Komatsu MOTOR GRADER GD675-7E0 Shop Manual SEN06962-01 PDF

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Komatsu MOTOR GRADER GD675-7E0 Shop Manual SEN06962-01 – PDF DOWNLOAD

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Komatsu MOTOR GRADER GD675-7E0 Shop Manual SEN06962-01 – PDF DOWNLOAD

Language : English
Pages :4868
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DESCRIPTION:

Komatsu MOTOR GRADER GD675-7E0 Shop Manual SEN06962-01 – PDF DOWNLOAD

SERIAL NUMBERS 65001 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.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in 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.
00 Index and Foreword How to Read the Shop Manual
GD675-7E0 00-29
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu MOTOR GRADER GD675-7E0 Shop Manual SEN06962-01 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 31
How to Read the Shop Manual 31
Safety Notice for Operation 33
Precautions to Prevent Fire 41
Procedures If Fire Occurs 43
Precautions for Disposing of Waste Materials 44
Procedures for Exhaust Gas Regulations 45
Precautions for DEF 46
General Character and Precautions for Handling 46
Precautions for Adding 46
Precautions for Storage 46
Precautions for Fire Hazard and Leakage 46
Other Precautions 46
Store DEF 47
Precautions When You Handle Hydraulic Equipment 48
Precautions When You Disconnect and Connect Pipings 51
Precautions When You Handle Electrical Equipment 58
Precautions When You Handle Fuel System Equipment 60
Precautions When You Handle Intake System Equipment 61
Practical Use of KOMTRAX 62
Disconnect and Connect Push-Pull Type Coupler 63
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 63
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 64
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 65
Precautions for Disconnection and Connection of Connectors 67
How to Disconnect and Connect Deutsch Connector 71
How to Disconnect and Connect Slide Lock Type Connector 72
How to Disconnect and Connect Connector with Lock to Pull 74
How to Disconnect and Connect Connector with Lock to Push 75
How to Disconnect and Connect Connector with Housing to Rotate 77
How to Read the Codes for Electric Cable 78
Explanation of Terms for Maintenance Standard 82
Standard Tightening Torque Table 85
Conversion Table 92
Abbreviation List 97
01 Specifications 101
Table of Contents 102
Specifications 103
Specification Drawing 103
Specification Drawing: GD675-7E0 103
Specifications 105
Specifications GD675-7E0 105
Weight Table 111
Weight Table: GD675-7E0 111
Fuel, Coolant, Lubricant 112
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 112
10 Structure and Function 115
Table of Contents 116
Urea SCR System 120
Layout Drawing of Urea SCR System 120
Urea SCR System Diagram 123
Function of Urea SCR System 124
FUNCTION OF DEF SYSTEM (MACHINE WITHOUT DEF purge relay)(APPLICABLE MACHINE: 65001 to 65391) 124
FUNCTION OF DEF SYSTEM (MACHINE WITHOUT DEF purge relay)(APPLICABLE MACHINE: 65392 and up) 126
FUNCTION OF DEF SYSTEM (MACHINE WITH DEF purge relay)(APPLICABLE MACHINE: 65001 to 65391) 128
FUNCTION OF DEF SYSTEM (MACHINE WITH DEF purge relay)(APPLICABLE MACHINE: 65392 and up) 130
Inducement Strategy 133
Component Parts of Urea SCR System 141
DEF Mixing Tube 141
SCR Assembly 142
DEF Tank 144
DEF Pump 146
DEF Injector 148
DEF Hose 149
DEF Tank Heating Valve 150
Boot-up System 151
Layout Drawing of Boot-up System 151
System Operating Lamp System 153
System Diagram of System Operating Lamp System 153
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 153
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine Without DEF purge relay) 153
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Machine with DEF purge relay) 153
Battery Disconnect Switch 155
Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal) 155
Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine Without DEF purge relay) 155
Function of Battery Disconnect Switch (Machine with Gateway Function Controller) (Machine with DEF purge relay) 156
Operation of Battery Disconnect Switch 156
Preheating System 157
System Diagram of Preheating System 157
Function of Automatic Preheating System 157
Operation of Automatic Preheating System 157
Function of Manual Preheating System 158
Operation of Manual Preheating System 158
Engine Shutdown Secondary Switch 159
Function of Engine Shutdown Secondary Switch 159
Operation of Engine Shutdown Secondary Switch 159
Engine System 160
Layout Drawing of Engine System 160
Engine Control System 161
System Diagram of Engine Control 161
Engine Automatic Warm-up Function 162
Engine Automatic Warm-up Cancel Function 162
Operation of Engine Control System 162
Engine Power Mode Selector System 164
Engine Power Mode Selector System Diagram 164
Function of Engine Power Mode Selector System 164
Operation of Engine Power Mode Selector System 164
Automatic Idle Stop System 165
Function of Automatic Idle Stop System 165
Component Parts of Engine System 166
VGT 166
EGR System 171
EGR Valve 173
EGR Cooler 175
KCCV System 177
KCCV Ventilator 179
KDPF 181
Cooling System 185
Layout Drawing of Cooling System 185
Specifications of Cooling System 186
Cooling Fan Control System 187
System Diagram of Cooling Fan Control System 187
Function of Cooling Fan Control System 188
Component Parts of Cooling System 190
Brake and Cooling Fan Pump 190
Cooling Fan Motor 191
Control System 198
Layout Drawing of Control System (Machine with Gateway Function Controller) 198
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 200
Machine Monitor System 202
System Diagram of Machine Monitor System 202
Function of Machine Monitor System 203
Rearview Monitor System 204
System Diagram of Rearview Monitor System 204
Function of Rearview Monitor System 204
KOMTRAX System 205
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 205
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 205
Function of KOMTRAX System 206
Seating Switch System 207
Seating Switch System Diagram (Serial No: 65001 to 65481) 207
Function of Seating Switch System (Serial No: 65001 to 65481) 207
Operator Detection System 209
System Diagram of Operator Detection System (Serial No: 65482 and Up) 209
Function of Operator Detection System (Serial No: 65482 and Up) 209
Component Parts of Control System 211
Machine Monitor 211
Switch Panel 232
Rearview Monitor 233
Rearview Camera 235
Gateway Function Controller 236
Communication Terminal 239
KOMTRAX Terminal 241
Transmission Controller 244
Work Equipment Controller 248
Monitor Controller 252
CAN Terminating Resistor 257
Engine Controller 258
Accelerator Pedal 264
Inching Pedal 266
Hydraulic System 267
Layout Drawing of Hydraulic System 267
CLSS 268
System Diagram of CLSS 268
Function of CLSS 269
Component Parts of Hydraulic System 272
Hydraulic Tank 272
Steering and Work Equipment Pump 275
Power Train Pump and Differential Lock Pump 284
Control Valve 285
Assistance Valve for Startup at Low Temperature 306
Power Train System 307
Layout Drawing of Power Train System 307
Operation of Power Train System 311
Transmission Control System 312
Transmission Control System Diagram 312
Function of Transmission Control System 313
Transmission Protection Function 316
Engine Overrun Prevention Function 316
Very Low Speed Travel Control Function 316
Component Parts of Power Train System 317
Drive Shaft 317
Torque Converter 318
Lockup Clutch ECMV 321
Transmission 324
Transmission Control Valve 350
FL, FH, R, 1st, 2nd, 3rd, 4th Clutch ECMV 353
Valve Assembly (For Main Relief and Torque Converter Relief) 357
Axle 359
Differential 362
Final Drive 364
Tandem Drive 365
Solenoid Valve (Differential Lock) 367
Steering System 368
Layout Drawing of Steering System 368
Steering Column 370
Structure of Steering Column 370
Function of Steering Column 370
Steering Lever System 371
Layout Drawing of Steering Lever System 371
Steering Lever System Diagram 372
Function of Steering Lever System 372
Component Parts of Steering System 375
Priority Valve 375
Steering Unit 376
LS Logic Valve 377
Work Equipment System 378
Layout Drawing of Work Equipment System 378
Work Equipment Control System 382
Work Equipment Lever Operating Function System Diagram 382
Work Equipment Lever Operation Function 382
Blade Lift, Spool Calibration Function 382
Stop Shock Mitigate Filter Function 382
Work Equipment Lock System 383
Work Equipment Lock System Diagram 383
Function of Work Equipment Lock System (Serial No: 65001 to 65481) 383
Function of Work Equipment Lock System (Serial No: 65482 and Up) 384
Cross Slope System 385
System Diagram of Cross Slope System 385
Function of Cross Slope System 385
Component Parts of Work Equipment System 386
Solenoid Valve (Work Equipment Lock) 386
Solenoid Valve (Blade Accumulator, Blade FLOAT) 387
Blade Accumulator 388
Scarifier Relief Valve 389
Swivel Joint 390
Work Equipment Electric Lever 392
Circle Rotation Motor 395
Circle Rotation 396
IMU 398
Blade Rotation Angle Sensor 400
Brake System 401
Layout Drawing of Brake System 401
