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KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06650-07 – PDF DOWNLOAD
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KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06650-07 – PDF DOWNLOAD
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KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06650-07 – PDF DOWNLOAD
Language : English
Pages : 1578
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06650-07 – PDF DOWNLOAD
Cover................................................................................................................... 1 Notice of revision...................................................................................................... 3 00 Index and foreword................................................................................................... 11 Table of contents................................................................................................... 12 Acronyms............................................................................................................ 24 Foreword and general information.................................................................................... 29 Safety notice................................................................................................... 29 How to read the shop manual..................................................................................... 34 Explanation of terms for maintenance standard................................................................... 36 Handling of electric equipment and hydraulic components......................................................... 38 Handling of connectors newly used for engines................................................................... 47 How to read electric wire code.................................................................................. 50 Precautions when carrying out work.............................................................................. 53 Method of disassembling and connecting push-pull type coupler................................................... 56 Standard tightening torque table................................................................................ 59 Conversion table................................................................................................ 63 01 Specification........................................................................................................ 69 Contents............................................................................................................ 70 Acronyms............................................................................................................ 71 Specifications...................................................................................................... 76 Specification drawing........................................................................................... 76 Specifications.................................................................................................. 78 Weight table.................................................................................................... 84 Table of fuel, coolant, and lubricants.......................................................................... 85 10 Structure and function............................................................................................... 87 Contents............................................................................................................ 88 Acronyms............................................................................................................ 90 Engine and cooling system........................................................................................... 95 Cooling system.................................................................................................. 95 Cooling fan motor............................................................................................... 97 Power train system.................................................................................................. 105 Power train system drawing...................................................................................... 105 Power train piping drawing...................................................................................... 106 Transmission control............................................................................................ 107 Torque converter................................................................................................ 108 Transmission.................................................................................................... 111 Transmission control valve...................................................................................... 130 ECMV............................................................................................................ 132 Main relief valve and torque converter relief valve............................................................. 139 Front axle...................................................................................................... 141 Rear axle....................................................................................................... 144 Differential (Non-differential specification)................................................................... 145 Differential (Differential lock specification).................................................................. 147 Differential lock solenoid valve................................................................................ 150 Final drive..................................................................................................... 151 Tandem drive.................................................................................................... 153 Steering system..................................................................................................... 155 Steering piping drawing......................................................................................... 155 Priority valve.................................................................................................. 156 Steering valve.................................................................................................. 161 Brake system........................................................................................................ 168 Hydraulic piping drawing of brake system........................................................................ 168 Brake valve..................................................................................................... 169 Brake circuit accumulator....................................................................................... 174 Brake circuit accumulator charge valve.......................................................................... 175 Wheel brake..................................................................................................... 181 Parking brake solenoid valve and lifter lock pin solenoid valve................................................. 182 Parking brake................................................................................................... 183 Undercarriage and frame............................................................................................. 184 Frame........................................................................................................... 184 Tire............................................................................................................ 185 Hydraulic system.................................................................................................... 186 Hydraulic system................................................................................................ 186 Hydraulic piping drawing of work equipment...................................................................... 188 Work equipment control.......................................................................................... 190 Hydraulic tank.................................................................................................. 191 Work equipment pump and steering pump........................................................................... 192 Power train pump................................................................................................ 193 Power train pump and differential lock pump..................................................................... 194 Brake and cooling fan pump...................................................................................... 195 Control valve................................................................................................... 196 Functions and valve operations.................................................................................. 198 Hydraulic cylinder.............................................................................................. 199 Swivel joint.................................................................................................... 