Komatsu GD655-3E0, GD675-3E0 51501 & Up, 51301 & Up SEN01775-02 (Preview)
COVER
00 INDEX AND FOREWORD
INDEX
COMPOSITION OF SHOP MANUAL
TABLE OF CONTENTS
FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HOW TO READ ELECTRIC WIRE CODE
PRECAUTIONS WHEN CARRYING OUT OPERATION
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
01 SPECIFICATION
SPECIFICATION AND TECHNICAL DATA
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICANT SELECTION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
COOLING LINE
FAN DRIVE
POWER TRAIN
POWER TRAIN DIAGRAM
TRANSMISSION HYDRAULIC PIPING
TRANSMISSION CONTROL
TORQUE CONVERTER
TORQUE CONVERTER CONTROL VALVE
TRANSMISSION
TRANSMISSION CONTROL VALVE
ECMV
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
FINAL DRIVE
STEERING SYSTEM
STEERING HYDRAULIC PIPING DRAWING
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)
PRIORITY VALVE
ACCUMULATOR PRESSURE GOVERNOR VALVE
FRONT AXLE
BRAKE SYSTEM
BLAKE HYDRAULIC PIPING
BRAKE VALVE
WHEEL BRAKE
SLACK ADJUSTER
ACCUMULATOR
PARKING BRAKE
PARKING BRAKE AND BANK CONTROL VALVE
UNDERCARRIAGE AND FRAME
TANDEM DRIVE
MAIN FRAME
HYDRAULIC SYSTEM
WORK EQUIPMENT HYDRAULIC PIPING DRAWING
HYDRAULIC PUMP
MAIN CONTROL VALVE
CLSS
WORK EQUIPMENT
WORK EQUIPMENT CONTROL
HYDRAULIC SYSTEM
HYDRAULIC TANK
SWIVEL JOINT
PILOT CHECK VALVE
BLADE ACCUMULATOR, FLOAT VALVE
BLADE FLOAT DEVICE
CIRCLE ROTATION MOTOR
HYDRAULIC CYLINDER
CIRCLE, DRAWBAR
BLADE
CIRCLE ROTATION GEAR
SCARIFIER
RIPPER
CAB AND ITS ATTACHMENTS
AIR CONDITIONER (IF EQUIPPED)
ELECTRICAL SYSTEM
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEAT CIRCUIT
AUTOMATIC SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
MONITOR
SENSORS
COMMUNICATION CONTROLLER
KOMTRAX TERMINAL SYSTEM (IF EQUIPPED)
20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
30 TESTING AND ADJUSTING
TESTING AND ADJUSTING, PART 1
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING EXHAUST COLOR
MEASURING EXHAUST TEMPERATURE
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING BLOWBY PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE SPEED
TESTING FAN BELT TENSION
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION
MEASURING TORQUE CONVERTER STALL SPEED
CHECKING CLUTCH OIL PRESSURE
CHECKING TORQUE CONVERTER OIL PRESSURE
ADJUSTING SPEED SENSOR
FLUSHING TORQUE CONVERTER AND TRANSMISSION CIRCUIT
TESTING BRAKE DISC
TESTING AND ADJUSTING PARKING BRAKE
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE
TESTING ACCUMULATOR CHARGE PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
ADJUSTING PC VALVE
BLEEDING AIR FROM HYDRAULIC CIRCUIT
MEASURING INTERNAL CYLINDER LEAKAGE
TESTING AND ADJUSTING DIFFERENTIAL LOCK OIL PRESSURE [DIFFERENTIAL LOCK SPECIFICATION]
MEASURING STEERING AND BRAKE OIL PRESSURE
BLEEDING AIR FROM BRAKE PIPING
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE
TESTING AND ADJUSTING SLIP CLUTCH TYPE ROTARY DEVICE
MEMORIZING IDLE AND FULL POSITION PROCEDURE
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER
INSPECTION PROCEDURE OF DIODE
TESTING AND ADJUSTING, PART 2
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)
SELF-DIAGNOSIS DISPLAY OF GEAR SHIFT LEVER
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
PREPARATORY WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
ADJUSTING CAB STOPPER BOLT
