Service manual Komatsu GD655-6, GD675-6, GD675-6E0 & Up | SEN06997-03

Komatsu GD655-6, GD675-6, GD675-6E0 SEN06997-03 (Preview)

00 Index and Foreword
– Index
– Abbreviation List
– Foreword, Safety, Basic Information
— How to Read the Shop Manual
— Safety Notice for Operation
— Precautions to Prevent Fire
— Procedures If Fire Occurs
— Precautions for Disposing of Waste Materials
— Engine Technology to Conform Exhaust Gas Emission
— Precautions for DEF
— General Character and Precautions for Handling
— Precautions for Adding
— Precautions for Storage
— Precautions for Fire Hazard and Leakage
— Other Precautions
— Store DEF
— Precautions When You Handle Hydraulic Equipment
— Precautions When You Disconnect and Connect Pipings
— Precautions When You Handle Electrical Equipment
— Precautions When You Handle Fuel System Equipment
— Precautions When You Handle Intake System Equipment
— Practical Use of KOMTRAX
— Disconnect and Connect Push-Pull Type Coupler
— How to Disconnect and Connect Type 1 Push-Pull Type Coupler
— How to Disconnect and Connect Type 2 Push-Pull Type Coupler
— How to Disconnect and Connect Type 3 Push-Pull Type Coupler
— Precautions for Disconnection and Connection of Connectors
— How to Disconnect and Connect Deutsch Connector
— How to Disconnect and Connect Slide Lock Type Connector
— How to Disconnect and Connect Connector with Lock to Pull
— How to Disconnect and Connect Connector with Lock to Push
— How to Disconnect and Connect Connector with Housing to Rotate
— How to Read the Codes for Electric Cable
— Explanation of Terms for Maintenance Standard
— Standard Tightening Torque Table
— Conversion Table
01 Specifications
– Table of Contents
– Abbreviation List
– Specifications
— Specification Drawing
— Specification Drawing: GD655-6
— Specification Drawing: GD675-6
— Specification Drawing: GD675-6E0
— Specifications
— Specifications: GD655-6
— Specifications: GD675-6
— Specifications: GD675-6E0
— Weight Table
— Weight Table: GD655-6
— Weight Table: GD675-6
— Weight Table: GD675-6E0
— Table of Fuel, Coolant, and Lubricants
10 Structure and Function
– Table of Contents
– Abbreviation List
– Urea SCR System
— Layout Drawing of Urea SCR System
— Urea SCR System Diagram
— Function of Urea SCR System
— Function of DEF System (Machine Without DEF purge relay) (Applicable Machine: 60001 to 61072)
— Function of DEF System (Machine Without DEF purge relay) (Applicable Machine: 61073 and up)
— Function of DEF System (Machine with DEF purge relay) (Applicable Machine: 60001 to 61072)
— Function of DEF System (Machine with DEF purge relay) (Applicable Machine: 61073 and up)
— Inducement Strategy
— Component Parts of Urea SCR System
— DEF Mixing Tube
— SCR Assembly
— DEF Tank
— DEF Pump
— DEF Injector
— DEF Hose
— DEF Tank Heating Valve
– Boot-up System
— Layout Drawing of Boot-up System
— System Operating Lamp System
— System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal)
— System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)
— Function of System Operating Lamp System (Machine with KOMTRAX Terminal)
— Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine Without DEF purge relay)
— Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine with DEF purge relay)
— Battery Disconnect Switch
— Layout Drawing of Battery Disconnect Switch
— Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal)
— Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine Without DEF purge relay)
— Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine with DEF purge relay)
— Preheating System
— System Diagram of Preheating System
— Function of Automatic Preheating System
— Operation of Automatic Preheating System
– Engine System
— Layout Drawing of Engine System
— Function of Engine System
— Engine Control System
— System Diagram of Engine Control
— Function of Engine Control System
— Operation of Engine Control System
— Engine Power Mode Selector System
— Engine Power Mode Selector System Diagram
— Function of Engine Power Mode Selector System
— Operation of Engine Power Mode Selector System
— Automatic Idle Stop System
— Function of Automatic Idle Stop System
— Component Parts of Engine System
— VGT
— EGR System
— EGR Valve
— EGR Cooler
— KCCV System
— KCCV Ventilator
— KDPF
– Cooling System
— Layout Drawing of Cooling System
— Specifications of Cooling System
— Cooling Fan Control System
— System Diagram of Cooling Fan Control System
— Function of Cooling Fan Control System
— Component Parts of Cooling System
— Brake and Cooling Fan Pump
— Cooling Fan Motor
– Control System
— Layout Drawing of Control System
— Machine Monitor System
— System Diagram of Machine Monitor System
— Function of Machine Monitor System
— Rearview Monitor System
— System Diagram of Rearview Monitor System
— Function of Rearview Monitor System
— KOMTRAX System
— KOMTRAX System Diagram (Machine with KOMTRAX Terminal)
— System Diagram of KOMTRAX System (Machine with Gateway Function Controller)
— Function of KOMTRAX System
— Component Parts of Control System
— Machine Monitor
— Switch Panel
— Rearview Monitor
— Rearview Camera
— KOMTRAX Terminal
— Gateway Function Controller
— Communication Terminal
— Transmission Controller
— Monitor Controller
— CAN Terminating Resistor
— Engine Controller
— Accelerator Pedal
— Inching Pedal Potentiometer
– Hydraulic System
— Layout Drawing of Hydraulic System
— Hydraulic System Diagram
— Function of Hydraulic System
— CLSS
— Structure of CLSS
— Function of CLSS
— Component Parts of Hydraulic System
— Hydraulic Tank
— Steering and Work Equipment Pump
— Power Train Pump and Differential Lock Pump
— Control Valve
– Power Train System
— Layout Drawing of Power Train System
— Operation of Power Train System
— Automatic Shift Control System
— Automatic Shift Control System Diagram
— Function of Automatic Shift Control System
— Transmission Control System
— Transmission Control System Diagram
— Shift Lever Positions and Automatic Gear Shift Range
— Transmission Gear Shift Control System
— Variable Horsepower Control (VHPC) Function
— Transmission Protection Function
— Engine Overrun Prevention Function
— Very Low Speed Travel Control Function
— Component Parts of Power Train System
— Drive Shaft
— Torque Converter
— Lockup Clutch ECMV
— Transmission
— Transmission Control Valve
— F, R, 1st, 2nd, 3rd, 4th Clutch ECMV
— Main Relief Valve and Torque Converter Relief Valve
— Axle
— Differential
— Final Drive
— Tandem Drive
— Differential Lock Solenoid Valve
– Work Equipment System
— Layout Drawing of Work Equipment System
— Function of Work Equipment System
— Component Parts of Work Equipment System