Parking Brake Control System 403
System Diagram of Parking Brake Control System 403
Operation of Parking Brake Control System (Serial No: 65001 to 65481) 403
Operation of Parking Brake Control System (Serial No: 65482 and Up) 404
Component Parts of Brake System 405
Accumulator Charge Valve 405
Brake Accumulator 410
Brake Valve 411
Slack Adjuster 414
Brake 416
Solenoid Valve (Parking Brake, Lifter Lock) 417
Parking Brake 419
Undercarriage and Frame 420
Frame and Center Hinge Pin 420
Structure of Frame and Center Hinge Pin 420
Function of Frame and Center Hinge Pin 420
Tires 421
Features of Radial Tire When Compared with Bias Tire 421
Structure of Radial Tire 421
Function of Radial Tire 421
Structure of Bias Tire 422
Function of Bias Tire 422
Work Equipment 423
Circle, Draw Bar 423
Structure of Circle and Drawbar 423
Function of Circle and Drawbar 425
Blade 426
Structure of Blade 426
Function of Blade 427
Lifter 428
Structure of Lifter 428
Function of Lifter 429
CAB Related Parts 430
ROPS CAB 430
Structure of ROPS CAB 430
Function of ROPS CAB 430
20 Standard Value Table 431
Table of Contents 432
Standard Value Table for Engine 433
Standard Value Table for Engine: GD675-7E0 433
Standard Value Table for Machine 436
Standard Value Table for Machine: GD675-7E0 436
Machine Posture and Procedures to Measure Performance 450
30 Testing and Adjusting 451
Table of Contents 452
Precautions Before Work 456
Related Information on Testing and Adjusting 457
Differences In Machine Monitor Symbols 457
Tools for Testing and Adjusting 458
Sketch of Tools for Testing and Adjusting 470
Engine and Cooling System 471
Examine Engine Speed 471
How to Examine Engine Speed 471
Examine Boost Pressure 476
How to Examine Boost Pressure 476
Examine Exhaust Gas Temperature 479
How to Examine Exhaust Gas Temperature 479
Examine Exhaust Gas Color 482
How to Examine Exhaust Gas Color with the Handy Smoke Checker 482
How to Examine Exhaust Gas Color with Smoke Meter 484
Examine Mass Air Flow and Temperature Sensor 486
How to Examine Mass Air Flow and Temperature Sensor 486
Examine and Adjust Valve Clearance 488
How to Examine Valve Clearance 488
How to Adjust Valve Clearance 489
Examine Compression Pressure 490
How to Examine Compression Pressure 490
Examine Blowby Pressure 495
How to Examine Blowby Pressure 495
Examine Engine Oil Pressure 499
How to Examine Engine Oil Pressure 499
Examine EGR Valve and VGT Oil Pressure 502
How to Examine EGR Valve and VGT Oil Pressure 502
Examine Fuel Pressure 504
How to Examine Fuel Pressure 505
Examine Fuel Discharge, Return and Leakage 512
How to Examine Fuel Discharge, Return, and Leakage 513
Bleed Air from Fuel System 520
How to Bleed Air from Fuel System 520
Examine Fuel Circuit for Leakage 522
How to Examine Fuel System for Leakage 522
Handle Cylinder Cut-out Mode Operation 524
Handle No-Injection Cranking Operation 525
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 526
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 526
Examine Installation of Cylinder Head Cover and Manifolds 527
How to Examine Installed Condition of Cylinder Head covers and Manifolds 527
Examine Engine Piping for Damage and Looseness 528
How to Examine Engine Piping for Damage and Looseness 528
Examine and Adjust Air Conditioner Compressor Belt Tension 529
How to Examine Air Conditioner Compressor Belt Tension 529
How to Adjust Air Conditioner Compressor Belt Tension 529
Examine Alternator Belt 531
How to Examine Alternator Belt 531
Examine Automatic Tensioner 533
How to Examine Automatic Tensioner 533
Write Correction for Ash in Soot Accumulation to Engine Controller 537
How to Write Correction for Ash in Soot Accumulation to Engine Controller 537
Examine SCR Related Functions 538
Examine DEF Pump Raised Pressure 542
Examine Injection Volume from DEF Injector 546
Examine DEF Line Heater Relay 1 552
Examine DEF Line Heater Relay 2 556
Examine DEF Pump Heater Relay 560
Examine DEF Tank Heater Valve 565
Examine SCR Denitration Efficiency 569
Clean DEF Tank 573
How to Clean DEF Tank 573
Clean DEF Pump 578
How to Clean DEF Pump 578
Power Train 584
Examine Power Train Oil Pressure 584
How to Examine Power Train Oil Pressure 587
Adjust Transmission Input Shaft Speed Sensor 609
How to Adjust Transmission Input Shaft Speed Sensor 609
Adjust Transmission Intermediate Shaft Speed Sensor 610
How to Adjust Transmission Intermediate Shaft Speed Sensor 610
Adjust Transmission Output Shaft Speed Sensor 611
How to Adjust Transmission Output Shaft Speed Sensor 611
Adjust Travel Speed Sensor 1 for Steering Control Lever 612
How to Adjust Travel Speed Sensor 1 for Steering Control Lever 612
Adjust Travel Speed Sensor 2 for Steering Control Lever 613
How to Adjust Travel Speed Sensor 2 for Steering Control Lever 613
Examine After You Adjust Transmission Speed Sensor 614
How to Examine After Adjustment of Transmission Speed Sensor 614
Flush Torque Converter and Transmission Hydraulic Circuit 615
How to Flush Torque Converter and Transmission Hydraulic Circuit 615
Move Disabled Machine Due to Transmission Valve Failure 618
How to Move Disabled Machine Due to Transmission Valve Failure 619
Examine Drive Shaft for Looseness, Backlash, and Damage 621
How to Examine Drive Shaft for Looseness, Backlash, and Damage 621
Examine and Adjust Differential Lock Hydraulic Oil Pressure 622
How to Examine Differential Lock Oil Pressure 622
How to Adjust Differential Lock Oil Pressure 625
Steering System 626
Examine and Adjust Steering Circuit Oil Pressure 626
How to Examine Steering Circuit Oil Pressure 626
How to Adjust Steering Circuit Oil Pressure 627
Examine Internal Oil Leakage of Steering Cylinder 628
How to Examine Oil Leakage from Steering Cylinder 628
Bleed Air from Steering Circuit 630
How to Bleed Air from Steering Circuit 630
Set Steering Control Lever Calibration 631
How to Set Steering Control Lever Calibration 632
Examine and Adjust Toe-in 638
How to Examine Toe-in 638
How to Adjust Toe-in 639
Adjust Bearing Preload 640
How to Adjust Bearing Preload 640
Brake System 641
Release Remained Pressure from Brake Circuit 641
How to Release Remained Pressure from Brake Circuit 641
Examine Wheel Brake Oil Pressure 642
How to Examine Wheel Brake Oil Pressure 642
Examine and Adjust Accumulator Charge Pressure 645
How to Examine Accumulator Charge Pressure 645
How to Adjust Accumulator Charge Pressure 647
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 648
How to Examine Accumulator Nitrogen Gas Pressure for Brake 648
How to Charge Accumulator Nitrogen Gas Pressure for Brake 652
Bleed Air from Brake Circuit 657
How to Bleed Air from Brake Circuit 657
Examine Pressure Decrease of Wheel Brake 660
How to Examine Pressure Decrease of Wheel Brake 660
Examine Wear of Wheel Brake Disc 661
How to Examine Wear of Wheel Brake Disc 661
Examine Parking Brake Oil Pressure 663
How to Examine Parking Brake Oil Pressure 663
Release Parking Brake Manually 665
How to Release Parking Brake Manually 665
Examine and Adjust Parking Brake System 666
How to Examine Parking Brake System 666
How to Adjust Parking Brake System by Brake Tester 667
How to Adjust Parking Brake System in Engine Operating State 668
Hydraulic System 670
Release Remained Pressure from Work Equipment Circuit 670
How to Release Remained Pressure from Work Equipment Circuit 670
Examine and Adjust Work Equipment Oil Pressure 671
How to Examine Work Equipment Oil Pressure 671
How to Adjust Work Equipment Oil Pressure 676
Examine and Adjust Work Equipment EPC Oil Pressure 678
How to Examine Work Equipment EPC Oil Pressure 678
How to Adjust Work Equipment EPC Oil Pressure 679
Examine and adjust oil pressure in pump PC control circuit 680
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 680
How to Adjust Oil Pressure in Pump PC Control Circuit 682
Examine and Adjust Oil Pressure in Pump LS Control Circuit 684
How to Examine LS Differential Pressure 684
How to Adjust LS Valve 687
Examine Oil Pressure of Lifter Lock Pin Circuit 688
How to Examine Oil Pressure of Lifter Lock Pin Circuit 688
Bleed Air from Work Equipment Circuit 690
How to Bleed Air from Work Equipment Circuit 690
Examine Cooling Fan Speed 692
How to Examine Cooling Fan Speed 692
Examine Cooling Fan Circuit Oil Pressure 694
How to Examine Cooling Fan Circuit Oil Pressure 694
Examine Oil Leakage from Work Equipment Cylinder 697
How to Examine Oil Leakage from Blade Lift Cylinder 697
How to Examine Oil Leakage from Blade Side-Shift Cylinder 699
How to Examine Oil Leakage from Drawbar Side-Shift Cylinder 700
How to Examine Oil Leakage from Power Tilt Cylinder 701
How to Examine Oil Leakage from Articulate Cylinder 702
How to Examine Oil Leakage from Leaning Cylinder 703
Work Equipment 705
Adjust Clearance of Ball Joint 705
How to Adjust Clearance of Ball Joint 705
Examine and Adjust Clearance in Circle Guide 706
How to Examine Clearance in Circle Guide 707
How to Adjust Clearance in Circle Guide 707
Examine and Adjust Circle Rotation Gear 711