HOW TO START OPERATION OF KOMTRAX TERMINAL
LAMP DISPLAY OF KOMTRAX TERMINAL
PM-CLINIC
40 TROUBLESHOOTING
FAILURE CODE TABLE AND FUSE LOCATIONS
FAILURE CODE TABLE
FUSE LOCATIONS
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TESTING BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER BOX AND T-ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE, PART 1
FAILURE CODE [(DF1000)] NEUTRAL SAFETY
FAILURE CODE [2G42ZG] DECREASE OF ACCUMULATOR OIL PRESSURE (FRONT)
FAILURE CODE [2G43ZG] DECREASE OF ACCUMULATOR OIL PRESSURE (REAR)
FAILURE CODE [AB00L6] SIGNAL OF ALTERNATOR DISAGREES WITH OPERATING STATE OF ENGINE
FAILURE CODE [AB00MA] MALFUNCTION OF ALTERNATOR
FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE TOO LOW
FAILURE CODE [B@BCNS] ENGINE OVERHEAT
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE TOO HIGH
FAILURE CODE [B@CKNS] DIFFERENTIAL OIL OVERHEAT
FAILURE CODE [CA111] ABNORMALITY IN CONTROLLER
FAILURE CODE [CA115] ABNORMALITY IN ENGINE NE AND BKUP SPEED SENSORS
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR TOO HIGH
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR TOO LOW
FAILURE CODE [CA131] THROTTLE SENSOR TOO HIGH
FAILURE CODE [CA132] THROTTLE SENSOR TOO LOW
FAILURE CODE [CA144] COOLANT TEMPERATURE SENSOR TOO HIGH
FAILURE CODE [CA145] COOLANT TEMPERATURE SENSOR TOO LOW
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR TOO HIGH
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW
FAILURE CODE [CA155] CHARGE TEMPERATURE TOO HIGH AND ENGINE SPEED DERATED
FAILURE CODE [CA187] SENSOR POWER SOURCE 2 TOO LOW
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR TOO HIGH
FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW
FAILURE CODE [CA227] SENSOR POWER SOURCE 2 TOO HIGH
FAILURE CODE [CA234] ENGINE OVER SPEED
FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR
FAILURE CODE [CA271] SHORT CIRCUIT IN FUEL PUMP ACTUATOR
FAILURE CODE [CA272] DISCONNECTION IN FUEL PUMP ACTUATOR
FAILURE CODE [CA281] ABNORMAL SUPPLY PUMP PRESSURE BALANCE
FAILURE CODE [CA322] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.1
FAILURE CODE [CA323] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.5
FAILURE CODE [CA324] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.3
FAILURE CODE [CA325] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.6
FAILURE CODE [CA331] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.2
FAILURE CODE [CA332] DISCONNECTION OR SHORT CIRCUIT IN INJECTOR NO.4
TROUBLESHOOTING BY FAILURE CODE, PART 2
FAILURE CODE [CA342] ABNORMALITY IN ENGINE CONTROLLER DATA CONSISTENCY
FAILURE CODE [CA351] ABNORMALITY IN INJECTOR DRIVE CIRCUIT
FAILURE CODE [CA352] SENSOR POWER SOURCE 1 TOO LOW
FAILURE CODE [CA386] SENSOR POWER SOURCE 1 TOO HIGH
FAILURE CODE [CA428] WATER DETECTION SENSOR TOO HIGH
FAILURE CODE [CA429] WATER DETECTION SENSOR TOO LOW
FAILURE CODE [CA435] ABNORMALITY IN ENGINE OIL PRESSURE SWITCH
FAILURE CODE [CA441] POWER SUPPLY VOLTAGE TOO LOW
FAILURE CODE [CA442] POWER SUPPLY VOLTAGE TOO HIGH
FAILURE CODE [CA449] COMMON RAIL PRESSURE TOO HIGH (2)
FAILURE CODE [CA451] COMMON RAIL PRESSURE SENSOR TOO HIGH
FAILURE CODE [CA452] COMMON RAIL PRESSURE SENSOR TOO LOW
FAILURE CODE [CA488] CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED
FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1)
FAILURE CODE [CA559] SUPPLY PUMP NO PRESSURE (1)