— Blade Lift Circuit Accumulator Solenoid Valve
— Blade Lift Circuit Accumulator
— Scarifier Circuit Relief Valve
— Swivel Joint
— Circle Rotation Motor
— Circle Rotation Gear
– Steering System
— Layout Drawing of Steering System
— Function of Steering System
— Component Parts of Steering System
— Priority Valve
— Orbitrol Valve
— LS Pressure Reducing Valve
– Brake System
— Layout Drawing of Brake System
— Component Parts of Brake System
— Brake Circuit Accumulator
— Brake Valve
— Slack Adjuster
— Brake
— Parking Brake Solenoid Valve and Lifter Lock Pin Control Valve
— Parking Brake
– Undercarriage and Frame
— Frame and Center Hinge Pin
— Structure of Frame and Center Hinge Pin
— Function of Frame and Center Hinge Pin
— Tires
— Features of Radial Tire When Compared with Bias Tire
— Structure of Radial Tire
— Function of Radial Tire
— Structure of Bias Tire
— Function of Bias Tire
– Work Equipment
— Structure of Circle and Drawbar
— Function of Circle and Drawbar
— Structure of Blade
— Function of Blade
— Structure of Lifter
— Function of Lifter
– CAB Related Parts
— ROPS CAB
— Structure of ROPS CAB
— Function of ROPS CAB
20 Standard Value Table
– Table of Contents
– Abbreviation List
– Standard Value Table for Engine
— Standard Value Table for Engine: GD655-6
— Standard Value Table for Engine: GD675-6
— Standard Value Table for Engine: GD675-6E0
– Standard Value Table for Machine
— Standard Value Table for Machine: GD655-6
— Standard Value Table for Machine: GD675-6
— Standard Value Table for Machine: GD675-6E0
— Machine Posture and Procedures to Measure Performance
– Standard Value Table for Electricity
— Standard Value Table for Electricity
30 Testing and Adjusting
– Table of Contents
– Precautions Before Work
– Abbreviation List
– Related Information on Testing and Adjusting
— Tools for Testing and Adjusting
— Sketch of Tools for Testing and Adjusting
– Engine and Cooling System
— Examine Engine Speed
— How to Examine Engine Speed
— Examine Boost Pressure
— How to Examine Boost Pressure
— Examine Exhaust Gas Temperature
— How to Examine Exhaust Gas Temperature
— Examine Exhaust Gas Color
— How to Examine Exhaust Gas Color with the Handy Smoke Checker
— How to Examine Exhaust Gas Color with Smoke Meter
— Examine Mass Air Flow and Temperature Sensor
— How to Examine Mass Air Flow and Temperature Sensor
— Examine and Adjust Valve Clearance
— How to Examine Valve Clearance
— How to Adjust Valve Clearance
— Examine Compression Pressure
— How to Examine Compression Pressure
— Examine Blowby Pressure
— How to Examine Blowby Pressure
— Examine Engine Oil Pressure
— How to Examine Engine Oil Pressure
— Examine EGR Valve and VGT Oil Pressure
— How to Examine EGR Valve and VGT Oil Pressure
— Examine Fuel Pressure
— How to Examine Fuel Pressure
— Examine Fuel Discharge, Return and Leakage
— How to Examine Fuel Discharge, Return, and Leakage
— Bleed Air from Fuel System
— How to Bleed Air from Fuel System
— Examine Fuel Circuit for Leakage
— How to Examine Fuel System for Leakage
— Handle Cylinder Cut-out Mode Operation
— Handle No-Injection Cranking Operation
— Examine KDPF, SCR and Muffler Stack for Looseness and Damage
— How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage
— Examine Installed Condition of Cylinder Heads and Manifolds
— How to Examine Installed Condition of Cylinder Heads and Manifolds
— Examine Engine Piping for Damage and Looseness
— How to Examine Engine Piping for Damage and Looseness
— Examine and Adjust Air Conditioner Compressor Belt Tension
— How to Examine Air Conditioner Compressor Belt Tension
— How to Adjust Air Conditioner Compressor Belt Tension
— Examine Alternator Belt
— How to Examine Alternator Belt
— Examine Automatic Tensioner
— How to Examine Automatic Tensioner
— Correct Soot Accumulation Correction Value by Ash Influence
— How to Correct Soot Accumulation Correction Value by Ash Influence
— Examine SCR Related Functions
— Examine DEF Pump Raised Pressure
— Examine Injection Volume from DEF Injector
— Examine DEF Line Heater Relay 1
— Examine DEF Line Heater Relay 2
— Examine DEF Pump Heater Relay
— Examine DEF Tank Heater Valve
— Examine SCR Denitration Efficiency
— Clean DEF Tank
— How to Clean DEF Tank
— Clean DEF Pump
— How to Clean DEF Pump
– Power Train
— Examine Power Train Oil Pressure
— How to Examine Power Train Oil Pressure
— Adjust Transmission Input Shaft Speed Sensor
— How to Adjust Transmission Input Shaft Speed Sensor
— Adjust Transmission Intermediate Shaft Speed Sensor
— How to Adjust Transmission Intermediate Shaft Speed Sensor
— Adjust Transmission Output Shaft Speed Sensor
— How to Adjust Transmission Output Shaft Speed Sensor
— Examine After You Adjust Transmission Speed Sensor
— How to Examine After Adjustment of Transmission Speed Sensor
— Flush Torque Converter and Transmission Hydraulic Circuit
— How to Flush Torque Converter and Transmission Hydraulic Circuit
— Move Disabled Machine Due to Transmission Valve Failure
— How to Move Disabled Machine Due to Transmission Valve Failure
— Examine Drive Shaft for Looseness, Backlash, and Damage
— How to Examine Drive Shaft for Looseness, Backlash, and Damage
— Examine and Adjust Differential Lock Hydraulic Oil Pressure
— How to Examine Differential Lock Oil Pressure
— How to Adjust Differential Lock Oil Pressure
– Steering System
— Examine and Adjust Steering Circuit Oil Pressure
— How to Examine Steering Circuit Oil Pressure
— How to Adjust Steering Circuit Oil Pressure
— Examine Internal Oil Leakage of Steering Cylinder
— How to Examine Oil Leakage from Steering Cylinder
— Bleed Air from Steering Circuit
— How to Bleed Air from Steering Circuit
— Examine and Adjust Toe-in
— How to Examine Toe-in
— How to Adjust Toe-in
— Adjust Bearing Preload
— How to Adjust Bearing Preload
– Brake System
— Release Remained Pressure from Brake Circuit
— How to Release Remained Pressure from Brake Circuit
— Examine Wheel Brake Oil Pressure
— How to Examine Wheel Brake Oil Pressure
— Examine and Adjust Accumulator Charge Pressure
— How to Examine Accumulator Charge Pressure
— How to Adjust Accumulator Charge Pressure
— Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
— How to Examine Accumulator Nitrogen Gas Pressure for Brake
— How to Charge Brake Accumulator Nitrogen Gas
— Bleed Air from Brake Circuit
— How to Bleed Air from Brake Circuit
— Examine Pressure Decrease of Wheel Brake
— How to Examine Pressure Decrease of Wheel Brake
— Examine Wear of Wheel Brake Disc
— How to Examine Wear of Wheel Brake Disc
— Examine Parking Brake Oil Pressure
— How to Examine Parking Brake Oil Pressure
— Release Parking Brake Manually