200 Pilot check valve............................................................................................... 201 Work equipment system............................................................................................... 210 Circle and drawbar.............................................................................................. 210 Blade........................................................................................................... 212 Lifter.......................................................................................................... 214 Circle rotation motor........................................................................................... 216 Circle rotation gear............................................................................................ 218 Ripper.......................................................................................................... 220 Cab and its attachments............................................................................................. 221 ROPS cab........................................................................................................ 221 Electrical system................................................................................................... 222 Layout drawing of electrical system............................................................................. 222 System operating lamp system.................................................................................... 224 Battery disconnect switch....................................................................................... 225 Machine monitor................................................................................................. 226 Automatic gear shift control system............................................................................. 237 Transmission controller......................................................................................... 242 Engine controller............................................................................................... 245 KOMTRAX system.................................................................................................. 248 KOMTRAX terminal................................................................................................ 249 Rearview monitor system......................................................................................... 251 Rearview monitor................................................................................................ 252 Rearview camera................................................................................................. 253 Engine starting circuit......................................................................................... 254 Engine stop circuit............................................................................................. 256 Preheating circuit.............................................................................................. 257 Sensors......................................................................................................... 258 Engine power mode selector circuit.............................................................................. 267 Cooling fan control system...................................................................................... 268 20 Standard value table................................................................................................. 271 Contents............................................................................................................ 272 Acronyms............................................................................................................ 273 Standard value table................................................................................................ 278 Standard value table for engine................................................................................. 278 Standard value table for machine................................................................................ 280 30 Testing and adjusting................................................................................................ 291 Contents............................................................................................................ 292 Acronyms............................................................................................................ 294 Tools for testing, adjusting, and troubleshooting................................................................... 299 Tools for testing, adjusting, and troubleshooting............................................................... 299 Engine and cooling system........................................................................................... 306 Testing engine speed............................................................................................ 306 Testing boost pressure.......................................................................................... 308 Testing exhaust gas temperature................................................................................. 310 Testing exhaust gas color....................................................................................... 312 Adjusting valve clearance....................................................................................... 314 Testing compression pressure.................................................................................... 316 Testing blowby pressure......................................................................................... 319 Testing engine oil pressure..................................................................................... 320 Handling fuel system devices.................................................................................... 321 Releasing remaining pressure from fuel system................................................................... 322 Testing fuel pressure........................................................................................... 323 Bleeding air from fuel circuit.................................................................................. 324 Testing fuel circuit for leakage................................................................................ 325 Handling cylinder cutout mode operation......................................................................... 326 Handling no-injection cranking operation........................................................................ 327 Handling voltage circuit of engine controller................................................................... 328 Testing muffler (main body) and stacked muffler for looseness and damage........................................ 329 Testing muffler function........................................................................................ 330 Testing installed condition of cylinder heads and manifolds..................................................... 331 Testing of engine piping for damage and looseness............................................................... 332 Testing fuel discharge, return rate, and leakage................................................................ 333 Testing and adjusting air conditioner compressor belt tension................................................... 337 Checking and replacing alternator belt.......................................................................... 339 Checking and replacing auto-tensioner........................................................................... 341 Power train......................................................................................................... 344 Testing power train oil pressure................................................................................ 344 Adjusting transmission speed sensor............................................................................. 358 Retrieval of disabled machine due to transmission valve failure................................................. 361 Flushing procedure for torque converter and transmission circuits............................................... 364 Testing and adjusting toe-in.................................................................................... 366 Adjusting bearing preload....................................................................................... 368 Testing and adjusting differential lock oil pressure (differential lock specification).......................... 370 Steering system..................................................................................................... 372 Testing and adjusting steering oil pressure..................................................................... 372 Testing oil leakage of steering cylinder........................................................................ 373 Bleeding air from steering circuit.............................................................................. 374 Brake system........................................................................................................ 375 Releasing remaining pressure from brake circuit................................................................. 