FAILURE CODE [CA689] ABNORMALITY IN ENGINE NE SPEED SENSOR
FAILURE CODE [CA731] ABNORMALITY IN ENGINE BKUP SPEED SENSOR PHASE
FAILURE CODE [CA757] LOSS OF ALL ENGINE CONTROLLER DATA
FAILURE CODE [CA778] ABNORMALITY IN ENGINE BKUP SPEED SENSOR
FAILURE CODE [CA1633] ABNORMALITY IN KOMNET
FAILURE CODE [CA2185] ACCELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH
FAILURE CODE [CA2186] ACCELERATOR PEDAL SENSOR POWER SOURCE TOO LOW
FAILURE CODE [CA2249] SUPPLY PUMP NO PRESSURE (2)
FAILURE CODE [CA2265] DISCONNECTION IN ELECTRIC LIFT PUMP
FAILURE CODE [CA2266] SHORT CIRCUIT IN ELECTRIC LIFT PUMP
FAILURE CODE [CA2311] ABNORMAL RESISTANCE IN IMV SOLENOID
FAILURE CODE [CA2555] DISCONNECTION IN AIR INTAKE HEATER RELAY
FAILURE CODE [CA2556] SHORT CIRCUIT IN AIR INTAKE HEATER RELAY
TROUBLESHOOTING BY FAILURE CODE, PART 3
FAILURE CODE [D19CKZ] DISCONNECTION OR SHORT CIRCUIT IN DIFFERENTIAL CONTROL RELAY
FAILURE CODE [D5ZHL6] TERMINAL C SIGNAL DOES NOT MATCH STATE OF ENGINE
FAILURE CODE [DAQ0KK] POWER SOURCE VOLTAGE OF TRANSMISSION CONTROLLER TOO LOW
FAILURE CODE [DAQSKR] COMMUNICATION CONTROLLER CANNOT RECOGNIZE S-NET
FAILURE CODE [DB2RKR] COMMUNICATION LOST ENGINE CONTROLLER
FAILURE CODE [DBF0KK] POWER SOURCE VOLTAGE OF COMMUNICATION CONTROLLER TOO LOW
FAILURE CODE [DBF2KK] VOLTAGE OF 24 V SOLENOID POWER SUPPLY SYSTEM TOO LOW
FAILURE CODE [DBFRKR] COMMUNICATION LOST COMMUNICATION CONTROLLER
FAILURE CODE [DD1PKB] POWER SUPPLY LINE SHORT IN RPM SET SWITCH
FAILURE CODE [DD1QKB] SHORT CIRCUIT IN RPM SET MODE SWITCH
FAILURE CODE [DDTGKA] DISCONNECTION IN LOCK-UP CLUTCH FILL SWITCH
FAILURE CODE [DDTGKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (LOCK-UP CLUTCH FILL SWITCH)
FAILURE CODE [DDTHKA] DISCONNECTION IN FH CLUTCH FILL SWITCH
FAILURE CODE [DDTHKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (FH CLUTCH FILL SWITCH)
FAILURE CODE [DDTJKA] DISCONNECTION IN FL CLUTCH FILL SWITCH
FAILURE CODE [DDTJKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (FL CLUTCH FILL SWITCH)
FAILURE CODE [DDTKKA] DISCONNECTION IN 1ST CLUTCH FILL SWITCH
FAILURE CODE [DDTKKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (1ST CLUTCH FILL SWITCH)
FAILURE CODE [DDTLKA] DISCONNECTION IN 2ND CLUTCH FILL SWITCH
FAILURE CODE [DDTLKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (2ND CLUTCH FILL SWITCH)
FAILURE CODE [DDTMKA] DISCONNECTION IN 3RD CLUTCH FILL SWITCH
FAILURE CODE [DDTMKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (3RD CLUTCH FILL SWITCH)
FAILURE CODE [DDTNKA] DISCONNECTION IN R CLUTCH FILL SWITCH
FAILURE CODE [DDTNKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (R CLUTCH FILL SWITCH)
FAILURE CODE [DDTPKA] DISCONNECTION IN 4TH CLUTCH FILL SWITCH
FAILURE CODE [DDTPKB] FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF (4TH CLUTCH FILL SWITCH)
FAILURE CODE [DF10KA] DISCONNECTION IN TRANSMISSION SHIFT LEVER SWITCH
FAILURE CODE [DF10KB] SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER SWITCH
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE OUT OF RANGE
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE OUT OF RANGE
FAILURE CODE [DJF1KA] DISCONNECTION IN FUEL LEVEL SENSOR
FAILURE CODE [DK10KX] INPUT OF ACCELERATOR PEDAL POTENTIOMETER OUT OF NORMAL RANGE
FAILURE CODE [DK70KX] INPUT OF INCHING PEDAL POTENTIOMETER OUT OF NORMAL RANGE
