Komatsu GD705-5 26001 & Up SEN06489-03 (Preview)
Cover
Notice of revision
00 Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic components
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out work
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
List of Abbreviation
Conversion table
01 Specification
Specification drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure and function
Engine and cooling system
Cooling system
Cooling fan motor
Power train system
Power train system drawing
Power train piping drawing
Transmission control
Torque converter
Transmission
Transmission control valve
ECMV
Main relief and torque converter relief valve
Front axle
Final drive
Differential
Differential lock solenoid valve
Tandem drive
Steering system
Steering piping diagram
Priority valve
Steering valve
Brake system
Brake hydraulic piping diagram
Brake valve
Slack adjuster
Accumulator (for brake)
Charge valve
Wheel brake
Parking brake and bank control valve
Parking brake
Undercarriage and frame
Frame
Tire
Hydraulic system
Hydraulic system
Work equipment hydraulic component layout
Work equipment control
Hydraulic tank
Main pump
Power train pump
Control valve
CLSS
Functions and operation by valve
Swivel joint
Pilot check valve
Separately installed safety valve
Accumulator (for blade)
Work equipment
Circle and drawbar
Blade
Lifter
Circle rotation motor
Circle rotation gear
Cab
Cab
Electrical system
Machine monitor
Automatic shift control system
Transmission controller
Engine controller
KOMTRAX system
Starting engine circuit
Stopping engine circuit
Preheating circuit
Engine power mode select circuit
Cooling fan control function
Sensor
20 Standard value table
Standard value table
Standard value table for engine
Standard value table for machine
Machine posture and procedure for measuring performance
30 Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling equipment of fuel system devices
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing muffler (main body) and stuck muffler for looseness and damage
Testing muffler function
Testing installed condition of cylinder heads and manifolds
Testing of engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Power train
Testing power train oil pressure
Adjusting transmission speed sensor
Retrieval of disabled machine due to transmission valve failure
Flushing procedure for torque converter and transmission circuits
Testing and adjusting toe-in
Testing and adjusting differential lock oil pressure
Steering system
Testing and adjusting steering oil pressure
Testing oil leakage of steering cylinder
Bleeding air from steering circuit
Brake system
Testing and adjusting brake oil pressure
Releasing remaining pressure from brake circuit
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing and adjusting parking brake
Parking brake emergency releasing procedure
Procedure for charging brake accumulator with nitrogen gas
Hydraulic system
Testing and adjusting work equipment oil pressure
Testing and adjusting pump LS differential pressure
Testing lift arm lock cylinder circuit oil pressure
Testing oil leakage of work equipment cylinder
Bleeding air from work equipment circuit
Testing cooling fan pump circuit oil pressure
Work equipment system
Adjusting drawbar ball joint clearance
Testing and adjusting circle guide clearance
Adjusting circle rotation gear
Procedure for charging blade accumulator with nitrogen gas
Electrical system
Special functions of machine monitor
KOMTRAX terminal start-up procedure (ORBCOMM)
Lamp indication of KOMTRAX terminal (ORBCOMM)
KOMTRAX terminal start-up procedure (GPRS)
Lamp indication of KOMTRAX terminal (GPRS)
Handling voltage circuit of engine controller
Testing diodes
Pm Clinic
Pm Clinic service
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Preparation work for troubleshooting of electrical system
Classification and procedures for troubleshooting
Failure codes table
Failure and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Locations of fuses
Troubleshooting by failure code
Failure code [1500L0] TORQFLOW transmission: Double engagement
Failure code [15G0MW] Transmission R clutch: Slip
Failure code [15H0MW] Transmission FH clutch: Slip
Failure code [15J0MW] Transmission FL clutch: Slip
Failure code [15K0MW] Transmission 1st clutch: Slip
Failure code [15L0MW] Transmission 2nd clutch: Slip
Failure code [15M0MW] Transmission 3rd speed clutch: Slip
Failure code [15N0MW] Transmission 4th clutch: Slip
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF
Failure code [15SBMA] ECMV R clutch: Malfunction
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF
Failure code [15SCMA] ECMV FH clutch: Malfunction
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF
Failure code [15SDMA] ECMV FL clutch: Malfunction
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF
Failure code [15SEMA] ECMV 1st clutch: Malfunction
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF
Failure code [15SFMA] ECMV 2nd clutch: Malfunction
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF
Failure code [15SGMA] ECMV 3rd clutch: Malfunction
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF
Failure code [15SHMA] ECMV 4th clutch: Malfunction
Failure code [15SJMA] ECMV lockup clutch: Malfunction
Failure code [15U0NT] Inching clutch: Overheating
Failure code [2G42ZG] Front accumulater: Oil pressure drop
Failure code [2G43ZG] Rear accumulater: Pressure drop
Failure code [AA1ANX] Air cleaner: Clogging
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.
