Komatsu MOTOR GRADER GD705-5 Shop Manual SEN06489-10 PDF

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Komatsu MOTOR GRADER GD705-5 Shop Manual SEN06489-10 – PDF DOWNLOAD

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Komatsu MOTOR GRADER GD705-5 Shop Manual SEN06489-10 – PDF DOWNLOAD

Language : English
Pages :1468
Downloadable : Yes
File Type : PDF

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Komatsu MOTOR GRADER GD705-5 Shop Manual SEN06489-10 – PDF DOWNLOAD

SERIAL NUMBERS 26001 and up

Foreword and general information
Safety notice
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu MOTOR GRADER GD705-5 Shop Manual SEN06489-10 – PDF DOWNLOAD

SERIAL NUMBERS 26001 and up

Cover 1
00 Index and foreword 3
Foreword and general information 15
Safety notice 15
How to read the shop manual 20
Explanation of terms for maintenance standard 22
Handling of electric equipment and hydraulic components 24
Handling of connectors newly used for engines 33
How to read electric wire code 36
Precautions when carrying out work 39
Method of disassembling and connecting push-pull type coupler 42
Standard tightening torque table 45
List of Abbreviation 49
Conversion table 53
01 Specification 59
Specification drawing 61
Specifications 63
Weight table 69
Table of fuel, coolant and lubricants 70
10 Structure and function 73
Engine and cooling system 76
Cooling system 76
Cooling fan motor 78
Power train system 85
Power train system drawing 85
Power train piping drawing 86
Transmission control 87
Torque converter 88
Transmission 92
Transmission control valve 112
ECMV 114
Main relief and torque converter relief valve 121
Front axle 123
Final drive 126
Differential 129
Differential lock solenoid valve 131
Tandem drive 132
Steering system 135
Steering piping diagram 135
Priority valve 136
Steering valve 142
Brake system 150
Brake hydraulic piping diagram 150
Brake valve 151
Slack adjuster 156
Accumulator (for brake) 158
Charge valve 159
Wheel brake 164
Parking brake and bank control valve 165
Parking brake 166
Undercarriage and frame 167
Frame 167
Tire 168
Hydraulic system 169
Hydraulic system 169
Work equipment hydraulic component layout 172
Work equipment control 175
Hydraulic tank 177
Main pump 178
Power train pump 190
Control valve 192
CLSS 201
Functions and operation by valve 204
Swivel joint 214
Pilot check valve 215
Separately installed safety valve 219
Accumulator (for blade) 220
Work equipment 222
Circle and drawbar 222
Blade 224
Lifter 226
Circle rotation motor 228
Circle rotation gear 230
Cab 232
Cab 232
Electrical system 234
Machine monitor 234
Automatic shift control system 237
Transmission controller 245
Engine controller 248
KOMTRAX system 251
Starting engine circuit 256
Stopping engine circuit 258
Preheating circuit 259
Engine power mode select circuit 260
Cooling fan control function 261
Sensor 265
20 Standard value table 277
Standard value table 279
Standard value table for engine 279
Standard value table for machine 281
Machine posture and procedure for measuring performance 289
30 Testing and adjusting 291
Precautions before work 294
Related information on testing and adjusting 296
Tools for testing and adjusting 296
Sketch of tools for testing and adjusting 299
Engine and cooling system 300
Testing engine speed 300
Testing boost pressure 303
Testing exhaust gas temperature 305
Testing exhaust gas color 307
Testing and adjusting valve clearance 309
Testing compression pressure 312
Testing blowby pressure 316
Testing engine oil pressure 317
Handling equipment of fuel system devices 318
Releasing remaining pressure from fuel system 318
Testing fuel pressure 319
Testing fuel return rate and leakage 324
Bleeding air from fuel circuit 327
Testing fuel circuit for leakage 328
Handling cylinder cutout mode operation 329
Handling no-injection cranking operation 329
Testing muffler (main body) and stuck muffler for looseness and damage 330
Testing muffler function 330
Testing installed condition of cylinder heads and manifolds 330
Testing of engine piping for damage and looseness 330
Testing and adjusting air conditioner compressor belt tension 331
Replacing alternator belt 332
Checking and replacing auto-tensioner 334
Power train 337
Testing power train oil pressure 337
Adjusting transmission speed sensor 350
Retrieval of disabled machine due to transmission valve failure 353
Flushing procedure for torque converter and transmission circuits 356
Testing and adjusting toe-in 358
Adjusting bearing preload 359
Testing and adjusting differential lock oil pressure 361
Steering system 364
Testing and adjusting steering oil pressure 364
Testing oil leakage of steering cylinder 365
Bleeding air from steering circuit 365
Brake system 366
Testing and adjusting brake oil pressure 366
Releasing remaining pressure from brake circuit 370
Bleeding air from brake circuit 371
Testing wear of wheel brake disc 372
Testing and adjusting parking brake 373
Parking brake emergency releasing procedure 375
Procedure for charging brake accumulator with nitrogen gas 376
Hydraulic system 379
Testing and adjusting work equipment oil pressure 379
Testing and adjusting pump LS differential pressure 382