FAILURE CODE [DKD0KA] DISCONNECTION IN ARTICULATE SENSOR
FAILURE CODE [DLE2KA] DISCONNECTION IN ENGINE SPEED SENSOR
FAILURE CODE [DLF1KA] DISCONNECTION IN TRANSMISSION INPUT SPEED SENSOR
FAILURE CODE [DLT3KA] DISCONNECTION IN TRANSMISSION OUTPUT SPEED SENSOR
FAILURE CODE [DV00KB] SHORT CIRCUIT IN CAUTION BUZZER
FAILURE CODE [DW4BKA] DISCONNECTION IN PARKING BRAKE RELAY
FAILURE CODE [DXH1KA] DISCONNECTION IN LOCK-UP ECMV SOLENOID
FAILURE CODE [DXH1KY] POWER SUPPLY LINE SHORT IN LOCK-UP ECMV SOLENOID
FAILURE CODE [DXH2KA] DISCONNECTION IN FH CLUTCH ECMV SOLENOID
FAILURE CODE [DXH2KY] POWER SUPPLY LINE SHORT IN FH CLUTCH ECMV SOLENOID
FAILURE CODE [DXH3KA] DISCONNECTION IN FL CLUTCH ECMV SOLENOID
FAILURE CODE [DXH3KY] POWER SUPPLY LINE SHORT IN FL CLUTCH ECMV SOLENOID
FAILURE CODE [DXH4KA] DISCONNECTION IN 1ST CLUTCH ECMV SOLENOID
FAILURE CODE [DXH4KY] POWER SUPPLY LINE SHORT IN 1ST, 3RD CLUTCH ECMV SOLENOID
FAILURE CODE [DXH5KA] DISCONNECTION IN 2ND CLUTCH ECMV SOLENOID
FAILURE CODE [DXH5KY] POWER SUPPLY LINE SHORT IN 2ND, 4TH CLUTCH ECMV SOLENOID
FAILURE CODE [DXH6KA] DISCONNECTION IN 3RD CLUTCH ECMV SOLENOID
FAILURE CODE [DXH7KA] DISCONNECTION IN R CLUTCH ECMV SOLENOID
FAILURE CODE [DXH7KY] POWER SUPPLY LINE SHORT IN R CLUTCH ECMV SOLENOID
FAILURE CODE [DXHHKA] DISCONNECTION IN 4TH CLUTCH ECMV SOLENOID
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
CONTENTS OF TROUBLESHOOTING TABLE
E-1 ENGINE DOES NOT START AT ALL OR DOES NOT START EASILY
E-2 TRANSMISSION MODE DOES NOT CHANGE
E-3 DIFFERENTIAL LOCK FUNCTION DOES NOT WORK OR IS NOT RESET [DIFFERENTIAL LOCK SPECIFICATION]
E-4 WHEEL BRAKE DOES NOT WORK NORMALLY
E-5 PARKING BRAKE DOES NOT WORK OR IS NOT RESET
E-6 LIFT ARM LOCK PIN IS NOT LOCKED OR RESET [LIFT ARM SPECIFICATION]
E-7 BLADE ACCUMULATOR FUNCTION DOES NOT WORK OR IS NOT RESET [BLADE ACCUMULATOR AND FLOAT SPECIFICATION]
E-8 BLADE FLOAT FUNCTION DOES NOT WORK OR IS NOT RESET [BLADE ACCUMULATOR AND FLOAT SPECIFICATION]
E-9 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DOES NOT OPERATE NORMALLY
E-10 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR IS NOT RESET TO ORDINARY DISPLAY
E-11 WHEN STARTING SWITCH IS TURNED ON, CAUTION ITEM LIGHTS UP
E-12 WHILE ENGINE IS RUNNING, EMERGENCY STOP ITEM LIGHTS UP
E-13 INDICATION OF SPEEDOMETER AND ENGINE TACHOMETER IS ABNORMAL
E-14 INDICATION OF ENGINE COOLANT TEMPERATURE GAUGE IS ABNORMAL
E-15 INDICATION OF ARTICULATE GAUGE IS ABNORMAL
E-16 INDICATION OF TORQUE CONVERTER OIL TEMPERATURE GAUGE IS ABNORMAL
E-17 INDICATION OF FUEL LEVEL GAUGE IS ABNORMAL
E-18 DISPLAY OF CHARACTER DISPLAY IS ABNORMAL
E-19 CENTRALIZED WARNING LAMP DOES NOT LIGHT UP OR GO OFF
E-20 ALARM BUZZER DOES NOT SOUND OR STOP
E-21 MACHINE MONITOR MODE SELECTOR SWITCH DOES NOT FUNCTION
E-22 HEADLAMP, CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OFF
E-23 WORKING LAMP DOES NOT LIGHT UP OR GO OFF
E-24 TURN SIGNAL LAMP AND HAZARD LAMP DO NOT BLINK OR GO OFF
E-25 BRAKE LAMP DOES NOT LIGHT UP OR GO OFF
E-26 BACKUP LAMP DOES NOT LIGHT UP OR GO OFF
E-27 BACKUP BUZZER DOES NOT SOUND OR STOP
E-28 AIR CONDITIONER DOES NOT WORK OR STOP
E-29 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
CONTENTS OF TROUBLESHOOTING TABLE
H-1 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
H-2 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE DIRECTION
