Komatsu Motor Graders GD705, GD705A Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD705, GD705A, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD705, GD705A workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,451 + 429 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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SEN06489-03 - Motor Grader GD705-5 Shop Manual.pdf
MAIN SECTIONS
Cover...1
Notice of revision...3
00 Index and foreword...11
Foreword and general information...23
Safety notice...23
How to read the shop manual...28
Explanation of terms for maintenance standard...30
Handling of electric equipment and hydraulic components...32
Handling of connectors newly used for engines...41
How to read electric wire code...44
Precautions when carrying out work...47
Method of disassembling and connecting push-pull type coupler...50
Standard tightening torque table...53
List of Abbreviation...57
Conversion table...61
01 Specification...67
Specification drawing...69
Specifications...71
Weight table...77
Table of fuel, coolant and lubricants...78
10 Structure and function...81
Engine and cooling system...84
Cooling system...84
Cooling fan motor...86
Power train system...93
Power train system drawing...93
Power train piping drawing...94
Transmission control...95
Torque converter...96
Transmission...100
Transmission control valve...120
ECMV...122
Main relief and torque converter relief valve...129
Front axle...131
Final drive...134
Differential...137
Differential lock solenoid valve...139
Tandem drive...140
Steering system...143
Steering piping diagram...143
Priority valve...144
Steering valve...150
Brake system...158
Brake hydraulic piping diagram...158
Brake valve...159
Slack adjuster...164
Accumulator (for brake)...166
Charge valve...167
Wheel brake...172
Parking brake and bank control valve...173
Parking brake...174
Undercarriage and frame...175
Frame...175
Tire...176
Hydraulic system...177
Hydraulic system...177
Work equipment hydraulic component layout...180
Work equipment control...183
Hydraulic tank...185
Main pump...186
Power train pump...198
Control valve...200
CLSS...209
Functions and operation by valve...212
Swivel joint...222
Pilot check valve...223
Separately installed safety valve...227
Accumulator (for blade)...228
Work equipment...230
Circle and drawbar...230
Blade...232
Lifter...234
Circle rotation motor...236
Circle rotation gear...238
Cab...240
Cab...240
Electrical system...242
Machine monitor...242
Automatic shift control system...245
Transmission controller...253
Engine controller...256
KOMTRAX system...259
Starting engine circuit...264
Stopping engine circuit...266
Preheating circuit...267
Engine power mode select circuit...268
Cooling fan control function...269
Sensor...273
20 Standard value table...285
Standard value table...287
Standard value table for engine...287
Standard value table for machine...289
Machine posture and procedure for measuring performance...297
30 Testing and adjusting...299
Related information on testing and adjusting...302
Tools for testing and adjusting...302
Sketch of tools for testing and adjusting...305
Engine and cooling system...306
Testing engine speed...306
Testing boost pressure...309
Testing exhaust gas temperature...311
Testing exhaust gas color...313
Testing and adjusting valve clearance...315
Testing compression pressure...318
Testing blowby pressure...322
Testing engine oil pressure...323
Handling equipment of fuel system devices...324
Releasing remaining pressure from fuel system...324
Testing fuel pressure...325
Testing fuel return rate and leakage...330
Bleeding air from fuel circuit...333
Testing fuel circuit for leakage...334
Handling cylinder cutout mode operation...335
Handling no-injection cranking operation...335
Testing muffler (main body) and stuck muffler for looseness and damage...336
Testing muffler function...336
Testing installed condition of cylinder heads and manifolds...336
Testing of engine piping for damage and looseness...336
Testing and adjusting air conditioner compressor belt tension...337
Replacing alternator belt...338
Power train...339
Testing power train oil pressure...339
Adjusting transmission speed sensor...352
Retrieval of disabled machine due to transmission valve failure...355
Flushing procedure for torque converter and transmission circuits...358
Testing and adjusting toe-in...360
Testing and adjusting differential lock oil pressure...361
Steering system...364
Testing and adjusting steering oil pressure...364
Testing oil leakage of steering cylinder...365
Bleeding air from steering circuit...365
Brake system...366
Testing and adjusting brake oil pressure...366
Releasing remaining pressure from brake circuit...370
Bleeding air from brake circuit...371
Testing wear of wheel brake disc...372
Testing and adjusting parking brake...373
Parking brake emergency releasing procedure...375
Procedure for charging brake accumulator with nitrogen gas...376
Hydraulic system...379
Testing and adjusting work equipment oil pressure...379
Testing and adjusting pump LS differential pressure...382
Testing lift arm lock cylinder circuit oil pressure...384
Testing oil leakage of work equipment cylinder...385
Bleeding air from work equipment circuit...388
Testing cooling fan pump circuit oil pressure...389
Work equipment system...391
