove Transmission Controller Assembly..................................................................................2902 Install Transmission Controller Assembly.................................................................................2903 Remove and Install Machine Monitor Assembly..................................................................................2904 Remove Machine Monitor Assembly..........................................................................................2904 Install Machine Monitor Assembly.........................................................................................2905 Remove and Install Mass Air Flow and Temperature Sensor......................................................................2907 How to Remove Mass Air Flow and Temperature Sensor.......................................................................2907 How to Install Mass Air Flow and Temperature Sensor......................................................................2909 Remove and Install KCCV Crankcase Pressure Sensor............................................................................2912 How to Remove KCCV Crankcase Pressure Sensor.............................................................................2912 How to Install KCCV Crankcase Pressure Sensor............................................................................2914 Remove and Install KDPF Temperature Sensor...................................................................................2916 How to Remove KDPF Temperature Sensor....................................................................................2916 How to Install KDPF Temperature Sensor...................................................................................2919 Remove and Install KDPF Differential Pressure Sensor.........................................................................2923 How to Remove KDPF Differential Pressure Sensor..........................................................................2923 How to Install KDPF Differential Pressure Sensor.........................................................................2927 Remove and Install SCR Temperature Sensor....................................................................................2931 How to Remove SCR Temperature Sensor.....................................................................................2931 How to Install SCR Temperature Sensor....................................................................................2934 Remove and Install Ammonia Sensor............................................................................................2938 How to Remove Ammonia Sensor.............................................................................................2938 How to Install Ammonia Sensor............................................................................................2940 Remove and Install SCR Outlet NOx Sensor.....................................................................................2943 How to Remove SCR Outlet NOx Sensor......................................................................................2943 How to Install SCR Outlet NOx Sensor.....................................................................................2946 Remove and Install KOMTRAX Terminal Assembly.................................................................................2949 Remove KOMTRAX Terminal Assembly.........................................................................................2949 Install KOMTRAX Terminal Assembly........................................................................................2950 Remove and Install Gateway Function Controller Assembly......................................................................2952 How to Remove Gateway Function Controller Assembly.......................................................................2952 How to Install Gateway Function Controller Assembly......................................................................2953 Remove and Install Communication Terminal....................................................................................2955 How to Remove Communication Terminal.....................................................................................2955 How to Install Communication Terminal....................................................................................2956 60 Maintenance Standard..............................................................................................................2959 Table of Contents................................................................................................................2960 Abbreviation List................................................................................................................2961 Engine and Cooling System........................................................................................................2967 Maintenance Standard for Engine Mount........................................................................................2967 Maintenance Standard for Cooling System......................................................................................2968 Maintenance Standard for Cooling Fan Motor...................................................................................2969 Power Train......................................................................................................................2971 Maintenance Standard for Drive Shaft.........................................................................................2971 Maintenance Standard for Torque Converter....................................................................................2972 Maintenance Standard for Lockup Clutch ECMV..................................................................................2974 Maintenance Standard for Transmission........................................................................................2975 Maintenance Standard for FL, R Clutch....................................................................................2981 Maintenance Standard for FH, 1st Clutch..................................................................................2983 Maintenance Standard for 2nd, 3rd Clutch.................................................................................2985 Maintenance Standard for 4th Clutch......................................................................................2986 Maintenance Standard for Transmission Control Valve..........................................................................2987 Maintenance Standard for F, R, 1st, 2nd, 3rd, 4th Clutch ECMV................................................................2988 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve.................................................2989 Maintenance Standard for Front Axle..........................................................................................2990 Maintenance Standard for Rear Axle...........................................................................................2993 Maintenance Standard for Differential........................................................................................2994 Maintenance Standard for Final Drive.........................................................................................2996 Maintenance Standard for Tandem Drive........................................................................................2998 Steering System..................................................................................................................2999 Maintenance Standard for Steering Cylinder...................................................................................2999 Brake System.....................................................................................................................3000 Maintenance Standard for Slack Adjuster......................................................................................3000 Maintenance Standard for Brake...............................................................................................3001 Undercarriage and Frame..........................................................................................................3002 Maintenance Standard for Frame and Center Hinge Pin..........................................................................3002 Hydraulic System.................................................................................................................3003 Maintenance Standard for Hydraulic Tank......................................................................................3003 Maintenance Standard for Steering and Work Equipment Pump....................................................................3004 Maintenance Standard for Servo Valve of Steering and Work Equipment Pump.................................................3007 Maintenance Standard for Power Train Pump and Differential Lock Pump.........................................................3009 Maintenance Standard for Control Valve.......................................................................................3010 Maintenance Standard for Differential Lock Solenoid Valve....................................................................3020 Maintenance Standard for Parking Brake Solenoid Valve and Lifter Lock Pin Control Valve......................................3021 Work Equipment...................................................................................................................3022 Maintenance Standard for Circle and Drawbar..................................................................................3022 Maintenance Standard for Blade...............................................................................................3024 Maintenance Standard for Lifter..............................................................................................3026 Maintenance Standard for Circle Rotation Gear................................................................................3027 Maintenance Standard for Blade Lift Cylinder.................................................................................3028 Maintenance Standard for Blade Side Shift Cylinder...........................................................................3029 Maintenance Standard for Leaning Cylinder....................................................................................3030 Maintenance Standard for Articulate Cylinder.................................................................................3031 Maintenance Standard for Drawbar Side Shift Cylinder.........................................................................3032 Maintenance Standard for Blade Power Tilt Cylinder...........................................................................3033 80 Appendix..........................................................................................................................3035 Table of Contents................................................................................................................3036 Precautions Before Work..........................................................................................................3038 Abbreviation List................................................................................................................3039 Air Conditioner System...........................................................................................................3045 Precautions for Refrigerant..................................................................................................3045 Air Conditioner Component....................................................................................................3046 Specifications of Air Conditioner............................................................................................3049 Structure and Function of Refrigeration Cycle................................................................................3050 Outline of Refrigeration Cycle...............................................................................................3051 Component Parts of Air Conditioner System........................................................................................3053 Air Conditioner Unit.........................................................................................................3053 Configuration Diagram of Air Conditioner Unit............................................................................3053 Function of Air Conditioner