H-3 TRANSMISSION DOES NOT SHIFT UP OR SHIFT DOWN
H-4 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING
H-5 TORQUE CONVERTER LOCKUP FUNCTION CANNOT BE ACTUATED OR CANCELED
H-6 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR
H-7 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
H-8 DIFFERENTIAL LOCK FUNCTION IS NOT OPERATED OR RESET [DIFFERENTIAL LOCK SPECIFICATION]
H-9 MACHINE IS SLOW OR LACKS POWER WHEN STEERING
H-10 WHEEL BRAKE DOES NOT WORK NORMALLY
H-11 PARKING BRAKE IS NOT APPLIED OR RELEASED
H-12 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER
H-13 NO WORK EQUIPMENT MOVES
H-14 ABNORMAL NOISE GENERATED AROUND PUMP
H-15 BLADE IS SLOW OR LACKS POWER IN LIFTING
H-16 EXCESSIVE BLADE DRIFT
H-17 DRAWBAR SIDE SHIFT OPERATION IS SLOW OR LACKS POWER
H-18 BLADE SIDE SHIFT OPERATION IS SLOW OR LACKS POWER
H-19 POWER TILT OPERATION IS SLOW OR LACKS POWER
H-20 ARTICULATE OPERATION IS SLOW OR LACKS POWER
H-21 LEANING OPERATION IS SLOW OR LACKS POWER
H-22 EXCESSIVE DRIFT OF LEANING
H-23 BLADE DOES NOT ROTATE
H-24 LIFT ARM LOCK PIN IS NOT LOCKED OR RESET [LIFT ARM SPECIFICATION]
H-25 BLADE ACCUMULATOR FUNCTION IS NOT OPERATED OR RESET [BLADE ACCUMULATOR AND FLOAT SPECIFICATION]
H-26 BLADE FLOAT FUNCTION IS NOT OPERATED OR RESET [BLADE ACCUMULATOR AND FLOAT SPECIFICATION]
TROUBLESHOOTING OF ENGINE (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)
S-12 OIL PRESSURE DROPS
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
50 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK, HYDRAULIC TANK AND COOLANT SUB TANK ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION OF OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD
POWER TRAIN, PART 1
REMOVAL AND INSTALLATION OF ENGINE AND TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY
POWER TRAIN, PART 2
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL BRAKE CASE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF SIDE CASE ASSEMBLY (FOR STANDARD FINAL DRIVE)
DISASSEMBLY AND ASSEMBLY OF BEVEL GEAR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BEVEL GEAR SHAFT
DISASSEMBLY AND ASSEMBLY OF BEVEL PINION ASSEMBLY
STEERING SYSTEM
REMOVAL AND INSTALLATION OF STEERING VALVE (ORBIT-ROLL)
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE
HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
REMOVAL AND INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)
DISASSEMBLY AND ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)
DISASSEMBLY AND ASSEMBLY OF CIRCLE ROTATION GEAR ASSEMBLY (WITH SLIP CLUTCH)
CAB AND ITS ATTACHMENTS
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
ELECTRICAL SYSTEM
REMOVAL AND INSTALLATION OF MACHINE MONITOR ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF KOMTRAX CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF COMMUNICATION CONTROLLER ASSEMBLY
90 DIAGRAMS AND DRAWINGS
HYDRAULIC DIAGRAMS AND DRAWINGS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT DIAGRAM (1/2)
HYDRAULIC CIRCUIT DIAGRAM (2/2)
ELECTRICAL DIAGRAMS AND DRAWINGS
ELECTRICAL CIRCUIT DIAGRAM (1/6)
ELECTRICAL CIRCUIT DIAGRAM (2/6)
ELECTRICAL CIRCUIT DIAGRAM (3/6)
ELECTRICAL CIRCUIT DIAGRAM (4/6)
ELECTRICAL CIRCUIT DIAGRAM (5/6)
ELECTRICAL CIRCUIT DIAGRAM (6/6)
CONNECTOR ARRANGEMENT DIAGRAM
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