375 Testing and adjusting brake oil pressure........................................................................ 376 Bleeding air from brake circuit................................................................................. 379 Testing wear of wheel brake disc................................................................................ 380 Testing and adjusting parking brake pad......................................................................... 381 Releasing parking brake manually................................................................................ 384 Charging brake accumulator with gas............................................................................. 385 Hydraulic system.................................................................................................... 387 Testing work equipment oil pressure............................................................................. 387 Testing lifter lock pin circuit pressure........................................................................ 389 Testing cooling fan speed....................................................................................... 391 Testing cooling fan circuit oil pressure........................................................................ 392 Testing oil leakage of work equipment cylinder.................................................................. 394 Bleeding air from work equipment circuit........................................................................ 397 Work equipment...................................................................................................... 398 Adjusting drawbar ball joint clearance.......................................................................... 398 Testing and adjusting circle guide clearance.................................................................... 399 Testing and adjusting slip clutch type circle drive............................................................. 401 Electrical system................................................................................................... 403 Procedure for testing diodes.................................................................................... 403 Special functions of machine monitor............................................................................ 405 Handling high-voltage circuit of engine controller.............................................................. 454 KOMTRAX terminal start-up procedure............................................................................. 455 Adjusting rearview camera angle................................................................................. 459 Handle battery disconnect switch................................................................................ 461 Preparatory work for troubleshooting of electrical system failure............................................... 462 Pm Clinic........................................................................................................... 464 Pm Clinic....................................................................................................... 464 40 Troubleshooting...................................................................................................... 475 Contents............................................................................................................ 476 Acronyms............................................................................................................ 482 Information related to troubleshooting.............................................................................. 487 Points to remember when troubleshooting......................................................................... 487 How to proceed in troubleshooting............................................................................... 488 Checks before troubleshooting................................................................................... 489 Inspection procedure before troubleshooting..................................................................... 491 Troubleshooting procedure....................................................................................... 506 Failure code list............................................................................................... 508 Symptoms and troubleshooting numbers............................................................................ 516 Information described in troubleshooting table.................................................................. 519 Diagnosis of open harness in pressure sensor system............................................................. 521 Connector list and layout....................................................................................... 523 Connector pin layout............................................................................................ 537 T-box and T-adapter list........................................................................................ 573 Locations of fuses.............................................................................................. 578 Troubleshooting by failure code (display of code)................................................................... 581 Failure code [1500L0] Double Engagement of T/M Clutches......................................................... 581 Failure code [15G0MW] Failure of R-Clutch System................................................................ 582 Failure code [15H0MW] Failure of Clutch System (FH)............................................................. 583 Failure code [15J0MW] Failure of Clutch System (FL)............................................................. 584 Failure code [15K0MW] Failure of Clutch System (1st)............................................................ 585 Failure code [15L0MW] Failure of Clutch System (2nd)............................................................ 586 Failure code [15M0MW] Failure of Clutch System (3rd)............................................................ 587 Failure code [15N0MW] Failure of Clutch System (4th)............................................................ 588 Failure code [15SBL1] Release Trouble of ECMV (R)............................................................... 589 Failure code [15SBMA] Malfunction of ECMV (R)................................................................... 591 Failure code [15SCL1] Release Trouble of ECMV (FH).............................................................. 593 Failure code [15SCMA] Malfunction of ECMV (FH).................................................................. 595 Failure code [15SDL1] Release Trouble of ECMV (FL).............................................................. 597 Failure code [15SDMA] Malfunction of ECMV (FL).................................................................. 599 Failure code [15SEL1] Release Trouble of ECMV (1st)............................................................. 601 Failure code [15SEMA] Malfunction of ECMV (1st)................................................................. 603 Failure code [15SFL1] Release Trouble of ECMV (2nd)............................................................. 605 Failure code [15SFMA] Malfunction of ECMV (2nd)................................................................. 607 Failure code [15SGL1] Release Trouble of ECMV (3rd)............................................................. 609 Failure code [15SGMA] Malfunction of ECMV (3rd)................................................................. 611 Failure code [15SHL1] Release Trouble of ECMV (4th)............................................................. 613 Failure code [15SHMA] Malfunction of ECMV (4th)................................................................. 615 Failure code [15SJMA] Malfunction of ECMV (L/U)................................................................. 617 Failure code [15U0NT] Overload of Inching Clutch................................................................ 618 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)...................................................... 619 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)....................................................... 621 Failure code [989L00] Engine Controller Lock Caution 1.......................................................... 623 Failure code [989M00] Engine Controller Lock Caution 2.......................................................... 624 Failure code [989N00] Engine Controller Lock Caution 3.......................................................... 625 Failure code [AB00KE] Charge Voltage Low........................................................................ 626 Failure code [AB00KY] Hot Short of Alternator R Terminal........................................................ 627 Failure code [B@BAZG] Derating in speed due to engine oil pressure drop......................................... 628 Failure code [B@BCNS] Engine Overheat........................................................................... 