Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
$37.95
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
Language : English
Pages : 1580
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
Cover................................................................................................................... 1 00 Index and foreword................................................................................................... 3 Table of contents................................................................................................... 4 Acronyms............................................................................................................ 16 Foreword and general information.................................................................................... 21 Safety notice................................................................................................... 21 How to read the shop manual..................................................................................... 26 Explanation of terms for maintenance standard................................................................... 28 Handling of electric equipment and hydraulic components......................................................... 30 Handling of connectors newly used for engines................................................................... 39 How to read electric wire code.................................................................................. 42 Precautions when carrying out work.............................................................................. 45 Method of disassembling and connecting push-pull type coupler................................................... 48 Standard tightening torque table................................................................................ 51 Conversion table................................................................................................ 55 01 Specification........................................................................................................ 61 Contents............................................................................................................ 62 Acronyms............................................................................................................ 63 Specifications...................................................................................................... 69 Specification drawing (Canopy specification).................................................................... 69 Specification drawing (Cab specification)....................................................................... 70 Specifications (Canopy specification)........................................................................... 72 Specifications (Cab specification).............................................................................. 78 Weight table.................................................................................................... 84 Table of fuel, coolant, and lubricants.......................................................................... 85 10 Structure and function............................................................................................... 87 Contents............................................................................................................ 88 Acronyms............................................................................................................ 90 Engine and cooling system........................................................................................... 96 Cooling system.................................................................................................. 96 Fan drive....................................................................................................... 98 Power train system.................................................................................................. 99 Power train system drawing...................................................................................... 99 Power train piping drawing...................................................................................... 100 Transmission control............................................................................................ 101 Torque converter................................................................................................ 102 Transmission.................................................................................................... 106 Transmission control valve...................................................................................... 125 ECMV............................................................................................................ 127 Main relief valve and torque converter relief valve............................................................. 134 Front axle...................................................................................................... 136 Rear axle....................................................................................................... 139 Differential (Non-differential specification)................................................................... 140 Differential (Differential lock specification).................................................................. 142 Differential lock solenoid valve................................................................................ 145 Final drive..................................................................................................... 146 Tandem drive.................................................................................................... 148 Steering system..................................................................................................... 151 Steering piping drawing......................................................................................... 151 Priority valve.................................................................................................. 152 Steering valve.................................................................................................. 157 Brake system........................................................................................................ 165 Hydraulic piping drawing of brake system........................................................................ 165 Brake valve..................................................................................................... 166 Brake circuit accumulator....................................................................................... 171 Brake circuit accumulator charge valve.......................................................................... 172 Wheel brake..................................................................................................... 178 Parking brake solenoid valve and lifter lock pin solenoid valve................................................. 179 Parking brake................................................................................................... 180 Undercarriage and frame............................................................................................. 181 Frame........................................................................................................... 181 Tire............................................................................................................ 182 Hydraulic system.................................................................................................... 184 Hydraulic system................................................................................................ 184 Hydraulic piping drawing of work equipment...................................................................... 186 Work equipment control.......................................................................................... 188 Hydraulic tank.................................................................................................. 189 Work equipment pump and steering pump........................................................................... 190 Power train pump................................................................................................ 191 Power train pump and differential lock pump..................................................................... 192 Brake pump...................................................................................................... 193 Control valve................................................................................................... 194 Functions and valve operations.................................................................................. 196 Hydraulic cylinder.............................................................................................. 197 Swivel joint.................................................................................................... 