How to Examine Circle Rotation Gear 711
How to Adjust Circle Rotation Gear 712
Charge Blade Accumulator Nitrogen Gas Pressure 715
How to Charge Blade Accumulator Nitrogen Gas Pressure 715
Electrical System 720
Set and Adjust Each Equipment 720
Set and Operate Machine Monitor 723
Operator Mode 727
Function to Show Technician Identification Status Screen 727
Function to Show Operator Identification Input Screen 727
Examine Function by LCD (Liquid Crystal Display) 728
Examine Function of Service Meter and Odometer 729
How to Set Usage Limitation and Change Maintenance Password 729
Service Mode 734
How to Operate Service Mode 734
How to See Pre-defined Monitoring Information 738
How to Examine Monitoring Information 746
Abnormality Record Menu 761
How to See Maintenance Record 766
Maintenance Mode Setting 768
How to Set Phone Number Entry 774
Default Setting Menu 776
Testing Menu 793
Adjustment Menu 807
No-Injection Cranking Operation 865
KOMTRAX Settings Menu 868
How to Show Service Message 872
How to Start Up KOMTRAX Terminal 874
Adjust Rearview Camera Angle 880
How to Adjust Rearview Camera Angle 880
Set Region of Bluetooth(R) Compatible Radio 882
How to Set Region of Bluetooth(R) Compatible Radio 882
Handle Voltage Circuit of Engine Controller 884
Handle Battery Disconnect Switch 885
Examine Diodes 886
How to Examine Diodes by Digital Tester 886
How to Examine Diodes by Analog Tester 886
Pm Clinic 887
Pm Clinic Service 887
Pm Clinic Check Sheet: GD675-7E0 889
40 Troubleshooting 899
Table of Contents 900
Precautions Before Work 919
Related Information for Troubleshooting 920
Precautions for Troubleshooting 920
Sequence of Events in Troubleshooting 921
General Troubleshooting Points 923
Troubleshooting Points for Urea SCR System 924
Checks Before Troubleshooting 938
Inspection Procedure Before Troubleshooting 940
Walk-Around Check 940
Test in Accordance with Testing Procedure 942
Examine Fuel Level and Type 942
Examine for Impure Ingredient in Fuel 943
Examine DEF Level and Type 943
Examine Fuel Prefilter 946
Examine Fuel Main Filter 948
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 950
Examine Coolant Level (Reservoir Tank) 951
Examine Air Cleaner Clogging 952
Clean Outer Element 952
Replace Element 955
Examine Hydraulic Oil Level 955
Examine Hydraulic Oil Strainer 957
Examine Hydraulic Oil Filter 958
Examine Oil Level in Transmission Case 960
Examine Transmission Case Strainer 962
Replace Transmission Oil Filter Cartridge 962
Examine Oil Level in Final Drive Case 963
Bleed Air from Fuel System 965
Bleed Air from Hydraulic System 965
How to Examine Electric Equipment 965
How to Connect Adapter for Troubleshooting Controller 977
How to Connect Adapter to Troubleshoot Monitor Controller 977
How to Connect Adapter to Troubleshoot Transmission Controller 982
How to Connect Adapter for Troubleshooting Work Equipment Controller 985
How to Connect Adapter to Troubleshoot KOMTRAX Terminal 988
How to Connect Adapter for Troubleshooting Gateway Function Controller 990
How to Connect Adapter for Troubleshooting Engine Controller 991
Procedure for Troubleshooting 994
Symptom and Troubleshooting Numbers 996
Information Shown in Troubleshooting Table1001
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness1003
Connectors List (Applicable Machine: 65001 to 65481)1006
Connector Layout (Applicable Machine: 65001 to 65481)1019
Connectors List (Applicable Machine: 65482 and up)1030
Connector Layout (Applicable Machine: 65482 and up)1043
Connector Contact Connection Table1054
T-Branch Box and T-Branch Adapter Table1101
Fuse Location Table1107
Fuse Location Table (Machine with Gateway Function Controller)1110
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1113
Prepare Troubleshoot Machine Monitor1117
Procedure to Make Harness Checker on Machine Monitor LCD Unit1119
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])1125
Failure Code Table1127
Troubleshooting by Failure Code (Display of Code)1163
Failure Code [1500L0]1163
Failure Code [15G0MW]1164
Failure Code [15H0MW]1165
Failure Code [15J0MW]1166
Failure Code [15K0MW]1167
Failure Code [15L0MW]1169
Failure Code [15M0MW]1171
Failure Code [15N0MW]1173
Failure Code [15SBL1]1175
Failure Code [15SBMA]1177
Failure Code [15SCL1]1180
Failure Code [15SCMA]1182
Failure Code [15SDL1]1185
Failure Code [15SDMA]1187
Failure Code [15SEL1]1190
Failure Code [15SEMA]1192
Failure Code [15SFL1]1195
Failure Code [15SFMA]1197
Failure Code [15SGL1]1200
Failure Code [15SGMA]1202
Failure Code [15SHL1]1205
Failure Code [15SHMA]1207
Failure Code [15SJMA]1210
Failure Code [15U0NT]1211
Failure Code [2F00MA]1212
Failure Code [2F00MB]1215
Failure Code [2G42ZG]1218
Failure Code [2G43ZG]1220
Failure Code [989L00]1222
Failure Code [989M00]1223
Failure Code [989N00]1224
Failure Code [A1U0N3]1225
Failure Code [A1U0N4]1227
Failure Code [AA10NX]1229
Failure Code [AB00KE]1231
Failure Code [AB00KY]1233
Failure Code [AQ10N3]1235
Failure Code [AS00N3]1237
Failure Code [AS00R2]1239
Failure Code [AS00R3]1240
Failure Code [AS00R4]1241
Failure Code [AS00R5]1242
Failure Code [AS00R6]1243
Failure Code [AS00ZK]1244
Failure Code [AS10KM]1245
Failure Code [AS10NR]1246
Failure Code [AS10NT]1247
Failure Code [B@BAZG]1248
Failure Code [B@BCNS]1249
Failure Code [B@BCQA]1250
Failure Code [B@BCZK]1252
Failure Code [B@CENS]1254
Failure Code [B@CKNS]1255
Failure Code [B@HANS]1257
Failure Code [CA115]1259
Failure Code [CA122]1260
Failure Code [CA123]1262
Failure Code [CA131]1264
Failure Code [CA132]1266
Failure Code [CA144]1269
Failure Code [CA145]1271
Failure Code [CA153]1273
Failure Code [CA154]1276
Failure Code [CA187]1278
Failure Code [CA221]1280
Failure Code [CA222]1282
Failure Code [CA227]1284
Failure Code [CA234]1285
Failure Code [CA238]1286
Failure Code [CA239]1288
Failure Code [CA249]1290
Failure Code [CA256]1292
Failure Code [CA271]1294
Failure Code [CA272]1296
Failure Code [CA322]1298
Failure Code [CA323]1300
Failure Code [CA324]1302
Failure Code [CA325]1304
Failure Code [CA331]1306
Failure Code [CA332]1308
Failure Code [CA343]1310
Failure Code [CA351]1311
Failure Code [CA352]1312
Failure Code [CA356]1315
Failure Code [CA357]1317
Failure Code [CA386]1320
Failure Code [CA428]1321
Failure Code [CA429]1323
Failure Code [CA431]1325
Failure Code [CA432]1328
Failure Code [CA435]1332
Failure Code [CA441]1334
Failure Code [CA442]1336
Failure Code [CA449]1337
Failure Code [CA451]1338
Failure Code [CA452]1340
Failure Code [CA488]1342
Failure Code [CA515]1343
Failure Code [CA516]1345
Failure Code [CA553]1347
Failure Code [CA555]1348
Failure Code [CA556]1349
Failure Code [CA559]1350
Failure Code [CA595]1353
Failure Code [CA687]1354
Failure Code [CA689]1356
Failure Code [CA691]1359
Failure Code [CA692]1361
Failure Code [CA697]1363
Failure Code [CA698]1364
Failure Code [CA731]1365
Failure Code [CA778]1367
Failure Code [CA1117]1372
Failure Code [CA1664]1373
Failure Code [CA1669]1376
Failure Code [CA1673]1377
Failure Code [CA1677]1378
Failure Code [CA1678]1379
Failure Code [CA1682]1380
Failure Code [CA1683]1385
Failure Code [CA1684]1387
Failure Code [CA1686]1389
Failure Code [CA1691]1390
Failure Code [CA1694]1393
Failure Code [CA1695]1396
Failure Code [CA1696]1397
Failure Code [CA1712]1399
Failure Code [CA1713]1402
Failure Code [CA1714]1404
Failure Code [CA1715]1405
Failure Code [CA1776]1406
Failure Code [CA1777]1409
Failure Code [CA1843]1412
Failure Code [CA1844]1414
Failure Code [CA1879]1417
Failure Code [CA1881]1420
Failure Code [CA1883]1423
Failure Code [CA1885]1427
Failure Code [CA1887]1429
Failure Code [CA1921]1431
Failure Code [CA1922]1434
Failure Code [CA1942]1439
Failure Code [CA1993]1440
Failure Code [CA2185]1443
Failure Code [CA2186]1445
Failure Code [CA2249]1447
Failure Code [CA2271]1448
Failure Code [CA2272]1451
Failure Code [CA2288]1454
Failure Code [CA2311]1455
Failure Code [CA2349]1456
Failure Code [CA2353]1459
Failure Code [CA2357]1461
Failure Code [CA2381]1462
Failure Code [CA2382]1465
Failure Code [CA2383]1468
Failure Code [CA2386]1471
Failure Code [CA2387]1473
Failure Code [CA2555]1474
Failure Code [CA2556]1477
Failure Code [CA2637]1479
Failure Code [CA2639]1481
Failure Code [CA2771]1484
Failure Code [CA2777]1490
Failure Code [CA2976]1493
Failure Code [CA3133]1495
Failure Code [CA3134]1498
Failure Code [CA3135]1500
Failure Code [CA3142]1504
Failure Code [CA3143]1505
Failure Code [CA3144]1506
Failure Code [CA3146]1509
Failure Code [CA3147]1510
Failure Code [CA3148]1511
Failure Code [CA3151]1514
Failure Code [CA3165]1520
Failure Code [CA3229]1522
Failure Code [CA3231]1524
Failure Code [CA3232]1526
Failure Code [CA3235]1530
Failure Code [CA3239]1532
Failure Code [CA3241]1535
Failure Code [CA3242]1538
Failure Code [CA3251]1541
Failure Code [CA3253]1543
Failure Code [CA3254]1546
Failure Code [CA3255]1549
Failure Code [CA3256]1553
Failure Code [CA3311]1555
Failure Code [CA3312]1557
Failure Code [CA3313]1560
Failure Code [CA3314]1561
Failure Code [CA3315]1562
Failure Code [CA3316]1565
Failure Code [CA3317]1566
Failure Code [CA3318]1567
