Komatsu GD955-7 Motor Grader Shop Manual SEN06936-08 PDF

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Komatsu GD955-7 Motor Grader Shop Manual SEN06936-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GD955-7 Motor Grader Shop Manual SEN06936-08 – PDF DOWNLOAD 

Language : English
Pages : 6600
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu GD955-7 Motor Grader Shop Manual SEN06936-08 – PDF DOWNLOAD 

SERIAL NUMBERS 10001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 30
How to Read the Shop Manual 30
Safety Notice for Operation 32
Precautions to Prevent Fire 40
Procedures If Fire Occurs 42
Precautions for Disposing of Waste Materials 43
Procedures for Exhaust Gas Regulations 44
Precautions for DEF 45
General Character and Precautions for Handling 45
Precautions for Adding 45
Precautions for Storage 45
Precautions for Fire Hazard and Leakage 45
Other Precautions 45
Store DEF 46
Precautions When You Handle Hydraulic Equipment 47
Precautions When You Disconnect and Connect Pipings 50
Precautions When You Handle Electrical Equipment 57
Precautions When You Handle Fuel System Equipment 59
Precautions When You Handle Intake System Equipment 60
Practical Use of KOMTRAX 61
Disconnect and Connect Push-Pull Type Coupler 62
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 62
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 63
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 64
Precautions for Disconnection and Connection of Connectors 66
How to Disconnect and Connect Deutsch Connector 70
How to Disconnect and Connect Slide Lock Type Connector 71
How to Disconnect and Connect Connector with Lock to Pull 73
How to Disconnect and Connect Connector with Lock to Push 74
How to Disconnect and Connect Connector with Housing to Rotate 76
Standard Tightening Torque Table 77
Conversion Table 84
Abbreviation List 89
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: GD955-7 95
Specifications 97
Specifications: GD955-7 97
Weight Table 105
Weight Table: GD955-7 105
Fuel, Coolant, Lubricant 106
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 106
10 Structure and Function 109
Table of Contents 110
Urea SCR System 115
Layout Drawing of Urea SCR System 115
Urea SCR System Diagram 118
Function of Urea SCR System 119
Function of DEF System 119
Inducement Strategy 122
Component Parts of Urea SCR System 129
DEF Mixing Tube 129
SCR Assembly 130
DEF Tank 132
DEF Pump 134
DEF Injector 135
DEF Hose 136
DEF Tank Heating Valve 137
Boot-up System 138
Layout Drawing of Boot-up System 138
System Operating Lamp System 141
System Diagram of System Operating Lamp System 141
Function of Operation Lamp System 141
Operation of System Operating Lamp System 141
Battery Disconnect Switch 142
Function of Battery Disconnect Switch 142
Operation of Battery Disconnect Switch 142
Starting Motor Disconnect Switch 143
Function of Starting Motor Disconnect Switch 143
Operation of Starting Motor Disconnect Switch 143
Preheating System 144
System Diagram of Preheating System 144
Function of Automatic Preheating System 144
Operation of Automatic Preheating System 144
Function of Manual Preheating System 145
Operation of Manual Preheating System 145
Engine Shutdown Secondary Switch 146
Function of Engine Shutdown Secondary Switch 146
Operation of Engine Shutdown Secondary Switch 146
Emergency Engine Stop Switch 147
Function of Emergency Engine Stop Switch 147
Operation of Emergency Engine Stop Switch 147
External Power Supply Engine Preheater 148
Layout Drawing of External Power Supply Engine Preheater 148
Function of External Power Supply Engine Preheater 149
Engine System 150
Layout Drawing of Engine System 150
Function of Engine System 151
Engine Control System 152
System Diagram of Engine Control 152
Function of Engine Control System 153
Engine Automatic Warm-up Function 153
Engine Automatic Warm-up Cancel Function 154
Operation of Engine Control System 155
Engine Power Mode Selector System 157
Engine Power Mode Selector System Diagram 157
Function of Engine Power Mode Selector System 157
Operation of Engine Power Mode Selector System 157
Automatic Idle Stop System 158
Function of Automatic Idle Stop System 158
Operation of Automatic Idle Stop System 158
RPM Set 160
Function of RPM Set 160
Operation of RPM Set 162
Component Parts of Engine System 164
Fuel Tank 164
Damper 165
VGT 167
EGR System 171
EGR Valve 174
EGR Cooler 176
KCCV System 178
KCCV Ventilator 180
KDPF 183
Cooling System 187
Layout Drawing of Cooling System 187
Specifications of Cooling System 188
Cooling Fan Control System 189
System Diagram of Cooling Fan Control System 189
Function of Cooling Fan Control System 190
Component Parts of Cooling System 192
Radiator 192
Pump Assembly (Brake and Cooling Fan) 193
Cooling Fan Motor 201
Control System 207
Layout Drawing of Control System 207
Machine Monitor System 209
System Diagram of Machine Monitor System 209
Function of Machine Monitor System 210
Rearview Monitor System 211
System Diagram of Rearview Monitor System 211
Function of Rearview Monitor System 211
KOMTRAX Plus System 212
System Diagram of KOMTRAX Plus System 212
Function of KOMTRAX Plus System 213
Machine Lock-out System 214
Layout Drawing of Machine Lock-out System 214
Machine Lock-out System Drawing 215
Function of Machine Lock-out System 216
Operation of Machine Lock-out System 217
Seating Switch System 218
Seating Switch System Diagram 218
Function of Seating Switch System 219
Component Parts of Control System 220
Machine Monitor 220
Switch Panel 240
Rearview Monitor 241
Rearview Camera 243
KOMTRAX Terminal 244
KOMTRAX Plus Controller 246
Transmission Controller 251
Work Equipment Controller 255
Fan Controller 259
Monitor Controller 263
CAN Terminating Resistor 268
Engine Controller 269
Accelerator Pedal 276
Inching Pedal 278
Fuel Feed Pump 279
Fuel Feed Pump Switch 280
Hydraulic System 282
Layout Drawing of Hydraulic System 282
CLSS 283
System Diagram of CLSS 283
Function of CLSS 284
Component Parts of Hydraulic System 287
Hydraulic Tank 287
Work Equipment Pump 290
Pump Assembly (Power Train Control, Power Train Lubrication, Differential Lock) 299
Control Valve 301
Individual Safety Valve 327
Power Train System 330
Layout Drawing of Power Train System 330
Operation of Power Train System 333
Transmission Control System 334
Transmission Control System Diagram 334
Function of Transmission Control System 335
Transmission Protection Function 337
Engine Overrun Prevention Function 337
Inching Clutch Protection Function 337
Component Parts of Power Train System 338
Drive Shaft 338
Torque Converter 340
Transmission 344
Transmission Control Valve 371
Lockup Clutch ECMV 374
F, R, 1st, 2nd, 3rd, 4th Clutch ECMV 377
H, L Clutch ECMV 381
Valve Assembly (For Main Relief and Torque Converter Relief) 385
Axle 388
Differential 391
Final Drive 393
Tandem Drive 395
Differential Lock Solenoid Valve 397
Steering System 398
Layout Drawing of Steering System 398
Secondary Steering System 400
Secondary Steering System Diagram 400
Function of Secondary Steering System 400
Steering Column 401
Structure of Steering Column 401
Function of Steering Column 401
Steering Lever System 402
Layout Drawing of Steering Lever System 402
Steering Lever System Diagram 403
Function of Steering Lever System 403
Component Parts of Steering System 406
Steering Unit 406
Steering Pump 407
Cross Relief Valve 408
Secondary Steering Pump 409
Secondary Steering Motor 410
Steering Angle Sensor 411
Articulate Angle Sensor 412
Work Equipment System 413
Layout Drawing of Work Equipment System 413
Work Equipment Control System 416
Work Equipment Lever Operating Function System Diagram 416
Work Equipment Lever Operation Function 416
Blade Lift, Spool Calibration Function 416
Stop Shock Mitigate Filter Function 416
Work Equipment Lock System 417
Work Equipment Lock System Diagram 417
Function of Work Equipment Lock System 418
Component Parts of Work Equipment System 419
Work Equipment Lock Solenoid Valve 419
Solenoid Valve (Blade Accumulator, Blade FLOAT) 420
Work Equipment Cylinder 421
Blade Accumulator 425
Swivel Joint 426
Work Equipment Electric Lever 427
Circle Rotation Motor 430
Circle Rotation 431
Brake System 433
Layout Drawing of Brake System 433
Parking Brake Control System 435
System Diagram of Parking Brake Control System 435
Operation of Parking Brake Control System 435
Component Parts of Brake System 436
Accumulator Charge Valve 436
Brake Accumulator 441
Brake Valve 442
Slack Adjuster 445
Brake 447
Parking Brake Solenoid Valve 449
Parking Brake 451
Auto-Greasing System 452
Layout Drawing of Auto-Greasing System 452
Auto-Greasing System Diagram 458
Function of Auto-Greasing System 460
Auto-Greasing System 461
Auto-Greasing Pump 461
Auto-Greasing Injector 462
Service Center 465
Service Center 465
Function of Service Center 466
KOWA Oil Sampling System 467
Layout Drawing of KOWA Oil Sampling System 467
Function of KOWA Oil Sampling System 468
Undercarriage and Frame 469
Frame and Center Hinge Pin 469
Structure of Frame and Center Hinge Pin 469
Function of Frame and Center Hinge Pin 469
Tires 470
Features of Radial Tire When Compared with Bias Tire 470
Structure of Radial Tire 470
Function of Radial Tire 470
Structure of Bias Tire 471
Function of Bias Tire 471