198 Pilot check valve............................................................................................... 199 Work equipment system............................................................................................... 210 Circle and drawbar.............................................................................................. 210 Blade........................................................................................................... 212 Lifter.......................................................................................................... 214 Circle rotation motor........................................................................................... 216 Circle rotation gear............................................................................................ 218 Cab and its attachments............................................................................................. 220 ROPS canopy..................................................................................................... 220 ROPS cab........................................................................................................ 221 Electrical system................................................................................................... 222 Machine monitor................................................................................................. 222 Automatic gear shift control system............................................................................. 233 Transmission controller......................................................................................... 240 Engine controller............................................................................................... 243 KOMTRAX system.................................................................................................. 246 KOMTRAX terminal................................................................................................ 247 Engine starting circuit......................................................................................... 249 Engine stop circuit............................................................................................. 251 Preheating circuit.............................................................................................. 252 Sensors......................................................................................................... 253 Engine power mode selector circuit.............................................................................. 262 20 Standard value table................................................................................................. 263 Contents............................................................................................................ 264 Acronyms............................................................................................................ 265 Standard value table................................................................................................ 270 Standard value table for engine................................................................................. 270 Standard value table for machine................................................................................ 272 30 Testing and adjusting................................................................................................ 283 Contents............................................................................................................ 284 Acronyms............................................................................................................ 286 Tools for testing, adjusting, and troubleshooting................................................................... 291 Tools for testing, adjusting, and troubleshooting............................................................... 291 Engine and cooling system........................................................................................... 298 Testing engine speed............................................................................................ 298 Testing boost pressure.......................................................................................... 300 Testing exhaust gas temperature................................................................................. 302 Testing exhaust gas color....................................................................................... 304 Adjusting valve clearance....................................................................................... 306 Testing compression pressure.................................................................................... 308 Testing blowby pressure......................................................................................... 311 Testing engine oil pressure..................................................................................... 312 Handling fuel system devices.................................................................................... 313 Releasing remaining pressure from fuel system................................................................... 314 Testing fuel pressure........................................................................................... 315 Bleeding air from fuel circuit.................................................................................. 316 Testing fuel circuit for leakage................................................................................ 317 Handling cylinder cutout mode operation......................................................................... 318 Handling no-injection cranking operation........................................................................ 319 Handling voltage circuit of engine controller................................................................... 320 Testing muffler (main body) and stacked muffler for looseness and damage........................................ 321 Testing muffler function........................................................................................ 322 Testing installed condition of cylinder heads and manifolds..................................................... 323 Testing of engine piping for damage and looseness............................................................... 324 Testing fuel discharge, return rate, and leakage................................................................ 325 Checking and replacing alternator belt.......................................................................... 329 Checking and replacing auto-tensioner........................................................................... 331 Power train......................................................................................................... 334 Testing power train oil pressure................................................................................ 334 Adjusting transmission speed sensor............................................................................. 348 Retrieval of disabled machine due to transmission valve failure................................................. 351 Flushing procedure for torque converter and transmission circuits............................................... 354 Testing and adjusting toe-in.................................................................................... 356 Adjusting bearing preload....................................................................................... 358 Testing and adjusting differential lock oil pressure (differential lock specification).......................... 360 Steering system..................................................................................................... 362 Testing and adjusting steering oil pressure..................................................................... 362 Testing oil leakage of steering cylinder........................................................................ 363 Bleeding air from steering circuit.............................................................................. 364 Brake system........................................................................................................ 365 Releasing remaining pressure from brake circuit................................................................. 365 Testing and adjusting brake oil pressure........................................................................ 366 Bleeding air from brake circuit................................................................................. 369 Testing wear of wheel brake disc................................................................................ 370 Testing and adjusting parking brake pad......................................................................... 371 Releasing parking brake manually................................................................................ 