Adjusting drawbar ball joint clearance...391
Testing and adjusting circle guide clearance...392
Adjusting circle rotation gear...394
Procedure for charging blade accumulator with nitrogen gas...397
Electrical system...398
Special functions of machine monitor...398
KOMTRAX terminal start-up procedure (ORBCOMM)...446
Lamp indication of KOMTRAX terminal (ORBCOMM)...451
KOMTRAX terminal start-up procedure (GPRS)...454
Lamp indication of KOMTRAX terminal (GPRS)...457
Handling voltage circuit of engine controller...460
Testing diodes...461
Pm Clinic...462
Pm Clinic service...462
40 Troubleshooting...469
General information on troubleshooting...476
Points to remember when troubleshooting...476
Sequence of events in troubleshooting...477
Checks before troubleshooting...478
Preparation work for troubleshooting of electrical system...499
Classification and procedures for troubleshooting...502
Failure codes table...503
Failure and troubleshooting numbers...510
Information in troubleshooting table...512
Troubleshooting method for open circuit in wiring harness of pressure sensor system...514
Connector list and layout...516
Connection table for connector pin numbers...530
T- branch box and T- branch adapter table...566
Locations of fuses...569
Troubleshooting by failure code...571
Failure code [1500L0] TORQFLOW transmission: Double engagement...571
Failure code [15G0MW] Transmission R clutch: Slip...572
Failure code [15H0MW] Transmission FH clutch: Slip...573
Failure code [15J0MW] Transmission FL clutch: Slip...573
Failure code [15K0MW] Transmission 1st clutch: Slip...574
Failure code [15L0MW] Transmission 2nd clutch: Slip...575
Failure code [15M0MW] Transmission 3rd speed clutch: Slip...576
Failure code [15N0MW] Transmission 4th clutch: Slip...577
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF...578
Failure code [15SBMA] ECMV R clutch: Malfunction...580
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF...582
Failure code [15SCMA] ECMV FH clutch: Malfunction...584
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF...586
Failure code [15SDMA] ECMV FL clutch: Malfunction...588
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF...590
Failure code [15SEMA] ECMV 1st clutch: Malfunction...592
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF...594
Failure code [15SFMA] ECMV 2nd clutch: Malfunction...596
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF...598
Failure code [15SGMA] ECMV 3rd clutch: Malfunction...600
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF...602
Failure code [15SHMA] ECMV 4th clutch: Malfunction...604
Failure code [15SJMA] ECMV lockup clutch: Malfunction...606
Failure code [15U0NT] Inching clutch: Overheating...606
Failure code [2G42ZG] Front accumulater: Oil pressure drop...607
Failure code [2G43ZG] Rear accumulater: Pressure drop...607
Failure code [AA1ANX] Air cleaner: Clogging...608
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched...610
Failure code [AB00MA] Alternator: Malfunction...612
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop...614
Failure code: [B@BCNS] Engine coolant overheat...614
Failure code [B@BEBF] Water in fuel error...615
Failure code: [B@CENS] Torque converter oil overheat...616
Failure code: [B@CKNS] Differential case: Overheat...618
Failure code: [B@HANS] Hydraulic oil: Overheating...620
Failure code [CA111] Engine controller internal error...622
Failure code [CA115] Engine Ne, Bkup speed sensor error...623
Failure code [CA122] Charge pressure sensor high error...624
Failure code [CA123] Charge pressure sensor low error...626
Failure code [CA131] Throttle sensor high error...628
Failure code [CA132] Throttle sensor low error...630
Failure code [CA144] Coolant sensor high error...632
Failure code [CA145] Coolant sensor low error...634
Failure code [CA153] Charge temperature sensor high error...636
Failure code [CA154] Charge temperature sensor low error...638
Failure code [CA155] Speed derating error by high charge temperature...640
Failure code [CA187] Sensor power supply 2 low error...642
Failure code [CA221] Atmospheric pressure sensor high error...644
Failure code [CA222] Atmospheric pressure sensor low error...646
Failure code [CA227] Sensor power supply 2 high error...648
Failure code [CA234] Engine overspeed...648
Failure code [CA238] Ne speed sensor power supply error...649
Failure code [CA271] IMV/IMA: Short circuit...650
Failure code [CA272] IMV/IMA open circuit...652
Failure code [CA281] Abnormal supply pump pressure balance...654
Failure code [CA322] Injector #1 (L#1) open/short...656
Failure code [CA323] Injector #5 (L#5) open/short...658
Failure code [CA324] Injector #3 (L#3) open/short...660
Failure code [CA325] Injector #6 (L#6) open/short...662
Failure code [CA331] Injector #2 (L#2) open/short...664
Failure code [CA332] Injector #4 (L#4) open/short...666
Failure code [CA342] Data compatibility error in engine controller...668
Failure code [CA351] Injector drive circuit error...669
Failure code [CA352] Sensor power supply 1 low error...670
Failure code [CA386] Sensor power supply 1 high error...671
Failure code [CA428] Water-in-fuel sensor high error...672
Failure code [CA429] Water-in-fuel sensor low error...674
Failure code [CA431] Idle validation switch error...676
Failure code [CA432] Idle validation action error...680
Failure code [CA435] Engine oil pressure switch error...683