Work Equipment 472
Bearing Type Circle and Drawbar 472
Structure of Bearing Type Circle and Drawbar 472
Function of Bearing Type Circle and Drawbar 474
Blade 475
Structure of Blade 475
Function of Blade 476
Lifter 477
Structure of Lifter 477
Function of Lifter 477
Ripper 478
Structure of Ripper 478
Function of Ripper 478
CAB Related Parts 479
ROPS CAB 479
Structure of ROPS CAB 479
Function of ROPS CAB 479
CAB Mount 480
Structure of CAB Mount 480
Function of CAB Mount 480
20 Standard Value Table 481
Table of Contents 482
Standard Value Table for Engine 483
Standard Value Table for Engine: GD955-7 483
Standard Value Table for Machine 487
Standard Value Table for Machine: GD955-7 487
30 Testing and Adjusting 501
Table of Contents 502
Precautions Before Work 507
Related Information on Testing and Adjusting 508
Tools for Testing and Adjusting 508
Sketch of Tools for Testing and Adjusting 523
Engine and Cooling System 524
Examine Engine Speed 524
How to Examine Engine Speed 524
Examine Boost Pressure 529
How to Examine Boost Pressure on Machine Monitor 529
How to Examine Boost Pressure by Testing Tool 531
Examine Exhaust Gas Temperature 534
How to Test Exhaust Gas Temperature by the Machine Monitor 534
How to Examine Exhaust Temperature by Testing Tools 536
Examine Exhaust Gas Color 539
How to Examine Exhaust Gas Color with the Handy Smoke Checker 539
How to Examine Exhaust Gas Color with Smoke Meter 542
Examine Mass Air Flow and Temperature Sensor 546
How to Examine Mass Air Flow and Temperature Sensor 546
Examine and Adjust Valve Clearance 549
How to Examine Valve Clearance 549
How to Adjust Valve Clearance 550
Examine Compression Pressure 552
How to Examine Compression Pressure 552
Examine Blowby Pressure 555
How to Examine Blowby Pressure 555
Examine Engine Oil Pressure 559
How to Examine Engine Oil Pressure on Machine Monitor 559
How to Examine Engine Oil Pressure by Testing Tool 560
Examine EGR Valve and VGT Oil Pressure 561
How to Examine EGR Valve and VGT Oil Pressure 561
Examine Fuel Pressure 563
How to Examine Fuel Pressure 563
Examine Fuel Return Rate and Leakage 565
How to Examine Fuel Return Rate and Leakage 566
Bleed Air from Fuel System 571
How to Bleed Air from Fuel System 572
Examine Fuel Circuit for Leakage 574
How to Examine Fuel System for Leakage 574
Test Fuel Low Pressure Circuit Devices 575
How to Test Fuel Low Pressure Circuit Devices 575
Handle Cylinder Cut-out Mode Operation 579
Handle No-Injection Cranking Operation 580
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 581
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 581
Examine Installation of Cylinder Head Cover and Manifolds 582
How to Examine Installed Condition of Cylinder Head covers and Manifolds 582
Examine Engine Piping for Damage and Looseness 583
How to Examine Engine Piping for Damage and Looseness 583
Clean Fuel Doser 584
How to Clean Fuel Doser 584
Write Injector Compensation Value to Engine Controller 587
How to Write Injector Compensation Value to Engine Controller 587
Write Correction for Ash in Soot Accumulation to Engine Controller 594
How to Write Correction for Ash in Soot Accumulation to Engine Controller 594
Examine Alternator Belt 595
How to Examine Alternator Belt 595
Examine SCR Related Functions 597
Examine DEF Pump Raised Pressure 601
Examine Injection Volume from DEF Injector 605
Examine DEF Line Heater Relay 1 611
Examine DEF Line Heater Relay 2 615
Examine DEF Pump Heater Relay 619
Examine DEF Tank Heater Valve 624
Examine SCR Denitration Efficiency 628
Clean DEF Tank 632
How to Clean DEF Tank 632
Clean DEF Pump 638
How to Clean DEF Pump 638
Power Train 645
Examine Power Train Oil Pressure 645
How to Prepare for Idle Running 648
How to Examine Main Relief Pressure of Power Train 649
How to Examine Inlet Pressure of Torque Converter 650
How to Examine Outlet Pressure of Torque Converter 651
How to Examine Operating Pressure of Torque Converter Lockup Clutch ECMV 653
How to Examine Forward Clutch Operating Pressure of Forward Clutch ECMV 655
How to Examine Reverse Clutch Operating Pressure of Reverse Clutch ECMV 657
How to Examine 1st Clutch Operating Pressure of 1st Clutch ECMV 659
How to Examine 2nd Clutch Operating Pressure of 2nd Clutch ECMV 661
How to Examine 3rd Clutch Operating Pressure of 3rd Clutch ECMV 663
How to Examine 4th Clutch Operating Pressure of 4th Clutch ECMV 665
How to Examine High Clutch Operating Pressure of High Clutch ECMV 668
How to Examine Low Clutch Operating Pressure of Low Clutch ECMV 670
How to Examine Transmission Lubrication Pressure 672
Adjust Transmission Input Shaft Speed Sensor 674
How to Adjust Transmission Input Shaft Speed Sensor 674
How to Adjust Transmission Intermediate Shaft Speed Sensor (Upper) 675
How to Adjust Transmission Intermediate Shaft Speed Sensor (Upper) 675
Adjust Transmission Intermediate Shaft Speed Sensor (Lower) 676
How to Adjust Transmission Intermediate Shaft Speed Sensor (Lower) 676
Adjust Transmission Output Shaft Speed Sensor 677
How to Adjust Transmission Output Shaft Speed Sensor 677
Examine After You Adjust Transmission Speed Sensor 678
How to Examine After Adjustment of Transmission Speed Sensor 678
Adjust Travel Speed Sensor 1 (Sub Steering) 679
How to Adjust Travel Speed Sensor 1 (Sub Steering) 679
Adjust Travel Speed Sensor 2 (Sub Steering) 680
How to Adjust Travel Speed Sensor 2 (Sub Steering) 680
Flush Torque Converter and Transmission Hydraulic Circuit 681
How to Flush Torque Converter and Transmission Hydraulic Circuit 681
Move Disabled Machine Due to Transmission Valve Failure 686
How to Move Disabled Machine Due to Transmission Valve Failure 687
Examine Drive Shaft for Looseness, Backlash, and Damage 689
How to Examine Drive Shaft for Looseness, Backlash, and Damage 689
Examine and Adjust Differential Lock Hydraulic Oil Pressure 690
How to Examine Discharged Pressure of Differential Lock Pump 690
How to Examine Outlet Pressure of Differential Lock Valve 692
How to Adjust Differential Lock Oil Pressure 693
Steering System 694
Examine and Adjust Steering Circuit Oil Pressure 694
How to Examine Steering Circuit Oil Pressure 694
Adjust Steering Circuit Oil Pressure 695
Bleed Air from Steering Circuit 696
How to Bleed Air from Steering Circuit 696
Calibrate Steering Control Lever 697
How to Calibrate Steering Control Lever 698
Examine and Adjust Toe-in 704
How to Examine Toe-in 704
How to Adjust Toe-in 705
Brake System 706
Release Remained Pressure from Brake Circuit 706
How to Release Remained Pressure from Brake Circuit 706
Examine Wheel Brake Oil Pressure 707
Examine Wheel Brake Oil Pressure on Machine Monitor 707
How to Examine Wheel Brake Oil Pressure by Testing Tool 708
Examine and Adjust Accumulator Charge Pressure 711
How to Examine Accumulator Charge Pressure on Machine Monitor 711
How to Examine Accumulator Charge Pressure by Testing Tool 711
How to Adjust Accumulator Charge Pressure 713
Examine and Charge Accumulator Nitrogen Gas Pressure for Brake 714
How to Examine Accumulator Nitrogen Gas Pressure for Brake 714
How to Charge Accumulator Nitrogen Gas Pressure for Brake 718
How to Release Nitrogen Gas When You Discard Accumulator 722
Bleed Air from Brake Circuit 724
How to Bleed Air from Wheel Brake Circuit 724
Bleed Air from Parking Brake Circuit 726
Examine Brake Performance 729
How to Examine Wheel Brake Performance 729
Examine Brake Pedal 730
How to Examine Brake Pedal 730
Examine Pressure Decrease of Brake 732
How to Examine Pressure Decrease of Wheel Brake 732
How to Examine Pressure Decrease of Parking Brake by Machine Monitor 732
How to Examine Pressure Decrease of Parking Brake by Testing Tool 734
Examine Wear of Wheel Brake Disc 736
How to Examine Wear of Wheel Brake Disc 736
Examine Releasing Pressure of Parking Brake 737
Examine Releasing Pressure of Parking Brake by Machine Monitor 737
How to Examine Releasing Pressure of Parking Brake by Testing Tool 737
Release Parking Brake Manually 740
How to Release Parking Brake Manually 740
Hydraulic System 742
Release Remained Pressure from Work Equipment Circuit 742
How to Release Remained Pressure from Work Equipment Circuit 742
Examine and Adjust Work Equipment Oil Pressure 743
How to Examine Unload Pressure 743
How to Examine Work Equipment Relief Pressure 744
How to Adjust Work Equipment Oil Pressure 745
Examine and Adjust Work Equipment EPC Oil Pressure 747
How to Examine Work Equipment EPC Oil Pressure 747
How to Adjust Work Equipment EPC Oil Pressure 748
Examine and adjust oil pressure in pump PC control circuit 749
How to Examine Outlet Pressure in PC Valve 749
How to Adjust Oil Pressure in Pump PC Control Circuit 751
Examine and Adjust Oil Pressure in Pump LS Control Circuit 753
How to Examine LS Differential Pressure 753
How to Adjust LS Differential Pressure 755
Bleed Air from Work Equipment Circuit 756
How to Bleed Air from Hydraulic Cylinder 756
Examine Cooling Fan Speed 757
How to Examine Cooling Fan Maximum Speed 757
How to Examine Cooling Fan Minimum Speed 757
Examine Cooling Fan Circuit Oil Pressure 759
How to Examine Cooling Fan Circuit Oil Pressure 759
Examine Oil Leakage from Hydraulic Cylinder 762
How to Examine Oil Leakage from Steering Cylinder 762
How to Examine Oil Leakage from Blade Lift Cylinder 763