374 Charging brake accumulator with gas............................................................................. 375 Hydraulic system.................................................................................................... 377 Testing work equipment oil pressure............................................................................. 377 Testing lifter lock pin circuit pressure........................................................................ 379 Testing oil leakage of work equipment cylinder.................................................................. 381 Bleeding air from work equipment circuit........................................................................ 384 Work equipment...................................................................................................... 385 Adjusting drawbar ball joint clearance.......................................................................... 385 Testing and adjusting circle guide clearance.................................................................... 386 Testing and adjusting slip clutch type circle drive............................................................. 388 Electrical system................................................................................................... 390 Procedure for testing diodes.................................................................................... 390 Special functions of machine monitor............................................................................ 392 Handling high-voltage circuit of engine controller.............................................................. 439 KOMTRAX terminal start-up procedure............................................................................. 440 Preparatory work for troubleshooting of electrical system failure............................................... 444 Pm Clinic........................................................................................................... 446 Pm Clinic....................................................................................................... 446 40 Troubleshooting...................................................................................................... 455 Contents............................................................................................................ 456 Acronyms............................................................................................................ 462 Information related to troubleshooting.............................................................................. 467 Points to remember when troubleshooting......................................................................... 467 How to proceed in troubleshooting............................................................................... 468 Checks before troubleshooting................................................................................... 469 Inspection procedure before troubleshooting..................................................................... 471 Troubleshooting procedure....................................................................................... 486 Failure code list............................................................................................... 488 Symptoms and troubleshooting numbers............................................................................ 496 Information described in troubleshooting table.................................................................. 499 Diagnosis of open harness in pressure sensor system............................................................. 501 Connector list and layout....................................................................................... 503 Connector pin layout............................................................................................ 521 T-box and T-adapter list........................................................................................ 557 Locations of fuses.............................................................................................. 562 Troubleshooting by failure code (display of code)................................................................... 565 Failure code [1500L0] Double Engagement of T/M Clutches......................................................... 565 Failure code [15G0MW] Failure of R-Clutch System................................................................ 566 Failure code [15H0MW] Failure of Clutch System (FH)............................................................. 567 Failure code [15J0MW] Failure of Clutch System (FL)............................................................. 568 Failure code [15K0MW] Failure of Clutch System (1st)............................................................ 569 Failure code [15L0MW] Failure of Clutch System (2nd)............................................................ 570 Failure code [15M0MW] Failure of Clutch System (3rd)............................................................ 571 Failure code [15N0MW] Failure of Clutch System (4th)............................................................ 572 Failure code [15SBL1] Release Trouble of ECMV (R)............................................................... 573 Failure code [15SBMA] Malfunction of ECMV (R)................................................................... 575 Failure code [15SCL1] Release Trouble of ECMV (FH).............................................................. 577 Failure code [15SCMA] Malfunction of ECMV (FH).................................................................. 579 Failure code [15SDL1] Release Trouble of ECMV (FL).............................................................. 581 Failure code [15SDMA] Malfunction of ECMV (FL).................................................................. 583 Failure code [15SEL1] Release Trouble of ECMV (1st)............................................................. 585 Failure code [15SEMA] Malfunction of ECMV (1st)................................................................. 587 Failure code [15SFL1] Release Trouble of ECMV (2nd)............................................................. 589 Failure code [15SFMA] Malfunction of ECMV (2nd)................................................................. 591 Failure code [15SGL1] Release Trouble of ECMV (3rd)............................................................. 593 Failure code [15SGMA] Malfunction of ECMV (3rd)................................................................. 595 Failure code [15SHL1] Release Trouble of ECMV (4th)............................................................. 597 Failure code [15SHMA] Malfunction of ECMV (4th)................................................................. 599 Failure code [15SJMA] Malfunction of ECMV (L/U)................................................................. 601 Failure code [15U0NT] Overload of Inching Clutch................................................................ 602 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)...................................................... 603 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)....................................................... 605 Failure code [989L00] Engine Controller Lock Caution 1.......................................................... 607 Failure code [989M00] Engine Controller Lock Caution 2.......................................................... 608 Failure code [989N00] Engine Controller Lock Caution 3.......................................................... 609 Failure code [AB00KE] Charge Voltage Low........................................................................ 610 Failure code [AB00KY] Hot Short of Alternator R Terminal........................................................ 611 Failure code [B@BAZG] Derating in speed due to engine oil pressure drop......................................... 612 Failure code [B@BCNS] Engine Overheat........................................................................... 613 Failure code [B@CENS] T/C Oil Temp. Overheat.................................................................... 614 Failure code [B@CKNS] DIFF Oil Temp. Overheat................................................................... 615 Failure code [B@HANS] HYD Oil Temp. Overheat.................................................................... 617 Failure code [CA111] Engine NE, controller internal error....................................................... 619 Failure code [CA115] Engine NE, Bkup speed sensor error......................................................... 620 Failure code [CA122] Charge pressure sensor high error.......................................................... 621 Failure code [CA123] Charge pressure sensor low error........................................................... 623 Failure code [CA131] Throttle sensor high error................................................................. 