629 Failure code [B@CENS] T/C Oil Temp. Overheat.................................................................... 630 Failure code [B@CKNS] DIFF Oil Temp. Overheat................................................................... 631 Failure code [B@HANS] HYD Oil Temp. Overheat.................................................................... 633 Failure code [CA111] Engine NE, controller internal error....................................................... 635 Failure code [CA115] Engine NE, Bkup speed sensor error......................................................... 636 Failure code [CA122] Charge pressure sensor high error.......................................................... 637 Failure code [CA123] Charge pressure sensor low error........................................................... 639 Failure code [CA131] Throttle sensor high error................................................................. 641 Failure code [CA132] Throttle sensor low error.................................................................. 643 Failure code [CA144] Coolant sensor high error.................................................................. 646 Failure code [CA145] Coolant sensor low error................................................................... 648 Failure code [CA153] Charge temperature sensor high error....................................................... 650 Failure code [CA154] Charge temperature sensor low error........................................................ 652 Failure code [CA155] Speed derating error by high charge temperature............................................ 654 Failure code [CA187] Sensor power supply 2 low error............................................................ 655 Failure code [CA221] Atmospheric pressure sensor high error..................................................... 657 Failure code [CA222] Atmospheric pressure sensor low error...................................................... 659 Failure code [CA227] Sensor power supply 2 high error........................................................... 661 Failure code [CA234] Engine overspeed........................................................................... 662 Failure code [CA238] Ne speed sensor power supply error......................................................... 663 Failure code [CA271] IMV short-circuit error.................................................................... 664 Failure code [CA272] IMV open circuit........................................................................... 666 Failure code [CA322] Injector #1 (L/B #1) open/short............................................................ 668 Failure code [CA323] Injector #5 (L/B #5) open/short............................................................ 670 Failure code [CA324] Injector #3 (L/B #3) open/short............................................................ 672 Failure code [CA325] Injector #6 (L/B #6) open/short............................................................ 674 Failure code [CA331] Injector #2 (L/B #2) open/short............................................................ 676 Failure code [CA332] Injector #4 (L/B #4) open/short............................................................ 678 Failure code [CA342] Data compatibility error in engine controller.............................................. 680 Failure code [CA351] Injector drive circuit error............................................................... 681 Failure code [CA352] Sensor power supply 1 low error............................................................ 682 Failure code [CA386] Sensor power supply 1 high error........................................................... 684 Failure code [CA428] Water-in-fuel sensor high error............................................................ 685 Failure code [CA429] Water-in-fuel sensor low error............................................................. 687 Failure code [CA431] Idle validation switch error............................................................... 689 Failure code [CA432] Idle validation action error............................................................... 693 Failure code [CA435] Engine oil pressure switch error........................................................... 696 Failure code [CA441] Power supply voltage low error............................................................. 697 Failure code [CA442] Power supply voltage high error............................................................ 699 Failure code [CA449] Common rail pressure high error 2.......................................................... 700 Failure code [CA451] Common rail pressure sensor high error..................................................... 701 Failure code [CA452] Common rail pressure sensor low error...................................................... 703 Failure code [CA488] Torque derating error by high charge temperature........................................... 705 Failure code [CA553] Common rail pressure high error 1.......................................................... 706 Failure code [CA559] Supply pump pressure low error 1........................................................... 707 Failure code [CA689] Engine Ne speed sensor error............................................................... 709 Failure code [CA731] Engine Bkup speed sensor phase error....................................................... 711 Failure code [CA757] All continuous data lost error............................................................. 713 Failure code [CA778] Engine Bkup speed sensor error............................................................. 714 Failure code [CA1633] KOMNET (CAN communication) error.......................................................... 718 Failure code [CA2185] Throttle sensor power supply high error................................................... 722 Failure code [CA2186] Throttle sensor power supply low error.................................................... 724 Failure code [CA2249] Supply pump pressure low error 2.......................................................... 726 Failure code [CA2311] Abnormality in IMV (IMA) solenoid......................................................... 727 Failure code [CA2555] Intake heater relay open circuit.......................................................... 728 Failure code [CA2556] Intake heater relay short circuit......................................................... 730 Failure code [D160KA] Disconnection of Backup Light Relay....................................................... 732 Failure code [D160KB] Ground Fault of Backup Light Relay........................................................ 734 Failure code [D160KY] Hot Short of Back Lamp Relay Output....................................................... 736 Failure code [D19JKZ] Personal Code Relay Abnormality........................................................... 738 Failure code [D19KKZ] Failure of Diff Control Relay............................................................. 740 Failure code [D1EHKA] Disconnection of Engine Start Relay....................................................... 742 Failure code [D1EHKB] Ground Fault of Engine Start Relay........................................................ 743 Failure code [D1EHKY] Hot Short of Engine Start Relay........................................................... 744 Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay................................................... 745 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2................................................................... 747 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)..................................................................... 748 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON).................................................. 750 Failure code [DAF0MB] Monitor ROM Abnormality................................................................... 751 Failure code [DAF0MC] Monitor Error............................................................................. 752 Failure code [DAF3KK] Controller Power Source Low (MON)......................................................... 753 Failure code [DAFLKA] Op Lamp Open Cir (Mon).................................................................... 755 Failure code [DAFLKB] Op Lamp Shrt Cir (Mon).................................................................... 757 Failure code [DAQ0KK] Controller Power Source Low (T/M)......................................................... 759 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M).................................................. 761 Failure code [DAQ0MC] T/M Con Error............................................................................. 762 Failure code [DAQ1KA] Disconnection of Key SW ACC............................................................... 763 Failure code [DAQ2KK] Solenoid Power Source Low (T/M)........................................................... 765 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M).................................................... 