Failure Code [CA3319]1570
Failure Code [CA3321]1571
Failure Code [CA3322]1573
Failure Code [CA3419]1576
Failure Code [CA3421]1578
Failure Code [CA3497]1580
Failure Code [CA3498]1581
Failure Code [CA3543]1582
Failure Code [CA3545]1589
Failure Code [CA3547]1591
Failure Code [CA3558]1592
Failure Code [CA3559]1594
Failure Code [CA3562]1596
Failure Code [CA3563]1598
Failure Code [CA3567]1601
Failure Code [CA3568]1604
Failure Code [CA3571]1610
Failure Code [CA3572]1612
Failure Code [CA3574]1614
Failure Code [CA3575]1617
Failure Code [CA3577]1619
Failure Code [CA3578]1621
Failure Code [CA3582]1623
Failure Code [CA3583]1631
Failure Code [CA3596]1633
Failure Code [CA3649]1636
Failure Code [CA3681]1638
Failure Code [CA3682]1643
Failure Code [CA3713]1649
Failure Code [CA3717]1652
Failure Code [CA3718]1653
Failure Code [CA3725]1654
Failure Code [CA3741]1657
Failure Code [CA3748]1658
Failure Code [CA3751]1661
Failure Code [CA3755]1663
Failure Code [CA3866]1665
Failure Code [CA3867]1669
Failure Code [CA3868]1672
Failure Code [CA3899]1676
Failure Code [CA3911]1678
Failure Code [CA3912]1682
Failure Code [CA3932]1684
Failure Code [CA3933]1686
Failure Code [CA3934]1688
Failure Code [CA3935]1691
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Failure Code [CA4151]1695
Failure Code [CA4152]1699
Failure Code [CA4155]1703
Failure Code [CA4156]1706
Failure Code [CA4157]1709
Failure Code [CA4158]1711
Failure Code [CA4159]1712
Failure Code [CA4161]1713
Failure Code [CA4162]1716
Failure Code [CA4163]1719
Failure Code [CA4164]1721
Failure Code [CA4165]1723
Failure Code [CA4166]1725
Failure Code [CA4168]1727
Failure Code [CA4169]1730
Failure Code [CA4171]1732
Failure Code [CA4249]1735
Failure Code [CA4251]1737
Failure Code [CA4259]1739
Failure Code [CA4261]1742
Failure Code [CA4277]1745
Failure Code [CA4281]1749
Failure Code [CA4459]1752
Failure Code [CA4461]1754
Failure Code [CA4658]1757
Failure Code [CA4731]1761
Failure Code [CA4732]1762
Failure Code [CA4739]1763
Failure Code [CA4768]1764
Failure Code [CA4769]1766
Failure Code [CA4842]1769
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1773
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1775
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1777
Failure Code [CA5115]1779
Failure Code [CA5179]1782
Failure Code [CA5181]1784
Failure Code [CA5383]1786
Failure Code [D110L4]1788
Failure Code [D132KA]1790
Failure Code [D132KB]1792
Failure Code [D132KY]1794
Failure Code [D132MB]1796
Failure Code [D132MC]1797
Failure Code [D160KA]1799
Failure Code [D160KB]1801
Failure Code [D160KY]1803
Failure Code [D199KA]1805
Failure Code [D199KB]1807
Failure Code [D199KY]1809
Failure Code [D19JKZ]1811
Failure Code [D19KKZ]1813
Failure Code [D1EHKA]1816
Failure Code [D1EHKB]1817
Failure Code [D1EHKY]1818
Failure Code [D1FBKB]1819
Failure Code [D5ZHKZ]1821
Failure Code [D5ZHL6]1824
Failure Code [D811MC]1826
Failure Code [D862KA]1827
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1828
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1830
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1832
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1834
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1836
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1838
Failure Code [D8AQK4]1840
Failure Code [D8AQKR]1846
Failure Code [D8G1KT]1852
Failure Code [D8G6KT]1853
Failure Code [DAF0KT]1854
Failure Code [DAF0MB]1855
Failure Code [DAF0MC]1856
Failure Code [DAF3KK]1857
Failure Code [DAF8KB]1859
Failure Code [DAFDKB]1861
Failure Code [DAFGMC]1863
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)1864
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1866
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1868
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)1870
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1872
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1874
Failure Code [DAFQKR]1876
Failure Code [DAQ0KK]1882
Failure Code [DAQ0KT]1886
Failure Code [DAQ0MC]1887
Failure Code [DAQ1KA]1888
Failure Code [DAQ200]1890
Failure Code [DAQ2KK]1891
Failure Code [DAQ2KT]1895
Failure Code [DAQ9KQ]1896
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)1897
Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1899
Failure Code [DAQLKA] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1901
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)1904
Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1906
Failure Code [DAQLKB] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1908
Failure Code [DAQQKR]1910
Failure Code [DAQRKR]1919
Failure Code [DAQRMA]1929
Failure Code [DB2QKR]1930
Failure Code [DB2RKR]1939
Failure Code [DB3RKR]1948
Failure Code [DB90KK]1953
Failure Code [DB90KT]1956
Failure Code [DB90MC]1957
Failure Code [DB91KA]1958
Failure Code [DB9200]1960
Failure Code [DB92KK]1961
Failure Code [DB92KT]1964
Failure Code [DB95KX]1965
Failure Code [DB96KX]1968
Failure Code [DB99KQ]1971
Failure Code [DB9LKA] (Machine with KOMTRAX Terminal)1972
Failure Code [DB9LKA] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1974
Failure Code [DB9LKA] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1976
Failure Code [DB9LKB] (Machine with KOMTRAX Terminal)1978
Failure Code [DB9LKB] (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65216)1980
Failure Code [DB9LKB] (Machine with Gateway Function Controller) (Applicable Machine: 65217 and Up)1982
Failure Code [DB9QKR]1984
Failure Code [DB9RKR]1992
Failure Code [DB9RMA]2000
Failure Code [DD19KA]2001
Failure Code [DD19L4]2003
Failure Code [DD1PKB]2005
Failure Code [DD1QKB]2007
Failure Code [DDAAL6]2009
Failure Code [DDB4L4]2011
Failure Code [DDB6L4]2014
Failure Code [DDE9KA]2019
Failure Code [DDE9KB]2021
Failure Code [DDK3KA]2023
Failure Code [DDK3KB]2025
Failure Code [DDK5KA]2027
Failure Code [DDK5KB]2029
Failure Code [DDKAKY]2031
Failure Code [DDKLKA]2033
Failure Code [DDKLKB]2036
Failure Code [DDKLKY]2039
Failure Code [DDKVKA]2041
Failure Code [DDKVKB]2043
Failure Code [DDKVKY]2045
Failure Code [DDL3KY]2047
Failure Code [DDL4KY]2049
Failure Code [DDL5KY]2051
Failure Code [DDL6KY]2053
Failure Code [DDL7KY]2055
Failure Code [DDL8KY]2057
Failure Code [DDL9KY]2059
Failure Code [DDLAKY]2061
Failure Code [DDLBKA]2063
Failure Code [DDLBL4]2065
Failure Code [DDNRKA]2067
Failure Code [DDNRKY]2070
Failure Code [DDNRL4]2072
Failure Code [DDTHKA]2075
Failure Code [DDTJKA]2076
Failure Code [DDTKKA]2077
Failure Code [DDTLKA]2078
Failure Code [DDTMKA]2079
Failure Code [DDTNKA]2080
Failure Code [DDTPKA]2081
Failure Code [DFA5KA]2082
Failure Code [DFA5KY]2085
Failure Code [DFA5L8]2088
Failure Code [DFA6KA]2093
Failure Code [DFA6KY]2096
Failure Code [DFA8KA]2099
Failure Code [DFA8KY]2102
Failure Code [DFA8L8]2105
Failure Code [DFA9KA]2110
Failure Code [DFA9KY]2113
Failure Code [DFAGKA]2116
Failure Code [DFAGKY]2119
Failure Code [DFAGL8]2122
Failure Code [DFAHKA]2127
Failure Code [DFAHKY]2130
Failure Code [DFAJKA]2133
Failure Code [DFAJKY]2136
Failure Code [DFAJL8]2139
Failure Code [DFAKKA]2144
Failure Code [DFAKKY]2147
Failure Code [DFALKA]2150
Failure Code [DFALKY]2153
Failure Code [DFALL8]2156
Failure Code [DFAMKA]2161
Failure Code [DFAMKY]2164
Failure Code [DFANKA]2167
Failure Code [DFANKY]2170
Failure Code [DFANL8]2173
Failure Code [DFAPKA]2178
Failure Code [DFAPKY]2181
Failure Code [DFAQKA]2184
Failure Code [DFAQKY]2187
Failure Code [DFAQL8]2190
Failure Code [DFARKA]2195
Failure Code [DFARKY]2198
Failure Code [DFC1KA]2201
Failure Code [DFC1KY]2204
Failure Code [DFC1L8]2207
Failure Code [DFC3KA]2212
Failure Code [DFC3KY]2215
Failure Code [DFC3L8]2218
Failure Code [DFC4KA]2223
Failure Code [DFC4KY]2226
Failure Code [DFC4L8]2229
Failure Code [DFC6KA]2234
Failure Code [DFC6KY]2237
Failure Code [DFC8KA]2240
Failure Code [DFC8KY]2243
Failure Code [DFC9KA]2246
Failure Code [DFC9KY]2249
Failure Code [DGF1KX]2252
Failure Code [DGH2KB]2254
Failure Code [DGT1KX]2256
Failure Code [DGT7KB]2258
Failure Code [DHA4KA]2260
Failure Code [DHAAMA]2262
Failure Code [DHACMA]2264
Failure Code [DHT8KA]2266
Failure Code [DHT8KB]2268
Failure Code [DHT8ZG]2270
Failure Code [DHZ1KX]2271
Failure Code [DHZ2KA]2273
Failure Code [DJF1KA]2275
Failure Code [DK70KX]2277
Failure Code [DK83KR]2279
Failure Code [DK83KT]2284
Failure Code [DK84KR]2286
Failure Code [DK84KT]2291
Failure Code [DKD0KA]2293
Failure Code [DKD0KY]2295
Failure Code [DLF1KA]2297
Failure Code [DLF1LC]2299
Failure Code [DLF2KA]2301
Failure Code [DLF2LC]2303
Failure Code [DLM3KA]2305
Failure Code [DLM3LC]2307
Failure Code [DLM3MB]2309
Failure Code [DLPAKR]2310
Failure Code [DLPAKT]2314
Failure Code [DLPAMA]2316
Failure Code [DLT3KA]2318
Failure Code [DLT3KX]2320
Failure Code [DLT3LC]2322
Failure Code [DPQ1KR]2325
Failure Code [DPQ2KR]2328
Failure Code [DPQ3KR]2331
Failure Code [DV00KB]2334
Failure Code [DW4BKA]2336
Failure Code [DW4BKB]2340
Failure Code [DW4BKY]2343
Failure Code [DW7BKA]2346
Failure Code [DW7BKB]2348
Failure Code [DW7BKY]2350
Failure Code [DW9DKA]2352
Failure Code [DW9DKB]2354
Failure Code [DW9DKY]2356