Testing lift arm lock cylinder circuit oil pressure 384
Testing oil leakage of work equipment cylinder 385
Bleeding air from work equipment circuit 388
Testing cooling fan pump circuit oil pressure 389
Work equipment system 391
Adjusting drawbar ball joint clearance 391
Testing and adjusting circle guide clearance 392
Adjusting circle rotation gear 394
Procedure for charging blade accumulator with nitrogen gas 397
Electrical system 398
Special functions of machine monitor 398
KOMTRAX terminal start-up procedure (ORBCOMM) 446
Lamp indication of KOMTRAX terminal (ORBCOMM) 451
KOMTRAX terminal start-up procedure (GPRS) 454
Lamp indication of KOMTRAX terminal (GPRS) 457
Handling voltage circuit of engine controller 460
Testing diodes 461
Pm Clinic 462
Pm Clinic service 462
40 Troubleshooting 469
Precautions before work 476
General information on troubleshooting 478
Points to remember when troubleshooting 478
Sequence of events in troubleshooting 479
Checks before troubleshooting 480
Preparation work for troubleshooting of electrical system 501
Classification and procedures for troubleshooting 504
Failure codes table 505
Failure and troubleshooting numbers 512
Information in troubleshooting table 514
Troubleshooting method for open circuit in wiring harness of pressure sensor system 516
Connector list and layout 518
Connection table for connector pin numbers 532
T- branch box and T- branch adapter table 568
Locations of fuses 571
Troubleshooting by failure code 573
Failure code [1500L0] TORQFLOW transmission: Double engagement 573
Failure code [15G0MW] Transmission R clutch: Slip 574
Failure code [15H0MW] Transmission FH clutch: Slip 575
Failure code [15J0MW] Transmission FL clutch: Slip 575
Failure code [15K0MW] Transmission 1st clutch: Slip 576
Failure code [15L0MW] Transmission 2nd clutch: Slip 577
Failure code [15M0MW] Transmission 3rd speed clutch: Slip 578
Failure code [15N0MW] Transmission 4th clutch: Slip 579
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF 580
Failure code [15SBMA] ECMV R clutch: Malfunction 582
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF 584
Failure code [15SCMA] ECMV FH clutch: Malfunction 586
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF 588
Failure code [15SDMA] ECMV FL clutch: Malfunction 590
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF 592
Failure code [15SEMA] ECMV 1st clutch: Malfunction 594
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF 596
Failure code [15SFMA] ECMV 2nd clutch: Malfunction 598
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF 600
Failure code [15SGMA] ECMV 3rd clutch: Malfunction 602
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF 604
Failure code [15SHMA] ECMV 4th clutch: Malfunction 606
Failure code [15SJMA] ECMV lockup clutch: Malfunction 608
Failure code [15U0NT] Inching clutch: Overheating 608
Failure code [2G42ZG] Front accumulater: Oil pressure drop 609
Failure code [2G43ZG] Rear accumulater: Pressure drop 609
Failure code [AA1ANX] Air cleaner: Clogging 610
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched 612
Failure code [AB00MA] Alternator: Malfunction 614
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop 616
Failure code: [B@BCNS] Engine coolant overheat 616
Failure code [B@BEBF] Water in fuel error 617
Failure code: [B@CENS] Torque converter oil overheat 618
Failure code: [B@CKNS] Differential case: Overheat 620
Failure code: [B@HANS] Hydraulic oil: Overheating 622
Failure code [CA111] Engine controller internal error 624
Failure code [CA115] Engine Ne, Bkup speed sensor error 625
Failure code [CA122] Charge pressure sensor high error 626
Failure code [CA123] Charge pressure sensor low error 628
Failure code [CA131] Throttle sensor high error 630
Failure code [CA132] Throttle sensor low error 632
Failure code [CA144] Coolant sensor high error 634
Failure code [CA145] Coolant sensor low error 636
Failure code [CA153] Charge temperature sensor high error 638
Failure code [CA154] Charge temperature sensor low error 640
Failure code [CA155] Speed derating error by high charge temperature 642
Failure code [CA187] Sensor power supply 2 low error 644
Failure code [CA221] Atmospheric pressure sensor high error 646
Failure code [CA222] Atmospheric pressure sensor low error 648
Failure code [CA227] Sensor power supply 2 high error 650
Failure code [CA234] Engine overspeed 650
Failure code [CA238] Ne speed sensor power supply error 651
Failure code [CA271] IMV/IMA: Short circuit 652
Failure code [CA272] IMV/IMA open circuit 654
Failure code [CA281] Abnormal supply pump pressure balance 656
Failure code [CA322] Injector #1 (L#1) open/short 658
Failure code [CA323] Injector #5 (L#5) open/short 660
Failure code [CA324] Injector #3 (L#3) open/short 662
Failure code [CA325] Injector #6 (L#6) open/short 664
Failure code [CA331] Injector #2 (L#2) open/short 666
Failure code [CA332] Injector #4 (L#4) open/short 668
Failure code [CA342] Data compatibility error in engine controller 670
Failure code [CA351] Injector drive circuit error 671
Failure code [CA352] Sensor power supply 1 low error 672
Failure code [CA386] Sensor power supply 1 high error 673