767 Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont)............................................................... 768 Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont)............................................................... 770 Failure code [DAQQKR] CAN2 Discon (Transmission Con)............................................................ 772 Failure code [DAQRMA] Inconsistency of Option Selection (T/M)................................................... 773 Failure code [DB2QKR] CAN2 Discon (Engine Con).................................................................. 774 Failure code [DD1PKB] Abnormality of RPM Switch................................................................. 778 Failure code [DD1QKB] Abnormality of RPM Set Mode Switch........................................................ 780 Failure code [DDB6L4] Parking brake signal error................................................................ 782 Failure code [DDTHKA] Disconnection of Fill Switch (FH)......................................................... 784 Failure code [DDTJKA] Disconnection of Fill Switch (FL)......................................................... 785 Failure code [DDTKKA] Disconnection of Fill Switch (1st)........................................................ 786 Failure code [DDTLKA] Disconnection of Fill Switch (2nd)........................................................ 787 Failure code [DDTMKA] Disconnection of Fill Switch (3rd)........................................................ 788 Failure code [DDTNKA] Disconnection of Fill Switch (R).......................................................... 789 Failure code [DDTPKA] Disconnection of Fill Switch (4th)........................................................ 790 Failure code [DF10KA] Disconnection of Shift Lever Input........................................................ 791 Failure code [DF10L4] Gear Speed/Travel Direction Signal Error.................................................. 795 Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor...................................................... 798 Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S..................................................... 800 Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor...................................................... 802 Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C)...................................................... 804 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor................................................. 805 Failure code [DHT5L6] Failure of T/C Oil Press Sensor........................................................... 807 Failure code [DJF1KA] Disconnection of Fuel Level Sensor........................................................ 809 Failure code [DK70KX] Out of Range of Inching Potentio.......................................................... 811 Failure code [DKD0KX] Out of Range of Articulated Angle Sensor.................................................. 813 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor................................................... 815 Failure code [DLF1LC] Failure of T/M Input Speed Sensor......................................................... 817 Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor.................................................. 819 Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor.................................................. 821 Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir.............................................................. 823 Failure code [DLM3LC] Rad Fan Spd Sen Sig Error................................................................. 825 Failure code [DLM3MB] Rad Fan Spd Sen Error..................................................................... 826 Failure code [DLT3KA] Disconnection of T/M output Speed Sensor.................................................. 827 Failure code [DW4BKA] Disconnection of Parking Brake Valve...................................................... 829 Failure code [DW4BKB] Ground Fault of Parking Brake Valve....................................................... 831 Failure code [DW4BKY] Hot Short of Parking Brake Solenoid....................................................... 833 Failure code [DW7BKA] Rad Fan R Sol Opn Cir..................................................................... 835 Failure code [DW7BKB] Rad Fan R Sol Gnd Flt..................................................................... 837 Failure code [DW7BKY] Rad Fan R Sol Shrt Cir.................................................................... 839 Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir.............................................................. 841 Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt.............................................................. 843 Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir.............................................................. 845 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)................................................... 847 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup).................................................... 849 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)....................................................... 851 Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)..................................................... 853 Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)...................................................... 855 Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)......................................................... 857 Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)...................................................... 859 Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)....................................................... 861 Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low).......................................................... 863 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)...................................................... 865 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)....................................................... 867 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st).......................................................... 869 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)...................................................... 871 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)....................................................... 873 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).......................................................... 875 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)...................................................... 877 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)....................................................... 879 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd).......................................................... 881 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................................. 883 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)................................................... 885 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)...................................................... 887 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)...................................................... 889 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)....................................................... 891 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th).......................................................... 893 Troubleshooting of electrical system (E-mode)....................................................................... 895 E-1 Engine does not start (Starting motor does not rotate)...................................................... 895 E-2 Manual preheating system does not work...................................................................... 899 E-3 When starting switch is turned ON, machine monitor displays nothing......................................... 905 E-4 LCD panel backlight of machine monitor fails (goes out or flickers)......................................... 908 E-5 LCD display failure of machine monitor...................................................................... 909 E-6 The switch of machine monitor switch panel does not work.................................................... 910 E-7 Two-switch operation of switch panel on machine monitor does not function................................... 911 E-8 Machine monitor buzzer does not sound....................................................................... 912 E-9 Some gauges or caution lamps of machine monitor do not work normally........................................ 913 E-10 Rearview monitor does not light up or backlight flickers................................................... 914 E-11 Rearview monitor images are not displayed clearly.......................................................... 916 E-12 Rearview monitor brightness cannot be adjusted............................................................. 