Failure Code [DW9EKA]2358
Failure Code [DW9EKB]2360
Failure Code [DW9EKY]2362
Failure Code [DW9FKA]2364
Failure Code [DW9FKB]2366
Failure Code [DW9FKY]2368
Failure Code [DW9GKA]2370
Failure Code [DW9GKB]2372
Failure Code [DW9GKY]2374
Failure Code [DW9HKA]2376
Failure Code [DW9HKB]2378
Failure Code [DW9HKY]2380
Failure Code [DW9JKA]2382
Failure Code [DW9JKB]2384
Failure Code [DW9JKY]2386
Failure Code [DWM1KA]2388
Failure Code [DWM1KB]2389
Failure Code [DWM1KY]2391
Failure Code [DWNHKA]2393
Failure Code [DWNHKB]2395
Failure Code [DWNHKY]2397
Failure Code [DWP5KA]2399
Failure Code [DWP5KB]2401
Failure Code [DWP5KY]2403
Failure Code [DWP6KA]2405
Failure Code [DWP6KB]2407
Failure Code [DWP6KY]2409
Failure Code [DWP7KA]2411
Failure Code [DWP7KB]2413
Failure Code [DWP7KY]2415
Failure Code [DWP8KA]2417
Failure Code [DWP8KB]2419
Failure Code [DWP8KY]2421
Failure Code [DX16KA]2423
Failure Code [DX16KB]2425
Failure Code [DX16KY]2427
Failure Code [DXH1KA]2429
Failure Code [DXH1KB]2431
Failure Code [DXH1KY]2433
Failure Code [DXH2KA]2435
Failure Code [DXH2KB]2437
Failure Code [DXH2KY]2439
Failure Code [DXH3KA]2444
Failure Code [DXH3KB]2446
Failure Code [DXH3KY]2448
Failure Code [DXH4KA]2453
Failure Code [DXH4KB]2455
Failure Code [DXH4KY]2457
Failure Code [DXH5KA]2462
Failure Code [DXH5KB]2464
Failure Code [DXH5KY]2466
Failure Code [DXH6KA]2471
Failure Code [DXH6KB]2473
Failure Code [DXH6KY]2475
Failure Code [DXH7KA]2480
Failure Code [DXH7KB]2482
Failure Code [DXH7KY]2484
Failure Code [DXHHKA]2489
Failure Code [DXHHKB]2491
Failure Code [DXHHKY]2493
Failure Code [DXHVKA]2498
Failure Code [DXHVKB]2500
Failure Code [DXHVKY]2502
Failure Code [DXS1KA]2504
Failure Code [DXS1KB]2506
Failure Code [DXS1KY]2508
Failure Code [DXS2KA]2510
Failure Code [DXS2KB]2512
Failure Code [DXS2KY]2514
Failure Code [DXS3KA]2516
Failure Code [DXS3KB]2518
Failure Code [DXS3KY]2520
Failure Code [DXS4KA]2522
Failure Code [DXS4KB]2524
Failure Code [DXS4KY]2526
Failure Code [DXS5KA]2528
Failure Code [DXS5KB]2530
Failure Code [DXS5KY]2532
Failure Code [DXS6KA]2534
Failure Code [DXS6KB]2536
Failure Code [DXS6KY]2538
Failure Code [DXS7KA]2540
Failure Code [DXS7KB]2542
Failure Code [DXS7KY]2544
Failure Code [DXS8KA]2546
Failure Code [DXS8KB]2548
Failure Code [DXS8KY]2550
Failure Code [DXS9KA]2552
Failure Code [DXS9KB]2554
Failure Code [DXS9KY]2556
Failure Code [DXS9MC]2558
Failure Code [DXSAKA]2560
Failure Code [DXSAKB]2562
Failure Code [DXSAKY]2564
Failure Code [DXSBKA]2566
Failure Code [DXSBKB]2568
Failure Code [DXSBKY]2570
Failure Code [F313KA]2572
Failure Code [F313KB]2574
Failure Code [F314KA]2575
Failure Code [F314KB]2577
Failure Code [F315KB]2579
Failure Code [F315KY]2581
Failure Code [F316KB]2583
Failure Code [F316KY]2585
Failure Code [F318KB]2587
Failure Code [F318KY]2589
Failure Code [F31AKB]2590
Failure Code [F31AKY]2592
Failure Code [F31BKB]2594
Failure Code [F31BKY]2596
Failure Code [F31CKB]2598
Failure Code [F31CKY]2600
Failure Code [F31DKB]2602
Failure Code [F31DKY]2604
Failure Code [F31EKB]2606
Failure Code [F31EKY]2608
Failure Code [FS10ZE]2610
Failure Code [#Q0001]2611
Failure Code [#Q0002]2612
Failure Code [#Q0003]2613
Failure Code [#Q0004]2616
Failure Code [#Q0005]2619
Failure Code [#Q0006]2622
Failure Code [#Q0007]2624
Failure Code [#Q0008]2626
Failure Code [#Q0009]2627
Failure Code [#Q0010]2629
Failure Code [#Q0011]2631
Failure Code [#Q0012]2635
Failure Code [#Q0013]2638
Failure Code [#Q0014]2641
Failure Code [#Q0015]2644
Failure Code [#Q0016]2650
Failure Code [#Q0017]2656
Failure Code [#Q0018]2662
Failure Code [#Q0019]2668
Failure Code [#Q0020]2672
Failure Code [#Q0021]2676
Failure Code [#Q0022]2680
Failure Code [#Q0023]2684
Failure Code [#Q0024]2688
Failure Code [#Q0025]2692
Failure Code [#Q0026]2696
Failure Code [#Q0027]2700
Failure Code [#Q0028]2704
Failure Code [#Q0029]2707
Failure Code [#Q0030]2710
Failure Code [#Q0031]2713
Failure Code [#Q0032]2718
Failure Code [#Q0033]2722
Failure Code [#Q0034]2726
Failure Code [#Q0035]2730
Failure Code [#Q0036]2734
Failure Code [#Q0037]2738
Failure Code [#Q0038]2742
Failure Code [#Q0039]2746
Failure Code [#Q0040]2751
Failure Code [#Q0041]2755
Failure Code [#Q0042]2759
Failure Code [#Q0043]2763
Failure Code [#Q0044]2766
Failure Code [#Q0045]2769
Failure Code [#Q0046]2772
Failure Code [#Q0047]2775
Failure Code [#Q0048]2778
Failure Code [#Q0049]2781
Failure Code [#Q0050]2784
Failure Code [#Q0051]2787
Failure Code [#Q0052]2790
Failure Code [#Q0053]2793
Failure Code [#Q0054]2796
Failure Code [#Q0055]2799
Failure Code [#Q0056]2802
Failure Code [#Q0057]2805
Failure Code [#Q0058]2808
Failure Code [#Q0059]2811
Failure Code [#Q0060]2814
Failure Code [#Q0061]2817
Failure Code [#Q0062]2820
Failure Code [#Q0063]2823
Failure Code [#Q0064]2826
Failure Code [#Q0065]2831
Failure Code [#Q0066]2834
Failure Code [#Q0067]2837
Failure Code [#Q0068]2840
Failure Code [#Q0069]2843
Failure Code [#Q0070]2846
Failure Code [#Q0071]2849
Failure Code [#Q0072]2852
Failure Code [#Q0073]2857
Failure Code [#Q0074]2862
Failure Code [#Q0075]2865
Failure Code [#Q0076]2868
Failure Code [#Q0077]2871
Failure Code [#Q0078]2874
Failure Code [#Q0079]2877
Failure Code [#Q0080]2880
Failure Code [#Q0081]2883
Failure Code [#Q0082]2886
Failure Code [#Q0083]2889
Failure Code [#Q0084]2892
Failure Code [#Q0085]2895
Failure Code [#Q0086]2898
Failure Code [#Q0087]2901
Failure Code [#Q0088]2904
Failure Code [#Q0089]2907
Failure Code [#Q0090]2910
Failure Code [#Q0091]2913
Failure Code [#Q0092]2916
Failure Code [#Q0093]2919
Failure Code [#Q0094]2922
Failure Code [#Q0095]2925
Failure Code [#Q0096]2928
Failure Code [#Q0097]2931
Failure Code [#Q0098]2934
Failure Code [#Q0099]2939
Failure Code [#Q0100]2945
Failure Code [#Q0101]2948
Failure Code [#Q0102]2951
Failure Code [#Q0103]2955
Failure Code [#Q0104]2959
Failure Code [#Q0105]2963
Failure Code [#Q0106]2966
Failure Code [#Q0107]2969
Failure Code [#Q0108]2972
Failure Code [#Q0109]2975
Failure Code [#Q0110]2979
Failure Code [#Q0501]2980
Failure Code [#Q0502]2981
Failure Code [#Q0503]2982
Failure Code [#Q0504]2985
Failure Code [#Q0505]2988
Failure Code [#Q0506]2991
Failure Code [#Q0507]2993
Failure Code [#Q0508]2995
Failure Code [#Q0509]2996
Failure Code [#Q0510]2998
Failure Code [#Q0511]3000
Failure Code [#Q0512]3004
Failure Code [#Q0513]3007
Failure Code [#Q0514]3010
Failure Code [#Q0515]3013
Failure Code [#Q0516]3019
Failure Code [#Q0517]3025
Failure Code [#Q0518]3031
Failure Code [#Q0519]3037
Failure Code [#Q0520]3041
Failure Code [#Q0521]3045
Failure Code [#Q0522]3049
Failure Code [#Q0523]3053
Failure Code [#Q0524]3057
Failure Code [#Q0525]3061
Failure Code [#Q0526]3065
Failure Code [#Q0527]3069
Failure Code [#Q0528]3073
Failure Code [#Q0529]3076
Failure Code [#Q0530]3079
Failure Code [#Q0531]3082
Failure Code [#Q0532]3087
Failure Code [#Q0533]3091
Failure Code [#Q0534]3095
Failure Code [#Q0535]3099
Failure Code [#Q0536]3103
Failure Code [#Q0537]3107
Failure Code [#Q0538]3111
Failure Code [#Q0539]3115
Failure Code [#Q0540]3120
Failure Code [#Q0541]3124
Failure Code [#Q0542]3128
Failure Code [#Q0543]3132
Failure Code [#Q0544]3135
Failure Code [#Q0545]3138
Failure Code [#Q0546]3141
Failure Code [#Q0547]3144
Failure Code [#Q0548]3147
Failure Code [#Q0549]3150
Failure Code [#Q0550]3153
Failure Code [#Q0551]3156
Failure Code [#Q0552]3159
Failure Code [#Q0553]3162
Failure Code [#Q0554]3165
Failure Code [#Q0555]3168
Failure Code [#Q0556]3171
Failure Code [#Q0557]3174
Failure Code [#Q0558]3177
Failure Code [#Q0559]3180
Failure Code [#Q0560]3183
Failure Code [#Q0561]3186
Failure Code [#Q0562]3189
Failure Code [#Q0563]3192
Failure Code [#Q0564]3195
Failure Code [#Q0565]3200
Failure Code [#Q0566]3203
Failure Code [#Q0567]3206
Failure Code [#Q0568]3209
Failure Code [#Q0569]3212
Failure Code [#Q0570]3215
Failure Code [#Q0571]3218
Failure Code [#Q0572]3221
Failure Code [#Q0573]3226
Failure Code [#Q0574]3231
Failure Code [#Q0575]3234
Failure Code [#Q0576]3237
Failure Code [#Q0577]3240
Failure Code [#Q0578]3243
Failure Code [#Q0579]3246
Failure Code [#Q0580]3249
Failure Code [#Q0581]3252
Failure Code [#Q0582]3255
Failure Code [#Q0583]3258
Failure Code [#Q0584]3261
Failure Code [#Q0585]3264
Failure Code [#Q0586]3267
Failure Code [#Q0587]3270
Failure Code [#Q0588]3273
Failure Code [#Q0589]3276
Failure Code [#Q0590]3279
Failure Code [#Q0591]3282
Failure Code [#Q0592]3285
Failure Code [#Q0593]3288
Failure Code [#Q0594]3291
Failure Code [#Q0595]3294
Failure Code [#Q0596]3297
Failure Code [#Q0597]3300
Failure Code [#Q0598]3303
Failure Code [#Q0599]3308
Failure Code [#Q0600]3314
Failure Code [#Q0601]3317
Failure Code [#Q0602]3320
Failure Code [#Q0603]3324
Failure Code [#Q0604]3328
Failure Code [#Q0605]3332
Failure Code [#Q0606]3335
Failure Code [#Q0607]3338
Failure Code [#Q0608]3341
Failure Code [#Q0609]3344
Failure Code [#Q0610]3348
Troubleshooting of Electrical System (E-Mode)3349
Engine Does Not Start (Engine Does Not Crank)3349
Manual Preheating System Does Not Operate3356
Automatic Preheating System Does Not Operate3359
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On3361
