Komatsu Motor Grader GD555-5, GD655-5, GD675-5 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Grader GD555-5, GD655-5, GD675-5, with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Motor Grader GD555-5, GD655-5, GD675-5 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: 3,174 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN05215-06 - Motor Grader GD555-5, GD655-5, GD675-5 Shop Manual.pdf
TEN00368-01 - Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00369-01 - Motor Grader GD675-5 Operation & Maintenance Manual.pdf
TEN00445-02 - Motor Grader GD555-5 Operation & Maintenance Manual.pdf
TEN00446-02 - Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00447-02 - Motor Grader GD675-5 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
Notice of revision...3
00 Index and foreword...11
Table of contents...12
Table of contents...12
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...70
Weight table...76
Table of fuel, coolant and lubricants...77
10 Structure, function and maintenance standard...79
Engine and Cooling...82
Cooling system...82
Cooling fan pump...84
Power train system...92
Power train system drawing...92
Power train piping drawing...94
Transmission control...96
Torque converter...98
Transmission...102
Transmission control valve...124
ECMV...128
Main relief and torque converter relief valve...136
Front axle...138
Final drive (no differential specification)...142
Final drive (differential/ differential lock specification)...144
Differential lock solenoid valve...146
Tandem drive...148
Steering system...150
Steering piping diagram...150
Priority valve...152
Steering valve...158
Brake system...166
Brake hydraulic piping diagram...166
Brake valve...167
Slack adjuster...174
Accumulator (for brake)...176
Charge valve...177
Wheel brake...184
Parking brake and bank control valve...186
Parking brake...188
Undercarriage frame...190
Frame...190
Tire...192
Hydraulic system...194
Hydraulic system...194
Work equipment hydraulic piping diagram...198
Work equipment control...202
Hydraulic tank...204
Main pump...206
Power train pump...218
Control valve...220
CLSS...230
Functions and operation by valve...234
Hydraulic cylinder...244
Swivel joint...246
Pilot check valve...248
Accumulator (for blade)...256
Work equipment...258
Circle and drawbar...258
Blade...260
Lifter...262
Circle rotation motor...264
Circle rotation gear...266
Cab...268
Cab...268
Electrical system...270
Machine monitor...270
Automatic shift control system...274
Transmission controller...282
Engine controller...286
KOMTRAX system...290
Starting engine circuit...294
Stopping engine circuit...296
Preheating circuit...298
Sensor...300
Engine power mode select circuit...312
Cooling fan control function...314
20 Standard value table...319
Standard value table...321
Standard value table for engine...321
Standard value table for machine...323
30 Testing and adjusting...331
Tools for testing, adjusting, and troubleshooting...334
Tools for testing, adjusting, and troubleshooting...334
Engine and cooling system...340
Testing engine speed...340
Testing intake air pressure (boost pressure)...342
Testing exhaust gas temperature...344
Testing exhaust gas color...346
Adjusting valve clearance...348
Testing compression pressure...350
Testing blowby pressure...353
Testing engine oil pressure...355
Handling fuel system device...356
Releasing remaining pressure from fuel system...357
Testing fuel pressure...358
Bleeding air from fuel circuit...359
Testing fuel circuit for leakage...360
Cylinder cut-out test mode...361
No injection cranking...362
Handling voltage circuit of engine controller...363
Checking muffler body and muffler stack for looseness and damage...364
Checking muffler function...365
Checking cylinder head and manifolds for looseness...366
Checking engine piping for damage and looseness...367
Checking fuel delivery, return rate and leakage...368
Replacing fan belt...371
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]...372
Power train...374
Testing power train oil pressure...374
Adjusting transmission speed sensor...386
Emergency escape method in case of transmission valve failure...390
Flushing torque converter and trasmission circuits...394
Testing and adjusting toe-in...396
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]...398
Steering system...400
Testing and adjusting steering oil pressure...400
Testing steering cylinder oil leakage...401
Bleeding air from steering circuit...402
Brake system...404
Testing and adjusting brake oil pressure...404
Releasing remaining pressure from brake circuit...408
Bleeding air from brake circuit...409
Testing wheel brake disc wear...410
Testing and adjusting parking brake...412
Emergency release method of parking brake...414
Filling gas into brake accumulator...416
Hydraulic system...418
Testing and adjusting work equipment oil pressure...418
Testing and adjusting pump LS differential pressure...421
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut]...423
Testing work equipment cylinder oil leakage amount...424
Bleeding air from work equipment circuit...427
Work equipment...428
Clearance adjustment of drawbar ball joint...428
Testing and adjusting circle guide clearance...429
Testing and adjusting slip clutch type circle rotator...431