How to Examine Oil Leakage from Blade Side-Shift Cylinder 764
How to Examine Oil Leakage from Drawbar Side-Shift Cylinder 765
How to Examine Oil Leakage from Blade Power Tilt Cylinder 766
How to Examine Oil Leakage from Articulate Cylinder 767
How to Examine Oil Leakage from Leaning Cylinder 768
Work Equipment 770
Adjust Clearance of Ball Joint 770
How to Adjust Clearance of Ball Joint 770
Adjust Circle Rotation Device 771
How to Adjust Circle Rotation Device 771
How to Work for Clutch Warm-Up 774
Charge Blade Accumulator Nitrogen Gas Pressure 776
How to Charge Blade Accumulator Nitrogen Gas Pressure 776
CAB Related Parts 781
Adjust Play of Operator’s Seat 781
How to Adjust Play of Operator’s Seat 781
Electrical System 782
Set and Adjust Each Equipment 782
Set and Operate Machine Monitor 786
Operator Mode 790
Function to Show Technician Identification Status Screen 790
Function to Show Operator Identification Input Screen 790
Examine Function by LCD (Liquid Crystal Display) 791
Examine Function of Service Meter and Odometer 792
Usage Limitation Setting, Change Password 792
Service Mode 797
How to Operate Service Mode 797
How to See Pre-defined Monitoring Information 800
How to Examine Monitoring Information 809
Abnormality Record Menu 827
How to See Maintenance Record 832
Maintenance Mode Setting 834
How to Set Phone Number Entry 840
Default Setting Menu 842
Testing Menu 865
Adjustment Menu 879
No-Injection Cranking Operation 933
KOMTRAX Settings Menu 935
How to Show Service Message 939
How to Operate Snap Shot Manually 941
How to Start Up KOMTRAX Terminal 946
How to Stop Use of KOMTRAX Terminal 951
Default Setting of KOMTRAX Plus Controller 953
Default Setting of KOMTRAX Plus Controller 953
Default Setting of Wireless LAN Modem 956
Default Setting of Wireless LAN Modem 956
How to Examine Wireless LAN Modem Communication 957
Download Data from KOMTRAX Plus Controller 959
How to Download Data from KOMTRAX Plus Controller 959
How to Download Data from Service Connector in Cab 959
How to Download Data Through the Service Connector Outside CAB (Ground Level Download Specification) 961
How to Download Data from Wireless LAN (Wireless LAN Spec) 962
Adjust After Replacement of KOMTRAX Plus Controller 964
How to Adjust After Replacement of KOMTRAX Plus Controller 964
Adjust After Replacement of Wireless LAN Modem 967
How to Adjust After Replacement of Wireless LAN Modem 967
Adjust Rearview Camera Angle 970
How to Adjust Rearview Camera Angle 970
Set Region of Bluetooth(R) Compatible Radio 971
How to Set Region of Bluetooth(R) Compatible Radio 971
Handle Voltage Circuit of Engine Controller 973
Handle Battery Disconnect Switch 974
Examine Diodes 975
How to Examine Diodes by Digital Tester 975
How to Examine Diodes by Analog Tester 975
Pm Clinic 976
Pm Clinic Service 976
Pm Clinic Check Sheet: GD955-7 979
40 Troubleshooting 989
Table of Contents 990
Precautions Before Work 1008
Related Information for Troubleshooting 1009
Precautions for Troubleshooting 1009
Sequence of Events in Troubleshooting 1010
General Troubleshooting Points 1012
Troubleshooting Points for Urea SCR System 1013
Checks Before Troubleshooting 1025
Inspection Procedure Before Troubleshooting 1027
Walk-Around Check 1027
Test in Accordance with Testing Procedure 1029
Examine Fuel Level and Type 1029
Examine for Impure Ingredient in Fuel 1031
Examine DEF Level and Type 1031
Examine Fuel Prefilter 1034
Examine Fuel Main Filter 1035
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 1037
Examine Coolant Level (Expansion Tank) 1039
Examine Air Cleaner Clogging 1041
Clean Outer Element 1042
Replace Element 1044
Examine Hydraulic Oil Level 1046
Examine Hydraulic Oil Strainer 1048
Examine Hydraulic Oil Filter 1051
Examine Oil Level in Transmission Case 1052
Examine Transmission Case Strainer 1054
Replace Transmission Oil Filter Cartridge 1056
Examine Oil Level in Final Drive Case 1057
Bleed Air from Fuel System 1058
Bleed Air from Hydraulic System 1058
How to Examine Electric Equipment 1058
Preparation for Troubleshooting of Electrical System 1065
Preparation for Troubleshooting of Machine Monitor 1065
Preparation for Troubleshooting of Monitor Controller 1065
Preparation for Troubleshooting of Transmission Controller 1066
Preparation for Troubleshooting of Work Equipment Controller 1066
Preparation for Troubleshooting of Fan Controller 1066
Preparation for Troubleshooting of KOMTRAX Terminal 1067
Preparation for Troubleshooting of KOMTRAX Plus Controller 1067
Preparation for Troubleshooting of KomVision Controller 1067
Preparation for Troubleshooting of Engine Controller 1068
How to Disconnect and Connect Connector with a Special Lock 1069
Procedure for Troubleshooting 1074
Symptom and Troubleshooting Numbers 1077
Information Shown in Troubleshooting 1082
Connector List and Layout 1085
Connector Layout 1 1103
Connector Layout 2 1105
Connector Layout 3 1107
Connector Layout 4 1109
Connector Layout 5 1111
Connector Layout 6 1113
Connector Layout 7 1115
Connector Layout 8 1116
Connector Layout 9 1117
Connector Layout 10 1118
Connector Layout 11 1119
Connector Layout 12 1121
Connector Layout 13 1123
Connector Contact Connection Table 1125
T-Branch Box and T-Branch Adapter Table 1172
Fuse Location Table 1178
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1183
Prepare Troubleshoot Machine Monitor 1187
Procedure to Make Harness Checker on Machine Monitor LCD Unit 1189
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1194
Failure Code Table 1196
Troubleshooting by Failure Code (Display of Code) 1233
Failure Code [1500L0] 1233
Failure Code [15B0NX] 1235
Failure Code [15F0MW] 1238
Failure Code [15G0MW] 1240
Failure Code [15H0MW] 1242
Failure Code [15J0MW] 1244
Failure Code [15K0MW] 1247
Failure Code [15L0MW] 1249
Failure Code [15M0MW] 1251
Failure Code [15N0MW] 1253
Failure Code [15SAL1] 1255
Failure Code [15SAMA] 1258
Failure Code [15SBL1] 1261
Failure Code [15SBMA] 1264
Failure Code [15SCL1] 1268
Failure Code [15SCMA] 1271
Failure Code [15SDL1] 1275
Failure Code [15SDMA] 1278
Failure Code [15SEL1] 1282
Failure Code [15SEMA] 1285
Failure Code [15SFL1] 1289
Failure Code [15SFMA] 1292
Failure Code [15SGL1] 1296
Failure Code [15SGMA] 1299
Failure Code [15SHL1] 1303
Failure Code [15SHMA] 1306
Failure Code [15SJMA] 1310
Failure Code [15U0NT] 1312
Failure Code [2E47NS] 1314
Failure Code [2F00MB] 1316
Failure Code [2G42ZG] 1321
Failure Code [2G43ZG] 1324
Failure Code [989L00] 1327
Failure Code [989M00] 1328
Failure Code [989N00] 1329
Failure Code [9YF1PQ] 1330
Failure Code [A1U0N3] 1331
Failure Code [A1U0N4] 1333
Failure Code [AA10NX] 1335
Failure Code [AB00KE] 1338
Failure Code [AB00KY] 1342
Failure Code [AQ10N3] 1344
Failure Code [AS00N3] 1346
Failure Code [AS00R2] 1348
Failure Code [AS00R3] 1349
Failure Code [AS00R4] 1350
Failure Code [AS00R5] 1351
Failure Code [AS00R6] 1352
Failure Code [AS00ZK] 1353
Failure Code [AS10KM] 1354
Failure Code [AS10NR] 1355
Failure Code [AS10NT] 1356
Failure Code [B@BAZG] 1357
Failure Code [B@BAZK] 1358
Failure Code [B@BCNS] 1361
Failure Code [B@BCQA] 1362
Failure Code [B@BCZK] 1365
Failure Code [B@CENS] 1368
Failure Code [B@CKNS] 1371
Failure Code [B@HANS] 1374
Failure Code [CA115] 1377
Failure Code [CA122] 1378
Failure Code [CA123] 1380
Failure Code [CA131] 1382
Failure Code [CA132] 1384
Failure Code [CA135] 1387
Failure Code [CA141] 1389
Failure Code [CA144] 1391
Failure Code [CA145] 1393
Failure Code [CA153] 1395
Failure Code [CA154] 1398
Failure Code [CA187] 1401
Failure Code [CA221] 1403
Failure Code [CA222] 1405
Failure Code [CA227] 1408
Failure Code [CA234] 1409
Failure Code [CA238] 1410
Failure Code [CA239] 1412
Failure Code [CA249] 1414
Failure Code [CA256] 1416
Failure Code [CA271] 1418
Failure Code [CA272] 1420
Failure Code [CA273] 1421
Failure Code [CA274] 1423
Failure Code [CA322] 1424
Failure Code [CA323] 1426
Failure Code [CA324] 1428
Failure Code [CA325] 1430
Failure Code [CA331] 1432
Failure Code [CA332] 1434
Failure Code [CA343] 1436
Failure Code [CA351] 1437
Failure Code [CA352] 1438
Failure Code [CA356] 1441
Failure Code [CA357] 1443
Failure Code [CA386] 1445
Failure Code [CA431] 1446
Failure Code [CA432] 1449
Failure Code [CA441] 1452
Failure Code [CA442] 1455
Failure Code [CA449] 1456
Failure Code [CA451] 1457
Failure Code [CA452] 1459
Failure Code [CA515] 1461
Failure Code [CA516] 1463
Failure Code [CA553] 1465
Failure Code [CA555] 1466
Failure Code [CA556] 1467
Failure Code [CA559] 1468
Failure Code [CA595] 1470
Failure Code [CA687] 1471
Failure Code [CA689] 1473
Failure Code [CA691] 1476
Failure Code [CA692] 1478
Failure Code [CA697] 1480
Failure Code [CA698] 1481
Failure Code [CA731] 1482
Failure Code [CA778] 1483
Failure Code [CA1117] 1486
Failure Code [CA1664] 1487
Failure Code [CA1669] 1489
Failure Code [CA1673] 1490
Failure Code [CA1677] 1491
Failure Code [CA1678] 1492
Failure Code [CA1682] 1493
Failure Code [CA1683] 1497
Failure Code [CA1684] 1499
Failure Code [CA1686] 1501
Failure Code [CA1691] 1502
Failure Code [CA1694] 1505
Failure Code [CA1695] 1507
Failure Code [CA1696] 1508
Failure Code [CA1712] 1511
Failure Code [CA1713] 1514
Failure Code [CA1714] 1517
Failure Code [CA1715] 1518
Failure Code [CA1776] 1519
Failure Code [CA1777] 1522
Failure Code [CA1843] 1525