Failure code [CA441] Power supply voltage low error...684
Failure code [CA442] Power supply voltage high error...686
Failure code [CA449] Common rail pressure high error 2...687
Failure code [CA451] Common rail pressure sensor high error...688
Failure code [CA452] Common rail pressure sensor low error...690
Failure code [CA488] Torque derating error by high charge temperature...692
Failure code [CA553] Common rail pressure high error 1...693
Failure code [CA559] Rail Press Low Error...694
Failure code [CA689] Eng Ne Speed Sensor Error...696
Failure code [CA731] Eng Bkup Speed Sens Phase Error...698
Failure code [CA757] All continuous data lost error...699
Failure code [CA778] Eng Bkup Speed Sensor Error...700
Failure code [CA1633] KOMNET (CAN communication) error...703
Failure code [CA2185] Throttle sensor power supply high error...704
Failure code [CA2186] Throttle sensor power supply low error...706
Failure code [CA2249] Supply pump pressure low error 2...708
Failure code [CA2265] Fuel Feed Pump Open Error...710
Failure code [CA2266] Fuel Feed Pump Short Error...712
Failure code [CA2311] Abnormality in IMV (IMA) solenoid...713
Failure code [CA2555] Intake heater relay open circuit...714
Failure code [CA2556] Intake heater relay short circuit...716
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness...718
Failure code [D160KB] Backup lamp relay: Ground fault...720
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault...722
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state...724
Failure code [DAFRKR] CAN communication failure (monitor panel)...726
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)...728
Failure code [DAQOKT] Transmission controller: Non-volatile memory error...730
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)...732
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement...734
Failure code [DAQRKR] Transmission controller CAN communication: Communication error...736
Failure code [DAQRMA] Transmission controller option setting: Malfunction...740
Failure code [DB2RKR] Engine controller CAN communication: Communication error...741
Failure code [DD1PKB] RPM set switch power supply short circuit...748
Failure code [DD1QKB] RPM set mode switch short circuit...750
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error...752
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit...755
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit...755
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit...756
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit...756
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit...757
Failure code [DDTNKA] Fill switch for R clutch: Open circuit...758
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit...759
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input...760
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error...764
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range...766
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault...768
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range...770
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault...772
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor...774
Failure code [DHT5L6] Failure of T/C Oil Press Sensor...776
Failure code [DJF1KA] Fuel level sensor: Open circuit...778
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range...780
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range...782
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit...784
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match...785
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit...786
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match...787
Failure code [DLM3KA] Fan speed sensor: Open circuit...788
Failure code [DLM3LC] Fan speed sensor: Short circuit...789
Failure code [DLM3MB] Radiator Fan Control Mismatch...790
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit...791
Failure code [DV00KB] Buzzer: Short circuit...792
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit...794
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit...796
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit...797
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit...798
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line...800
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit...802
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit...803
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line...804
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit...806
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit...807
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line...808
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit...810
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit...811
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line...812
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit...814
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit...815
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line...816
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit...818
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit...819
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line...820
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit...822