Failure code [AB00MA] Alternator: Malfunction
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop
Failure code: [B@BCNS] Engine coolant overheat
Failure code [B@BEBF] Water in fuel error
Failure code: [B@CENS] Torque converter oil overheat
Failure code: [B@CKNS] Differential case: Overheat
Failure code: [B@HANS] Hydraulic oil: Overheating
Failure code [CA111] Engine controller internal error
Failure code [CA115] Engine Ne, Bkup speed sensor error
Failure code [CA122] Charge pressure sensor high error
Failure code [CA123] Charge pressure sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA144] Coolant sensor high error
Failure code [CA145] Coolant sensor low error
Failure code [CA153] Charge temperature sensor high error
Failure code [CA154] Charge temperature sensor low error
Failure code [CA155] Speed derating error by high charge temperature
Failure code [CA187] Sensor power supply 2 low error
Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA227] Sensor power supply 2 high error
Failure code [CA234] Engine overspeed
Failure code [CA238] Ne speed sensor power supply error
Failure code [CA271] IMV/IMA: Short circuit
Failure code [CA272] IMV/IMA open circuit
Failure code [CA281] Abnormal supply pump pressure balance
Failure code [CA322] Injector #1 (L#1) open/short
Failure code [CA323] Injector #5 (L#5) open/short
Failure code [CA324] Injector #3 (L#3) open/short
Failure code [CA325] Injector #6 (L#6) open/short
Failure code [CA331] Injector #2 (L#2) open/short
Failure code [CA332] Injector #4 (L#4) open/short
Failure code [CA342] Data compatibility error in engine controller
Failure code [CA351] Injector drive circuit error
Failure code [CA352] Sensor power supply 1 low error
Failure code [CA386] Sensor power supply 1 high error
Failure code [CA428] Water-in-fuel sensor high error
Failure code [CA429] Water-in-fuel sensor low error
Failure code [CA431] Idle validation switch error
Failure code [CA432] Idle validation action error
Failure code [CA435] Engine oil pressure switch error
Failure code [CA441] Power supply voltage low error
Failure code [CA442] Power supply voltage high error
Failure code [CA449] Common rail pressure high error 2
Failure code [CA451] Common rail pressure sensor high error
Failure code [CA452] Common rail pressure sensor low error
Failure code [CA488] Torque derating error by high charge temperature
Failure code [CA553] Common rail pressure high error 1
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All continuous data lost error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET (CAN communication) error
Failure code [CA2185] Throttle sensor power supply high error
Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2249] Supply pump pressure low error 2
Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2311] Abnormality in IMV (IMA) solenoid
Failure code [CA2555] Intake heater relay open circuit
Failure code [CA2556] Intake heater relay short circuit
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness
Failure code [D160KB] Backup lamp relay: Ground fault
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state
Failure code [DAFRKR] CAN communication failure (monitor panel)
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)
Failure code [DAQOKT] Transmission controller: Non-volatile memory error
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement
Failure code [DAQRKR] Transmission controller CAN communication: Communication error
Failure code [DAQRMA] Transmission controller option setting: Malfunction
Failure code [DB2RKR] Engine controller CAN communication: Communication error
Failure code [DD1PKB] RPM set switch power supply short circuit
Failure code [DD1QKB] RPM set mode switch short circuit
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit
Failure code [DDTNKA] Fill switch for R clutch: Open circuit
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT5L6] Failure of T/C Oil Press Sensor
Failure code [DJF1KA] Fuel level sensor: Open circuit
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match
Failure code [DLM3KA] Fan speed sensor: Open circuit
Failure code [DLM3LC] Fan speed sensor: Short circuit
Failure code [DLM3MB] Radiator Fan Control Mismatch
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit
Failure code [DV00KB] Buzzer: Short circuit
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Starting motor does not turn)
E-2 Preheating does not work
E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen
E-6 Emergency stop monitor lights up while engine is running
E-7 Speedometer or engine tachometer does not indicate correctly
E-8 Engine coolant temperature gauge does not indicate correctly
E-9 Articulation angle indicator does not indicate correctly
E-10 Torque converter oil temperature gauge does not indicate correctly
E-11 Fuel level gauge does not indicate correctly
E-12 Character display does not display correctly
E-13 Centralized warning lamp does not light up or does not go off
E-14 Alarm buzzer does not sound or does not stop sounding
E-15 Machine monitor mode selector switch does not work
E-16 Transmission mode does not switch
E-17 Engine mode does not switch
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]
E-21 Horn does not sound or does not stop sounding
E-22 Backup alarm does not sound or does not stop sounding
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off
E-24 Working lamp does not light up or does not go off
E-25 Fog lamp does not light up or does not go off
E-26 Turn signal lamp and hazard lamp do not flash.