— How to Release Parking Brake Manually
— Examine and Adjust Parking Brake Pad
— How to Examine Wear of Parking Brake Pad
— How to Adjust Clearance of Parking Brake Pad
– Hydraulic System
— Examine and Adjust Work Equipment Oil Pressure
— How to Examine Work Equipment Oil Pressure
— How to Adjust Work Equipment Oil Pressure
— Examine and adjust oil pressure in pump PC control circuit
— How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)
— How to Adjust Oil Pressure in Pump PC Control Circuit
— Examine and Adjust Oil Pressure in Pump LS Control Circuit
— How to Examine LS Differential Pressure
— How to Adjust LS Valve
— Examine Oil Pressure of Lifter Lock Pin Circuit
— How to Examine Oil Pressure of Lifter Lock Pin Circuit
— Bleed Air from Work Equipment Circuit
— How to Bleed Air from Work Equipment Circuit
— Examine Cooling Fan Speed
— How to Examine Cooling Fan Speed
— Examine Cooling Fan Circuit Oil Pressure
— How to Examine Cooling Fan Circuit Oil Pressure
— Examine Oil Leakage from Work Equipment Cylinder
— How to Examine Oil Leakage from Blade Lift Cylinder
— How to Examine Oil Leakage from Blade Side-Shift Cylinder
— How to Examine Oil Leakage from Drawbar Side-Shift Cylinder
— How to Examine Oil Leakage from Power Tilt Cylinder
— How to Examine Oil Leakage from Articulate Cylinder
— How to Examine Oil Leakage from Leaning Cylinder
– Work Equipment
— Adjust Clearance in Drawbar Joint
— How to Adjust Clearance in Drawbar Joint
— Examine and Adjust Clearance in Circle Guide
— How to Examine Clearance in Circle Guide
— How to Adjust Clearance in Circle Guide
— Examine and Adjust Circle Rotation Gear
— How to Examine Circle Rotation Gear
— How to Adjust Circle Rotation Gear
— Charge Blade Accumulator Nitrogen Gas Pressure
— How to Charge Blade Accumulator Nitrogen Gas
– Electrical System
— Set and Adjust Each Equipment
— Set and Operate Machine Monitor
— Operator Mode
— Function to Show Technician Identification Status Screen
— Function to Show Operator Identification Input Screen
— Examine Function by LCD (Liquid Crystal Display)
— Examine Function of Service Meter and Odometer
— How to Set Usage Limitation and Change Maintenance Password
— Service Mode
— How to Operate Service Mode
— How to See Pre-defined Monitoring Information
— How to Examine Self-Define Monitor Information
— Abnormality Record Menu
— How to See Maintenance Record
— Maintenance Mode Setting
— How to Set Phone Number Entry
— Default Menu
— Diagnostic Tests Menu
— Adjustment Menu
— No-Injection Cranking Operation
— KOMTRAX Settings Menu
— How to Show Service Message
— How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)
— How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)
— How to Start Up KOMTRAX System (Machine with Gateway Function Controller)
— How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)
— Adjust Rearview Camera Angle
— How to Adjust Rearview Camera Angle
— Set Region of Bluetooth(R) Compatible Radio
— How to Set Region of Bluetooth(R) Compatible Radio
— Handle Voltage Circuit of Engine Controller
— Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)
— Handle Battery Disconnect Switch (Machine with Gateway Function Controller)
— Examine Diodes
— How to Examine Diodes by Digital Tester
— How to Examine Diodes by Analog Tester
– Pm Clinic
— Pm Clinic Service
— Pm Clinic Check Sheet: GD655-6
— Pm Clinic Check Sheet: GD675-6
— Pm Clinic Check Sheet: GD675-6E0
40 Troubleshooting
– Table of Contents
– Precautions Before Work
– Abbreviation List
– Related Information to Troubleshooting
— General Troubleshooting Points
— Troubleshooting Points for Urea SCR System
— Sequence of Events in Troubleshooting
— Checks Before Troubleshooting
— Inspection Procedure Before Troubleshooting
— Walk-Around Check
— Test in Accordance with Testing Procedure
— Examine Fuel Level and Type
— Examine for Impure Ingredient in Fuel
— Examine DEF Level and Type
— Examine Fuel Prefilter
— Examine Fuel Main Filter
— Examine Water Pump for Leakage
— Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type
— Examine Coolant Level (Reservoir Tank)
— Examine Air Cleaner Clogging
— Clean Outer Element
— Replace Element
— Examine Hydraulic Oil Level
— Examine Hydraulic Oil Strainer
— Examine Hydraulic Oil Filter
— Examine Oil Level in Transmission Case
— Examine Transmission Case Strainer
— Replace Transmission Oil Filter Cartridge
— Examine Oil Level in Final Drive Case
— Bleed Air from Fuel System
— Bleed Air from Hydraulic System
— How to Examine Electric Equipment
— Preparation for Troubleshooting of Electrical System
— Procedure for Troubleshooting
— Symptom and Troubleshooting Numbers
— Information Shown in Troubleshooting Table
— How to Diagnose Wiring Harness for Open Circuit of Pressure Sensor System
— Connector List and Layout (Machine with KOMTRAX Terminal)
— Connector List and Layout (Machine with Gateway Function Controller)
— Connector Contact Connection Table
— T-Branch Box and T-Branch Adapter Table
— Fuse Location Table (Machine with KOMTRAX Terminal)
— Fuse Location Table (Machine with Gateway Function Controller)
— Precautions When You Clean and Replace KDPF (KCSF and KDOC)
— Prepare Troubleshoot Machine Monitor
— Procedure to Make Harness Checker on Machine Monitor LCD Unit
— Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
— Failure Code Table
– Troubleshooting by Failure Code (Display of Code)
— Failure Code [1500L0]
— Failure Code [15G0MW]
— Failure Code [15H0MW]
— Failure Code [15J0MW]
— Failure Code [15K0MW]
— Failure Code [15L0MW]
— Failure Code [15M0MW]
— Failure Code [15N0MW]
— Failure Code [15SBL1]
— Failure Code [15SBMA]
— Failure Code [15SCL1]
— Failure Code [15SCMA]
— Failure Code [15SDL1]
— Failure Code [15SDMA]
— Failure Code [15SEL1]
— Failure Code [15SEMA]
— Failure Code [15SFL1]
— Failure Code [15SFMA]
— Failure Code [15SGL1]
— Failure Code [15SGMA]
— Failure Code [15SHL1]
— Failure Code [15SHMA]
— Failure Code [15SJMA]
— Failure Code [15U0NT]
— Failure Code [2F00MA]
— Failure Code [2F00MB]
— Failure Code [2G42ZG]
— Failure Code [2G43ZG]
— Failure Code [989L00]
— Failure Code [989M00]
— Failure Code [989N00]
— Failure Code [A1U0N3]
— Failure Code [A1U0N4]
— Failure Code [AA10NX]
— Failure Code [AB00KE]
— Failure Code [AB00KY]
— Failure Code [AQ10N3]
— Failure Code [AS00N3]
— Failure Code [AS00R2]
— Failure Code [AS00R3]
— Failure Code [AS00R4]
— Failure Code [AS00R5]
— Failure Code [AS00R6]
— Failure Code [AS00ZK]
— Failure Code [AS10KM]
— Failure Code [AS10NR]
— Failure Code [AS10NT]
— Failure Code [B@BAZG]
— Failure Code [B@BCNS]
— Failure Code [B@BCQA]
— Failure Code [B@BCZK]