Filling gas into blade accumulator [machine with blade accumulator]...433
Electrical system...434
Procedure for testing diodes...434
Special functions of machine monitor (EMMS)...435
Handling high voltage circuit of engine controller...484
How to start KOMTRAX terminal operations...486
Indicator lamps of KOMTRAX terminal...495
Preparation work for troubleshooting of electrical system...502
Pm clinic...504
40 Troubleshooting...513
General information on troubleshooting...519
Points to remember when troubleshooting...519
Sequence of events in troubleshooting...520
Checks before troubleshooting...521
Classification and procedures for troubleshooting...541
Failure codes table...542
Failure and troubleshooting numbers...549
Information in troubleshooting table...551
Troubleshooting method for open circuit in wiring harness of pressure sensor system...553
Connector list and layout...555
Connection table for connector pin numbers...570
T- branch box and T- branch adapter table...606
Locations of fuses...609
Troubleshooting by failurecode...611
Failure code [1500LO] TORQUEFLOW transmission: Double engagement...611
Failure code [15G0MW] Transmission R clutch: Slip...612
Failure code [15H0MW] Transmission FH clutch: Slip...613
Failure code [15J0MW] Transmission FL clutch: Slip...613
Failure code [15K0MW] Transmission 1st clutch: Slip...614
Failure code [15L0MW] Transmission 2nd clutch: Slip...615
Failure code [15M0MW] Transmission 3rd speed clutch: Slip...616
Failure code [15N0MW] Transmission 4th clutch: Slip...617
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF...618
Failure code [15SBMA] ECMV R clutch: Malfunction...620
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF...622
Failure code [15SCMA] ECMV FH clutch: Malfunction...624
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF...626
Failure code [15SDMA] ECMV FL clutch: Malfunction...628
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF...630
Failure code [15SEMA] ECMV 1st clutch: Malfunction...632
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF...634
Failure code [15SFMA] ECMV 2nd clutch: Malfunction...636
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF...638
Failure code [15SGMA] ECMV 3rd clutch: Malfunction...640
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF...642
Failure code [15SHMA] ECMV 4th clutch: Malfunction...644
Failure code [15SJMA] ECMV lockup clutch: Malfunction...646
Failure code [15UONT] Inching clutch: Overheating...646
Failure code [2G42ZG] Front accumulater: Oil pressure drop...647
Failure code [2G43ZG] Rear accumulater: Pressure drop...647
Failure code [AA1ANX] Air cleaner: Clogging...648
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched...650
Failure code [AB00MA] Alternator: Malfunction...652
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop...654
Failure code: [B@BCNS] Engine coolant overheat...654
Failure code: [B@CENS] Torque converter oil overheat...655
Failure code: [B@CKNS] Differential case: Overheat...656
Failure code: [B@HANS] Hydraulic oil: Overheating...658
Failure code [CA111] Engine controller internal error...660
Failure code [CA115] Engine Ne, Bkup speed sensor error...661
Failure code [CA122] Charge pressure sensor high error...662
Failure code [CA123] Charge pressure sensor low error...664
Failure code [CA131] Throttle sensor high error...666
Failure code [CA132] Throttle sensor low error...668
Failure code [CA144] Coolant sensor high error...670
Failure code [CA145] Coolant sensor low error...672
Failure code [CA153] Charge temperature sensor high error...674
Failure code [CA154] Charge temperature sensor low error...676
Failure code [CA155] Speed derating error by high charge temperature...678
Failure code [CA187] Sensor power supply 2 low error...680
Failure code [CA221] Atmospheric pressure sensor high error...682
Failure code [CA222] Atmospheric pressure sensor low error...684
Failure code [CA227] Sensor power supply 2 high error...686
Failure code [CA234] Engine overspeed...686
Failure code [CA238] Ne speed sensor power supply error...687
Failure code [CA271] IMV/IMA: Short circuit...688
Failure code [CA272] IMV/IMA open circuit...690
Failure code [CA322] Injector #1 (L#1) open/short...692
Failure code [CA323] Injector #5 (L#5) open/short...694
Failure code [CA324] Injector #3 (L#3) open/short...696
Failure code [CA325] Injector #6 (L#6) open/short...698
Failure code [CA331] Injector #2 (L#2) open/short...700
Failure code [CA332] Injector #4 (L#4) open/short...702
Failure code [CA342] Data compatibility error in engine controller...704
Failure code [CA351] Injector drive circuit error...705
Failure code [CA352] Sensor power supply 1 low error...706
Failure code [CA386] Sensor power supply 1 high error...707
Failure code [CA428] Water-in-fuel sensor high error...708
Failure code [CA429] Water-in-fuel sensor low error...710
Failure code [CA431] Idle validation switch error...712
Failure code [CA432] Idle validation action error...716
Failure code [CA435] Engine oil pressure switch error...719
Failure code [CA441] Power supply voltage low error...720
Failure code [CA442] Power supply voltage high error...722
Failure code [CA449] Common rail pressure high error 2...723