Failure Code [CA1844] 1527
Failure Code [CA1879] 1529
Failure Code [CA1881] 1531
Failure Code [CA1883] 1533
Failure Code [CA1885] 1537
Failure Code [CA1887] 1539
Failure Code [CA1921] 1541
Failure Code [CA1922] 1544
Failure Code [CA1923] 1549
Failure Code [CA1924] 1551
Failure Code [CA1925] 1554
Failure Code [CA1927] 1557
Failure Code [CA1928] 1559
Failure Code [CA1942] 1561
Failure Code [CA1963] 1562
Failure Code [CA1977] 1567
Failure Code [CA1993] 1570
Failure Code [CA2185] 1573
Failure Code [CA2186] 1575
Failure Code [CA2249] 1577
Failure Code [CA2265] 1578
Failure Code [CA2266] 1580
Failure Code [CA2271] 1583
Failure Code [CA2272] 1585
Failure Code [CA2349] 1588
Failure Code [CA2353] 1590
Failure Code [CA2357] 1592
Failure Code [CA2381] 1593
Failure Code [CA2382] 1595
Failure Code [CA2383] 1597
Failure Code [CA2386] 1599
Failure Code [CA2387] 1601
Troubleshooting Flowchart 1605
Failure Code [CA2555] 1606
Failure Code [CA2556] 1609
Failure Code [CA2637] 1611
Failure Code [CA2639] 1613
Failure Code [CA2732] 1616
Failure Code [CA2733] 1618
Failure Code [CA2741] 1620
Failure Code [CA2765] 1622
Failure Code [CA2771] 1623
Failure Code [CA2777] 1629
Failure Code [CA2878] 1632
Failure Code [CA2881] 1636
Failure Code [CA2976] 1640
Failure Code [CA3133] 1642
Failure Code [CA3134] 1644
Failure Code [CA3135] 1646
Failure Code [CA3142] 1650
Failure Code [CA3143] 1651
Failure Code [CA3144] 1652
Failure Code [CA3146] 1655
Failure Code [CA3147] 1656
Failure Code [CA3148] 1657
Failure Code [CA3151] 1660
Failure Code [CA3165] 1666
Failure Code [CA3167] 1669
Failure Code [CA3229] 1672
Failure Code [CA3231] 1674
Failure Code [CA3232] 1676
Failure Code [CA3235] 1680
Failure Code [CA3239] 1682
Failure Code [CA3241] 1685
Failure Code [CA3242] 1688
Failure Code [CA3251] 1691
Failure Code [CA3253] 1693
Failure Code [CA3254] 1697
Failure Code [CA3255] 1700
Failure Code [CA3256] 1704
Failure Code [CA3311] 1706
Failure Code [CA3312] 1709
Failure Code [CA3313] 1712
Failure Code [CA3314] 1713
Failure Code [CA3315] 1714
Failure Code [CA3316] 1717
Failure Code [CA3317] 1719
Failure Code [CA3318] 1720
Failure Code [CA3319] 1723
Failure Code [CA3321] 1724
Failure Code [CA3322] 1726
Failure Code [CA3419] 1729
Failure Code [CA3421] 1731
Failure Code [CA3497] 1733
Failure Code [CA3498] 1734
Failure Code [CA3543] 1735
Failure Code [CA3545] 1742
Failure Code [CA3547] 1745
Failure Code [CA3558] 1746
Failure Code [CA3559] 1748
Failure Code [CA3562] 1750
Failure Code [CA3563] 1752
Failure Code [CA3567] 1755
Failure Code [CA3568] 1759
Failure Code [CA3571] 1764
Failure Code [CA3572] 1766
Failure Code [CA3574] 1768
Failure Code [CA3575] 1771
Failure Code [CA3577] 1773
Failure Code [CA3578] 1775
Failure Code [CA3582] 1777
Failure Code [CA3583] 1784
Failure Code [CA3596] 1787
Failure Code [CA3649] 1791
Failure Code [CA3681] 1794
Failure Code [CA3682] 1799
Failure Code [CA3713] 1804
Failure Code [CA3717] 1807
Failure Code [CA3718] 1808
Failure Code [CA3725] 1809
Failure Code [CA3748] 1812
Failure Code [CA3751] 1815
Failure Code [CA3755] 1817
Failure Code [CA3866] 1819
Failure Code [CA3867] 1823
Failure Code [CA3868] 1826
Failure Code [CA3899] 1830
Failure Code [CA3911] 1832
Failure Code [CA3912] 1836
Failure Code [CA3932] 1838
Failure Code [CA3933] 1840
Failure Code [CA3934] 1842
Failure Code [CA3935] 1846
Failure Code [CA3936] 1848
Failure Code [CA4151] 1850
Failure Code [CA4152] 1854
Failure Code [CA4155] 1858
Failure Code [CA4156] 1861
Failure Code [CA4157] 1864
Failure Code [CA4158] 1866
Failure Code [CA4159] 1867
Failure Code [CA4161] 1868
Failure Code [CA4162] 1871
Failure Code [CA4163] 1874
Failure Code [CA4164] 1877
Failure Code [CA4165] 1879
Failure Code [CA4166] 1881
Failure Code [CA4168] 1883
Failure Code [CA4169] 1886
Failure Code [CA4171] 1890
Failure Code [CA4249] 1894
Failure Code [CA4251] 1898
Failure Code [CA4259] 1902
Failure Code [CA4261] 1905
Failure Code [CA4277] 1908
Failure Code [CA4281] 1911
Failure Code [CA4459] 1915
Failure Code [CA4461] 1918
Failure Code [CA4658] 1921
Failure Code [CA4731] 1925
Failure Code [CA4732] 1926
Failure Code [CA4739] 1927
Failure Code [CA4768] 1928
Failure Code [CA4769] 1930
Failure Code [CA4842] 1932
Failure Code [CA4952] 1935
Failure Code [CA5115] 1937
Failure Code [CA5179] 1940
Failure Code [CA5181] 1942
Failure Code [CA5383] 1944
Failure Code [D110L4] 1946
Failure Code [D150KB] 1949
Failure Code [D150KZ] 1952
Failure Code [D160KA] 1955
Failure Code [D160KB] 1958
Failure Code [D160KY] 1961
Failure Code [D19HKA] 1963
Failure Code [D19HKB] 1966
Failure Code [D19HKY] 1969
Failure Code [D19JKZ] 1971
Failure Code [D19KKZ] 1976
Failure Code [D1EHKA] 1980
Failure Code [D1EHKB] 1983
Failure Code [D1EHKY] 1986
Failure Code [D1J0KB] 1988
Failure Code [D5ZHKA] 1993
Failure Code [D5ZHKY] 1998
Failure Code [D5ZHKZ] 2001
Failure Code [D5ZHL6] 2005
Failure Code [D862KA] 2008
Failure Code [DA80KY] 2011
Failure Code [DA80L4] 2014
Failure Code [DAF0KT] 2018
Failure Code [DAF0MB] 2019
Failure Code [DAF0MC] 2020
Failure Code [DAF3KK] 2021
Failure Code [DAF8KB] 2025
Failure Code [DAFDKB] 2028
Failure Code [DAFGMC] 2031
Failure Code [DAFLKA] 2032
Failure Code [DAFLKB] 2035
Failure Code [DAFQKR] 2038
Failure Code [DAQ0KK] 2051
Failure Code [DAQ0KT] 2056
Failure Code [DAQ0MC] 2058
Failure Code [DAQ1KA] 2059
Failure Code [DAQ2KK] 2062
Failure Code [DAQ9KQ] 2066
Failure Code [DAQLKA] 2068
Failure Code [DAQLKB] 2071
Failure Code [DAQQKR] 2074
Failure Code [DAQRKR] 2088
Failure Code [DAQRMA] 2102
Failure Code [DB2QKR] 2104
Failure Code [DB2RKR] 2119
Failure Code [DB3RKR] 2134
Failure Code [DB90KK] 2145
Failure Code [DB90KT] 2150
Failure Code [DB90MC] 2151
Failure Code [DB91KA] 2152
Failure Code [DB92KK] 2155
Failure Code [DB96KX] 2160
Failure Code [DB99KQ] 2165
Failure Code [DB9LKA] 2167
Failure Code [DB9LKB] 2171
Failure Code [DB9QKR] 2174
Failure Code [DB9RKR] 2187
Failure Code [DB9RMA] 2200
Failure Code [DBP0KM] 2202
Failure Code [DBP0KT] 2204
Failure Code [DBP0MC] 2207
Failure Code [DBP0NR] 2208
Failure Code [DBP5KP] 2209
Failure Code [DBPLKA] 2213
Failure Code [DBPLKB] 2217
Failure Code [DBPQKR] 2220
Failure Code [DBPRKR] 2234
Failure Code [DBPRMA] 2248
Failure Code [DBPUKR] 2250
Failure Code [DBPVKR] 2261
Failure Code [DBPWKR] 2273
Failure Code [DBPXKR] 2275
Failure Code [DBV0MC] 2278
Failure Code [DBV1KK] 2279
Failure Code [DBV6KB] 2283
Failure Code [DBV7KB] 2285
Failure Code [DBVLKA] 2288
Failure Code [DBVLKB] 2292
Failure Code [DBVQK4] 2295
Failure Code [DBVQKR] 2309
Failure Code [DBVRKR] 2323
Failure Code [DBVVKR] 2337
Failure Code [DBVWKR] 2339
Failure Code [DD1PKB] 2341
Failure Code [DD1QKB] 2345
Failure Code [DDAAL6] 2349
Failure Code [DDACL4] 2352
Failure Code [DDADKA] 2357
Failure Code [DDB6L4] 2361
Failure Code [DDK3KA] 2367
Failure Code [DDK3KB] 2373
Failure Code [DDK5KA] 2377
Failure Code [DDK5KB] 2383
Failure Code [DDKAKY] 2387
Failure Code [DDKLKA] 2390
Failure Code [DDKLKB] 2395
Failure Code [DDKLKY] 2399
Failure Code [DDKVKA] 2402
Failure Code [DDKVKB] 2405
Failure Code [DDKVKY] 2408
Failure Code [DDLAKY] 2411
Failure Code [DDNRKY] 2414
Failure Code [DDTHKA] 2417
Failure Code [DDTJKA] 2419
Failure Code [DDTKKA] 2421
Failure Code [DDTLKA] 2423
Failure Code [DDTMKA] 2425
Failure Code [DDTNKA] 2427
Failure Code [DDTPKA] 2429
Failure Code [DDTQKA] 2431
Failure Code [DDUAKR] 2433
Failure Code [DDXPKB] 2446
Failure Code [DDXSKA] 2450
Failure Code [DDXSKB] 2454
Failure Code [DFA5KA] 2457
Failure Code [DFA5KY] 2462
Failure Code [DFA5L8] 2465
Failure Code [DFA6KA] 2470
Failure Code [DFA6KY] 2475
Failure Code [DFA8KA] 2478
Failure Code [DFA8KY] 2482
Failure Code [DFA8L8] 2485
Failure Code [DFA9KA] 2490
Failure Code [DFA9KY] 2494
Failure Code [DFAGKA] 2497
Failure Code [DFAGKY] 2501
Failure Code [DFAGL8] 2504
Failure Code [DFAHKA] 2509
Failure Code [DFAHKY] 2513
Failure Code [DFAJKA] 2516
Failure Code [DFAJKY] 2521
Failure Code [DFAJL8] 2524
Failure Code [DFAKKA] 2529
Failure Code [DFAKKY] 2534
Failure Code [DFALKA] 2537
Failure Code [DFALKY] 2542
Failure Code [DFALL8] 2545
Failure Code [DFAMKA] 2551
Failure Code [DFAMKY] 2556
Failure Code [DFANKA] 2559
Failure Code [DFANKY] 2564
Failure Code [DFANL8] 2567
Failure Code [DFAPKA] 2572
Failure Code [DFAPKY] 2577
Failure Code [DFAQKA] 2580
Failure Code [DFAQKY] 2585
Failure Code [DFAQL8] 2588
Failure Code [DFARKA] 2593
Failure Code [DFARKY] 2598
Failure Code [DFC1KA] 2601
Failure Code [DFC1KY] 2606
Failure Code [DFC1L8] 2609
Failure Code [DFC3KA] 2615
Failure Code [DFC3KY] 2619
Failure Code [DFC3L8] 2622
Failure Code [DFC6KA] 2627
Failure Code [DFC6KY] 2632
Failure Code [DFC8KA] 2635
Failure Code [DFC8KY] 2639
Failure Code [DGF1KX] 2642
Failure Code [DGH2KX] 2646
Failure Code [DGT1KX] 2649
Failure Code [DGT4KA] 2653
Failure Code [DGT4KY] 2657
Failure Code [DGT7KB] 2660
Failure Code [DH1AKX] 2663
Failure Code [DH2AKX] 2667
Failure Code [DH3AKX] 2671
Failure Code [DH4AKX] 2675
Failure Code [DH5AKX] 2679
Failure Code [DH6AKX] 2683
Failure Code [DHA4KA] 2687
Failure Code [DHAAMA] 2689
Failure Code [DHACMA] 2691
Failure Code [DHPSKA] 2693
Failure Code [DHPSKY] 2697
Failure Code [DHT2L6] 2700
Failure Code [DHT5KX] 2703
Failure Code [DHT5L6] 2707
Failure Code [DHT8KX] 2709
Failure Code [DHT8ZG] 2713
Failure Code [DHU2KX] 2715