625 Failure code [CA132] Throttle sensor low error.................................................................. 627 Failure code [CA144] Coolant sensor high error.................................................................. 630 Failure code [CA145] Coolant sensor low error................................................................... 632 Failure code [CA153] Charge temperature sensor high error....................................................... 634 Failure code [CA154] Charge temperature sensor low error........................................................ 636 Failure code [CA155] Speed derating error by high charge temperature............................................ 638 Failure code [CA187] Sensor power supply 2 low error............................................................ 639 Failure code [CA221] Atmospheric pressure sensor high error..................................................... 641 Failure code [CA222] Atmospheric pressure sensor low error...................................................... 643 Failure code [CA227] Sensor power supply 2 high error........................................................... 645 Failure code [CA234] Engine overspeed........................................................................... 646 Failure code [CA238] Ne speed sensor power supply error......................................................... 647 Failure code [CA271] IMV short-circuit error.................................................................... 648 Failure code [CA272] IMV open circuit........................................................................... 650 Failure code [CA322] Injector #1 (L/B #1) open/short............................................................ 652 Failure code [CA323] Injector #5 (L/B #5) open/short............................................................ 654 Failure code [CA324] Injector #3 (L/B #3) open/short............................................................ 656 Failure code [CA325] Injector #6 (L/B #6) open/short............................................................ 658 Failure code [CA331] Injector #2 (L/B #2) open/short............................................................ 660 Failure code [CA332] Injector #4 (L/B #4) open/short............................................................ 662 Failure code [CA342] Data compatibility error in engine controller.............................................. 664 Failure code [CA351] Injector drive circuit error............................................................... 665 Failure code [CA352] Sensor power supply 1 low error............................................................ 666 Failure code [CA386] Sensor power supply 1 high error........................................................... 668 Failure code [CA428] Water-in-fuel sensor high error............................................................ 669 Failure code [CA429] Water-in-fuel sensor low error............................................................. 671 Failure code [CA431] Idle validation switch error............................................................... 673 Failure code [CA432] Idle validation action error............................................................... 676 Failure code [CA435] Engine oil pressure switch error........................................................... 679 Failure code [CA441] Power supply voltage low error............................................................. 680 Failure code [CA442] Power supply voltage high error............................................................ 682 Failure code [CA449] Common rail pressure high error 2.......................................................... 683 Failure code [CA451] Common rail pressure sensor high error..................................................... 684 Failure code [CA452] Common rail pressure sensor low error...................................................... 686 Failure code [CA488] Torque derating error by high charge temperature........................................... 688 Failure code [CA553] Common rail pressure high error 1.......................................................... 689 Failure code [CA559] Supply pump pressure low error 1........................................................... 690 Failure code [CA689] Engine Ne speed sensor error............................................................... 692 Failure code [CA731] Engine Bkup speed sensor phase error....................................................... 694 Failure code [CA757] All continuous data lost error............................................................. 696 Failure code [CA778] Engine Bkup speed sensor error............................................................. 697 Failure code [CA1633] KOMNET (CAN communication) error.......................................................... 701 Failure code [CA2185] Throttle sensor power supply high error................................................... 704 Failure code [CA2186] Throttle sensor power supply low error.................................................... 706 Failure code [CA2249] Supply pump pressure low error 2.......................................................... 708 Failure code [CA2311] Abnormality in IMV (IMA) solenoid......................................................... 709 Failure code [CA2555] Intake heater relay open circuit.......................................................... 710 Failure code [CA2556] Intake heater relay short circuit......................................................... 712 Failure code [D160KA] Disconnection of Backup Light Relay....................................................... 714 Failure code [D160KB] Ground Fault of Backup Light Relay........................................................ 716 Failure code [D160KY] Hot Short of Back Lamp Relay Output....................................................... 718 Failure code [D19JKZ] Personal Code Relay Abnormality........................................................... 720 Failure code [D19KKZ] Failure of Diff Control Relay............................................................. 722 Failure code [D1EHKA] Disconnection of Engine Start Relay....................................................... 724 Failure code [D1EHKB] Ground Fault of Engine Start Relay........................................................ 725 Failure code [D1EHKY] Hot Short of Engine Start Relay........................................................... 726 Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay................................................... 727 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2................................................................... 729 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)..................................................................... 730 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON).................................................. 732 Failure code [DAF0MB] Monitor ROM Abnormality................................................................... 733 Failure code [DAF0MC] Monitor Error............................................................................. 734 Failure code [DAF3KK] Controller Power Source Low (MON)......................................................... 735 Failure code [DAQ0KK] Controller Power Source Low (T/M)......................................................... 737 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M).................................................. 739 Failure code [DAQ0MC] T/M Con Error............................................................................. 740 Failure code [DAQ1KA] Disconnection of Key SW ACC............................................................... 741 Failure code [DAQ2KK] Solenoid Power Source Low (T/M)........................................................... 743 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M).................................................... 745 Failure code [DAQQKR] CAN2 Discon (Transmission Con)............................................................ 746 Failure code [DAQRMA] Inconsistency of Option Selection (T/M)................................................... 747 Failure code [DB2QKR] CAN2 Discon (Engine Con).................................................................. 748 Failure code [DD1PKB] Abnormality of RPM Switch................................................................. 752 Failure code [DD1QKB] Abnormality of RPM Set Mode Switch........................................................ 754 Failure code [DDB6L4] Parking brake signal error................................................................ 756 Failure code [DDTHKA] Disconnection of Fill Switch (FH)......................................................... 758 Failure code [DDTJKA] Disconnection of Fill Switch (FL)......................................................... 