— Failure Code [B@CENS]
— Failure Code [B@CKNS]
— Failure Code [B@HANS]
— Failure Code [CA115]
— Failure Code [CA122]
— Failure Code [CA123]
— Failure Code [CA131]
— Failure Code [CA132]
— Failure Code [CA144]
— Failure Code [CA145]
— Failure Code [CA153]
— Failure Code [CA154]
— Failure Code [CA187]
— Failure Code [CA221]
— Failure Code [CA222]
— Failure Code [CA227]
— Failure Code [CA234]
— Failure Code [CA238]
— Failure Code [CA239]
— Failure Code [CA249]
— Failure Code [CA256]
— Failure Code [CA271]
— Failure Code [CA272]
— Failure Code [CA322]
— Failure Code [CA323]
— Failure Code [CA324]
— Failure Code [CA325]
— Failure Code [CA331]
— Failure Code [CA332]
— Failure Code [CA343]
— Failure Code [CA351]
— Failure Code [CA352]
— Failure Code [CA356]
— Failure Code [CA357]
— Failure Code [CA386]
— Failure Code [CA428]
— Failure Code [CA429]
— Failure Code [CA431]
— Failure Code [CA432]
— Failure Code [CA435]
— Failure Code [CA441]
— Failure Code [CA442]
— Failure Code [CA449]
— Failure Code [CA451]
— Failure Code [CA452]
— Failure Code [CA488]
— Failure Code [CA515]
— Failure Code [CA516]
— Failure Code [CA553]
— Failure Code [CA555]
— Failure Code [CA556]
— Failure Code [CA559]
— Failure Code [CA595]
— Failure Code [CA687]
— Failure Code [CA689]
— Failure Code [CA691]
— Failure Code [CA692]
— Failure Code [CA697]
— Failure Code [CA698]
— Failure Code [CA731]
— Failure Code [CA778]
— Failure Code [CA1117]
— Failure Code [CA1664]
— Failure Code [CA1669]
— Failure Code [CA1673]
— Failure Code [CA1677]
— Failure Code [CA1678]
— Failure Code [CA1682]
— Failure Code [CA1683]
— Failure Code [CA1684]
— Failure Code [CA1686]
— Failure Code [CA1691]
— Failure Code [CA1694]
— Failure Code [CA1695]
— Failure Code [CA1696]
— Failure Code [CA1712]
— Failure Code [CA1713]
— Failure Code [CA1714]
— Failure Code [CA1715]
— Failure Code [CA1776]
— Failure Code [CA1777]
— Failure Code [CA1843]
— Failure Code [CA1844]
— Failure Code [CA1879]
— Failure Code [CA1881]
— Failure Code [CA1883] (GD655-6, GD675-6)
— Failure Code [CA1883] (GD675-6E0)
— Failure Code [CA1885]
— Failure Code [CA1887]
— Failure Code [CA1921]
— Failure Code [CA1922]
— Failure Code [CA1942]
— Failure Code [CA1993] (GD655-6, GD675-6)
— Failure Code [CA1993] (GD675-6E0)
— Failure Code [CA2185]
— Failure Code [CA2186]
— Failure Code [CA2249]
— Failure Code [CA2271]
— Failure Code [CA2272]
— Failure Code [CA2288]
— Failure Code [CA2311]
— Failure Code [CA2349]
— Failure Code [CA2353]
— Failure Code [CA2357]
— Failure Code [CA2381]
— Failure Code [CA2382]
— Failure Code [CA2383]
— Failure Code [CA2386]
— Failure Code [CA2387]
— Troubleshooting Flowchart
— Failure Code [CA2555]
— Failure Code [CA2556]
— Failure Code [CA2637]
— Failure Code [CA2639]
— Failure Code [CA2771]
— Failure Code [CA2777]
— Failure Code [CA2976]
— Failure Code [CA3133]
— Failure Code [CA3134]
— Failure Code [CA3135]
— Failure Code [CA3142]
— Failure Code [CA3143]
— Failure Code [CA3144]
— Failure Code [CA3146]
— Failure Code [CA3147]
— Failure Code [CA3148]
— Failure Code [CA3151]
— Failure Code [CA3165]
— Failure Code [CA3229]
— Failure Code [CA3231]
— Failure Code [CA3232]
— Failure Code [CA3235]
— Failure Code [CA3239]
— Failure Code [CA3241]
— Failure Code [CA3242]
— Failure Code [CA3251]
— Failure Code [CA3253]
— Failure Code [CA3254]
— Failure Code [CA3255]
— Failure Code [CA3256]
— Failure Code [CA3311]
— Failure Code [CA3312]
— Failure Code [CA3313]
— Failure Code [CA3314]
— Failure Code [CA3315]
— Failure Code [CA3316]
— Failure Code [CA3317]
— Failure Code [CA3318]
— Failure Code [CA3319]
— Failure Code [CA3321]
— Failure Code [CA3322]
— Failure Code [CA3419]
— Failure Code [CA3421]
— Failure Code [CA3497]
— Failure Code [CA3498]
— Failure Code [CA3543]
— Failure Code [CA3545]
— Failure Code [CA3547]
— Failure Code [CA3558]
— Failure Code [CA3559]
— Failure Code [CA3562]
— Failure Code [CA3563]
— Failure Code [CA3567]
— Failure Code [CA3568]
— Failure Code [CA3571]
— Failure Code [CA3572]
— Failure Code [CA3574]
— Failure Code [CA3575]
— Failure Code [CA3577]
— Failure Code [CA3578]
— Failure Code [CA3582]
— Failure Code [CA3583]
— Failure Code [CA3596]
— Failure Code [CA3649]
— Failure Code [CA3681]
— Failure Code [CA3682]
— Failure Code [CA3713]
— Failure Code [CA3717]
— Failure Code [CA3718]
— Failure Code [CA3725]
— Failure Code [CA3741]
— Failure Code [CA3748]
— Failure Code [CA3751]
— Failure Code [CA3755]
— Failure Code [CA3866]
— Failure Code [CA3867]
— Failure Code [CA3868]
— Failure Code [CA3899]
— Failure Code [CA3911]
— Failure Code [CA3912]
— Failure Code [CA3932]
— Failure Code [CA3933]
— Failure Code [CA3934]
— Failure Code [CA3935]
— Failure Code [CA3936]
— Failure Code [CA4151]
— Failure Code [CA4152]
— Failure Code [CA4155]
— Failure Code [CA4156]
— Failure Code [CA4157]
— Failure Code [CA4158]
— Failure Code [CA4159]
— Failure Code [CA4161]
— Failure Code [CA4162]
— Failure Code [CA4163]
— Failure Code [CA4164]
— Failure Code [CA4165]
— Failure Code [CA4166]
— Failure Code [CA4168]
— Failure Code [CA4169]
— Failure Code [CA4171]
— Failure Code [CA4249]
— Failure Code [CA4251]
— Failure Code [CA4259]
— Failure Code [CA4261]
— Failure Code [CA4277]
— Failure Code [CA4281]
— Failure Code [CA4459]
— Failure Code [CA4461]
— Failure Code [CA4658]
— Failure Code [CA4731]
— Failure Code [CA4732]
— Failure Code [CA4739]
— Failure Code [CA4768]
— Failure Code [CA4769]
— Failure Code [CA4842]
— Failure Code [CA4952] (Machine with KOMTRAX Terminal)
— Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [CA5115]
— Failure Code [CA5179]
— Failure Code [CA5181]
— Failure Code [CA5383]
— Failure Code [D160KA]
— Failure Code [D160KB]
— Failure Code [D160KY]
— Failure Code [D19JKZ]
— Failure Code [D19KKZ]
— Failure Code [D1EHKA]
— Failure Code [D1EHKB]
— Failure Code [D1EHKY]
— Failure Code [D1FBKB]
— Failure Code [D5ZHL6]
— Failure Code [D811MC]
— Failure Code [D862KA]
— Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)
— Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)
— Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [D8AQK4]
— Failure Code [D8AQKR]
— Failure Code [D8G1KT]
— Failure Code [D8G6KT]
— Failure Code [DAF0KT]
— Failure Code [DAF0MB]
— Failure Code [DAF0MC]
— Failure Code [DAF3KK]
— Failure Code [DAF8KB]
— Failure Code [DAFDKB]
— Failure Code [DAFGMC]
— Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)
— Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)
— Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [DAFQKR]
— Failure Code [DAQ0KK]
— Failure Code [DAQ0KT]
— Failure Code [DAQ0MC]
— Failure Code [DAQ1KA]
— Failure Code [DAQ2KK]
— Failure Code [DAQ9KQ]
— Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)
— Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)
— Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873)
— Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 60874 and Up)
— Failure Code [DAQQKR]
— Failure Code [DAQRKR]
— Failure Code [DAQRMA]
— Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)
— Failure Code [DB2QKR] (Machine with Gateway Function Controller)
— Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)
— Failure Code [DB2RKR] (Machine with Gateway Function Controller)
— Failure Code [DD1PKB]
— Failure Code [DD1QKB]
— Failure Code [DDAAL6]
— Failure Code [DDB6L4]
— Failure Code [DDTHKA]
— Failure Code [DDTJKA]
— Failure Code [DDTKKA]
— Failure Code [DDTLKA]
— Failure Code [DDTMKA]
— Failure Code [DDTNKA]
— Failure Code [DDTPKA]
— Failure Code [DF10KA]
— Failure Code [DF10L4]
— Failure Code [DGF1KX]
— Failure Code [DGH2KB]
— Failure Code [DGT1KX]
— Failure Code [DGT7KB]
— Failure Code [DHA4KA]
— Failure Code [DHAAMA]
— Failure Code [DHACMA]
— Failure Code [DHT8KA]
— Failure Code [DHT8KB]
— Failure Code [DHT8ZG]
— Failure Code [DJF1KA]
— Failure Code [DK70KX]
— Failure Code [DKD0KX]
— Failure Code [DLF1KA]
— Failure Code [DLF1LC]
— Failure Code [DLF2KA]
— Failure Code [DLF2LC]
— Failure Code [DLM3KA]
— Failure Code [DLM3LC]
— Failure Code [DLM3MB]
— Failure Code [DLT3KA]
— Failure Code [DPQ1KR]
— Failure Code [DPQ2KR]
— Failure Code [DPQ3KR]
— Failure Code [DV00KB]
— Failure Code [DW4BKA]
— Failure Code [DW4BKB]
— Failure Code [DW4BKY]
— Failure Code [DW7BKA]
— Failure Code [DW7BKB]
— Failure Code [DW7BKY]
— Failure Code [DX16KA]
— Failure Code [DX16KB]
— Failure Code [DX16KY]
— Failure Code [DXH1KA]
— Failure Code [DXH1KB]
— Failure Code [DXH1KY]
— Failure Code [DXH2KA]
— Failure Code [DXH2KB]
— Failure Code [DXH2KY]
— Failure Code [DXH3KA]
— Failure Code [DXH3KB]
— Failure Code [DXH3KY]
— Failure Code [DXH4KA]
— Failure Code [DXH4KB]
— Failure Code [DXH4KY]
— Failure Code [DXH5KA]
— Failure Code [DXH5KB]
— Failure Code [DXH5KY]
— Failure Code [DXH6KA]
— Failure Code [DXH6KB]
— Failure Code [DXH6KY]
— Failure Code [DXH7KA]
— Failure Code [DXH7KB]
— Failure Code [DXH7KY]
— Failure Code [DXHHKA]
— Failure Code [DXHHKB]
— Failure Code [DXHHKY]
— Failure Code [F313KA]
— Failure Code [F313KB]
— Failure Code [F314KA]
— Failure Code [F314KB]
— Failure Code [F315KB]
— Failure Code [F315KY]
— Failure Code [F316KB]
— Failure Code [F316KY]
— Failure Code [F318KB]
— Failure Code [F318KY]
— Failure Code [F31AKB]
— Failure Code [F31AKY]
— Failure Code [F31BKB]
— Failure Code [F31BKY]
— Failure Code [F31CKB]
— Failure Code [F31CKY]
— Failure Code [F31DKB]
— Failure Code [F31DKY]
— Failure Code [F31EKB]
— Failure Code [F31EKY]
— Failure Code [FS10ZE]
– Troubleshooting of Electrical System (E-Mode)
— Engine Does Not Start (Engine Does Not Crank)
— Manual Preheating System Does Not Operate
— Automatic Preheating System Does Not Operate
— While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On
— Engine Coolant Temperature Gauge Does Not Show Correct Temperature
— LCD Unit and LED Unit on Machine Monitor Do Not Show Anything
— LCD Unit on Machine Monitor Shows Nothing
— Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)
— LCD Screen on Machine Monitor Does Not Show Correctly
— LED Unit Lamp on Machine Monitor is Abnormal
— Switch of Switch Panel on Machine Monitor Does Not Operate
— Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate
— Switch Panel Buzzer of Machine Monitor is Abnormal
— Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally
— DEF Level is Not Shown Correctly
— Rearview Monitor Does Not Come On or Backlight Flickers
— Rearview Monitor Images are Not Shown Clearly
— Rearview Monitor Brightness Cannot be Adjusted
— Night Mode Lamp of Rearview Monitor is Abnormal
— Air Cleaner Clogging Caution Lamp Does Not Come On
— Radiator Coolant Level Caution Lamp Does Not Come On
— Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low
— Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low
— Speedometer Does Not Show Normally
— Engine Tachometer Does Not Show Normally
— Fuel Gauge Does Not Show Normally
— Torque Converter Oil Temperature Gauge Does Not Show Normally
— Articulation Indicator Does Not Show Actual Articulated Angle
— Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On
— Seatbelt Caution Lamp Does Not Show Normally
— Alarm Buzzer Does Not Operate
— Alarm Buzzer Does Not Stop
— Engine Mode Selector Function Does Not Operate Correctly
— Transmission Selector Function Does Not Operate Normally
— Differential Lock Function Does Not Operate or Cannot be Cancelled
— Lock by Lifter Lock Pin Cannot be Done or Cannot be Cancelled
— Lifter Lock Pin Pilot Lamp Does Not Show Correctly
— Blade Accumulator Function Does Not Operate or Cannot be Cancelled
— Blade Accumulator Pilot Lamp Does Not Show Correctly
— Horn Does Not Sound
— Horn Does Not Stop
— Backup Alarm Does Not Sound
— Backup Alarm Continues to Sound and Backup Lamp Keeps Lit
— Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On
— Headlamp Does Not Come On or Go Out
— Headlamp Selection (Low or High Beam) Cannot be Done
— Headlamp (High Beam) Does Not Come On
— Front Working Lamp Does Not Come On or Go Out
— Working Lamp Pilot Lamp Does Not Come On or Go Out
— Rear Working Lamp Does Not Come On or Go Out
— Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Off
— Turn Signal Lamp Does Not Come On or Go Out
— Hazard Lamp Does Not Come On or Go Out
— Turn Signal Lamp Does Not Come On or Go Off
— Brake Lamp Does Not Come On or Stays Lit
— Backup Lamp Does Not Come On
— No Wiper Operates
— Front Wiper Does Not Operate
— Rear Wiper Does Not Operate
— Right and Left Door Wipers Do Not Operate
— Left Door Wiper Does Not Operate
— Right Door Wiper Does Not Operate
— Front or Door Washer Does Not Operate
— Rear Washer Does Not Operate
— KOMTRAX System Does Not Operate Correctly
– Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
— Information Shown in Troubleshooting Table (H-Mode)
— Failure Mode and Cause Table
— Machine Does Not Start
— Lockup is Not Released
— Torque Converter Lockup Clutch Does Not Engage
— Machine Does Not Upshift or Downshift from Neutral
— Machine Does Not Upshift or Downshift
— Travel Speed or Power is Low
— Travel Speed or Power is Low in Specified Gear
— Time Lag is Large When You Start Machine or Shift Gears
— Torque Converter Oil Temperature is High
— Differential Lock Function Does Not Operate or Cannot be Cancelled
— Unusual Noise is Heard from Around Hydraulic Pump
— Engine Speed Drops Largely or Engine Stops
— Steering Wheel is Disabled