Failure Code [DHU3KX] 2719
Failure Code [DHUCKX] 2723
Failure Code [DHUDKX] 2727
Failure Code [DHUGKX] 2731
Failure Code [DHUJKX] 2734
Failure Code [DHYCKX] 2738
Failure Code [DHZ1KX] 2742
Failure Code [DHZ2KA] 2746
Failure Code [DJE7KY] 2750
Failure Code [DJE7KZ] 2753
Failure Code [DJF1KA] 2757
Failure Code [DK30KR] 2760
Failure Code [DK30KT] 2764
Failure Code [DK30L8] 2766
Failure Code [DK30MA] 2767
Failure Code [DK70KX] 2769
Failure Code [DKD0KR] 2773
Failure Code [DKD0KT] 2777
Failure Code [DKD0L8] 2780
Failure Code [DKD0MA] 2782
Failure Code [DKR2KY] 2785
Failure Code [DKR2KZ] 2788
Failure Code [DKR2NX] 2791
Failure Code [DLF1KA] 2794
Failure Code [DLF1LC] 2796
Failure Code [DLF2KA] 2800
Failure Code [DLF2LC] 2802
Failure Code [DLF3KA] 2806
Failure Code [DLF3LC] 2808
Failure Code [DLM3KA] 2812
Failure Code [DLM3LC] 2814
Failure Code [DLM3MB] 2816
Failure Code [DLT3KA] 2818
Failure Code [DPQ1KR] 2820
Failure Code [DPQ2KR] 2824
Failure Code [DPQ3KR] 2828
Failure Code [DPQ4KB] 2834
Failure Code [DQ11KM] 2837
Failure Code [DQ11KT] 2840
Failure Code [DQ12KM] 2843
Failure Code [DQ12KT] 2846
Failure Code [DQ13KM] 2849
Failure Code [DQ13KT] 2852
Failure Code [DQ14KM] 2855
Failure Code [DQ14KT] 2858
Failure Code [DQ15KM] 2861
Failure Code [DQ15KT] 2864
Failure Code [DR10KA] 2867
Failure Code [DR20KA] 2871
Failure Code [DR30KA] 2875
Failure Code [DR40KA] 2879
Failure Code [DR50KA] 2883
Failure Code [DUMBKB] 2888
Failure Code [DV00KB] 2891
Failure Code [DV01KB] 2894
Failure Code [DW4BK4] 2897
Failure Code [DW4BKA] 2899
Failure Code [DW4BKB] 2902
Failure Code [DW4BKY] 2906
Failure Code [DW4BMA] 2909
Failure Code [DW7BKA] 2911
Failure Code [DW7BKB] 2913
Failure Code [DW7BKY] 2916
Failure Code [DW9DKA] 2918
Failure Code [DW9DKB] 2920
Failure Code [DW9DKY] 2923
Failure Code [DW9EKA] 2925
Failure Code [DW9EKB] 2927
Failure Code [DW9EKY] 2930
Failure Code [DW9FKA] 2932
Failure Code [DW9FKB] 2934
Failure Code [DW9FKY] 2937
Failure Code [DW9GKA] 2939
Failure Code [DW9GKB] 2941
Failure Code [DW9GKY] 2944
Failure Code [DW9HKA] 2946
Failure Code [DW9HKB] 2948
Failure Code [DW9HKY] 2951
Failure Code [DW9JKA] 2953
Failure Code [DW9JKB] 2955
Failure Code [DW9JKY] 2958
Failure Code [DWM1KA] 2960
Failure Code [DWM1KB] 2963
Failure Code [DWM1KY] 2966
Failure Code [DWNHKA] 2968
Failure Code [DWNHKB] 2971
Failure Code [DWNHKY] 2974
Failure Code [DWP5KA] 2977
Failure Code [DWP5KB] 2979
Failure Code [DWP5KY] 2982
Failure Code [DWP6KA] 2984
Failure Code [DWP6KB] 2986
Failure Code [DWP6KY] 2989
Failure Code [DX16KA] 2991
Failure Code [DX16KB] 2993
Failure Code [DX16KY] 2996
Failure Code [DXF5K4] 2998
Failure Code [DXF5KA] 3001
Failure Code [DXF5KB] 3003
Failure Code [DXF5KY] 3006
Failure Code [DXF5MA] 3009
Failure Code [DXF6KA] 3013
Failure Code [DXF6KB] 3015
Failure Code [DXF6KY] 3018
Failure Code [DXH1KA] 3020
Failure Code [DXH1KB] 3022
Failure Code [DXH1KY] 3025
Failure Code [DXH2KA] 3027
Failure Code [DXH2KB] 3030
Failure Code [DXH2KY] 3033
Failure Code [DXH3KA] 3035
Failure Code [DXH3KB] 3038
Failure Code [DXH3KY] 3041
Failure Code [DXH4KA] 3043
Failure Code [DXH4KB] 3046
Failure Code [DXH4KY] 3049
Failure Code [DXH5KA] 3051
Failure Code [DXH5KB] 3054
Failure Code [DXH5KY] 3057
Failure Code [DXH6KA] 3059
Failure Code [DXH6KB] 3062
Failure Code [DXH6KY] 3065
Failure Code [DXH7KA] 3067
Failure Code [DXH7KB] 3070
Failure Code [DXH7KY] 3073
Failure Code [DXH8KA] 3075
Failure Code [DXH8KB] 3078
Failure Code [DXH8KY] 3081
Failure Code [DXHHKA] 3083
Failure Code [DXHHKB] 3086
Failure Code [DXHHKY] 3089
Failure Code [DXHVKA] 3091
Failure Code [DXHVKB] 3094
Failure Code [DXHVKY] 3097
Failure Code [DXS1KA] 3100
Failure Code [DXS1KB] 3102
Failure Code [DXS1KY] 3105
Failure Code [DXS2KA] 3107
Failure Code [DXS2KB] 3109
Failure Code [DXS2KY] 3112
Failure Code [DXS3KA] 3114
Failure Code [DXS3KB] 3116
Failure Code [DXS3KY] 3119
Failure Code [DXS4KA] 3121
Failure Code [DXS4KB] 3123
Failure Code [DXS4KY] 3126
Failure Code [DXS5KA] 3128
Failure Code [DXS5KB] 3130
Failure Code [DXS5KY] 3133
Failure Code [DXS6KA] 3135
Failure Code [DXS6KB] 3137
Failure Code [DXS6KY] 3140
Failure Code [DXS7KA] 3142
Failure Code [DXS7KB] 3144
Failure Code [DXS7KY] 3147
Failure Code [DXS8KA] 3149
Failure Code [DXS8KB] 3151
Failure Code [DXS8KY] 3154
Failure Code [DXS9KA] 3156
Failure Code [DXS9KB] 3159
Failure Code [DXS9KY] 3162
Failure Code [DXS9MC] 3165
Failure Code [DXSAKA] 3168
Failure Code [DXSAKB] 3170
Failure Code [DXSAKY] 3173
Failure Code [DXSBKA] 3175
Failure Code [DXSBKB] 3177
Failure Code [DXSBKY] 3180
Failure Code [DY30MA] 3182
Failure Code [DY30MC] 3187
Failure Code [DY30ME] 3194
Failure Code [F@BYNR] 3197
Failure Code [F@BYNS] 3199
Failure Code [F412KK] 3201
Failure Code [F412KT] 3205
Failure Code [F412MC] 3207
Failure Code [F414KR] 3208
Failure Code [F414MA] 3221
Failure Code [F415KR] 3222
Failure Code [F418KQ] 3235
Failure Code [F41AKX] 3237
Failure Code [F41BKX] 3242
Failure Code [F41CKA] 3246
Failure Code [F41CKB] 3249
Failure Code [F41DKB] 3252
Failure Code [F41DKZ] 3255
Failure Code [F41EKA] 3257
Failure Code [F41FKK] 3260
Failure Code [FL1AKB] 3264
Failure Code [FL1ALD] 3266
Failure Code [FL1BKB] 3268
Failure Code [FL1BLD] 3271
Failure Code [FL1CLD] 3273
Failure Code [FL1DKB] 3275
Failure Code [FL1DLD] 3278
Failure Code [FL1EKB] 3280
Failure Code [FL1ELD] 3283
Failure Code [FL1FLD] 3285
Failure Code [FL1GLD] 3287
Failure Code [FL1HLD] 3289
Failure Code [FL1JLD] 3291
Failure Code [FL1KLD] 3293
Failure Code [FL1LLD] 3295
Failure Code [FL1MLD] 3297
Failure Code [#Q0001] 3299
Failure Code [#Q0002] 3300
Failure Code [#Q0003] 3301
Failure Code [#Q0004] 3307
Failure Code [#Q0005] 3313
Failure Code [#Q0006] 3320
Failure Code [#Q0007] 3323
Failure Code [#Q0008] 3326
Failure Code [#Q0009] 3327
Failure Code [#Q0010] 3331
Failure Code [#Q0011] 3334
Failure Code [#Q0012] 3340
Failure Code [#Q0013] 3346
Failure Code [#Q0014] 3352
Failure Code [#Q0015] 3358
Failure Code [#Q0016] 3368
Failure Code [#Q0017] 3379
Failure Code [#Q0018] 3390
Failure Code [#Q0019] 3401
Failure Code [#Q0020] 3408
Failure Code [#Q0021] 3415
Failure Code [#Q0022] 3422
Failure Code [#Q0023] 3428
Failure Code [#Q0024] 3435
Failure Code [#Q0025] 3442
Failure Code [#Q0026] 3449
Failure Code [#Q0027] 3455
Failure Code [#Q0028] 3464
Failure Code [#Q0029] 3471
Failure Code [#Q0030] 3477
Failure Code [#Q0031] 3483
Failure Code [#Q0032] 3493
Failure Code [#Q0033] 3500
Failure Code [#Q0034] 3507
Failure Code [#Q0035] 3514
Failure Code [#Q0036] 3520
Failure Code [#Q0037] 3526
Failure Code [#Q0038] 3533
Failure Code [#Q0039] 3539
Failure Code [#Q0040] 3550
Failure Code [#Q0041] 3557
Failure Code [#Q0042] 3564
Failure Code [#Q0043] 3572
Failure Code [#Q0044] 3578
Failure Code [#Q0045] 3584
Failure Code [#Q0046] 3591
Failure Code [#Q0047] 3597
Failure Code [#Q0048] 3603
Failure Code [#Q0049] 3610
Failure Code [#Q0050] 3616
Failure Code [#Q0051] 3622
Failure Code [#Q0052] 3628
Failure Code [#Q0053] 3634
Failure Code [#Q0054] 3640
Failure Code [#Q0055] 3646
Failure Code [#Q0056] 3652
Failure Code [#Q0057] 3658
Failure Code [#Q0058] 3664
Failure Code [#Q0059] 3670
Failure Code [#Q0060] 3677
Failure Code [#Q0061] 3683
Failure Code [#Q0062] 3689
Failure Code [#Q0063] 3696
Failure Code [#Q0064] 3703
Failure Code [#Q0065] 3714
Failure Code [#Q0066] 3720
Failure Code [#Q0067] 3726
Failure Code [#Q0068] 3732
Failure Code [#Q0069] 3739
Failure Code [#Q0070] 3745
Failure Code [#Q0071] 3751
Failure Code [#Q0072] 3757
Failure Code [#Q0073] 3765
Failure Code [#Q0074] 3773
Failure Code [#Q0075] 3779
Failure Code [#Q0076] 3786
Failure Code [#Q0077] 3793
Failure Code [#Q0078] 3800
Failure Code [#Q0079] 3807
Failure Code [#Q0080] 3814
Failure Code [#Q0081] 3820
Failure Code [#Q0082] 3826
Failure Code [#Q0083] 3832
Failure Code [#Q0084] 3838
Failure Code [#Q0085] 3844
Failure Code [#Q0086] 3851
Failure Code [#Q0087] 3857
Failure Code [#Q0088] 3863
Failure Code [#Q0089] 3869
Failure Code [#Q0090] 3875
Failure Code [#Q0091] 3882
Failure Code [#Q0092] 3888
Failure Code [#Q0093] 3894
Failure Code [#Q0094] 3900
Failure Code [#Q0095] 3907
Failure Code [#Q0096] 3914
Failure Code [#Q0097] 3920
Failure Code [#Q0098] 3926
Failure Code [#Q0099] 3937
Failure Code [#Q0100] 3947
Failure Code [#Q0101] 3953
Failure Code [#Q0102] 3959
Failure Code [#Q0103] 3966
Failure Code [#Q0104] 3973
Failure Code [#Q0105] 3980
Failure Code [#Q0106] 3986
Failure Code [#Q0107] 3993
Failure Code [#Q0108] 4000
Failure Code [#Q0109] 4006
Failure Code [#Q0110] 4012
Troubleshooting of Electrical System (E-Mode) 4014
Engine Does Not Start (Engine Does Not Crank) 4014
Manual Preheating System Does Not Operate 4024
Automatic Preheating System Does Not Operate 4029
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On 4033
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 4036
LCD Unit and LED Unit of Machine Monitor Show Nothing 4039
LCD Unit on Machine Monitor Shows Nothing 4049
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 4052
LCD Screen on Machine Monitor Does Not Show Correctly 4055
LED Unit Lamp on Machine Monitor is Abnormal 4058
Switch of Switch Panel on Machine Monitor Does Not Operate 4064
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 4070
Switch Panel Buzzer of Machine Monitor is Abnormal 4078
