MOTORGRADER
Hydraulicdrivefanspecification
SERIALNUMBERSB10001andup
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00Indexandforeword
Tableofcontents 1
00Indexandforeword
Tableofcontents.........................................................................................................................................00-2
Acronyms..................................................................................................................................................00-12
Forewordandgeneralinformation............................................................................................................00-17
Safetynotice..........................................................................................................................................00-17
Howtoreadtheshopmanual................................................................................................................00-22
Explanationoftermsformaintenancestandard....................................................................................00-24
Handlingofelectricequipmentandhydrauliccomponents....................................................................00-26
Handlingofconnectorsnewlyusedforengines....................................................................................00-35
Howtoreadelectricwirecode...............................................................................................................00-38
Precautionswhencarryingoutwork......................................................................................................00-41
Methodofdisassemblingandconnectingpush-pulltypecoupler..........................................................00-44
Standardtighteningtorquetable............................................................................................................00-47
Conversiontable....................................................................................................................................00-51
01Specification
Acronyms....................................................................................................................................................01-3
Specifications..............................................................................................................................................01-8
Specificationdrawing...............................................................................................................................01-8
Specifications.........................................................................................................................................01-10
Weighttable...........................................................................................................................................01-16
Tableoffuel,coolant,andlubricants......................................................................................................01-17
10Structureandfunction
Acronyms....................................................................................................................................................10-4
Engineandcoolingsystem.........................................................................................................................10-9
Coolingsystem........................................................................................................................................10-9
Coolingfanmotor...................................................................................................................................10-11
Powertrainsystem...................................................................................................................................10-19
Powertrainsystemdrawing...................................................................................................................10-19
Powertrainpipingdrawing.....................................................................................................................10-20
Transmissioncontrol..............................................................................................................................10-21
Torqueconverter....................................................................................................................................10-22
Transmission..........................................................................................................................................10-25
Transmissioncontrolvalve.....................................................................................................................10-44
ECMV.....................................................................................................................................................10-46
Mainreliefvalveandtorqueconverterreliefvalve.................................................................................10-53
Frontaxle...............................................................................................................................................10-55
Rearaxle................................................................................................................................................10-58
Differential(Non-differentialspecification).............................................................................................10-59
Differential(Differentiallockspecification).............................................................................................10-61
Differentiallocksolenoidvalve...............................................................................................................10-64
Finaldrive..............................................................................................................................................10-65
Tandemdrive.........................................................................................................................................10-67
Steeringsystem........................................................................................................................................10-69
Steeringpipingdrawing..........................................................................................................................10-69
Priorityvalve..........................................................................................................................................10-70
Steeringvalve........................................................................................................................................10-75
Brakesystem............................................................................................................................................10-82
Hydraulicpipingdrawingofbrakesystem.............................................................................................10-82
Brakevalve............................................................................................................................................10-83
Brakecircuitaccumulator.......................................................................................................................10-88
Brakecircuitaccumulatorchargevalve.................................................................................................10-89
Wheelbrake...........................................................................................................................................10-95
Parkingbrakesolenoidvalveandlifterlockpinsolenoidvalve.............................................................10-96
Parkingbrake.........................................................................................................................................10-97
Undercarriageandframe..........................................................................................................................10-98
Frame.....................................................................................................................................................10-98
Tire.........................................................................................................................................................10-99
Hydraulicsystem.....................................................................................................................................10-100
Hydraulicsystem..................................................................................................................................10-100
Hydraulicpipingdrawingofworkequipment.......................................................................................10-102
Workequipmentcontrol.......................................................................................................................10-104
Hydraulictank......................................................................................................................................10-105