Failure code [CA451] Common rail pressure sensor high error...724
Failure code [CA452] Common rail pressure sensor low error...726
Failure code [CA488] Torque derating error by high charge temperature...728
Failure code [CA553] Common rail pressure high error 1...729
Failure code [CA559] Supply pump pressure low error 1...730
Failure code [CA689] Engine Ne speed sensor error...731
Failure code [CA731] Engine Bkup speed sensor phase error...733
Failure code [CA757] All continuous data lost error...734
Failure code [CA778] Engine Bkup speed sensor error...735
Failure code [CA1633] KOMNET (CAN communication) error...738
Failure code [CA2185] Throttle sensor power supply high error...740
Failure code [CA2186] Throttle sensor power supply low error...742
Failure code [CA2249] Supply pump pressure low error 2...744
Failure code [CA2311] Abnormality in IMV (IMA) solenoid...745
Failure code [CA2555] Intake heater relay open circuit...746
Failure code [CA2556] Intake heater relay short circuit...748
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness...750
Failure code [D160KB] Backup lamp relay: Ground fault...752
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault...754
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state...756
Failure code [DAFRKR] CAN communication failure (monitor panel)...758
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)...760
Failure code [DAQOKT] Transmission controller: Non-volatile memory error...762
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)...764
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement...766
Failure code [DAQRKR] Transmission controller CAN communication: Communication error...768
Failure code [DAQRMA] Transmission controller option setting: Malfunction...772
Failure code [DB2RKR] Engine controller CAN communication: Communication error...773
Failure code [DD1NLD] Fan reverse switch signal: Short circuit...780
Failure code [DD1PKB] RPM set switch power supply short circuit...782
Failure code [DD1QKB] RPM set mode switch short circuit...784
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error...786
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit...788
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit...788
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit...789
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit...789
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit...790
Failure code [DDTNKA] Fill switch for R clutch: Open circuit...791
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit...792
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input...793
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error...797
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range...800
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault...802
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range...804
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault...806
Failure code [DJF1KA] Fuel level sensor: Open circuit...808
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range...810
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range...812
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit...814
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match...815
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit...816
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match...817
Failure code [DLM3KA] Fan speed sensor: Open circuit...818
Failure code [DLM3LC] Fan speed sensor: Short circuit...819
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit...820
Failure code [DV00KB] Buzzer: Short circuit...822
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit...824
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit...826
Failure code [DW7BKA] Fan reverse solenoid: Open circuit...827
Failure code [DW7BKB] Fan reverse solenoid: Short circuit...828
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line...830
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit...832
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit...833
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line...834
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit...836
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit...837
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line...838
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit...840
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit...841
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line...842
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit...844
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit...846
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line...848
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit...850
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit...852
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line...854
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit...856
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit...858
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line...860
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit...862
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit...864
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line...866