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly 4086
DEF Level is Not Shown Correctly 4087
DEF Level Correspondence Diagram 4090
Rearview Monitor Does Not Come On or Backlight Flickers 4091
Rearview Monitor Images are Not Shown Clearly 4097
Rearview Monitor Brightness Cannot be Adjusted 4104
Night Mode Lamp of Rearview Monitor is Abnormal 4109
Air Cleaner Clogging Caution Lamp Does Not Come On 4112
Transmission Oil Filter Clogging Caution Lamp Does Not Come On 4115
Radiator Coolant Level Caution Lamp Does Not Come On 4118
Rearview Monitor is Not Shown in REVERSE Travel When Reverse-Interlock Selection Mode is ON 4121
Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is Turned ON 4124
Parking Brake Pilot Lamp Does Not Come On When Parking Brake is ON (Parking) Position 4127
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low 4130
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low 4132
Speedometer Does Not Show Normally 4134
Engine Tachometer Does Not Show Normally 4137
Fuel Gauge Does Not Show Normally 4140
Torque Converter Oil Temperature Gauge Does Not Show Normally 4143
Articulation Indicator Does Not Show Actual Articulated Angle 4145
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On 4148
Seatbelt Caution Lamp Does Not Show Normally 4151
Operator Seat Caution Lamp Comes On Even When You Seat 4154
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 4156
Alarm Buzzer Does Not Operate 4160
Alarm Buzzer Does Not Stop 4163
Parking Brake Does Not Work Even if It is Applied, or Parking Brake Drags When It is Released and Forward or Reverse Travel is Operated 4165
Engine Power Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated 4168
Transmission Selector Function Does Not Operate Normally 4173
Differential Lock Function Does Not Operate or Cannot be Cancelled 4178
Blade Accumulator Function Does Not Operate or Cannot be Cancelled 4185
Blade Accumulator Pilot Lamp Does Not Show Correctly 4192
Fuel Feed Pump Does Not Operate or Stop Automatically 4195
Horn Does Not Sound 4203
Horn Does Not Stop 4208
None of Headlamp, Clearance Lamp, and Tail Lamp Comes on 4210
Clearance Lamp and Tail Lamp Do Not Come on or Go Off 4215
Headlamp Does Not Come On or Go Out 4221
Headlamp Selection (Low or High Beam) Cannot be Done 4226
Headlamp (High Beam) Does Not Come On 4230
Passing Lamp Does Not Come On 4232
Front Working Lamp, Blade Front Working Lamp, and Floor Lower Front Working Lamp Do Not Come On or Go Off 4236
Front Working Lamp and Blade Front Working Lamp Do Not Come On or Go Off 4239
Floor Lower Front Working Lamp Does Not Come On or Go Off 4244
Rear Working Lamp Does Not Come on or Go off 4249
Cab Mount Working Lamp Does Not Come On or Go Off 4254
Working Lamp Pilot Lamp Does Not Come On or Go Out 4260
Turn-Signal Lamp and Hazard Lamp Do Not Come on or Go off 4263
Turn Signal Lamp Does Not Come On or Go Out 4267
Hazard Lamp Does Not Come On or Go Off 4273
Turn Signal Lamp Does Not Come On or Go Off 4280
Stop Lamp Does Not Come On, or Stays On 4282
Access Lamp Does Not Come On or Go Off 4286
Engine Room Lamp Does Not Come On or Go Out 4292
Backup Lamp Does Not Come On 4295
Backup Alarm Does Not Sound 4299
Backup Alarm Continues to Sound and Backup Lamp Keeps Lit 4303
No Wiper Operates 4306
Front Wiper Does Not Operate 4310
Rear Wiper Does Not Operate 4318
Right and Left Upper Door Wipers Do Not Operate 4325
Left Upper Door Wiper Does Not Operate 4331
Right Upper Door Wiper Does Not Operate 4335
Right and Left Lower Door Wipers Do Not Operate 4339
Left Lower Door Wiper Does Not Operate 4345
Right Lower Door Wiper Does Not Operate 4349
Front or Door Washer Does Not Operate 4353
Front Washer and Door Washer Do Not Work with Wipers 4358
Rear Washer Does Not Operate 4361
KOMTRAX Plus System Does Not Operate Normally 4365
Data Download with Wireless LAN Does Not Operate 4368
KomVision Monitor Does Not Come On or Backlight Flickers 4369
KomVision Monitor Images are Not Shown Clearly 4374
KomVision Monitor Brightness Cannot be Adjusted 4384
Night Mode Lamp of KomVision Monitor is Abnormal 4389
A Part of Camera Image of KomVision Monitor is Not Shown 4393
Example of Black Out on KomVision Monitor 4395
KomVision Monitor is Not Shown Correctly After Calibration 4396
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 4398
Information Shown in Troubleshooting Table (H-Mode) 4398
Failure Mode and Cause Table 4399
Machine Does Not Start 4405
ECMV Operation Table 4414
Lockup is Not Released 4415
Torque Converter Lockup Clutch Does Not Engage 4417
Machine Does Not Upshift or Downshift from Neutral 4419
Combination Table of Gear Speed and Clutch Used 4423
Machine Does Not Upshift or Downshift 4424
Combination Table of Gear Speed and Clutch Used 4428
Travel Speed or Power is Low 4429
Combination Table of Gear Speed and Clutch Used 4436
Travel Speed or Power is Low in Specified Gear 4438
Combination Table of Gear Speed and Clutch Used 4442
Time Lag is Large When You Start Machine or Shift Gears 4443
Combination Table of Gear Speed and Clutch Used 4447
Torque Converter Oil Temperature is High 4448
Differential Lock Function Does Not Operate or Cannot be Cancelled 4456
Steering Wheel Does Not Move or is Heavy to Operate 4459
Steering Speed or Power is Low (Steering Wheel, Steering Lever) 4461
Machine Sways During Steering (Steering Wheel, Steering Lever) 4464
Machine Naturally Turns to One Side During Travel 4466
Wheel Brakes Do Not Operate or are Weak 4468
Wheel Brakes are Not Released or Drag 4472
Parking Brake Does Not Operate or is Weak 4474
Parking Brake is Not Released or Drags 4476
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment 4478
Unusual Noise is Heard from Around Hydraulic Pump 4482
All Work Equipment Operate Slowly 4485
All Work Equipment Do Not Operate 4491
Blade Lift Speed or Power is Low 4497
Drawbar Side-Shift Speed or Power is Low 4501
Blade Side-Shift Speed or Power is Low 4504
Power Tilt Speed or Power is Low 4507
Articulate Speed or Power is Low 4510
Leaning Speed or Power is Low 4513
Hydraulic Drift of Blade Lift is Large 4516
Hydraulic Drift of Leaning is Large 4519
Blade Does Not Rotate 4521
Blade Accumulator Function Does Not Operate or Cannot be Cancelled 4523
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 4525
Unusual Noise is Heard from Around Fan 4530
Troubleshooting of Engine (S-Mode) 4531
Information Shown in Troubleshooting Table (S-Mode) 4531
Engine Does Not Crank When Starting Switch is Turned to Start Position 4532
Engine Cranks but No Exhaust Smoke Comes Out 4533
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 4534
Engine Startability is Unsatisfactory 4535
Engine Does Not Pick Up Smoothly 4537
Engine Stops During Operation 4539
Engine Does Not Rotate Smoothly 4541
Engine Lacks Output (or Lacks Power) 4542
KDPF Becomes Clogged in a Short Time 4544
Engine Oil Consumption is Excessive 4546
Engine Oil Becomes Dirty Quickly 4547
Fuel Consumption is Excessive 4548
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 4549
Engine Oil Pressure Drops 4550
Fuel Mixes Into Engine Oil 4552
Water Mixes Into Engine Oil (Milky) 4553
Coolant Temperature Increases Too High (Overheat) 4554
Unusual Noise is Heard 4555
Vibration is Excessive 4556
Air Cannot be Bled from Fuel Circuit 4557
Active Regeneration is Done Frequently 4558
Active Regeneration Continues Long 4560
White Smoke is Exhausted During Active Regeneration 4561
DEF Consumption is Excessive 4562
There is an Unusual Smell (Irritating Odor) 4564
Foreign Materials Enter DEF (DEF Increases) 4565
50 Disassembly and Assembly 4567
Table of Contents 4568
Related Information on Disassembly and Assembly 4574
How to Read This Manual 4574
Coating Materials List 4575
Special Tool List 4580
Sketches of Special Tools 4619
Engine and Cooling System 4648
Remove and Install Supply Pump Assembly 4648
How to Remove Supply Pump Assembly 4649
How to Install Supply Pump Assembly 4657
Remove and Install Injector Assembly 4670
How to Remove Injector Assembly 4671
How to Install Injector Assembly 4706
Remove and Install Fuel Doser Assembly 4741
How to Remove Fuel Doser Assembly 4741
How to Install Fuel Doser Assembly 4743
Remove and Install Cylinder Head Assembly 4748
How to Remove Cylinder Head Assembly 4749
How to Install Cylinder Head Assembly 4797
Remove and Install EGR Valve Assembly 4857
How to Remove EGR Valve Assembly 4858
How to Install EGR Valve Assembly 4865
Remove and Install EGR Cooler Assembly 4872
How to Remove EGR Cooler Assembly 4872
How to Install EGR Cooler Assembly 4878
Remove and Install Starting Motor Assembly 4889
How to Remove Starting Motor Assembly 4889
How to Install Starting Motor Assembly 4893
Remove and Install Alternator Belt 4896
How to Remove Alternator Belt 4896
How to Install Alternator Belt 4898
Remove and Install Auto-Tensioner 4900
How to Remove Auto-Tensioner 4900
How to Install Auto-Tensioner 4901
Remove and Install Radiator Assembly 4903
How to Remove Radiator Assembly 4904
How to Install Radiator Assembly 4913
Remove and Install Engine Assembly 4922
How to Remove Engine Assembly 4923
How to Install Engine Assembly 4948
Remove and Install Engine Front Oil Seal 4972
How to Remove Engine Front Oil Seal 4972
How to Install Engine Front Oil Seal 4974
Remove and Install Engine Rear Oil Seal 4979