759 Failure code [DDTKKA] Disconnection of Fill Switch (1st)........................................................ 760 Failure code [DDTLKA] Disconnection of Fill Switch (2nd)........................................................ 761 Failure code [DDTMKA] Disconnection of Fill Switch (3rd)........................................................ 762 Failure code [DDTNKA] Disconnection of Fill Switch (R).......................................................... 763 Failure code [DDTPKA] Disconnection of Fill Switch (4th)........................................................ 764 Failure code [DF10KA] Disconnection of Shift Lever Input........................................................ 765 Failure code [DF10L4] Gear Speed/Travel Direction Signal Error.................................................. 769 Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor...................................................... 772 Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S..................................................... 774 Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor...................................................... 776 Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C)...................................................... 778 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor................................................. 779 Failure code [DHT5L6] Failure of T/C Oil Press Sensor........................................................... 781 Failure code [DJF1KA] Disconnection of Fuel Level Sensor........................................................ 783 Failure code [DK70KX] Out of Range of Inching Potentio.......................................................... 785 Failure code [DKD0KX] Out of Range of Articulated Angle Sensor.................................................. 787 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor................................................... 789 Failure code [DLF1LC] Failure of T/M Input Speed Sensor......................................................... 791 Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor.................................................. 793 Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor.................................................. 795 Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir.............................................................. 797 Failure code [DLM3LC] Rad Fan Spd Sen Sig Error................................................................. 799 Failure code [DLM3MB] Rad Fan Spd Sen Error..................................................................... 800 Failure code [DLT3KA] Disconnection of T/M output Speed Sensor.................................................. 801 Failure code [DW4BKA] Disconnection of Parking Brake Valve...................................................... 803 Failure code [DW4BKB] Ground Fault of Parking Brake Valve....................................................... 805 Failure code [DW4BKY] Hot Short of Parking Brake Solenoid....................................................... 807 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)................................................... 809 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup).................................................... 811 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)....................................................... 812 Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)..................................................... 814 Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)...................................................... 816 Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)......................................................... 818 Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)...................................................... 820 Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)....................................................... 822 Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low).......................................................... 824 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)...................................................... 826 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)....................................................... 828 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st).......................................................... 830 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)...................................................... 832 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)....................................................... 834 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).......................................................... 836 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)...................................................... 838 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)....................................................... 840 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd).......................................................... 842 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................................. 844 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)................................................... 846 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)...................................................... 848 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)...................................................... 850 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)....................................................... 852 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th).......................................................... 854 Troubleshooting of electrical system (E-mode)....................................................................... 856 E-1 Engine does not start (Starting motor does not rotate)...................................................... 856 E-2 Manual preheating system does not work...................................................................... 860 E-3 When starting switch is turned ON, machine monitor displays nothing......................................... 866 E-4 LCD panel backlight of machine monitor fails (goes out or flickers)......................................... 869 E-5 LCD display failure of machine monitor...................................................................... 870 E-6 The switch of machine monitor switch panel does not work.................................................... 871 E-7 Two-switch operation of switch panel on machine monitor does not function................................... 872 E-8 Machine monitor buzzer does not sound....................................................................... 873 E-9 Some gauges or caution lamps of machine monitor do not work normally........................................ 874 E-10 Speedometer or engine speed display is abnormal............................................................ 875 E-11 Engine coolant temperature is displayed abnormally......................................................... 876 E-12 Articulated meter display is abnormal...................................................................... 878 E-13 Torque converter oil temperature is displayed abnormally................................................... 880 E-14 Fuel gauge is displayed abnormally......................................................................... 882 E-15 Centralized warning lamps do not light or do not go out.................................................... 884 E-16 Alarm buzzer does not sound or does not stop sounding...................................................... 885 E-17 Transmission mode cannot be switched....................................................................... 887 E-18 Engine mode cannot be switched............................................................................. 889 E-19 Differential gear lock function does not operate or is not canceled (for differential gear lock model)..... 891 E-20 Cannot be locked or canceled by the lifter lock pin........................................................ 893 E-21 Horn does not sound or does not stop sounding.............................................................. 895 E-22 Backup alarm does not sound or does not stop sounding...................................................... 897 E-23 Headlamps, clearance lamps, and tail lamps do not light up or go out....................................... 900 E-24 Working lamps do not light up or go out.................................................................... 908 E-25 Turn indicator light or emergency flashing light does not flash............................................ 