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit...823
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line...824
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit...826
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit...827
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line...828
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit...830
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit...831
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line...832
Troubleshooting of electrical system (E-mode)...834
E-1 Engine does not start (Starting motor does not turn)...834
E-2 Preheating does not work...840
E-3 When starting switch is turned to ON position, machine monitor displays nothing...845
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen...848
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen...848
E-6 Emergency stop monitor lights up while engine is running...849
E-7 Speedometer or engine tachometer does not indicate correctly...853
E-8 Engine coolant temperature gauge does not indicate correctly...854
E-9 Articulation angle indicator does not indicate correctly...856
E-10 Torque converter oil temperature gauge does not indicate correctly...858
E-11 Fuel level gauge does not indicate correctly...860
E-12 Character display does not display correctly...862
E-13 Centralized warning lamp does not light up or does not go off...864
E-14 Alarm buzzer does not sound or does not stop sounding...866
E-15 Machine monitor mode selector switch does not work...868
E-16 Transmission mode does not switch...872
E-17 Engine mode does not switch...874
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]...876
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]...880
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]...882
E-21 Horn does not sound or does not stop sounding...886
E-22 Backup alarm does not sound or does not stop sounding...888
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off...891
E-24 Working lamp does not light up or does not go off...898
E-25 Fog lamp does not light up or does not go off...904
E-26 Turn signal lamp and hazard lamp do not flash...906
E-27 Stop lamp does not light up or does not go off...912
E-28 Backup lamp does not light up or does not go off...914
E-29 Windshield wiper does not operate...916
E-30 Window washer does not operate...924
E-31 KOMTRAX system does not operate correctly...928
Troubleshooting for hydraulic and mechanical system (H-mode)...932
Information described in troubleshooting table (H-mode)...932
H-1 Engine speed drops significantly or engine stalls...933
H-2 Machine does not move off (both forward and reverse)...934
H-3 Gear speed does not shift...935
H-4 Travel speed or power is low...936
H-5 Torque converter lockup does not operate or is not canceled...938
H-6 Machine starts or gear speed shifts with long time lag...939
H-7 Torque converter oil temperature is high...940
H-8 Differential lock function does not operate or is not canceled...941
H-9 Steering speed or power is insufficient...942
H-10 Steering wheel does not move...943
H-11 Wheel brakes do not work or are weak...944
H-12 Wheel brakes are not released or drag...945
H-13 Parking brake does not work or it is weak...946
H-14 Parking brake (including emergency release system) is not released or drags...947
H-15 All work equipment operates slowly or lacks power...948
H-16 All work equipments do not operate...949
H-17 Unusual noise is heard from around hydraulic pump...950
H-18 Blade lift speed or power is low...951
H-19 Hydraulic drift of lifted blade is large...952
H-20 Drawbar side shift speed or power is low...953
H-21 Blade cross slide speed or power is low...954
H-22 Power tilt speed or power is low...955
H-23 Articulate speed or power is low...956
H-24 Leaning speed or power is insufficient...957
H-25 Hydraulic drift (tilting) of leaning is large...958
H-26 Blade does not rotate...959
H-27 Lift arm lock pin is not locked or is not canceled...960
H-28 Blade accumulator does not operate or is not canceled [blade accumulator specifications]...961
H-29 Fan rotation is abnormal (such as excessive noise or vibration of fan, or overheating)...962
H-30 Unusual noise is heard from around fan...963
Troubleshooting of engine (S-mode)...965
Method of using troubleshooting charts...965
S-1 Starting performance is poor...968
S-2 Engine does not start...969
S-3 Engine does not pick up smoothly...972
S-4 Engine stops during operations...973
S-5 Engine does not rotate smoothly...974
S-6 Engine lacks output (or lacks power)...975
S-7 Exhaust smoke is black (incomplete combustion)...976
S-8 Oil consumption is excessive (or exhaust smoke is blue)...977
S-9 Oil becomes contaminated quickly...978
S-10 Fuel consumption is excessive...979
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)...980
S-12 Oil pressure drops...981
S-13 Oil level rises (water, fuel in oil)...982
S-14 Coolant temperature becomes too high (overheating)...983
S-15 Abnormal noise is made...984
S-16 Vibration is excessive...985
Shop Manual...987
50 Disassembly and assembly...987
Related information on disassembly and assembly...990
How to read this manual...990
Coating materials list...992
Special tools list...996
Sketches of special tools...1001
Engine and cooling system...1035
Removal and installation of fuel supply pump assembly...1035