How to Remove Engine Rear Oil Seal 4979
How to Install Engine Rear Oil Seal 4984
Remove and Install Damper 4994
How to Remove Damper 4994
How to Install Damper 4996
Disassemble and Assemble Damper 4999
How to Disassemble Damper 4999
How to Assemble Damper 5000
Remove and Install Engine Hood Assembly 5003
How to Remove Engine Hood Assembly 5004
How to Install Engine Hood Assembly 5008
Remove and Install DEF Tank Assembly 5013
How to Remove DEF Tank Assembly 5014
How to Install DEF Tank Assembly 5029
Remove and Install DEF Tank Sensor Flange Assembly 5042
How to Remove DEF Tank Sensor Flange Assembly 5042
How to Install DEF Tank Sensor Flange Assembly 5043
Remove and Install DEF Tank Sensor 5047
How to Remove DEF Tank Sensor 5047
How to Install DEF Tank Sensor 5048
Remove and Install DEF Tank Strainer 5051
How to Remove DEF Tank Strainer 5051
How to Install DEF Tank Strainer 5051
Disassemble and Assemble KDPF Assembly 5054
How to Disassemble KDPF Assembly 5054
How to Assemble KDPF Assembly 5063
Remove and Install SCR Assembly 5079
How to Remove SCR Assembly 5079
How to Install SCR Assembly 5086
Remove and Install KDPF and SCR Assembly 5096
How to Remove KDPF and SCR Assembly 5097
How to Install KDPF and SCR Assembly 5107
Remove and Install KCCV Assembly 5117
How to Remove KCCV Assembly 5117
How to Install KCCV Assembly 5120
Remove and Install DEF Mixing Tube 5123
How to Remove DEF Mixing Tube 5123
How to Install DEF Mixing Tube 5129
Remove and Install DEF Injector 5137
How to Remove DEF Injector 5137
How to Install DEF Injector 5141
Remove and Install DEF Pump 5147
How to Remove DEF Pump 5148
How to Install DEF Pump 5156
Remove and Install DEF Hose 5166
How to Remove DEF Hose 5167
How to Install DEF Hose 5187
Remove and Install Air Cleaner Assembly 5209
How to Remove Air Cleaner Assembly 5209
How to Install Air Cleaner Assembly 5216
Remove and Install Air Conditioner Compressor Assembly 5224
How to Remove Air Conditioner Compressor Assembly 5224
How to Install Air Conditioner Compressor Assembly 5227
Remove and Install Air Conditioner Condenser Assembly 5230
How to Remove Air Conditioner Condenser Assembly 5231
How to Install Air Conditioner Condenser Assembly 5234
Drain and Add Fuel 5238
How to Drain Fuel 5238
How to Add Fuel 5238
Drain and Add Coolant 5240
How to Drain Coolant 5240
How to Add Coolant 5241
Collect and Refill Refrigerant 5242
How to Collect Refrigerant 5242
Refill Refrigerant 5243
Power Train 5244
Disassemble and Assemble Torque Converter Assembly 5244
How to Disassemble Torque Converter Assembly 5245
How to Assemble Torque Converter Assembly 5248
Disassemble and Assemble Transmission Assembly 5254
How to Disassemble Transmission Assembly 5256
How to Assemble Transmission Assembly 5282
Disassemble and Assemble Tandem Drive Assembly 5318
How to Disassemble Tandem Drive Assembly 5319
How to Assemble Tandem Drive Assembly 5331
Disassemble and Assemble Differential Assembly 5351
How to Disassemble Differential Assembly 5353
How to Assemble Differential Assembly 5360
Disassemble and Assemble Final Drive Assembly 5373
How to Disassemble Final Drive Assembly 5374
How to Assemble Final Drive Assembly 5382
Drain and Add Transmission Oil 5394
How to Drain Transmission Oil 5394
How to Add Transmission Oil 5395
Steering System 5396
Remove and Install Steering Valve Assembly 5396
How to Remove Steering Valve Assembly 5397
How to Install Steering Valve Assembly 5409
Brake System 5422
Disassemble and Assemble Wheel Brake Assembly 5422
How to Disassemble Wheel Brake Assembly 5423
How to Assemble Wheel Brake Assembly 5429
Remove and Install Brake Accumulator 5439
How to Remove Brake Accumulator 5440
How to Install Brake Accumulator 5447
Undercarriage and Frame 5456
Remove and Install Center Hinge Pin 5456
How to Remove Center Hinge Pin 5457
How to Install Center Hinge Pin 5475
Hydraulic System 5501
Remove and Install Hydraulic Tank, Battery, and Brake Accumulator Assembly 5501
How to Remove Hydraulic Tank, Battery, and Brake Accumulator Assembly 5502
How to Install Hydraulic Tank, Battery, and Brake Accumulator Assembly 5527
Remove and Install Hydraulic Tank Assembly 5552
How to Remove Hydraulic Tank Assembly 5553
How to Install Hydraulic Tank Assembly 5570
Remove and Install Pump Assembly (Brake and Cooling Fan) 5588
How to Remove Pump Assembly (Brake and Cooling Fan) 5589
How to Install Pump Assembly (Brake and Cooling Fan) 5592
Remove and Install Steering Pump 5595
How to Remove Steering Pump 5596
How to Install Steering Pump 5599
Remove and Install Work Equipment Pump 5604
How to Remove Work Equipment Pump 5605
How to Install Work Equipment Pump 5609
Remove and Install Pump Assembly (Power Train, Transmission Lubrication, Differential Lock) 5614
How to Remove Pump Assembly (Power Train, Transmission Lubrication, Differential Lock) 5615
How to Install Pump Assembly (Power Train, Transmission Lubrication, Differential Lock) 5618
Remove and Install Control Valve Assembly 5622
How to Remove Control Valve Assembly 5624
How to Install Control Valve Assembly 5642
Drain and Add Hydraulic Oil 5663
How to Drain Hydraulic Oil 5663
How to Add Hydraulic Oil 5664
Work Equipment 5666
Remove and Install Ripper Assembly 5666
How to Remove Ripper Assembly 5667
How to Install Ripper Assembly 5675
Remove and Install Blade Assembly 5685
How to Remove Blade Assembly 5685
How to Install Blade Assembly 5689
Remove and Install Circle and Drawbar Assembly 5695
How to Remove Circle and Drawbar Assembly 5696
How to Install Circle and Drawbar Assembly 5705
Remove and Install Circle Rotation Device Assembly 5715
How to Remove Circle Rotation Device Assembly 5716
How to Install Circle Rotation Device Assembly 5717
Disassemble and Assemble Circle Rotation Device Assembly 5719
Disassemble Circle Rotation Device Assembly 5721
How to Assemble Circle Rotation Device Assembly 5728
Remove and Install Blade Lift Cylinder 5738
How to Remove Blade Lift Cylinder Assembly 5739
How to Install Blade Lift Cylinder 5746
Remove and Install Drawbar Side-Shift Cylinder 5756
How to Remove Drawbar Side-Shift Cylinder 5757
How to Install Drawbar Side-Shift Cylinder 5763
Remove and Install Articulate Cylinder 5771
How to Remove Articulate Cylinder 5772
How to Install Articulate Cylinder 5776
Remove and Install Blade Power Tilt Cylinder 5782
How to Remove Blade Power Tilt Cylinder 5782
How to Install Blade Power Tilt Cylinder 5787
Remove and Install Blade Side-Shift Cylinder 5792
How to Remove Blade Side-Shift Cylinder 5792
How to Install Blade Side-Shift Cylinder 5795
Remove and Install Leaning Cylinder 5799
How to Remove Leaning Cylinder 5799
How to Install Leaning Cylinder 5802
Remove and Install Steering Cylinder 5807
How to Remove Steering Cylinder 5808
How to Install Steering Cylinder 5817
Remove and Install Ripper Cylinder 5828
How to Remove Ripper Cylinder 5829
How to Install Ripper Cylinder 5834
Disassemble and Assemble Hydraulic Cylinder Assembly 5840
How to Disassemble Hydraulic Cylinder Assembly 5844
How to Assemble Hydraulic Cylinder Assembly 5847
Disassemble and Assemble Ripper Cylinder Assembly 5852
How to Disassemble Ripper Cylinder Assembly 5852
How to Assemble Ripper Cylinder Assembly 5855
CAB Related Parts 5859
Remove and Install Operator Cab Door 5859
How to Remove Operator Cab Door 5859
How to Install Operator Cab Door 5862
Remove and Install Operator Cab Glass (Adhered Glass) 5871
How to Remove Operator Cab Glass (Adhered Glass) 5873
How to Install Operator Cab Glass (Adhered Glass) 5875
Remove and Install Air Conditioner Unit Assembly 5884
How to Remove Air Conditioner Unit Assembly 5884
How to Install Air Conditioner Unit Assembly 5898
Remove and Install Operator Seat 5912
How to Remove Operator Seat 5912
How to Install Operator Seat 5918
How to Remove and Install Seat Belt 5924
How to Remove Seat Belt 5924
How to Install Seatbelt 5926
Remove and Install Work Equipment Control Lever Assembly 5929
How to Remove Work Equipment Control Lever Assembly 5929
How to Install Work Equipment Control Lever Assembly 5935
Electrical System 5943
Remove and Install Engine Controller 5943
How to Remove Engine Controller 5943
How to Install Engine Controller 5948
Remove and Install Transmission Controller Assembly 5954
How to Remove Transmission Controller Assembly 5954
How to Install Transmission Controller Assembly 5956
Remove and Install Work Equipment Controller Assembly 5958
How to Remove Work Equipment Controller Assembly 5958
How to Install Work Equipment Controller Assembly 5959
Remove and Install Fan Controller Assembly 5961
How to Remove Fan Controller Assembly 5961
How to Install Fan Controller Assembly 5963
Remove and Install Machine Monitor Assembly 5965
How to Remove Machine Monitor Assembly 5965
How to Install Machine Monitor Assembly 5969
Remove and Install Monitor Controller Assembly 5972
How to Remove Monitor Controller Assembly 5972
How to Install Monitor Controller Assembly 5975
Remove and Install Mass Air Flow and Temperature Sensor 5979
How to Remove Mass Air Flow and Temperature Sensor 5979
How to Install Mass Air Flow and Temperature Sensor 5981
Remove and Install KCCV Crankcase Pressure Sensor 5984
How to Remove KCCV Crankcase Pressure Sensor 5984
How to Install KCCV Crankcase Pressure Sensor 5986