913 E-26 Stop lamp does not light up or does not go out............................................................. 922 E-27 Backup lamp does not light up or does not go out........................................................... 924 E-28 All wipers do not operate.................................................................................. 926 E-29 Front wiper does not operate............................................................................... 928 E-30 Rear wiper does not operate................................................................................ 932 E-31 Left and right door wiper does not operate................................................................. 935 E-32 Left door wiper does not operate........................................................................... 938 E-33 Right door wiper does not operate.......................................................................... 940 E-34 Front or door washer does not operate...................................................................... 942 E-35 Rear washer does not operate............................................................................... 944 E-36 KOMTRAX system does not operate normally................................................................... 946 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................... 948 How to use troubleshooting table................................................................................ 948 H-1 Engine speed drops significantly or engine stalls........................................................... 954 H-2 Machine does not move off................................................................................... 955 H-3 Gear speed does not shift................................................................................... 956 H-4 Travel speed or power is low................................................................................ 957 H-5 Torque converter lockup does not operate or is not canceled................................................. 960 H-6 Machine starts or gear speed shifts with long time lag...................................................... 961 H-7 Torque converter oil temperature is high.................................................................... 964 H-8 Differential gear lock function does not operate or is not canceled......................................... 967 H-9 Steering speed or power is insufficient..................................................................... 968 H-10 Steering wheel does not move............................................................................... 969 H-11 Wheel brakes do not work or are weak....................................................................... 970 H-12 Wheel brakes are not released or drag...................................................................... 971 H-13 Parking brake does not work or it is weak.................................................................. 972 H-14 Parking brake (including emergency release system) is not released or drags................................ 973 H-15 All work equipment operates slowly or lacks power.......................................................... 974 H-16 Work equipment does not operate............................................................................ 975 H-17 Unusual noise is heard from around hydraulic pump.......................................................... 976 H-18 Blade lift speed or power is low........................................................................... 977 H-19 Hydraulic drift of lifted blade is large................................................................... 978 H-20 Drawbar side shift speed or power is low................................................................... 979 H-21 Blade side shift speed or power is low..................................................................... 980 H-22 Power tilt speed or power is low........................................................................... 981 H-23 Articulate speed or power is low........................................................................... 982 H-24 Leaning speed or power is insufficient..................................................................... 983 H-25 Hydraulic drift (tilting) of leaning is large.............................................................. 984 H-26 Blade does not rotate...................................................................................... 985 H-27 Lifter lock pin is not locked or is not canceled........................................................... 986 Troubleshooting of engine (S-mode).................................................................................. 987 How to read matrix.............................................................................................. 987 S-1 Engine startability is poor................................................................................. 990 S-2 Engine does not start....................................................................................... 991 S-3 Engine does not pick-up smoothly............................................................................ 994 S-4 Engine stops during operation............................................................................... 995 S-5 Engine runs rough or is unstable............................................................................ 996 S-6 Engine lacks power.......................................................................................... 997 S-7 Exhaust smoke is black (Incomplete combustion).............................................................. 998 S-8 Large oil consumption (or blue exhaust gas)................................................................. 999 S-9 Oil becomes contaminated early..............................................................................1000 S-10 Fuel consumption is excessive..............................................................................1001 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................1002 S-12 Oil pressure drops.........................................................................................1003 S-13 Oil amount increases (due to water or fuel mixing).........................................................1004 S-14 Coolant temperature rises too high (overheating)...........................................................1005 S-15 Unusual noise is heard.....................................................................................1006 S-16 Vibration is excessive.....................................................................................1007 50 Disassembly and assembly.............................................................................................1009 Contents............................................................................................................1010 Acronyms............................................................................................................1013 Related information on disassembly and assembly.....................................................................1018 How to read this manual.........................................................................................1018 Coating materials list..........................................................................................1020 Special tool list...............................................................................................1024 Sketches of special tools.......................................................................................1034 Engine and cooling system...........................................................................................1081 Removal and installation of supply pump assembly................................................................1081 Removal and installation of injector assembly...................................................................1085 Removal and installation of cylinder head assembly..............................................................1094 Removal and installation of air conditioner compressor belt.....................................................1111 Removal and installation of alternator belt.....................................................................1113 Removal and installation of engine front oil seal...............................................................1115 Removal and installation of engine rear oil seal................................................................1119 Removal and installation of radiator assembly (Canopy specification)............................................1122 Removal and installation of radiator assembly (Cab specification)...............................................1126 Removal and installation of aftercooler assembly (Canopy specification).........................................1132 Removal and installation of aftercooler assembly (Cab specification)............................................1136 Removal and installation