Failure code [CA428] Water-in-fuel sensor high error 674
Failure code [CA429] Water-in-fuel sensor low error 676
Failure code [CA431] Idle validation switch error 678
Failure code [CA432] Idle validation action error 682
Failure code [CA435] Engine oil pressure switch error 685
Failure code [CA441] Power supply voltage low error 686
Failure code [CA442] Power supply voltage high error 688
Failure code [CA449] Common rail pressure high error 2 689
Failure code [CA451] Common rail pressure sensor high error 690
Failure code [CA452] Common rail pressure sensor low error 692
Failure code [CA488] Torque derating error by high charge temperature 694
Failure code [CA553] Common rail pressure high error 1 695
Failure code [CA559] Rail Press Low Error 696
Failure code [CA689] Eng Ne Speed Sensor Error 698
Failure code [CA731] Eng Bkup Speed Sens Phase Error 700
Failure code [CA757] All continuous data lost error 701
Failure code [CA778] Eng Bkup Speed Sensor Error 702
Failure code [CA1633] KOMNET (CAN communication) error 705
Failure code [CA2185] Throttle sensor power supply high error 706
Failure code [CA2186] Throttle sensor power supply low error 708
Failure code [CA2249] Supply pump pressure low error 2 710
Failure code [CA2265] Fuel Feed Pump Open Error 712
Failure code [CA2266] Fuel Feed Pump Short Error 714
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 715
Failure code [CA2555] Intake heater relay open circuit 716
Failure code [CA2556] Intake heater relay short circuit 718
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness 720
Failure code [D160KB] Backup lamp relay: Ground fault 722
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault 724
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state 726
Failure code [DAFRKR] CAN communication failure (monitor panel) 728
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input) 730
Failure code [DAQOKT] Transmission controller: Non-volatile memory error 732
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input) 734
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement 736
Failure code [DAQRKR] Transmission controller CAN communication: Communication error 738
Failure code [DAQRMA] Transmission controller option setting: Malfunction 742
Failure code [DB2RKR] Engine controller CAN communication: Communication error 743
Failure code [DD1PKB] RPM set switch power supply short circuit 750
Failure code [DD1QKB] RPM set mode switch short circuit 752
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error 754
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit 759
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit 759
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit 760
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit 760
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit 761
Failure code [DDTNKA] Fill switch for R clutch: Open circuit 762
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit 763
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input 764
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error 768
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range 772
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault 774
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range 776
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault 778
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 780
Failure code [DHT5L6] Failure of T/C Oil Press Sensor 782
Failure code [DJF1KA] Fuel level sensor: Open circuit 784
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range 786
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range 788
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit 790
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match 791
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit 792
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match 793
Failure code [DLM3KA] Fan speed sensor: Open circuit 794
Failure code [DLM3LC] Fan speed sensor: Short circuit 795
Failure code [DLM3MB] Radiator Fan Control Mismatch 796
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit 797
Failure code [DV00KB] Buzzer: Short circuit 798
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit 800
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit 802
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit 803
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit 804
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line 806
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit 808
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit 809
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line 810
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit 812
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit 813
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line 814
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit 816
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit 817
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line 818
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit 820
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit 821
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line 822