Unit.........................................................................................3055 Component Parts of Air Conditioner Unit......................................................................................3056 Function of Evaporator as Air Conditioner Unit Component.................................................................3056 Function of Heater Core as Air Conditioner Unit Component................................................................3056 Function of Air Mix Servo Motor as Air Conditioner Unit Component........................................................3056 Function of Blower Fan and Blower Motor as Air Conditioner Unit Component................................................3056 Function of Fresh/Recirc Air Changeover Servo Motor as Air Conditioner Unit Component....................................3056 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component..............................................3056 Function of Expansion Valve as Air Conditioner Unit Component............................................................3056 Function of Dual Pressure Switch.........................................................................................3057 Compressor...................................................................................................................3058 Structure of Compressor..................................................................................................3058 Specifications of Compressor.............................................................................................3058 Function of Compressor...................................................................................................3058 Condenser....................................................................................................................3059 Structure of Condenser...................................................................................................3059 Specifications of Condenser..............................................................................................3059 Function of Condenser....................................................................................................3059 Receiver Drier...............................................................................................................3060 Structure of Receiver Dryer..............................................................................................3060 Specifications of Receiver Dryer.........................................................................................3060 Function of Receiver Dryer...............................................................................................3060 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner......................................................3061 Circuit Diagram and Configuration of Connector Pins of Air Conditioner...........................................................3063 System Diagram of Air Conditioner................................................................................................3065 Input and Output Signals of Air Conditioner Control Panel....................................................................3066 Structure of Air Conditioner Control Panel...............................................................................3067 Function of Air Conditioner Control Panel................................................................................3068 Locations of Air Conditioner Parts and Layout of Connectors......................................................................3069 Examine Air Leakage (Duct).......................................................................................................3074 How to Examine Air Leakage (Duct)............................................................................................3074 Examine Air Conditioner with Self-Diagnosis Function.............................................................................3076 Examine Temperature Control Function.............................................................................................3078 How to Examine Temperature Control Function..................................................................................3078 Examine Fresh/Recirc Air Changeover..............................................................................................3079 How to Examine Fresh/Recirc Air Changeover...................................................................................3079 Examine Evaporator Temperature Sensor............................................................................................3080 How to Examine Evaporator Temperature Sensor.................................................................................3080 Examine Relay....................................................................................................................3081 How to Examine Relay.........................................................................................................3081 Examine Blower Amplifier.........................................................................................................3083 How to Examine Blower Amplifier..............................................................................................3083 Air Conditioner Troubleshooting Chart 1..........................................................................................3085 Air Conditioner Troubleshooting Chart 2..........................................................................................3086 Information Shown in Troubleshooting Table.......................................................................................3089 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).......................................................3090 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)........................................................3093 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...............................................3096 Troubleshooting for Temperature Control Function.................................................................................3099 Troubleshooting for Fresh/Recirc Air Changeover..................................................................................3102 Troubleshooting for Hot Water Cut Valve..........................................................................................3105 Troubleshooting by Gauge Pressure................................................................................................3107 Connect Service Tool.............................................................................................................3110 How to Connect Service Tool..................................................................................................3111 Precautions for Disconnection and Connection of Air Conditioner Piping...........................................................3112 Handle Compressor Oil............................................................................................................3114 90 Circuit Diagrams..................................................................................................................3117 Table of Contents................................................................................................................3118 Abbreviation List................................................................................................................3120 Hydraulic Circuit Diagram........................................................................................................3126 Symbols Used in Hydraulic Circuit Diagram....................................................................................3126 Hydraulic Circuit Diagram (1/2)..............................................................................................3131 Hydraulic Circuit Diagram (2/2)..............................................................................................3133 Power Train Hydraulic Circuit Diagram........................................................................................3135 Electrical Circuit Diagram.......................................................................................................3137 Symbols Used in Electric Circuit Diagram.....................................................................................3137 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/12)............................................................3141 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/12)............................................................3143 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/12)............................................................3145 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/12)............................................................3147 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/12)............................................................3149 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/12)............................................................3151 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/12)............................................................3153 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/12)............................................................3155 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/12)............................................................3157 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/12)...........................................................3159 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/12)...........................................................3161 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/12)...........................................................3163 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (1/15)............3165 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (2/15)............3167 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (3/15)............3169 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (4/15)............3171 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (5/15)............3173 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (6/15)............3175 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (7/15)............3177 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (8/15)............3179 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (9/15)............3181 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (10/15)...........3183 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (11/15)...........3185 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (12/15)...........3187 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (13/15)...........3189 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (14/15)...........3191 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (15/15)...........3193 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (1/16)..............3195 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (2/16)..............3197 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (3/16)..............3199 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (4/16)..............3201 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (5/16)..............3203 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (6/16)..............3205 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (7/16)..............3207 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (8/16)..............3209 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (9/16)..............3211 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (10/16).............3213 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (11/16).............3215 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (12/16).............3217 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (13/16).............3219 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (14/16).............3221 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (15/16).............3223 Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up) (16/16).............3225 Index.................................................................................................................................3227
DESCRIPTION:
KOMATSU GD655-6 GD675-6 MOTOR GRADER SHOP MANUAL SEN06523-14 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode. 00 Index and Foreword How to Read the Shop Manual GD655-6, GD675-6 00-27
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 29/12/24