Engine Coolant Temperature Gauge Does Not Show Correct Temperature3363
LCD Unit and LED Unit on Machine Monitor Do Not Show Anything3365
LCD Unit on Machine Monitor Shows Nothing3368
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)3370
LCD Screen on Machine Monitor Does Not Show Correctly3372
LED Unit Lamp on Machine Monitor is Abnormal3374
Switch of Switch Panel on Machine Monitor Does Not Operate3377
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate3380
Switch Panel Buzzer of Machine Monitor is Abnormal3383
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally3386
DEF Level is Not Shown Correctly3387
Rearview Monitor Does Not Come On or Backlight Flickers3390
Rearview Monitor Images are Not Shown Clearly3393
Rearview Monitor Brightness Cannot be Adjusted3396
Night Mode Lamp of Rearview Monitor is Abnormal3399
Air Cleaner Clogging Caution Lamp Does Not Come On3401
Radiator Coolant Level Caution Lamp Does Not Come On3403
Parking Brake Pilot Lamp Does Not Come On When Parking Brake is ON (Parking) Position3405
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low3408
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low3409
Speedometer Does Not Show Normally3410
Engine Tachometer Does Not Show Normally3412
Fuel Gauge Does Not Show Normally3413
Torque Converter Oil Temperature Gauge Does Not Show Normally3415
Articulation Indicator Does Not Show Actual Articulated Angle3417
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On3420
Seatbelt Caution Lamp Does Not Show Normally3422
Operator Seat Caution Lamp Comes On Even When You Seat3423
Alarm Buzzer Does Not Operate3425
Alarm Buzzer Does Not Stop3426
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in FORWARD or REVERSE Travel When Parking Brake is Released3427
Engine Power Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated3430
Transmission Selector Function Does Not Operate Normally3432
Differential Lock Function Does Not Operate or Cannot be Cancelled3434
Lock by Lifter Lock Pin Cannot be Done or Cannot be Cancelled3437
Lifter Lock Pin Pilot Lamp Does Not Show Correctly3439
Blade Accumulator Function Does Not Operate or Cannot be Cancelled3440
Blade Accumulator Pilot Lamp Does Not Show Correctly3443
Horn Does Not Sound3445
Horn Does Not Stop3448
Backup Alarm Does Not Sound3449
Backup Alarm Continues to Sound and Backup Lamp Keeps Lit3451
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On3452
Headlamp Does Not Come On or Go Out3454
Headlamp Selection (Low or High Beam) Cannot be Done3457
Headlamp (High Beam) Does Not Come On3460
Front Working Lamp Does Not Come On or Go Out3461
Working Lamp Pilot Lamp Does Not Come On or Go Out3465
Rear Working Lamp Does Not Come On or Go Out3467
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out3470
Turn Signal Lamp Does Not Come On or Go Out3475
Hazard Lamp Does Not Come On or Go Out3478
Turn Signal Lamp Does Not Come On or Go Off3482
Brake Lamp Does Not Come On or Stays Lit3483
Backup Lamp Does Not Come On3487
No Wiper Operates3490
Front Wiper Does Not Operate3492
Rear Wiper Does Not Operate3497
Right and Left Door Wipers Do Not Operate3501
Left Door Wiper Does Not Operate3505
Right Door Wiper Does Not Operate3507
Front or Door Washer Does Not Operate3509
Rear Washer Does Not Operate3512
KOMTRAX System Does Not Operate Correctly3514
Precision of Cross Slope is Not Good3515
One of Target Cross Slope Increase Switch and Target Cross Slope Decrease Switch Does Not Operate3519
One of Pre-set Selection 1 Switch and Pre-set Selection 2 Switch Does Not Operate3522
Blade Lift Switch Left (Auto/Manual) Does Not Operate3525
Blade Lift Switch Right (Auto/Manual) Does Not Operate3527
Slope Match Activation Switch Does Not Operate3529
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3531
Information Shown in Troubleshooting Table (H-Mode)3531
Failure Mode and Cause Table3532
Machine Does Not Start3543
Lockup is Not Released3544
Torque Converter Lockup Clutch Does Not Engage3545
Machine Does Not Upshift or Downshift from Neutral3546
Machine Does Not Upshift or Downshift3547
Travel Speed or Power is Low3549
Travel Speed or Power is Low in Specified Gear3551
Time Lag is Large When You Start Machine or Shift Gears3553
Torque Converter Oil Temperature is High3555
Differential Lock Function Does Not Operate or Cannot be Cancelled3557
Unusual Noise is Heard from Around Hydraulic Pump3558
Steering Speed or Power is Low (Steering Wheel, Steering Lever)3559
Steering Wheel Does Not Move or is Heavy to Operate3560
Machine Sways During Steering (Steering Wheel, Steering Lever)3561
Machine Naturally Turns to One Side During Travel3562
Wheel Brakes Do Not Operate or are Weak3563
Wheel Brakes are Not Released or Drag3565
Parking Brake Does Not Operate or is Weak3566
Parking Brake is Not Released or Drags3567
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment3568
Lock by Lifter Lock Pin Cannot be Done or Cannot be Cancelled3569
All Work Equipment Operate Slowly3570
All Work Equipment Do Not Operate3572
Blade Lift Speed or Power is Low3575
Drawbar Side-Shift Speed or Power is Low3576
Blade Side-Shift Speed or Power is Low3577
Power Tilt Speed or Power is Low3578
Articulate Speed or Power is Low3579
Leaning Speed or Power is Low3580
Hydraulic Drift of Blade Lift is Large3581
Hydraulic Drift of Leaning is Large3582
Blade Does Not Rotate or Power is Low3583
Blade Accumulator Function Does Not Operate or Cannot be Cancelled3584
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)3585
Unusual Noise is Heard from Around Fan3586
Troubleshooting of Engine (S-Mode)3587
Information Shown in Troubleshooting Table (S-Mode)3587
Engine Does Not Crank When Starting Switch is Turned to Start Position3588
Engine Cranks but No Exhaust Smoke Comes Out3589
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)3590
Engine Startability is Unsatisfactory3592
Engine Does Not Pick Up Smoothly3594
Engine Stops During Operation3596
Engine Does Not Rotate Smoothly3598
Engine Lacks Output (or Lacks Power)3599
KDPF Becomes Clogged in a Short Time3601
Engine Oil Consumption is Excessive3603
Engine Oil Becomes Dirty Quickly3604
Fuel Consumption is Excessive3605
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)3606
Engine Oil Pressure Drops3607
Fuel Mixes Into Engine Oil3609
Water Mixes Into Engine Oil (Milky)3610
Coolant Temperature Increases Too High (Overheat)3611
Unusual Noise is Heard3612
Vibration is Excessive3613
Air Cannot be Bled from Fuel Circuit3614
Active Regeneration is Done Frequently3615
Active Regeneration Continues Long3617
White Smoke is Exhausted During Active Regeneration3618
DEF Consumption is Excessive3619
There is an Unusual Smell (Irritating Odor)3621
Foreign Materials Enter DEF (DEF Increases)3622
50 Disassembly and Assembly3623
Table of Contents3624
Precautions Before Work3629
Related Information on Disassembly and Assembly3630
How to Read This Manual3630
Coating Materials List3632
Special Tool List3637
Sketches of Special Tools3653
Engine and Cooling System3678
Remove and Install Supply Pump Assembly3678
How to Remove Supply Pump Assembly3679
How to Install Supply Pump Assembly3683
Remove and Install Injector Assembly3687
How to Remove Injector Assembly3688
How to Install Injector Assembly3692
Remove and Install Cylinder Head Assembly3701
How to Remove Cylinder Head Assembly3703
How to Install Cylinder Head Assembly3714
Remove and Install EGR Valve Assembly3730
How to Remove EGR Valve Assembly3730
How to Install EGR Valve Assembly3732
Remove and Install EGR Cooler Assembly3735
How to Remove EGR Cooler Assembly3736
How to Install EGR Cooler Assembly3740
Remove and Install Starter Assembly3744
How to Remove Starting Motor Assembly3744
How to Install Starting Motor Assembly3747
Remove and Install Alternator Belt3750
How to Remove Alternator Belt3751
How to Install Alternator Belt3754
Remove and Install Automatic Tensioner3758
How to Remove Automatic Tensioner3758
How to Install Automatic Tensioner3758
Remove and Install Radiator Assembly3759
How to Remove Radiator Assembly3760
How to Install Radiator Assembly3766
Remove and Install Aftercooler Assembly3773
How to Remove Aftercooler Assembly3774
How to Install Aftercooler Assembly3778
Remove and Install Power Train Oil Cooler Assembly3783
How to Remove Power Train Oil Cooler Assembly3784
How to Install Power Train Oil Cooler Assembly3788
Remove and Install Cooling Fan Motor Assembly3793
How to Remove Cooling Fan Motor Assembly3794
How to Install Cooling Fan Motor Assembly3799
Remove and Install Engine, Torque Converter, and Transmission Assembly3804
How to Remove Engine, Torque Converter, and Transmission Assembly3805
How to Install Engine, Torque Converter, and Transmission Assembly3814
Disconnect and Connect Engine, Torque Converter, and Transmission Assembly3824
How to Disconnect Engine, Torque Converter, and Transmission Assembly3824
How to Connect Engine, Torque Converter, and Transmission Assembly3826
Remove and Install Engine Front Oil Seal3828