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit 824
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit 825
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line 826
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit 828
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit 829
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line 830
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit 832
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit 833
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line 834
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit 836
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit 837
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line 838
Troubleshooting of electrical system (E-mode) 840
E-1 Engine does not start (Starting motor does not turn) 840
E-2 Preheating does not work 846
E-3 When starting switch is turned to ON position, machine monitor displays nothing 851
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen 854
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen 854
E-6 Emergency stop monitor lights up while engine is running 855
E-7 Speedometer or engine tachometer does not indicate correctly 859
E-8 Engine coolant temperature gauge does not indicate correctly 860
E-9 Articulation angle indicator does not indicate correctly 862
E-10 Torque converter oil temperature gauge does not indicate correctly 864
E-11 Fuel level gauge does not indicate correctly 866
E-12 Character display does not display correctly 868
E-13 Centralized warning lamp does not light up or does not go off 870
E-14 Alarm buzzer does not sound or does not stop sounding 872
E-15 Machine monitor mode selector switch does not work 874
E-16 Transmission mode does not switch 878
E-17 Engine mode does not switch 880
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification] 882
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification] 886
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification] 888
E-21 Horn does not sound or does not stop sounding 892
E-22 Backup alarm does not sound or does not stop sounding 894
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off 897
E-24 Working lamp does not light up or does not go off 904
E-25 Fog lamp does not light up or does not go off 910
E-26 Turn signal lamp and hazard lamp do not flash 912
E-27 Stop lamp does not light up or does not go off 918
E-28 Backup lamp does not light up or does not go off 920
E-29 Windshield wiper does not operate 922
E-30 Window washer does not operate 930
E-31 KOMTRAX system does not operate correctly 934
Troubleshooting for hydraulic and mechanical system (H-mode) 938
Information described in troubleshooting table (H-mode) 938
H-1 Engine speed drops significantly or engine stalls 939
H-2 Machine does not move off (both forward and reverse) 940
H-3 Gear speed does not shift 941
H-4 Travel speed or power is low 942
H-5 Torque converter lockup does not operate or is not canceled 944
H-6 Machine starts or gear speed shifts with long time lag 945
H-7 Torque converter oil temperature is high 946
H-8 Differential lock function does not operate or is not canceled 947
H-9 Steering speed or power is insufficient 948
H-10 Steering wheel does not move 949
H-11 Wheel brakes do not work or are weak 950
H-12 Wheel brakes are not released or drag 951
H-13 Parking brake does not work or it is weak 952
H-14 Parking brake (including emergency release system) is not released or drags 953
H-15 All work equipment operates slowly or lacks power 954
H-16 All work equipments do not operate 955
H-17 Unusual noise is heard from around hydraulic pump 956
H-18 Blade lift speed or power is low 957
H-19 Hydraulic drift of lifted blade is large 958
H-20 Drawbar side shift speed or power is low 959
H-21 Blade cross slide speed or power is low 960
H-22 Power tilt speed or power is low 961
H-23 Articulate speed or power is low 962
H-24 Leaning speed or power is insufficient 963
H-25 Hydraulic drift (tilting) of leaning is large 964
H-26 Blade does not rotate 965
H-27 Lift arm lock pin is not locked or is not canceled 966
H-28 Blade accumulator does not operate or is not canceled [blade accumulator specifications] 967
H-29 Fan rotation is abnormal (such as excessive noise or vibration of fan, or overheating) 968
H-30 Unusual noise is heard from around fan 969
Troubleshooting of engine (S-mode) 971
Method of using troubleshooting charts 971
S-1 Starting performance is poor 974
S-2 Engine does not start 975
S-3 Engine does not pick up smoothly 978
S-4 Engine stops during operations 979
S-5 Engine does not rotate smoothly 980
S-6 Engine lacks output (or lacks power) 981
S-7 Exhaust smoke is black (incomplete combustion) 982
S-8 Oil consumption is excessive (or exhaust smoke is blue) 983
S-9 Oil becomes contaminated quickly 984
S-10 Fuel consumption is excessive 985
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 986
S-12 Oil pressure drops 987
S-13 Oil level rises (water, fuel in oil) 988
S-14 Coolant temperature becomes too high (overheating) 989
S-15 Abnormal noise is made 990
S-16 Vibration is excessive 991
Shop Manual 993
50 Disassembly and assembly 993
Precautions before work 996