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit...868
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit...869
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line...870
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit...872
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit...874
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line...876
Troubleshooting of electrical system (E-mode)...878
E-1 Engine does not start (starting motor does not turn)...878
E-2 Preheating does not work...884
E-3 When starting switch is turned to ON position, machine monitor displays nothing...889
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen...892
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen...892
E-6 Emergency stop monitor lights up while engine is running...893
E-7 Speedometer or engine tachometer does not indicate correctly...897
E-8 Engine coolant temperature gauge does not indicate correctly...898
E-9 Articulation angle indicator does not indicate correctly...900
E-10 Torque converter oil temperature gauge does not indicate correctly...902
E-11 Fuel level gauge does not indicate correctly...904
E-12 Character display does not display correctly...906
E-13 Centralized warning lamp does not light up or does not go off...908
E-14 Alarm buzzer does not sound or does not stop sounding...910
E-15 Machine monitor mode selector switch does not work...912
E-16 Transmission mode does not switch...916
E-17 Engine mode does not switch...918
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]...920
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]...924
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]...926
E-21 Horn does not sound or does not stop sounding...930
E-22 Backup alarm does not sound or does not stop sounding...932
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off...935
E-24 Working lamp does not light up or does not go off...942
E-25 Turn signal lamp and hazard lamp do not flash...948
E-26 Stop lamp does not light up or does not go off...954
E-27 Backup lamp does not light up or does not go off...956
E-28 Windshield wiper does not operate...958
E-29 Window washer does not operate...966
E-30 KOMTRAX system does not operate correctly...970
Troubleshooting of hydraulic and mechanical system (H-mode)...974
How to read troubleshooting matrix...974
H-1 Engine speed lowers significantly or engine stalls...980
H-2 Machine does not start...981
H-3Gear is not shifted...982
H-4 Travel lacks speed or power...983
H-5 Torque converter lockup does not work or is not released...988
H-6 A large time lag results at start or in gear shift...989
H-7 Oil temperature of torque converter is high...994
H-8 Differential lock-up function does not work or is not released...999
H-9 Steering lacks speed or power...1000
H-10 Steering wheel does not move...1001
H-11 Wheel brake does not work at all or sufficiently...1002
H-12 Wheel brake cannot be released or drags...1003
H-13 Parking brake does not work at all or insufficiently...1004
H-14 Parking brake (including emergency release system) cannot be released or drags...1005
H-15 All work equipment operation lacks speed or power...1006
H-16 Work equipment does not work at all...1007
H-17 Unusual noise comes out from around hydraulic pump...1008
H-18 Blade lift operation lacks speed or power...1009
H-19 Hydraulic drift of blade lift cylinders is large...1010
H-20 Drawbar side shift operation lacks speed or power...1011
H-21 Blade side shift operation lacks speed or power...1012
H-22 Power tilt operation lacks speed or power...1013
H-23 Articulate operation lacks speed or power...1014
H-24 Leaning operation lacks speed or power...1015
H-25 Hydraulic drift of leaning cylinders (leaning) is large...1016
H-26 Blade does not rotate...1017
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)...1018
H-28 Blade accumulator function does not work or cannot be released(for machine with blade accumulator float specification)...1019
H-29 Blade float function does not work or cannot be released...1020
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)...1021
Troubleshooting of engine (S-mode)...1022
Method of using troubleshooting chart...1022
S-1 Startability is poor...1026
S-2 Engine does not start...1027
S-3 Engine does not pick up smoothly...1030
S-4 Engine stops during operation...1031
S-5 Engine runs rough or is unstable...1032
S-6 Engine lacks power...1033
S-7 Exhaust smoke is black (incomplete combustion)...1034
S-8 Oil consumption is excessive (or exhaust smoke is blue)...1035
S-9 Oil becomes contaminated early...1036
S-10 Fuel consumption is excessive...1037
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)...1038
S-12 Oil pressure drops...1039
S-13 Oil level rises (coolant or fuel in oil)...1040
S-14 Coolant temperature rises too high (overheating)...1041
S-15 Unusual noise is made...1042
S-16 Vibration is excessive...1043
50 Disassembly and assembly...1045
General information on disassembly and assembly...1048
How to read this manual...1048
Coating materials list...1050
Special tools list...1053
Sketches of special tools...1057
Engine and cooling system...1061
Removal and installation of fuel supply pump assembly...1061