Removal and installation of fuel injector assembly...1038
Removal and installation of cylinder head assembly...1047
Removal and installation of engine front oil seal assembly...1060
Removal and installation of engine rear oil seal assembly...1063
Removal and installation of cooling fan pump assembly...1068
Removal and installation of cooling fan and fan motor assembly...1070
Removal and installation of radiator assembly...1075
Removal and installation of aftercooler assembly...1079
Removal and installation of power train oil cooler assembly...1082
Removal and installation of fuel tank assembly...1085
Removal and installation of engine hood assembly...1089
Power train...1091
Removal and installation of engine and transmission assembly...1091
Disconnection and connection of transmission and torque converter assembly from/to engine...1099
Disassembly and assembly of transmission assembly...1101
Disassembly and assembly of torque converter assembly...1140
Removal and installation of tandem drive and final drive assembly...1152
Disassembly and assembly of tandem drive assembly...1156
Disassembly and assembly of final drive assembly...1162
Steering system...1181
Removal and installation of steering valve (Orbitrol) assembly...1181
Disassembly and assembly of steering valve (Orbitrol)...1187
Brake system...1198
Disassembly and assembly of wheel brake assembly...1198
Undercarriage and frame...1206
Removal and installation of center hinge pin...1206
Hydraulic system...1219
Removal and installation of hydraulic tank, battery and frame assembly...1219
Removal and installation of hydraulic tank assembly...1224
Removal and installation of control valve assembly...1227
Disassembly and assembly of control valve assembly...1233
Disassembly and assembly of hydraulic cylinder assembly...1236
Work equipment...1240
Removal and installation of blade assembly...1240
Disassembly and assembly of circle drawbar assembly...1242
Removal and installation of circle rotation gear assembly...1245
Disassembly and assembly of circle rotation gear assembly...1248
Removal and installation of ripper assembly...1255
Cab and its attachments...1256
Removal and installation of operator's cab assembly...1256
Removal and installation of floor frame assembly...1268
Removal and installation of operator's cab glass (adhered window glass)...1272
Removal and installation of air conditioner unit assembly...1282
Electrical system...1288
Removal and installation of engine controller assembly...1288
Removal and installation of starting motor...1290
Removal and installation of battery...1292
Removal and installation of machine monitor assembly...1294
Removal and installation of transmission controller assembly...1296
Removal and installation of KOMTRAX terminal assembly (ORBCOMM)...1298
Removal and installation of KOMTRAX terminal assembly (GPRS)...1300
60 Maintenance standard...1303
Engine and cooling system...1305
Engine mount and transmission mount...1305
Cooling system...1306
Cooling fan motor...1307
Power train system...1310
Torque converter...1310
Transmission...1313
Transmission control valve...1322
ECMV...1323
Main relief valve and torque converter relief valve...1325
Front axle...1326
Final drive...1329
Differential...1332
Tandem drive...1334
Brake system...1336
Slack adjuster...1336
Wheel brake...1337
Parking brake...1338
Undercarriage and frame...1339
Frame...1339
Hydraulic system...1340
Main pump...1340
Power train pump...1344
Control valve...1346
Hydraulic cylinder...1355
Work equipment...1358
Circle and drawbar...1358
Blade...1360
Lifter...1362
Circle rotation gear...1363
80 Appendix...1365
Air conditioner...1367
Precautions for refrigerant...1367
Air conditioner components...1368
Structure and function of refrigeration system...1370
Overview of refrigeration system...1371
Air conditioner unit...1372
Compressor...1375
Condenser...1376
Receiver drier...1377
Air conditioner control panel...1378
Procedure for check and troubleshooting...1380
Circuit diagram and layout of connector pins...1382
System diagram...1384
Detail of air conditioner unit...1386
Parts and connectors layout...1388
Testing air leakage (ducts)...1390
Check with self-diagnosis (control panel display)...1392
Testing temperature control...1393
Testing Fresh/Recirc air changeover...1394
Testing evaporator temperature sensor...1395
Testing relays...1396
Testing blower amp...1397
Troubleshooting Chart 1...1398
Troubleshooting Chart 2...1400
Information in troubleshooting table...1402
Troubleshooting for power supply system (Air conditioner does not operate)...1404
Troubleshooting of compressor and refrigerant system (Air is not cooled)...1406
Troubleshooting for blower motor system (Air does not come out or air flow is improper)...1410
Troubleshooting for temperature control...1412
Troubleshooting for FRESH/RECIRC air changeover...1414
Troubleshooting with gauge pressure...1416
Connection of service tool...1418
Precautions for disconnecting and connecting air conditioner piping...1420
Handling compressor oil...1422
90 Diagrams and drawings...1425
Hydraulic diagrams and drawings...1427
Symbols used in hydraulic circuit diagrams...1427
Hydraulic circuit diagram...1429
Electrical diagrams and drawings...1431
Symbols used in electric circuit diagrams...1431
Electrical circuit diagram...1435
Index...1444