Related information on disassembly and assembly 998
How to read this manual 998
Coating materials list1000
Special tools list1004
Sketches of special tools1009
Engine and cooling system1045
Removal and installation of fuel supply pump assembly1045
Removal and installation of fuel injector assembly1048
Removal and installation of cylinder head assembly1057
Removal and installation of engine front oil seal assembly1070
Removal and installation of engine rear oil seal assembly1073
Removal and installation of cooling fan pump assembly1078
Removal and installation of cooling fan and fan motor assembly1080
Removal and installation of radiator assembly1085
Removal and installation of aftercooler assembly1089
Removal and installation of power train oil cooler assembly1092
Removal and installation of fuel tank assembly1095
Removal and installation of engine hood assembly1099
Power train1101
Removal and installation of engine and transmission assembly1101
Disconnection and connection of transmission and torque converter assembly from/to engine1109
Disassembly and assembly of transmission assembly1111
Disassembly and assembly of torque converter assembly1150
Removal and installation of tandem drive and final drive assembly1162
Disassembly and assembly of tandem drive assembly1166
Disassembly and assembly of final drive assembly1174
Steering system1193
Removal and installation of steering valve (Orbitrol) assembly1193
Brake system1200
Disassembly and assembly of wheel brake assembly1200
Undercarriage and frame1208
Removal and installation of center hinge pin1208
Hydraulic system1221
Removal and installation of hydraulic tank, battery and frame assembly1221
Removal and installation of hydraulic tank assembly1226
Removal and installation of control valve assembly1229
Disassembly and assembly of control valve assembly1235
Disassembly and assembly of hydraulic cylinder assembly1238
Work equipment1242
Removal and installation of blade assembly1242
Disassembly and assembly of circle drawbar assembly1244
Removal and installation of circle rotation gear assembly1247
Disassembly and assembly of circle rotation gear assembly1250
Removal and installation of ripper assembly1257
Cab and its attachments1258
Removal and installation of operator’s cab assembly1258
Removal and installation of floor frame assembly1270
Removal and installation of operator’s cab glass (adhered window glass)1274
Removal and installation of air conditioner unit assembly1284
Electrical system1290
Removal and installation of engine controller assembly1290
Removal and installation of starting motor1292
Removal and installation of battery1294
Removal and installation of machine monitor assembly1296
Removal and installation of transmission controller assembly1300
Removal and installation of KOMTRAX terminal assembly (ORBCOMM)1302
Removal and installation of KOMTRAX terminal assembly (GPRS)1304
60 Maintenance standard1307
Engine and cooling system1309
Engine mount and transmission mount1309
Cooling system1310
Cooling fan motor1311
Power train system1314
Torque converter1314
Transmission1317
Transmission control valve1326
ECMV1327
Main relief valve and torque converter relief valve1329
Front axle1330
Final drive1333
Differential1336
Tandem drive1338
Brake system1340
Slack adjuster1340
Wheel brake1341
Parking brake1342
Undercarriage and frame1343
Frame1343
Hydraulic system1344
Main pump1344
Power train pump1348
Control valve1350
Hydraulic cylinder1359
Work equipment1362
Circle and drawbar1362
Blade1364
Lifter1366
Circle rotation gear1367
80 Appendix1369
Precautions before work1371
Air conditioner1373
Precautions for refrigerant1373
Air conditioner components1374
Structure and function of refrigeration system1376
Overview of refrigeration system1377
Air conditioner unit1378
Compressor1381
Condenser1382
Receiver drier1383
Air conditioner control panel1384
Procedure for check and troubleshooting1386
Circuit diagram and layout of connector pins1388
System diagram1390
Detail of air conditioner unit1392
Parts and connectors layout1394
Testing air leakage (ducts)1396
Check with self-diagnosis (control panel display)1398
Testing temperature control1399
Testing Fresh/Recirc air changeover1400
Testing evaporator temperature sensor1401
Testing relays1402
Testing blower amp1403
Troubleshooting Chart 11404
Troubleshooting Chart 21406
Information in troubleshooting table1408
Troubleshooting for power supply system (Air conditioner does not operate)1410
Troubleshooting of compressor and refrigerant system (Air is not cooled)1412
Troubleshooting for blower motor system (Air does not come out or air flow is improper)1416
Troubleshooting for temperature control1418
Troubleshooting for FRESH/RECIRC air changeover1420
Troubleshooting with gauge pressure1422
Connection of service tool1424
Precautions for disconnecting and connecting air conditioner piping1426
Handling compressor oil1428
90 Diagrams and drawings1431
Hydraulic diagrams and drawings1433
Symbols used in hydraulic circuit diagrams1433
Hydraulic circuit diagram1435
Electrical diagrams and drawings1439
Symbols used in electric circuit diagrams1439
Electrical circuit diagram1443
Index1461

S.M 30/12/24