— Steering Speed or Power is Not Sufficient
— Steering Wheel Does Not Move or is Heavy to Operate
— Wheel Brakes Do Not Operate or are Weak
— Wheel Brakes are Not Released or Drag
— Parking Brake Does Not Operate or is Weak
— Parking Brake is Not Released or Drags
— Lifter Lock Pin is Not Locked or Not Cancelled
— All Work Equipment Operate Slowly
— All Work Equipment Do Not Operate
— Blade Lift Speed or Power is Low
— Drawbar Side-Shift Speed or Power is Low
— Blade Side-Shift Speed or Power is Low
— Power Tilt Speed or Power is Low
— Articulate Speed or Power is Low
— Leaning Speed or Power is Low
— Hydraulic Drift of Blade Lift is Large
— Hydraulic Drift of Leaning is Large
— Blade Does Not Rotate
— Blade Accumulator Function Does Not Operate or Cannot be Cancelled
— Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
— Unusual Noise is Heard from Around Fan
– Troubleshooting of Engine (S-Mode)
— Information Shown in Troubleshooting Table (S-Mode)
— Engine Does Not Crank When Starting Switch is Turned to Start Position
— Engine Cranks but No Exhaust Smoke Comes Out
— Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
— Engine Startability is Unsatisfactory
— Engine Does Not Pick Up Smoothly
— Engine Stops During Operation
— Engine Does Not Rotate Smoothly
— Engine Lacks Output (or Lacks Power)
— KDPF Becomes Clogged in a Short Time
— Engine Oil Consumption is Excessive
— Engine Oil Becomes Dirty Quickly
— Fuel Consumption is Excessive
— Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
— Engine Oil Pressure Drops
— Fuel Mixes Into Engine Oil
— Water Mixes Into Engine Oil (Milky)
— Coolant Temperature Increases Too High (Overheat)
— Unusual Noise is Heard
— Vibration is Excessive
— Air Cannot be Bled from Fuel Circuit
— Active Regeneration is Done Frequently
— Active Regeneration Continues Long
— White Smoke is Exhausted During Active Regeneration
— DEF Consumption is Excessive
— There is an Unusual Smell (Irritating Odor)
— Foreign Materials Enter DEF (DEF Increases)
50 Disassembly and Assembly
– Table of Contents
– Precautions Before Work
– Abbreviation List
– Related Information on Disassembly and Assembly
— How to Read This Manual
— Coating Materials List
— Special Tool List
— Sketches of Special Tools
– Engine and Cooling System
— Remove and Install Supply Pump Assembly
— How to Remove Supply Pump Assembly
— How to Install Supply Pump Assembly
— Remove and Install Injector Assembly
— How to Remove Injector Assembly
— How to Install Injector Assembly
— Remove and Install Cylinder Head Assembly
— How to Remove Cylinder Head Assembly
— How to Install Cylinder Head Assembly
— Remove and Install EGR Valve Assembly
— How to Remove EGR Valve Assembly
— How to Install EGR Valve Assembly
— Remove and Install EGR Cooler Assembly
— How to Remove EGR Cooler Assembly
— How to Install EGR Cooler Assembly
— Remove and Install Starter Assembly
— How to Remove Starting Motor Assembly
— How to Install Starting Motor Assembly
— Remove and Install Alternator Belt
— How to Remove Alternator Belt
— How to Install Alternator Belt
— Remove and Install Automatic Tensioner
— How to Remove Automatic Tensioner
— How to Install Automatic Tensioner
— Remove and Install Radiator Assembly
— How to Remove Radiator Assembly
— How to Install Radiator Assembly
— Remove and Install Aftercooler Assembly
— How to Remove Aftercooler Assembly
— How to Install Aftercooler Assembly
— Remove and Install Power Train Oil Cooler Assembly
— How to Remove Power Train Oil Cooler Assembly
— How to Install Power Train Oil Cooler Assembly
— Remove and Install Cooling Fan Motor Assembly
— How to Remove Cooling Fan Motor Assembly
— How to Install Cooling Fan Motor Assembly
— Remove and Install Engine, Torque Converter, and Transmission Assembly
— How to Remove Engine, Torque Converter, and Transmission Assembly
— How to Install Engine, Torque Converter, and Transmission Assembly
— Disconnect and Connect Engine, Torque Converter, and Transmission Assembly
— How to Disconnect Engine, Torque Converter, and Transmission Assembly
— How to Connect Engine, Torque Converter, and Transmission Assembly
— Remove and Install Engine Front Oil Seal
— How to Remove Engine Front Oil Seal
— How to Install Engine Front Oil Seal
— Remove and Install Engine Rear Oil Seal
— How to Remove Engine Rear Oil Seal
— How to Install Engine Rear Oil Seal
— Remove and Install Engine Hood Assembly
— How to Remove Engine Hood Assembly
— How to Install Engine Hood Assembly
— Remove and Install Fuel Tank Assembly
— How to Remove Fuel Tank Assembly
— How to Install Fuel Tank Assembly
— Remove and Install DEF Tank Assembly
— How to Remove DEF Tank Assembly
— How to Install DEF Tank Assembly
— Remove and Install DEF Tank Sensor Flange Assembly
— How to Remove DEF Tank Sensor Flange Assembly
— How to Install DEF Tank Sensor Flange Assembly
— Remove and Install DEF Tank Sensor
— How to Remove DEF Tank Sensor
— How to Install DEF Tank Sensor
— Remove and Install DEF Tank Strainer
— How to Remove DEF Tank Strainer
— How to Install DEF Tank Strainer
— Remove and Install KDPF Assembly
— How to Remove KDPF Assembly
— How to Install KDPF Assembly
— Disassemble and Assemble KDPF Assembly
— How to Disassemble KDPF Assembly
— How to Assemble KDPF Assembly
— Remove and Install SCR Assembly
— How to Remove SCR Assembly
— How to Install SCR Assembly
— Remove and Install KDPF and SCR Assembly
— How to Remove KDPF and SCR Assembly
— How to Install KDPF and SCR Assembly
— Remove and Install KCCV Assembly
— How to Remove KCCV Assembly
— How to Install KCCV Assembly
— Remove and Install DEF Mixing Tube
— How to Remove DEF Mixing Tube
— How to Install DEF Mixing Tube
— Remove and Install DEF Injector
— How to Remove DEF Injector
— How to Install DEF Injector
— Remove and Install DEF Pump
— How to Remove DEF Pump
— How to Install DEF Pump
— Remove and Install DEF Hose
— How to Remove DEF Hose
— How to Install DEF Hose
— Remove and Install Air Cleaner Assembly
— How to Remove Air Cleaner Assembly
— How to Install Air Cleaner Assembly
— Remove and Install Air Conditioner Compressor Assembly
— How to Remove Air Conditioner Compressor Assembly
— How to Install Air Conditioner Compressor Assembly
— Remove and Install Air Conditioner Condenser Assembly
— How to Remove Air Conditioner Condenser Assembly
— How to Install Air Conditioner Condenser Assembly
– Power Train
— Disassemble and Assemble Torque Converter Assembly
— How to Disassemble Torque Converter Assembly
— How to Assemble Torque Converter Assembly
— Disassemble and Assemble Transmission Assembly
— How to Disassemble Transmission Assembly