of power train oil cooler assembly (Canopy specification)..............................1142 Removal and installation of power train oil cooler assembly (Cab specification).................................1147 Removal and installation of fuel tank assembly..................................................................1153 Removal and installation of engine hood assembly................................................................1158 Removal and installation of air conditioner compressor assembly.................................................1160 Power train.........................................................................................................1162 Removal and installation of engine, transmission, and torque converter assembly (Canopy specification)..........1162 Removal and installation of engine, transmission, and torque converter assembly (Cab specification).............1168 Disconnection and connection of engine, transmission, and torque converter assembly.............................1175 Disassembly and assembly of torque converter assembly...........................................................1177 Disassembly and assembly of transmission assembly...............................................................1190 Removal and installation of tandem drive and final drive assembly...............................................1229 Disassembly and assembly of tandem drive assembly...............................................................1232 Disassembly and assembly of differential assembly...............................................................1240 Disassembly and assembly of final drive assembly................................................................1255 Steering system.....................................................................................................1264 Removal and installation of Orbitrol valve assembly (Canopy specification)......................................1264 Removal and installation of Orbitrol valve assembly (Cab specification).........................................1269 Brake system........................................................................................................1275 Disassembly and assembly of wheel brake assembly................................................................1275 Undercarriage and frame.............................................................................................1283 Removal and installation of center hinge pin....................................................................1283 Hydraulic system....................................................................................................1293 Removal and installation of hydraulic tank, battery, and frame assembly.........................................1293 Removal and installation of hydraulic tank assembly.............................................................1301 Removal and installation of control valve assembly..............................................................1305 Disassembly and assembly of hydraulic cylinder assembly.........................................................1310 Work equipment......................................................................................................1314 Removal and installation of blade assembly......................................................................1314 Removal and installation of circle drawbar assembly.............................................................1315 Removal and installation of circle rotation gear assembly.......................................................1317 Disassembly and assembly of circle rotation gear assembly.......................................................1319 Canopy, cab and attachments.........................................................................................1324 Removal and installation of canopy assembly (Canopy specification)..............................................1324 Removal and installation of operator's cab assembly (Cab specification).........................................1329 Removal and installation of operator cab glass (adhered glass) (Cab specification)..............................1338 Removal and installation of floor frame assembly (Canopy specification).........................................1349 Removal and installation of floor frame assembly (Cab specification)............................................1352 Removal and installation of canopy and floor frame assembly (Canopy specification)..............................1356 Removal and installation of operator's cab and floor frame assembly (Cab specification).........................1359 Removal and installation of air conditioner unit assembly.......................................................1366 Removal and installation operator's seat........................................................................1372 Removal and installation seat belt..............................................................................1373 Electrical system...................................................................................................1375 Removal and installation of engine controller assembly..........................................................1375 Removal and installation of machine monitor assembly............................................................1377 Removal and installation of transmission controller assembly (Canopy specification).............................1378 Removal and installation of transmission controller assembly (Cab specification)................................1379 Removal and installation of KOMTRAX terminal assembly (Canopy specification)....................................1381 Removal and installation of KOMTRAX terminal assembly (Cab specification).......................................1382 60 Maintenance standard.................................................................................................1385 Contents............................................................................................................1386 Acronyms............................................................................................................1387 Engine and cooling system...........................................................................................1393 Engine mount and transmission mount.............................................................................1393 Cooling system..................................................................................................1394 Power train system..................................................................................................1396 Torque converter................................................................................................1396 Transmission....................................................................................................1398 Main relief valve and torque converter relief valve.............................................................1407 Front axle......................................................................................................1408 Rear axle.......................................................................................................1410 Differential (Non-differential specification)...................................................................1411 Differential (Differential lock specification)..................................................................1412 Final drive.....................................................................................................1414 Differential lock solenoid valve................................................................................1415 Tandem drive....................................................................................................1416 Steering system.....................................................................................................1417 Steering cylinder...............................................................................................1417 Brake system........................................................................................................1418 Wheel brake.....................................................................................................1418 Parking brake...................................................................................................1419 Undercarriage and frame.............................................................................................1420 Frame and center hinge pin......................................................................................1420 Hydraulic system....................................................................................................1421 Hydraulic tank..................................................................................................1421 Work equipment pump and steering