918 E-13 Night lighting lamp of rearview monitor is abnormal........................................................ 921 E-14 Speedometer or engine speed display is abnormal............................................................ 923 E-15 Engine coolant temperature is displayed abnormally......................................................... 924 E-16 Articulated meter display is abnormal...................................................................... 926 E-17 Torque converter oil temperature is displayed abnormally................................................... 928 E-18 Fuel gauge is displayed abnormally......................................................................... 930 E-19 Centralized warning lamps do not light or do not go out.................................................... 932 E-20 Alarm buzzer does not sound or does not stop sounding...................................................... 933 E-21 Transmission mode cannot be switched....................................................................... 935 E-22 Engine mode cannot be switched............................................................................. 937 E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model)..... 939 E-24 Cannot be locked or canceled by the lifter lock pin........................................................ 941 E-25 Horn does not sound or does not stop sounding.............................................................. 943 E-26 Backup alarm does not sound or does not stop sounding...................................................... 945 E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out....................................... 948 E-28 Working lamps do not light up or go out.................................................................... 956 E-29 Turn indicator light or emergency flashing light does not flash............................................ 961 E-30 Stop lamp does not light up or does not go out............................................................. 970 E-31 Backup lamp does not light up or does not go out........................................................... 972 E-32 All wipers do not operate.................................................................................. 974 E-33 Front wiper does not operate............................................................................... 976 E-34 Rear wiper does not operate................................................................................ 980 E-35 Left and right door wiper does not operate................................................................. 983 E-36 Left door wiper does not operate........................................................................... 986 E-37 Right door wiper does not operate.......................................................................... 988 E-38 Front or door washer does not operate...................................................................... 990 E-39 Rear washer does not operate............................................................................... 992 E-40 KOMTRAX system does not operate normally................................................................... 994 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................... 996 How to use troubleshooting table................................................................................ 996 H-1 Engine speed drops significantly or engine stalls...........................................................1002 H-2 Machine does not move off...................................................................................1003 H-3 Gear speed does not shift...................................................................................1004 H-4 Travel speed or power is low................................................................................1005 H-5 Torque converter lockup does not operate or is not canceled.................................................1008 H-6 Machine starts or gear speed shifts with long time lag......................................................1009 H-7 Torque converter oil temperature is high....................................................................1012 H-8 Differential gear lock function does not operate or is not canceled.........................................1015 H-9 Steering speed or power is insufficient.....................................................................1016 H-10 Steering wheel does not move...............................................................................1017 H-11 Wheel brakes do not work or are weak.......................................................................1018 H-12 Wheel brakes are not released or drag......................................................................1019 H-13 Parking brake does not work or it is weak..................................................................1020 H-14 Parking brake (including emergency release system) is not released or drags................................1021 H-15 All work equipment operates slowly or lacks power..........................................................1022 H-16 Work equipment does not operate............................................................................1023 H-17 Unusual noise is heard from around hydraulic pump..........................................................1024 H-18 Blade lift speed or power is low...........................................................................1025 H-19 Hydraulic drift of lifted blade is large...................................................................1026 H-20 Drawbar side shift speed or power is low...................................................................1027 H-21 Blade side shift speed or power is low.....................................................................1028 H-22 Power tilt speed or power is low...........................................................................1029 H-23 Articulate speed or power is low...........................................................................1030 H-24 Leaning speed or power is insufficient.....................................................................1031 H-25 Hydraulic drift (tilting) of leaning is large..............................................................1032 H-26 Blade does not rotate......................................................................................1033 H-27 Lifter lock pin is not locked or is not canceled...........................................................1034 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)...................1035 Troubleshooting of engine (S-mode)..................................................................................1037 How to read matrix..............................................................................................1037 S-1 Engine startability is poor.................................................................................1040 S-2 Engine does not start.......................................................................................1041 S-3 Engine does not pick-up smoothly............................................................................1044 S-4 Engine stops during operation...............................................................................1045 S-5 Engine runs rough or is unstable............................................................................1046 S-6 Engine lacks power..........................................................................................1047 S-7 Exhaust smoke is black (Incomplete combustion)..............................................................1048 S-8 Large oil consumption (or blue exhaust gas).................................................................1049 S-9 Oil becomes contaminated early..............................................................................1050 S-10 Fuel consumption is excessive..............................................................................1051 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................1052 S-12 Oil pressure drops.........................................................................................1053 S-13 Oil amount increases (due to water or fuel mixing).........................................................1054 S-14 Coolant temperature rises too high (overheating)...........................................................1055 S-15 Unusual noise is heard.....................................................................................1056 S-16 Vibration is excessive.....................................................................................1057 Contents........................................................................................................1060 Acronyms........................................................................................................1062 50 Disassembly and assembly.............................................................................................1059 Contents............................................................................................................1060 