— How to Assemble Transmission Assembly
— Remove and Install Tandem Drive and Final Drive Assembly
— How to Remove Tandem Drive and Final Drive Assembly
— How to Install Tandem Drive and Final Drive Assembly
— Disassemble and Assemble Tandem Drive Assembly
— How to Disassemble Tandem Drive Assembly
— How to Assemble Tandem Drive Assembly
— Disassemble and Assemble Differential Assembly
— How to Disassemble Differential Assembly
— How to Assemble Differential Assembly
— Disassemble and Assemble Final Drive Assembly
— How to Disassemble Final Drive Assembly
— How to Assemble Final Drive Assembly
– Steering System
— Remove and Install Steering Valve Assembly
— How to Remove Steering Valve Assembly
— How to Install Steering Valve Assembly
– Brake System
— Disassemble and Assemble Wheel Brake Assembly
— How to Disassemble Wheel Brake Assembly
— How to Assemble Wheel Brake Assembly
– Undercarriage and Frame
— Remove and Install Center Hinge Pin
— How to Remove Center Hinge Pin
— How to Install Center Hinge Pin
– Hydraulic System
— Remove and Install Hydraulic Tank, Battery and Frame Assembly
— How to Remove Hydraulic Tank, Battery and Frame Assembly
— How to Install Hydraulic Tank, Battery and Frame Assembly
— Remove and Install Hydraulic Tank Assembly
— How to Remove Hydraulic Tank Assembly
— How to Install Hydraulic Tank Assembly
— Remove and Install Cooling Fan Pump Assembly
— How to Remove Cooling Fan Pump Assembly
— How to Install Cooling Fan Pump Assembly
— Remove and Install Control Valve Assembly
— How to Remove Control Valve Assembly
— How to Install Control Valve Assembly
– Work Equipment
— Remove and Install Ripper Assembly
— How to Remove Ripper Assembly
— How to Install Ripper Assembly
— Remove and Install Blade Assembly
— How to Remove Blade Assembly
— How to Install Blade Assembly
— Remove and Install Circle and Drawbar Assembly
— How to Remove Circle and Drawbar Assembly
— How to Install Circle and Drawbar Assembly
— Remove and Install Circle Rotation Gear Assembly
— How to Remove Circle Rotation Gear Assembly
— How to Install Circle Rotation Gear Assembly
— Disassemble and Assemble Circle Rotation Gear Assembly
— How to Disassemble Circle Rotation Gear Assembly
— How to Assemble Circle Rotation Gear Assembly
— Disassemble and Assemble Work Equipment Cylinder Assembly
— How to Disassemble Work Equipment Cylinder Assembly
— How to Assemble Work Equipment Cylinder Assembly
– CAB Related Parts
— Remove and Install Operator Cab Assembly
— How to Remove Operator Cab Assembly
— How to Install Operator Cab Assembly
— Remove and Install Operator Cab Door
— How to Remove Operator Cab Door
— How to Install Operator Cab Door
— Remove and Install Operator Cab Glass (Adhered Glass)
— How to Remove Operator Cab Glass (Adhered Glass)
— How to Install Operator Cab Glass (Adhered Glass)
— Remove and Install Floor Frame Assembly
— How to Remove Floor Frame Assembly
— How to Install Floor Frame Assembly
— Remove and Install Air Conditioner Unit Assembly
— How to Remove Air Conditioner Unit Assembly
— How to Install Air Conditioner Unit Assembly
— Remove and Install Operator Seat
— How to Remove Operator Seat
— How to Install Operator Seat
— How to Remove and Install Seat Belt
— How to Remove Seat Belt
— How to Install Seat Belt
– Electrical System
— Remove and Install Engine Controller Assembly
— How to Remove Engine Controller Assembly
— How to Install Engine Controller Assembly
— Remove and Install Transmission Controller Assembly
— How to Remove Transmission Controller Assembly
— How to Install Transmission Controller Assembly
— Remove and Install Machine Monitor Assembly
— How to Remove Machine Monitor Assembly
— How to Install Machine Monitor Assembly
— Remove and Install Mass Air Flow and Temperature Sensor
— How to Remove Mass Air Flow and Temperature Sensor
— How to Install Mass Air Flow and Temperature Sensor
— Remove and Install KCCV Crankcase Pressure Sensor
— How to Remove KCCV Crankcase Pressure Sensor
— How to Install KCCV Crankcase Pressure Sensor
— Remove and Install KDPF Temperature Sensor
— How to Remove KDPF Temperature Sensor
— How to Install KDPF Temperature Sensor
— Remove and Install KDPF Differential Pressure Sensor
— How to Remove KDPF Differential Pressure Sensor
— How to Install KDPF Differential Pressure Sensor
— Remove and Install SCR Temperature Sensor
— How to Remove SCR Temperature Sensor
— How to Install SCR Temperature Sensor
— Remove and Install Ammonia Sensor
— How to Remove Ammonia Sensor
— How to Install Ammonia Sensor
— Remove and Install SCR Outlet NOx Sensor
— How to Remove SCR Outlet NOx Sensor
— How to Install SCR Outlet NOx Sensor
— Remove and Install KOMTRAX Terminal Assembly
— How to Remove KOMTRAX Terminal Assembly
— How to Install KOMTRAX Terminal Assembly
— Remove and Install Gateway Function Controller Assembly
— How to Remove Gateway Function Controller Assembly
— How to Install Gateway Function Controller Assembly
— Remove and Install Communication Terminal
— How to Remove Communication Terminal
— How to Install Communication Terminal
60 Maintenance Standard
– Table of Contents
– Abbreviation List
– Engine and Cooling System
— Maintenance Standard for Engine Mount
— Maintenance Standard for Cooling System
— Maintenance Standard for Cooling Fan Motor
– Power Train
— Maintenance Standard for Drive Shaft
— Maintenance Standard for Torque Converter
— Maintenance Standard for Lockup Clutch ECMV
— Maintenance Standard for Transmission
— Maintenance Standard for FL, R Clutch
— Maintenance Standard for FH, 1st Clutch
— Maintenance Standard for 2nd, 3rd Clutch
— Maintenance Standard for 4th Clutch
— Maintenance Standard for Transmission Control Valve
— Maintenance Standard for F, R, 1st, 2nd, 3rd, 4th Clutch ECMV
— Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
— Maintenance Standard for Front Axle
— Maintenance Standard for Rear Axle
— Maintenance Standard for Differential
— Maintenance Standard for Final Drive
— Maintenance Standard for Tandem Drive
– Steering System
— Maintenance Standard for Steering Cylinder
– Brake System
— Maintenance Standard for Slack Adjuster
— Maintenance Standard for Brake
– Undercarriage and Frame
— Maintenance Standard for Frame and Center Hinge Pin
– Hydraulic System
— Maintenance Standard for Hydraulic Tank
— Maintenance Standard for Steering and Work Equipment Pump
— Maintenance Standard for Servo Valve of Steering and Work Equipment Pump
— Maintenance Standard for Power Train Pump and Differential Lock Pump
— Maintenance Standard for Control Valve
— Maintenance Standard for Differential Lock Solenoid Valve