Removal and installation of fuel injector assembly...1066
Removal and installation of cylinder head assembly...1076
Removal and installation of engine front oil seal...1094
Removal and installation of engine rear oil seal...1097
Removal and installation of cooling fan pump assembly...1101
Removal and installation of cooling fan and fan motor assembly...1103
Removal and installation of radiator assembly...1107
Removal and installation of aftercooler assembly...1111
Removal and installation of power train oil cooler assembly...1114
Removal and installation of fuel tank assembly...1117
Removal and installation of engine hood assembly...1121
Power train...1123
Removal and installation of engine and transmission/torque converter assembly...1123
Disassembly and assembly of engine and transmission/torque converter assembly...1131
Disassembly and assembly of torque converter assembly...1133
Disassembly and assembly of transmission assembly...1141
Removal and installation of tandem drive and final drive assembly...1179
Disassembly and assembly of tandem drive assembly...1183
Disassembly and assembly of final drive assembly...1188
Steering system...1207
Removal and installation of steering valve (orbit-roll) assembly...1207
Disassembly and assembly of steering valve (orbit-roll) assembly...1213
Brake system...1224
Disassembly and assembly of wheel brake assembly...1224
Undercarriage and frame...1229
Removal and installation of center hinge pin...1229
Hydraulic system...1242
Removal and installation of hydraulic tank, battery and frame assembly...1242
Removal and installation of hydraulic tank assembly...1249
Removal and installation of control valve assembly...1256
Disassembly and assembly of control valve assembly...1262
Disassembly and assembly of hydraulic cylinder assembly...1265
Work equipment...1270
Removal and installation of blade assembly...1270
Removal and installation of circle drawbar assembly...1272
Removal and installation of circle rotation gear assembly...1275
Disassembly and assembly of circle rotation gear assembly...1277
Removal and installation of ripper assembly...1282
Cab and its attachments...1285
Removal and installation of operator cab assembly...1285
Removal and installation of floor frame assembly...1297
Removal and installation of operator cab glass (adhered glass)...1301
Removal and installation of air conditioner unit assembly...1311
Electrical system...1317
Removal and installation of engine controller assembly...1317
Removal and installation of machine monitor assembly...1319
Removal and installation of transmission controller assembly...1321
Removal and installation of KOMTRAX terminal assembly...1323
60 Maintenance standard...1325
Engine and Cooling...1328
Engine mount and transmission mount...1328
Cooling system...1330
Cooling fan motor...1332
Power train system...1336
Transmission control...1336
Torque converter...1338
Transmission...1340
Main relief valve and torque converter relief valve...1348
Front axle...1350
Final drive (no differential specification)...1354
Final drive (differential/ differential lock specification)...1356
Differential lock solenoid valve...1358
Tandem drive...1360
Brake system...1362
Slack adjuster...1362
Wheel brake...1364
Parking brake...1366
Hydraulic system...1368
Power train pump...1368
Control valve...1370
Hydraulic cylinder...1378
Work equipment...1380
Circle and drawbar...1380
Blade...1382
Lifter...1384
Circle rotation gear...1386
80 Appendix...1389
Air conditioner...1391
Precautions for refrigerant...1391
Air Conditioner Components...1392
Structure and Function of Refrigeration System...1394
Overview of Refrigeration System...1395
Air Conditioner Unit...1396
Compressor...1399
Condenser...1400
Receiver drier...1401
Air conditioner control panel...1402
Procedure for check and troubleshooting...1404
Circuit diagram and layout of connector pins...1406
System diagram...1408
Detail of air conditioner unit...1410
Parts and connectors layout...1412
Testing air leakage (ducts)...1414
Check with self-diagnosis (control panel display)...1415
Testing temperature control...1416
Testing Fresh/Recirc air changeover...1417
Testing evaporator temperature sensor...1418
Testing relays...1419
Testing blower amp...1420
Troubleshooting Chart 1...1421
Troubleshooting Chart 2...1423
Information in troubleshooting table...1425
Troubleshooting for power supply system (Air conditioner does not operate)...1426
Troubleshooting of compressor and refrigerant system (Air is not cooled)...1428
Troubleshooting for blower motor system (Air does not come out or air flow is improper)...1432
Troubleshooting for temperature control...1434
Troubleshooting for FRESH/RECIRC air changeover...1436
Troubleshooting with gauge pressure...1438
Connection of service tool...1440
Precautions for disconnecting and connecting air conditioner piping...1442
Handling compressor oil...1444
90 Diagrams and drawings...1447
Hydraulic diagrams and drawings...1449
Symbols used in hydraulic circuit diagrams...1449
Hydraulic circuit diagram...1451
Power train hydraulic circuit diagram...1453
Differential hydraulic circuit diagram...1454
Electrical diagrams and drawings...1455
Symbols used in electric circuit diagrams...1455
Electrical circuit diagram...1459
Index...1469