Acronyms............................................................................................................1062 Related information on disassembly and assembly.....................................................................1067 How to read this manual.........................................................................................1067 Coating materials list..........................................................................................1069 Special tool list...............................................................................................1073 Sketches of special tools.......................................................................................1083 Engine and cooling system...........................................................................................1129 Removal and installation of supply pump assembly................................................................1129 Removal and installation of injector assembly...................................................................1133 Removal and installation of cylinder head assembly..............................................................1142 Removal and installation of air conditioner compressor belt.....................................................1160 Removal and installation of alternator belt.....................................................................1161 Removal and installation of engine front oil seal...............................................................1163 Removal and installation of engine rear oil seal................................................................1166 Removal and installation of cooling fan pump assembly...........................................................1169 Removal and installation of cooling fan and fan motor assembly..................................................1171 Removal and installation of radiator assembly...................................................................1175 Removal and installation of aftercooler assembly................................................................1179 Removal and installation of power train oil cooler assembly.....................................................1183 Removal and installation of fuel tank assembly..................................................................1186 Removal and installation of engine hood assembly................................................................1190 Removal and installation of air conditioner compressor assembly.................................................1192 Power train.........................................................................................................1194 Removal and installation of engine, transmission, and torque converter assembly.................................1194 Disconnection and connection of engine, transmission, and torque converter assembly.............................1202 Disassembly and assembly of torque converter assembly...........................................................1204 Disassembly and assembly of transmission assembly...............................................................1217 Removal and installation of tandem drive and final drive assembly...............................................1256 Disassembly and assembly of tandem drive assembly...............................................................1259 Disassembly and assembly of differential assembly...............................................................1267 Disassembly and assembly of final drive assembly................................................................1282 Steering system.....................................................................................................1291 Removal and installation of Orbitrol valve assembly.............................................................1291 Brake system........................................................................................................1296 Disassembly and assembly of wheel brake assembly................................................................1296 Undercarriage and frame.............................................................................................1304 Removal and installation of center hinge pin....................................................................1304 Hydraulic system....................................................................................................1315 Removal and installation of hydraulic tank, battery, and frame assembly.........................................1315 Removal and installation of hydraulic tank assembly.............................................................1322 Removal and installation of control valve assembly..............................................................1326 Disassembly and assembly of hydraulic cylinder assembly.........................................................1331 Work equipment......................................................................................................1335 Removal and installation of blade assembly......................................................................1335 Removal and installation of circle drawbar assembly.............................................................1336 Removal and installation of circle rotation gear assembly.......................................................1338 Disassembly and assembly of circle rotation gear assembly.......................................................1340 Cab and its attachments.............................................................................................1345 Removal and installation of operator's cab assembly.............................................................1345 Removal and installation of operator cab glass (adhered glass)..................................................1354 Removal and installation of floor frame assembly................................................................1364 Removal and installation of operator's cab and floor frame assembly.............................................1368 Removal and installation of air conditioner unit assembly.......................................................1375 Removal and installation operator's seat........................................................................1381 Removal and installation seat belt..............................................................................1382 Electrical system...................................................................................................1384 Removal and installation of engine controller assembly..........................................................1384 Removal and installation of machine monitor assembly............................................................1386 Removal and installation of transmission controller assembly....................................................1387 Removal and installation of rearview camera.....................................................................1389 Removal and installation of KOMTRAX terminal assembly...........................................................1391 60 Maintenance standard.................................................................................................1393 Contents............................................................................................................1394 Acronyms............................................................................................................1395 Engine and cooling system...........................................................................................1400 Engine mount and transmission mount.............................................................................1400 Cooling system..................................................................................................1401 Cooling fan motor...............................................................................................1402 Power train system..................................................................................................1404 Torque converter................................................................................................1404 Transmission....................................................................................................1406 Main relief valve and torque converter relief valve.............................................................1415 Front axle......................................................................................................1416 Rear axle.......................................................................................................1418 Differential (Non-differential specification)...................................................................1419 Differential (Differential lock specification)..................................................................1420 Final drive.....................................................................................................1422 Differential lock solenoid valve................................................................................1423 Tandem drive....................................................................................................1424 