— Maintenance Standard for Parking Brake Solenoid Valve and Lifter Lock Pin Control Valve
– Work Equipment
— Maintenance Standard for Circle and Drawbar
— Maintenance Standard for Blade
— Maintenance Standard for Lifter
— Maintenance Standard for Circle Rotation Gear
— Maintenance Standard for Blade Lift Cylinder
— Maintenance Standard for Blade Side Shift Cylinder
— Maintenance Standard for Leaning Cylinder
— Maintenance Standard for Articulate Cylinder
— Maintenance Standard for Drawbar Side Shift Cylinder
— Maintenance Standard for Blade Power Tilt Cylinder
80 Appendix
– Table of Contents
– Precautions Before Work
– Abbreviation List
– Air Conditioner System
— Precautions for Refrigerant
— Air Conditioner Component
— Specifications of Air Conditioner
— Structure and Function of Refrigeration Cycle
— Outline of Refrigeration Cycle
– Component Parts of Air Conditioner System
— Air Conditioner Unit
— Configuration Diagram of Air Conditioner Unit
— Function of Air Conditioner Unit
— Component Parts of Air Conditioner Unit
— Function of Evaporator as Air Conditioner Unit Component
— Function of Heater Core as Air Conditioner Unit Component
— Function of Air Mix Servo Motor as Air Conditioner Unit Component
— Function of Blower Fan and Blower Motor as Air Conditioner Unit Component
— Function of Fresh/Recirc Air Changeover Servo Motor as Air Conditioner Unit Component
— Function of Evaporator Temperature Sensor as Air Conditioner Unit Component
— Function of Expansion Valve as Air Conditioner Unit Component
— Function of Dual Pressure Switch
— Compressor
— Structure of Compressor
— Specifications of Compressor
— Function of Compressor
— Condenser
— Structure of Condenser
— Specifications of Condenser
— Function of Condenser
— Receiver Drier
— Structure of Receiver Dryer
— Specifications of Receiver Dryer
— Function of Receiver Dryer
– Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
– Circuit Diagram and Configuration of Connector Pins of Air Conditioner
– System Diagram of Air Conditioner
— Input and Output Signals of Air Conditioner Control Panel
— Structure of Air Conditioner Control Panel
— Function of Air Conditioner Control Panel
– Locations of Air Conditioner Parts and Layout of Connectors
– Examine Air Leakage (Duct)
— How to Examine Air Leakage (Duct)
– Examine Air Conditioner with Self-Diagnosis Function
– Examine Temperature Control Function
— How to Examine Temperature Control Function
– Examine Fresh/Recirc Air Changeover
— How to Examine Fresh/Recirc Air Changeover
– Examine Evaporator Temperature Sensor
— How to Examine Evaporator Temperature Sensor
– Examine Relay
— How to Examine Relay
– Examine Blower Amplifier
— How to Examine Blower Amplifier
– Air Conditioner Troubleshooting Chart 1
– Air Conditioner Troubleshooting Chart 2
– Information Shown in Troubleshooting Table
– Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
– Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
– Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
– Troubleshooting for Temperature Control Function
– Troubleshooting for Fresh/Recirc Air Changeover
– Troubleshooting for Hot Water Cut Valve
– Troubleshooting by Gauge Pressure
– Connect Service Tool
— How to Connect Service Tool
– Precautions for Disconnection and Connection of Air Conditioner Piping
– Handle Compressor Oil
90 Circuit Diagrams
– Table of Contents
– Abbreviation List
– Hydraulic Circuit Diagram
— Symbols Used in Hydraulic Circuit Diagram
— Hydraulic Circuit Diagram (1/2)
— Hydraulic Circuit Diagram (2/2)
— Power Train Hydraulic Circuit Diagram
– Electrical Circuit Diagram
— Symbols Used in Electric Circuit Diagram
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/12)
— Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/12)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (1/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (2/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (3/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (4/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (5/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (6/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (7/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (8/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (9/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (10/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (11/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (12/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (13/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (14/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (15/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60001 to 60873) (16/16)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (1/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (2/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (3/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (4/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (5/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (6/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (7/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (8/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (9/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (10/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (11/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (12/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (13/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (14/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (15/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (16/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 60874 to 62011) (17/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (1/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (2/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (3/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (4/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (5/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (6/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (7/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (8/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (9/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (10/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (11/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (12/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (13/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (14/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (15/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (16/17)
— Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 62012 and Up) (17/17)
Index