E-27 Stop lamp does not light up or does not go off
E-28 Backup lamp does not light up or does not go off
E-29 Windshield wiper does not operate
E-30 Window washer does not operate
E-31 KOMTRAX system does not operate correctly
Troubleshooting for hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
H-1 Engine speed drops significantly or engine stalls
H-2 Machine does not move off (both forward and reverse)
H-3 Gear speed does not shift
H-4 Travel speed or power is low
H-5 Torque converter lockup does not operate or is not canceled
H-6 Machine starts or gear speed shifts with long time lag
H-7 Torque converter oil temperature is high
H-8 Differential lock function does not operate or is not canceled
H-9 Steering speed or power is insufficient
H-10 Steering wheel does not move
H-11 Wheel brakes do not work or are weak
H-12 Wheel brakes are not released or drag
H-13 Parking brake does not work or it is weak
H-14 Parking brake (including emergency release system) is not released or drags
H-15 All work equipment operates slowly or lacks power
H-16 All work equipments do not operate
H-17 Unusual noise is heard from around hydraulic pump
H-18 Blade lift speed or power is low
H-19 Hydraulic drift of lifted blade is large
H-20 Drawbar side shift speed or power is low
H-21 Blade cross slide speed or power is low
H-22 Power tilt speed or power is low
H-23 Articulate speed or power is low
H-24 Leaning speed or power is insufficient
H-25 Hydraulic drift (tilting) of leaning is large
H-26 Blade does not rotate
H-27 Lift arm lock pin is not locked or is not canceled
H-28 Blade accumulator does not operate or is not canceled [blade accumulator specifications]
H-29 Fan rotation is abnormal (such as excessive noise or vibration of fan, or overheating)
H-30 Unusual noise is heard from around fan
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
Shop Manual
50 Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools 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 oil seal assembly
Removal and installation of engine rear oil seal assembly
Removal and installation of cooling fan pump assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of power train oil cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Power train
Removal and installation of engine and transmission assembly
Disconnection and connection of transmission and torque converter assembly from/to engine
Disassembly and assembly of transmission assembly
Disassembly and assembly of torque converter assembly
Removal and installation of tandem drive and final drive assembly
Disassembly and assembly of tandem drive assembly
Disassembly and assembly of final drive assembly
Steering system
Removal and installation of steering valve (Orbitrol) assembly
Disassembly and assembly of steering valve (Orbitrol)
Brake system
Disassembly and assembly of wheel brake assembly
Undercarriage and frame
Removal and installation of center hinge pin
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of circle drawbar assembly
Removal and installation of circle rotation gear assembly
Disassembly and assembly of circle rotation gear assembly
Removal and installation of ripper assembly
Cab and its attachments
Removal and installation of operator’s cab assembly
Removal and installation of floor frame assembly
Removal and installation of operator’s cab glass (adhered window glass)
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of starting motor
Removal and installation of battery
Removal and installation of machine monitor assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX terminal assembly (ORBCOMM)
Removal and installation of KOMTRAX terminal assembly (GPRS)
60 Maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan motor
Power train system
Torque converter
Transmission
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Front axle
Final drive
Differential
Tandem drive
Brake system
Slack adjuster
Wheel brake
Parking brake
Undercarriage and frame
Frame
Hydraulic system
Main pump
Power train pump
Control valve
Hydraulic cylinder
Work equipment
Circle and drawbar
Blade
Lifter
Circle rotation gear
80 Appendix
Air conditioner
Precautions for refrigerant
Air conditioner components
Structure and function of refrigeration system
Overview of refrigeration system
Air conditioner unit
Compressor
Condenser
Receiver drier
Air conditioner control panel
Procedure for check and troubleshooting
Circuit diagram and layout of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (ducts)
Check with self-diagnosis (control panel display)
Testing temperature control
Testing Fresh/Recirc air changeover
Testing evaporator temperature sensor
Testing relays
Testing blower amp
Troubleshooting Chart 1
Troubleshooting Chart 2
Information in troubleshooting table
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting of compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (Air does not come out or air flow is improper)
Troubleshooting for temperature control
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling compressor oil
90 Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Electrical circuit diagram
Index
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