How to Remove Engine Front Oil Seal3829
How to Install Engine Front Oil Seal3830
Remove and Install Engine Rear Oil Seal3833
How to Remove Engine Rear Oil Seal3834
How to Install Engine Rear Oil Seal3835
Remove and Install Engine Hood Assembly3839
How to Remove Engine Hood Assembly3840
How to Install Engine Hood Assembly3844
Remove and Install KDPF Assembly3848
How to Remove KDPF Assembly3849
How to Install KDPF Assembly3857
Disassemble and Assemble KDPF Assembly3868
How to Disassemble KDPF Assembly3869
How to Assemble KDPF Assembly3872
Remove and Install KDPF and SCR Assembly3877
How to Remove KDPF and SCR Assembly3878
How to Install KDPF and SCR Assembly3886
Remove and Install Fuel Tank Assembly3897
How to Remove Fuel Tank Assembly3897
How to Install Fuel Tank Assembly3903
Remove and Install DEF Tank Assembly3909
How to Remove DEF Tank Assembly3910
How to Install DEF Tank Assembly3918
Remove and Install DEF Tank Sensor Flange Assembly3925
How to Remove DEF Tank Sensor Flange Assembly3926
How to Install DEF Tank Sensor Flange Assembly3932
Remove and Install DEF Tank Sensor3938
How to Remove DEF Tank Sensor3938
How to Install DEF Tank Sensor3939
Remove and Install DEF Tank Strainer3940
How to Remove DEF Tank Strainer3940
How to Install DEF Tank Strainer3940
Remove and Install SCR Assembly3942
How to Remove SCR Assembly3943
How to Install SCR Assembly3948
Remove and Install KCCV Assembly3955
How to Remove KCCV Assembly3956
How to Install KCCV Assembly3958
Remove and Install DEF Mixing Tube3961
How to Remove DEF Mixing Tube3962
How to Install DEF Mixing Tube3965
Remove and Install DEF Injector3971
How to Remove DEF Injector3972
How to Install DEF Injector3975
Remove and Install DEF Pump3980
How to Remove DEF Pump3981
How to Install DEF Pump3985
Remove and Install DEF Hose3990
How to Remove DEF Hose3991
How to Install DEF Hose4000
Remove and Install Air Cleaner Assembly4009
How to Remove Air Cleaner Assembly4009
How to Install Air Cleaner Assembly4010
Remove and Install Air Conditioner Compressor Assembly4012
How to Remove Air Conditioner Compressor Assembly4013
How to Install Air Conditioner Compressor Assembly4015
Remove and Install Air Conditioner Condenser Assembly4019
How to Remove Air Conditioner Condenser Assembly4019
How to Install Air Conditioner Condenser Assembly4021
Power Train4023
Disassemble and Assemble Torque Converter Assembly4023
How to Disassemble Torque Converter Assembly4024
How to Assemble Torque Converter Assembly4029
Disassemble and Assemble Transmission Assembly4036
How to Disassemble Transmission Assembly4038
How to Assemble Transmission Assembly4056
Remove and Install Tandem Drive and Final Drive Assembly4083
How to Remove Tandem Drive and Final Drive Assembly4083
How to Install Tandem Drive and Final Drive Assembly4087
Disassemble and Assemble Tandem Drive Assembly4091
How to Disassemble Tandem Drive Assembly4092
How to Assemble Tandem Drive Assembly4096
Disassemble and Assemble Differential Assembly4104
How to Disassemble Differential Assembly4105
How to Assemble Differential Assembly4110
Disassemble and Assemble Final Drive Assembly4121
How to Disassemble Final Drive Assembly4123
How to Assemble Final Drive Assembly4128
Steering System4137
Remove and Install Steering Valve Assembly4137
How to Remove Steering Valve Assembly4138
How to Install Steering Valve Assembly4147
Brake System4156
Disassemble and Assemble Wheel Brake Assembly4156
How to Disassemble Wheel Brake Assembly4157
How to Assemble Wheel Brake Assembly4161
Undercarriage and Frame4169
Remove and Install Center Hinge Pin4169
How to Remove Center Hinge Pin4171
How to Install Center Hinge Pin4183
Remove and Install Rear Fender Assembly4196
How to Remove Rear Fender Assembly4196
How to Install Rear Fender Assembly4199
Hydraulic System4205
Remove and Install Hydraulic Tank, Battery, and Frame Assembly4205
How to Remove Hydraulic Tank, Battery, and Frame Assembly4207
How to Install Hydraulic Tank, Battery, and Frame Assembly4218
Remove and Install Hydraulic Tank Assembly4231
How to Remove Hydraulic Tank Assembly4233
How to Install Hydraulic Tank Assembly4246
Remove and Install Cooling Fan Pump Assembly4259
How to Remove Cooling Fan Pump Assembly4260
How to Install Cooling Fan Pump Assembly4262
Remove and Install Control Valve Assembly4265
How to Remove Control Valve Assembly4267
How to Install Control Valve Assembly4276
Work Equipment4286
Remove and Install Ripper Assembly4286
How to Remove Ripper Assembly4287
How to Install Ripper Assembly4289
Remove and Install Blade Assembly4293
How to Remove Blade Assembly4293
How to Install Blade Assembly4294
Remove and Install Circle and Drawbar Assembly4295
How to Remove Circle and Drawbar Assembly4296
How to Install Circle and Drawbar Assembly4299
Remove and Install Circle Rotation Gear Assembly4303
How to Remove Circle Rotation Gear Assembly4304
How to Install Circle Rotation Gear Assembly4305
Disassemble and Assemble Circle Rotation Gear Assembly4308
How to Disassemble Circle Rotation Gear Assembly4309
How to Assemble Circle Rotation Gear Assembly4311
Disassemble and Assemble Work Equipment Cylinder Assembly4316
How to Disassemble Work Equipment Cylinder Assembly4318
How to Assemble Work Equipment Cylinder Assembly4320
CAB Related Parts4325
Remove and Install Operator Cab Assembly4325
How to Remove Operator Cab Assembly4326
How to Install Operator Cab Assembly4340
Remove and Install Operator Cab Door4354
How to Remove Operator Cab Door4354
How to Install Operator Cab Door4356
Remove and Install Operator Cab Glass (Adhered Glass)4362
How to Remove Operator Cab Glass (Adhered Glass)4365
How to Install Operator Cab Glass (Adhered Glass)4365
Remove and Install Floor Frame Assembly4375
How to Remove Floor Frame Assembly4377
How to Install Floor Frame Assembly4382
Remove and Install Air Conditioner Unit Assembly4387
How to Remove Air Conditioner Unit Assembly4388
How to Install Air Conditioner Unit Assembly4401
Remove and Install Operator Seat4415
How to Remove Operator Seat4415
How to Install Operator Seat4417
How to Remove and Install Seat Belt4420
How to Remove Seat Belt4420
How to Install Seatbelt4421
Remove and Install Work Equipment Control Lever Assembly4423
How to Remove Work Equipment Control Lever Assembly4423
How to Install Work Equipment Control Lever Assembly4430
Electrical System4438
Remove and Install Engine Controller Assembly4438
How to Remove Engine Controller Assembly4439
How to Install Engine Controller Assembly4441
Remove and Install Transmission Controller Assembly4445
How to Remove Transmission Controller Assembly4445
How to Install Transmission Controller Assembly4449
Remove and Install Work Equipment Controller Assembly4454
How to Remove Work Equipment Controller Assembly4454
How to Install Work Equipment Controller Assembly4458
Remove and Install Machine Monitor Assembly4463
How to Remove Machine Monitor Assembly4463
How to Install Machine Monitor Assembly4465
Remove and Install Mass Air Flow and Temperature Sensor4468
How to Remove Mass Air Flow and Temperature Sensor4468
How to Install Mass Air Flow and Temperature Sensor4470
Remove and Install KCCV Crankcase Pressure Sensor4473
How to Remove KCCV Crankcase Pressure Sensor4473
How to Install KCCV Crankcase Pressure Sensor4475
Remove and Install KDPF Temperature Sensor4477
How to Remove KDPF Temperature Sensor4478
How to Install KDPF Temperature Sensor4481
Remove and Install KDPF Differential Pressure Sensor4485
How to Remove KDPF Differential Pressure Sensor4486
How to Install KDPF Differential Pressure Sensor4490
Remove and Install SCR Temperature Sensor4493
How to Remove SCR Temperature Sensor4494
How to Install SCR Temperature Sensor4497
Remove and Install Ammonia Sensor4501
How to Remove Ammonia Sensor4502
How to Install Ammonia Sensor4504
Remove and Install SCR Outlet NOx Sensor4506
How to Remove SCR Outlet NOx Sensor4507
How to Install SCR Outlet NOx Sensor4509
Remove and Install KOMTRAX Terminal Assembly4513
How to Remove KOMTRAX Terminal Assembly4513
How to Install KOMTRAX Terminal Assembly4515
Remove and Install Gateway Function Controller Assembly4517
How to Remove Gateway Function Controller Assembly4518
How to Install Gateway Function Controller Assembly4519
Remove and Install Communication Terminal4522
How to Remove Communication Terminal4522
How to Install Communication Terminal4524
Remove and Install Machine IMU4527
How to Remove Machine IMU4527
How to Install Machine IMU4529
Remove and Install Drawbar IMU4531
How to Remove Drawbar IMU4531
How to Install Drawbar IMU4533
Remove and Install Blade Rotation Angle Sensor4535
How to Remove Blade Rotation Angle Sensor4535
How to Install Blade Rotation Angle Sensor4537
Remove and Install Cross Slope Enable Switch4540
How to Remove Cross Slope Enable Switch4540
How to Install Cross Slope Enable Switch4541
60 Maintenance Standard4543
Table of Contents4544
Explanation of Terms for Maintenance Standard4545
Engine and Cooling System4547
Maintenance Standard for Engine Mount4547