Remove and Install KDPF Temperature Sensor 5989
How to Remove KDPF Temperature Sensor 5989
How to Install KDPF Temperature Sensor 5991
Remove and Install KDPF Differential Pressure Sensor 5995
How to Remove KDPF Differential Pressure Sensor 5995
How to Install KDPF Differential Pressure Sensor 5998
Remove and Install SCR Temperature Sensor 6002
How to Remove SCR Temperature Sensor 6002
How to Install SCR Temperature Sensor 6005
Remove and Install Ammonia Sensor 6009
How to Remove Ammonia Sensor 6009
How to Install Ammonia Sensor 6012
Remove and Install SCR Outlet NOx Sensor 6015
How to Remove SCR Outlet NOx Sensor 6015
How to Install SCR Outlet NOx Sensor 6017
Remove and Install KOMTRAX Terminal Assembly 6019
How to Remove KOMTRAX Terminal Assembly 6019
How to Install KOMTRAX Terminal Assembly 6022
Remove and Install KomVision Camera Assembly 6025
How to Remove KomVision Camera Assembly 6026
How to Install KomVision Camera Assembly 6033
Remove and Install KomVision Radar Assembly 6039
Remove KomVision Radar Assembly 6040
How to Install KomVision Radar Assembly 6049
Remove and Install KomVision Controller 6060
How to Remove KomVision Controller 6060
How to Install KomVision Controller 6062
Remove And Install KOMTRAX Plus Controller Assembly 6065
How to Remove KOMTRAX Plus Controller Assembly 6065
How to Install KOMTRAX Plus Controller Assembly 6067
Remove and Install Rearview Camera 6070
How to Remove Rearview Camera 6070
How to Install Rearview Camera 6073
Remove and Install Wireless LAN Unit Assembly 6076
How to Remove Wireless LAN Unit Assembly 6076
How to Install Wireless LAN Unit Assembly 6079
60 Maintenance Standard 6083
Table of Contents 6084
Explanation of Terms for Maintenance Standard 6086
Engine and Cooling System 6088
Maintenance Standard of Fuel Tank 6088
Maintenance Standard for Engine Mount 6089
Maintenance Standard for Damper 6090
Maintenance Standard for Cooling System 6092
Maintenance Standard of Pump Assembly (Brake and Cooling Fan) 6093
Maintenance Standard of Servo Valve of Pump Assembly (Brake and Cooling Fan) 6095
Maintenance Standard for Cooling Fan Motor 6096
Power Train 6099
Maintenance Standard for Drive Shaft 6099
Maintenance Standard for Torque Converter 6100
Maintenance Standard for Lockup Clutch ECMV 6102
Maintenance Standard for Transmission 6103
Maintenance Standard for F, R Clutch 6110
Maintenance Standard of 1st, 2nd Clutch 6112
Maintenance Standard for 3rd, 4th Clutch 6114
Maintenance Standard of H, L Clutch 6116
Maintenance Standard for Transmission Control Valve 6118
Maintenance Standard for F, R, 1st, 2nd, 3rd, 4th Clutch ECMV 6119
Maintenance Standard of H, L Clutch ECMV 6120
Maintenance Standard for Valve Assembly (Main Relief, Torque Converter Relief) 6121
Maintenance Standard for Transmission Lubrication Relief Valve 6122
Maintenance Standard for Front Axle 6123
Maintenance Standard for Rear Axle 6126
Maintenance Standard for Differential 6127
Maintenance Standard for Final Drive 6130
Maintenance Standard for Tandem Drive 6132
Steering System 6133
Maintenance Standard for Steering Column 6133
Maintenance Standard for Steering Cylinder 6134
Maintenance Standard of Steering Angle Sensor 6135
Maintenance Standard of Articulate Angle Sensor 6136
Brake System 6137
Maintenance Standard for Accumulator Charge Valve 6137
Maintenance Standard of Brake and Parking Brake 6139
Undercarriage and Frame 6141
Maintenance Standard for Frame and Center Hinge Pin 6141
Hydraulic System 6143
Maintenance Standard for Hydraulic Tank 6143
Maintenance Standard for Work Equipment Pump 6144
Maintenance Standard for Servo Valve Work of Equipment Pump 6146
Maintenance Standard of Pump Assembly (Power Train Control, Power Train Lubrication, Differential Lock) 6148
Maintenance Standard for Control Valve 6150
Maintenance Standard for Differential Lock Solenoid Valve 6160
Maintenance Standard for Parking Brake Solenoid Valve 6161
Work Equipment 6162
Maintenance Standard of Bearing Type Circle 6162
Maintenance Standard for Work Equipment Lock Solenoid Valve 6164
Maintenance Standard for Blade 6165
Maintenance Standard for Lifter 6167
Maintenance Standard for Circle Rotation Device 6168
Maintenance Standard for Blade Lift Cylinder 6170
Maintenance Standard for Blade Side-Shift Cylinder 6171
Maintenance Standard for Leaning Cylinder 6172
Maintenance Standard for Articulate Cylinder 6173
Maintenance Standard for Drawbar Side-Shift Cylinder 6174
Maintenance Standard for Blade Power Tilt Cylinder 6175
Maintenance Standard of Ripper Cylinder 6176
CAB Related Parts 6177
Maintenance Standard for CAB Mount 6177
80 Others 6179
Table of Contents 6180
Precautions Before Work 6182
Air Conditioner System 6183
Precautions for Refrigerant 6183
Layout Drawing of Air Conditioner System 6184
Specifications of Air Conditioner 6186
Structure of Refrigeration Cycle 6187
Function of Refrigeration Cycle 6188
Component Parts of Air Conditioner System 6189
Air Conditioner Unit 6189
Air Conditioner Control Panel 6193
Compressor 6196
Condenser 6197
Receiver Drier 6198
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 6200
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 6202
System Diagram of Air Conditioner 6204
Locations of Air Conditioner Parts and Layout of Connectors 6205
Examine Air Conditioner with Self-Diagnosis Function 6210
Examine Air Leakage (Duct) 6212
How to Examine Air Leakage (Duct) 6212
Examine Temperature Control Function 6215
How to Examine Temperature Control Function 6215
Examine Fresh/Recirc Air Changeover 6217
How to Examine Fresh/Recirc Air Changeover 6217
Examine Evaporator Temperature Sensor 6219
How to Examine Evaporator Temperature Sensor 6219
Examine Relay 6221
How to Examine Relay 6221
Examine Blower Amplifier 6224
How to Examine Blower Amplifier 6224
Air Conditioner Troubleshooting Chart 1 6227
Air Conditioner Troubleshooting Chart 2 6228
Information Shown in Troubleshooting Table 6231
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 6232
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 6235
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 6238
Troubleshooting for Temperature Control Function 6241
Troubleshooting for Fresh/Recirc Air Changeover 6244
Troubleshooting for Hot Water Cut Valve 6247
Troubleshooting by Gauge Pressure 6249
Connect Service Tool 6252
How to Connect Service Tool 6253
Precautions for Disconnection and Connection of Air Conditioner Piping 6254
Handle Compressor Oil 6256
KomVision System 6258
Structure and Operation of KomVision System 6258
Precautions for KomVision System 6258
Layout Drawing of KomVision System 6259
Component Parts of KomVision System 6265
Examine and Adjust KomVision System 6278
Set and Operate KomVision Monitor 6278
Camera Calibration 6297
5 Camera Calibration 6298
1 Camera Calibration 6326
How to Adjust Radar 6332
How to Examine Details of Radar 6334
Troubleshooting for KomVision System 6335
Related Information to Troubleshooting 6335
Troubleshooting by Failure Code (Display of Code) 6354
Troubleshooting of Electrical System (E-Mode) 6467
90 Circuit Diagrams 6497
Table of Contents 6498
How to Read the Codes for Electric Cable 6499
Hydraulic Circuit Diagram 6503
Symbols Used in Hydraulic Circuit Diagram 6503
Hydraulic Circuit Diagram (1/2) 6507
Hydraulic Circuit Diagram (2/2) 6509
Hydraulic Circuit Diagram (When Blade Left Side Raise + Left Turn + Brake Push (Cut Out) + Parking Brake Released + Differential Lock Released) (1/2) 6511
Hydraulic Circuit Diagram (When Blade Left Side Raise + Left Turn + Brake Push (Cut Out) + Parking Brake Released + Differential Lock Released) (2/2) 6513
Electrical Circuit Diagram 6515
Symbols Used in Electric Circuit Diagram 6515
Electrical Circuit Diagram of Machine (1/15) 6519
Electrical Circuit Diagram of Machine (2/15) 6521
Electrical Circuit Diagram of Machine (3/15) 6523
Electrical Circuit Diagram of Machine (4/15) 6525
Electrical Circuit Diagram of Machine (5/15) 6527
Electrical Circuit Diagram of Machine (6/15) 6529
Electrical Circuit Diagram of Machine (7/15) 6531
Electrical Circuit Diagram of Machine (8/15) 6533
Electrical Circuit Diagram of Machine (9/15) 6535
Electrical Circuit Diagram of Machine (10/15) 6537
Electrical Circuit Diagram of Machine (11/15) 6539
Electrical Circuit Diagram of Machine (12/15) 6541
Electrical Circuit Diagram of Machine (13/15) 6543
Electrical Circuit Diagram of Machine (14/15) 6545
Electrical Circuit Diagram of Machine (15/15) 6547
Electrical Circuit Diagram of Floor (1/12) 6549
Electrical Circuit Diagram of Floor (2/12) 6551
Electrical Circuit Diagram of Floor (3/12) 6553
Electrical Circuit Diagram of Floor (4/12) 6555
Electrical Circuit Diagram of Floor (5/12) 6557
Electrical Circuit Diagram of Floor (6/12) 6559
Electrical Circuit Diagram of Floor (7/12) 6561
Electrical Circuit Diagram of Floor (8/12) 6563
Electrical Circuit Diagram of Floor (9/12) 6565
Electrical Circuit Diagram of Floor (10/12) 6567
Electrical Circuit Diagram of Floor (11/12) 6569
Electrical Circuit Diagram of Floor (12/12) 6571
Index 6573

DESCRIPTION:

Komatsu GD955-7 Motor Grader Shop Manual SEN06936-08 – PDF DOWNLOAD 

SERIAL NUMBERS 10001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

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