Workequipmentpumpandsteeringpump..........................................................................................10-106
Powertrainpump.................................................................................................................................10-107
Powertrainpumpanddifferentiallockpump.......................................................................................10-108
Brakeandcoolingfanpump................................................................................................................10-109
Controlvalve.........................................................................................................................................10-110
Functionsandvalveoperations............................................................................................................10-112
Hydrauliccylinder..................................................................................................................................10-113
Swiveljoint............................................................................................................................................10-114
Pilotcheckvalve...................................................................................................................................10-115
Workequipmentsystem.........................................................................................................................10-124
Circleanddrawbar...............................................................................................................................10-124
Blade....................................................................................................................................................10-126
Lifter.....................................................................................................................................................10-128
Circlerotationmotor.............................................................................................................................10-130
Circlerotationgear...............................................................................................................................10-132
Testingexhaustgastemperature...........................................................................................................30-20
Testingexhaustgascolor......................................................................................................................30-22
Adjustingvalveclearance......................................................................................................................30-24
Testingcompressionpressure...............................................................................................................30-26
Testingblowbypressure........................................................................................................................30-29
Testingengineoilpressure....................................................................................................................30-30
Handlingfuelsystemdevices................................................................................................................30-31
Releasingremainingpressurefromfuelsystem....................................................................................30-32
Testingfuelpressure..............................................................................................................................30-33
Bleedingairfromfuelcircuit...................................................................................................................30-34
Testingfuelcircuitforleakage................................................................................................................30-35
Handlingcylindercutoutmodeoperation...............................................................................................30-36
Handlingno-injectioncrankingoperation...............................................................................................30-37
Handlingvoltagecircuitofenginecontroller..........................................................................................30-38
Testingmuffler(mainbody)andstackedmufflerforloosenessanddamage........................................30-39
Testingmufflerfunction..........................................................................................................................30-40
Testinginstalledconditionofcylinderheadsandmanifolds..................................................................30-41
Testingofenginepipingfordamageandlooseness..............................................................................30-42
Testingfueldischarge,returnrate,andleakage....................................................................................30-43
Testingandadjustingairconditionercompressorbelttension..............................................................30-47
Checkingandreplacingalternatorbelt..................................................................................................30-49
Checkingandreplacingauto-tensioner.................................................................................................30-51
Powertrain................................................................................................................................................30-54
Testingpowertrainoilpressure.............................................................................................................30-54
Adjustingtransmissionspeedsensor....................................................................................................30-68
Retrievalofdisabledmachineduetotransmissionvalvefailure...........................................................30-71
Flushingprocedurefortorqueconverterandtransmissioncircuits........................................................30-74
Testingandadjustingtoe-in...................................................................................................................30-76
Testingandadjustingdifferentiallockoilpressure(differentiallockspecification).................................30-78
Steeringsystem........................................................................................................................................30-80
Testingandadjustingsteeringoilpressure............................................................................................30-80
Testingoilleakageofsteeringcylinder..................................................................................................30-81
Bleedingairfromsteeringcircuit............................................................................................................30-82
Brakesystem............................................................................................................................................30-83
Releasingremainingpressurefrombrakecircuit...................................................................................30-83
Testingandadjustingbrakeoilpressure................................................................................................30-84
Bleedingairfrombrakecircuit...............................................................................................................30-87
Testingwearofwheelbrakedisc...........................................................................................................30-88
Testingandadjustingparkingbrakepad................................................................................................30-89
Releasingparkingbrakemanually.........................................................................................................30-92
Chargingbrakeaccumulatorwithgas....................................................................................................30-93
Hydraulicsystem.......................................................................................................................................30-95
Testingworkequipmentoilpressure......................................................................................................30-95
Testinglifterlockpincircuitpressure.....................................................................................................30-97
Testingcoolingfanspeed......................................................................................................................30-99
Testingcoolingfancircuitoilpressure.................................................................................................30-100
Testingoilleakageofworkequipmentcylinder....................................................................................30-102
Bleedingairfromworkequipmentcircuit.............................................................................................30-105