pump...........................................................................1422 Power train pump................................................................................................1423 Power train pump and differential lock pump.....................................................................1424 Parking brake solenoid valve and lifter lock pin solenoid valve.................................................1425 Leaning cylinder................................................................................................1426 Articulate cylinder.............................................................................................1427 Blade lift cylinder.............................................................................................1428 Drawbar shift cylinder..........................................................................................1429 Blade side shift cylinder.......................................................................................1430 Power tilt cylinder.............................................................................................1431 Scarifier cylinder..............................................................................................1432 Work equipment......................................................................................................1433 Circle and drawbar..............................................................................................1433 Blade...........................................................................................................1435 Lifter..........................................................................................................1437 Circle rotation gear............................................................................................1438 80 Appendix.............................................................................................................1441 Contents............................................................................................................1442 Acronyms............................................................................................................1443 Air conditioner system..............................................................................................1448 Precautions for refrigerant.....................................................................................1448 Air conditioner component.......................................................................................1449 Specifications of air conditioner...............................................................................1452 Configuration and function of refrigeration cycle...............................................................1453 Outline of refrigeration cycle..................................................................................1454 Component parts of air conditioner system...........................................................................1456 Air conditioner unit............................................................................................1456 Component parts of air conditioner unit.........................................................................1459 Compressor......................................................................................................1461 Condenser.......................................................................................................1462 Receiver drier..................................................................................................1463 Explanation of procedure for testing and troubleshooting of air conditioner.....................................1464 Circuit diagram and arrangement of connector pins for air conditioner...........................................1466 Air conditioner system diagram..................................................................................1468 Input and output signals of air conditioner control panel.......................................................1469 Installation locations of air conditioner parts and arrangement of connectors...................................1472 Testing air leakage (duct)..........................................................................................1477 Method for testing air leakage (duct)...........................................................................1477 Testing air conditioner using self-diagnosis function...........................................................1479 Check temperature control function..................................................................................1480 Method for checking temperature control function................................................................1480 Testing fresh/recirc air changeover.................................................................................1481 Method for testing fresh/recirc air changeover..................................................................1481 Test evaporator temperature sensor..................................................................................1482 Method for checking evaporator temperature sensor...............................................................1482 Test relays.........................................................................................................1483 Method for testing relays.......................................................................................1483 Check blower AMP....................................................................................................1484 Method for checking blower AMP..................................................................................1484 Air conditioner troubleshooting chart 1.........................................................................1486 Air conditioner troubleshooting chart 2.........................................................................1488 Information described in troubleshooting table..................................................................1491 A-1 Troubleshooting for power supply system (air conditioner does not operate)..................................1492 A-2 Troubleshooting for compressor and refrigerant system (air is not cooled)...................................1494 A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal)..........................1497 A-4 Troubleshooting for temperature control function............................................................1500 A-5 Troubleshooting for fresh/recirc air changeover.............................................................1503 A-6 Troubleshooting for hot water cut valve.....................................................................1506 Troubleshooting using gauge pressure............................................................................1508 Connection of service tool..........................................................................................1510 Method for connecting service tool..............................................................................1511 Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings.........................1512 Handle compressor oil...........................................................................................1514 90 Diagrams and drawings................................................................................................1517 Contents............................................................................................................1518 Acronyms............................................................................................................1519 Hydraulic diagrams and drawings.....................................................................................1525 Symbols used in hydraulic circuit diagrams......................................................................1525 Hydraulic circuit diagram.......................................................................................1527 Power train hydraulic circuit diagram...........................................................................1531 Electrical diagrams and drawings....................................................................................1533 Symbols used in electric circuit diagrams.......................................................................1533 Chassis electric circuit diagram................................................................................1537 Floor electric circuit diagram (Canopy specification)...........................................................1547 Floor electric circuit diagram (Cab specification)..............................................................1559 Index...................................................................................................................1573
DESCRIPTION:
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06606-09 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition.
S.S 30/12/24