Maintenance Standard for Cooling System4548
Maintenance Standard for Cooling Fan Motor4549
Power Train4551
Maintenance Standard for Drive Shaft4551
Maintenance Standard for Torque Converter4552
Maintenance Standard for Lockup Clutch ECMV4554
Maintenance Standard for Transmission4555
Maintenance Standard for FL, R Clutch4561
Maintenance Standard for FH, 1st Clutch4563
Maintenance Standard for 2nd, 3rd Clutch4565
Maintenance Standard for 4th Clutch4566
Maintenance Standard for Transmission Control Valve4567
Maintenance Standard for FL, FH, R, 1st, 2nd, 3rd, 4th Clutch ECMV4568
Maintenance Standard for Valve Assembly (Main Relief, Torque Converter Relief)4569
Maintenance Standard for Front Axle4570
Maintenance Standard for Rear Axle4573
Maintenance Standard for Differential4574
Maintenance Standard for Final Drive4577
Maintenance Standard for Tandem Drive4579
Steering System4580
Maintenance Standard for Steering Column4580
Maintenance Standard for Steering Cylinder4581
Brake System4582
Maintenance Standard for Accumulator Charge Valve4582
Maintenance Standard for Slack Adjuster4585
Maintenance Standard for Brake4586
Maintenance Standard for Parking Brake4588
Undercarriage and Frame4589
Maintenance Standard for Frame and Center Hinge Pin4589
Hydraulic System4590
Maintenance Standard for Hydraulic Tank4590
Maintenance Standard for Steering and Work Equipment Pump4591
Maintenance Standard for Servo Valve of Steering and Work Equipment Pump4594
Maintenance Standard for Power Train Pump and Differential Lock Pump4596
Maintenance Standard for Front Control Valve4597
Maintenance Standard for Rear Control Valve4602
Maintenance Standard for Solenoid Valve (Differential Lock)4607
Maintenance Standard for Solenoid Valve (Parking Brake, Lifter Lock)4608
Work Equipment4609
Maintenance Standard for Solenoid Valve (Work Equipment Lock)4609
Maintenance Standard for Blade Rotation Angle Sensor4610
Maintenance Standard for Circle and Drawbar4611
Maintenance Standard for Blade4613
Maintenance Standard for Lifter4615
Maintenance Standard for Circle Rotation Device4616
Maintenance Standard for Blade Lift Cylinder4617
Maintenance Standard for Blade Side-Shift Cylinder4618
Maintenance Standard for Leaning Cylinder4619
Maintenance Standard for Articulate Cylinder4620
Maintenance Standard for Drawbar Side-Shift Cylinder4621
Maintenance Standard for Blade Power Tilt Cylinder4622
80 Others4623
Table of Contents4624
Precautions Before Work4626
Air Conditioner System4627
Precautions for Refrigerant4627
Layout Drawing of Air Conditioner System4628
Specifications of Air Conditioner4630
Structure of Refrigeration Cycle4631
Function of Refrigeration Cycle4632
Component Parts of Air Conditioner System4633
Air Conditioner Unit4633
Structure of Air Conditioner Unit4633
Function of Air Conditioner Unit4634
Component Parts of Air Conditioner Unit4634
Air Conditioner Control Panel4637
Structure of Air Conditioner Control Panel4637
Function of Air Conditioner Control Panel4638
Input and Output Signals of Air Conditioner Control Panel4638
Compressor4640
Structure of Compressor4640
Specifications of Compressor4640
Function of Compressor4640
Operation of Compressor4640
Condenser4641
Structure of Condenser4641
Specifications of Condenser4641
Function of Condenser4641
Receiver Drier4642
Structure of Receiver Dryer4642
Specifications of Receiver Dryer4642
Function of Receiver Dryer4642
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4644
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4646
System Diagram of Air Conditioner4648
Locations of Air Conditioner Parts and Layout of Connectors4649
Examine Air Conditioner with Self-Diagnosis Function4656
Examine Air Leakage (Duct)4658
How to Examine Air Leakage (Duct)4658
Examine Temperature Control Function4661
How to Examine Temperature Control Function4661
Examine Fresh/Recirc Air Changeover4664
How to Examine Fresh/Recirc Air Changeover4664
Examine Evaporator Temperature Sensor4668
How to Examine Evaporator Temperature Sensor4668
Examine Relay4672
How to Examine Relay4672
Examine Blower Amplifier4676
How to Examine Blower Amplifier4676
Air Conditioner Troubleshooting Chart 14680
Air Conditioner Troubleshooting Chart 24681
Information Shown in Troubleshooting Table4684
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4685
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4688
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4691
Troubleshooting for Temperature Control Function4694
Troubleshooting for Fresh/Recirc Air Changeover4697
Troubleshooting for Hot Water Cut Valve4700
Troubleshooting by Gauge Pressure4702
Connect Service Tool4705
How to Connect Service Tool4706
Precautions for Disconnection and Connection of Air Conditioner Piping4707
Handle Compressor Oil4709
90 Circuit Diagrams4711
Table of Contents4712
How to Read the Codes for Electric Cable4714
Hydraulic Circuit Diagram4718
Symbols Used in Hydraulic Circuit Diagram4718
Hydraulic Circuit Diagram for Work Equipment (1/2)4723
Hydraulic Circuit Diagram for Work Equipment (2/2)4725
Hydraulic Circuit Diagram for Work Equipment (When Blade Left Side Raise + Left Turn + Brake Push (Cut Out) + Parking Brake Released + Lifter Lock + Differential Lock Released) (1/2)4727
Hydraulic Circuit Diagram for Work Equipment (When Blade Left Side Raise + Left Turn + Brake Push (Cut Out) + Parking Brake Released + Lifter Lock + Differential Lock Released) (2/2)4729
Power Train Hydraulic Circuit Diagram4731
Electrical Circuit Diagram4733
Symbols Used in Electric Circuit Diagram4733
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (1/6)4737
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (2/6)4739
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (3/6)4741
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (4/6)4743
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (5/6)4745
Electrical Circuit Diagram of Machine (Applicable Machine: 65001 to 65216) (6/6)4747
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (1/7)4749
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (2/7)4751
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (3/7)4753
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (4/7)4755
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (5/7)4757
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (6/7)4759
Electrical Circuit Diagram of Machine (Applicable Machine: 65217 to 65481) (7/7)4761
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (1/7)4763
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (2/7)4765
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (3/7)4767
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (4/7)4769
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (5/7)4771
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (6/7)4773
Electrical Circuit Diagram of Machine (Applicable Machine: 65482 and Up) (7/7)4775
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (1/10)4777
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (2/10)4779
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (3/10)4781
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (4/10)4783
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (5/10)4785
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (6/10)4787
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (7/10)4789
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (8/10)4791
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (9/10)4793
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (10/10)4795
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (1/11)4797
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (2/11)4799
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (3/11)4801
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (4/11)4803
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (5/11)4805
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (6/11)4807
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (7/11)4809
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (8/11)4811
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (9/11)4813
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (10/11)4815
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65001 to 65481) (11/11)4817
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (1/11)4819
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (2/11)4821
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (3/11)4823
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (4/11)4825
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (5/11)4827
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (6/11)4829
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (7/11)4831
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (8/11)4833
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (9/11)4835
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (10/11)4837
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 65482 and Up) (11/11)4839
Electrical Circuit Diagram of ICT System4841
Index4843

S.M 31/12/24