Workequipment......................................................................................................................................30-106
Adjustingdrawbarballjointclearance.................................................................................................30-106
Testingandadjustingcircleguideclearance.......................................................................................30-107
Testingandadjustingslipclutchtypecircledrive................................................................................30-109
Electricalsystem......................................................................................................................................30-111
Procedurefortestingdiodes.................................................................................................................30-111
Specialfunctionsofmachinemonitor..................................................................................................30-113
Handlinghigh-voltagecircuitofenginecontroller................................................................................30-162
KOMTRAXterminalstart-upprocedure...............................................................................................30-163
Adjustingrearviewcameraangle.........................................................................................................30-167
Handlebatterydisconnectswitch........................................................................................................30-169
Preparatoryworkfortroubleshootingofelectricalsystemfailure........................................................30-170 PmClinic.................................................................................................................................................30-172
PmClinic..............................................................................................................................................30-172
40Troubleshooting
Acronyms....................................................................................................................................................40-8
Informationrelatedtotroubleshooting......................................................................................................40-13
Pointstorememberwhentroubleshooting............................................................................................40-13
Howtoproceedintroubleshooting........................................................................................................40-14
Checksbeforetroubleshooting..............................................................................................................40-15
Inspectionprocedurebeforetroubleshooting.........................................................................................40-17
Troubleshootingprocedure....................................................................................................................40-32
Failurecodelist......................................................................................................................................40-34
Symptomsandtroubleshootingnumbers..............................................................................................40-42
Informationdescribedintroubleshootingtable......................................................................................40-45
Diagnosisofopenharnessinpressuresensorsystem.........................................................................40-47
Connectorlistandlayout.......................................................................................................................40-49
Connectorpinlayout..............................................................................................................................40-63
T-boxandT-adapterlist.........................................................................................................................40-99
Locationsoffuses................................................................................................................................40-104
Troubleshootingbyfailurecode(displayofcode)...................................................................................40-107
Failurecode[1500L0]DoubleEngagementofT/MClutches..............................................................40-107 Failurecode[15G0MW]FailureofR-ClutchSystem...........................................................................40-108 Failurecode[15H0MW]FailureofClutchSystem(FH).......................................................................40-109 Failurecode[15J0MW]FailureofClutchSystem(FL).........................................................................40-110 Failurecode[15K0MW]FailureofClutchSystem(1st)........................................................................40-111 Failurecode[15L0MW]FailureofClutchSystem(2nd).......................................................................40-112 Failurecode[15M0MW]FailureofClutchSystem(3rd).......................................................................40-113 Failurecode[15N0MW]FailureofClutchSystem(4th)........................................................................40-114 Failurecode[15SBL1]ReleaseTroubleofECMV(R)..........................................................................40-115 Failurecode[15SBMA]MalfunctionofECMV(R)................................................................................40-117 Failurecode[15SCL1]ReleaseTroubleofECMV(FH).......................................................................40-119 Failurecode[15SCMA]MalfunctionofECMV(FH).............................................................................40-121 Failurecode[15SDL1]ReleaseTroubleofECMV(FL).......................................................................40-123 Failurecode[15SDMA]MalfunctionofECMV(FL).............................................................................40-125 Failurecode[15SEL1]ReleaseTroubleofECMV(1st)......................................................................40-127 Failurecode[15SEMA]MalfunctionofECMV(1st).............................................................................40-129 Failurecode[15SFL1]ReleaseTroubleofECMV(2nd).....................................................................40-131 Failurecode[15SFMA]MalfunctionofECMV(2nd)............................................................................40-133 Failurecode[15SGL1]ReleaseTroubleofECMV(3rd)......................................................................40-135 Failurecode[15SGMA]MalfunctionofECMV(3rd)............................................................................40-137
Failurecode[15SHL1]ReleaseTroubleofECMV(4th)......................................................................40-139
Failurecode[15SHMA]MalfunctionofECMV(4th).............................................................................40-141
Failurecode[15SJMA]MalfunctionofECMV(L/U).............................................................................40-143 Failurecode[15U0NT]OverloadofInchingClutch.............................................................................40-144 Failurecode[2G42ZG]AccumulatorOilPressureLow(Front)...........................................................40-145
Failurecode[2G43ZG]AccumulatorOilPressureLow(Rear)............................................................40-147
Failurecode[989L00]EngineControllerLockCaution1....................................................................40-149
Failurecode[989M00]EngineControllerLockCaution2...................................................................40-150
Failurecode[989N00]EngineControllerLockCaution3....................................................................40-151
Failurecode[AB00KE]ChargeVoltageLow.......................................................................................40-152
Failurecode[AB00KY]HotShortofAlternatorRTerminal..................................................................40-153
Failurecode[B@BAZG]Deratinginspeedduetoengineoilpressuredrop.......................................40-154
Failurecode[B@BCNS]EngineOverheat..........................................................................................40-155
Failurecode[B@CENS]T/COilTemp.Overheat...............................................................................40-156
Failurecode[B@CKNS]DIFFOilTemp.Overheat.............................................................................40-157
Failurecode[B@HANS]HYDOilTemp.Overheat..............................................................................40-159
Failurecode[CA111]EngineNE,controllerinternalerror...................................................................40-161
Failurecode[CA115]EngineNE,Bkupspeedsensorerror................................................................40-162