Steering system.....................................................................................................1425 Steering cylinder...............................................................................................1425 Brake system........................................................................................................1426 Wheel brake.....................................................................................................1426 Parking brake...................................................................................................1427 Undercarriage and frame.............................................................................................1428 Frame and center hinge pin......................................................................................1428 Hydraulic system....................................................................................................1429 Hydraulic tank..................................................................................................1429 Work equipment pump and steering pump...........................................................................1430 Power train pump................................................................................................1431 Power train pump and differential lock pump.....................................................................1432 Parking brake solenoid valve and lifter lock pin solenoid valve.................................................1433 Leaning cylinder................................................................................................1434 Articulate cylinder.............................................................................................1435 Blade lift cylinder.............................................................................................1436 Drawbar shift cylinder..........................................................................................1437 Blade side shift cylinder.......................................................................................1438 Power tilt cylinder.............................................................................................1439 Scarifier cylinder..............................................................................................1440 Ripper cylinder.................................................................................................1441 Work equipment......................................................................................................1442 Circle and drawbar..............................................................................................1442 Blade...........................................................................................................1444 Lifter..........................................................................................................1446 Circle rotation gear............................................................................................1447 Ripper..........................................................................................................1449 80 Appendix.............................................................................................................1451 Contents............................................................................................................1452 Acronyms............................................................................................................1453 Air conditioner system..............................................................................................1458 Precautions for refrigerant.....................................................................................1458 Air conditioner component.......................................................................................1459 Specifications of air conditioner...............................................................................1462 Configuration and function of refrigeration cycle...............................................................1463 Outline of refrigeration cycle..................................................................................1464 Component parts of air conditioner system...........................................................................1466 Air conditioner unit............................................................................................1466 Component parts of air conditioner unit.........................................................................1469 Compressor......................................................................................................1471 Condenser.......................................................................................................1472 Receiver drier..................................................................................................1473 Explanation of procedure for testing and troubleshooting of air conditioner.....................................1474 Circuit diagram and arrangement of connector pins for air conditioner...........................................1476 Air conditioner system diagram..................................................................................1478 Input and output signals of air conditioner control panel.......................................................1479 Installation locations of air conditioner parts and arrangement of connectors...................................1482 Testing air leakage (duct)..........................................................................................1487 Method for testing air leakage (duct)...........................................................................1487 Testing air conditioner using self-diagnosis function...........................................................1489 Check temperature control function..................................................................................1490 Method for checking temperature control function................................................................1490 Testing fresh/recirc air changeover.................................................................................1491 Method for testing fresh/recirc air changeover..................................................................1491 Test evaporator temperature sensor..................................................................................1492 Method for checking evaporator temperature sensor...............................................................1492 Test relays.........................................................................................................1493 Method for testing relays.......................................................................................1493 Check blower AMP....................................................................................................1494 Method for checking blower AMP..................................................................................1494 Air conditioner troubleshooting chart 1.........................................................................1496 Air conditioner troubleshooting chart 2.........................................................................1498 Information described in troubleshooting table..................................................................1501 A-1 Troubleshooting for power supply system (air conditioner does not operate)..................................1502 A-2 Troubleshooting for compressor and refrigerant system (air is not cooled)...................................1504 A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal)..........................1507 A-4 Troubleshooting for temperature control function............................................................1510 A-5 Troubleshooting for fresh/recirc air changeover.............................................................1513 A-6 Troubleshooting for hot water cut valve.....................................................................1516 Troubleshooting using gauge pressure............................................................................1518 Connection of service tool..........................................................................................1520 Method for connecting service tool..............................................................................1521 Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings.........................1522 Handle compressor oil...........................................................................................1524 90 Diagrams and drawings................................................................................................1527 Contents............................................................................................................1528 Acronyms............................................................................................................1529 Hydraulic diagrams and drawings.....................................................................................1534 Symbols used in hydraulic circuit diagrams......................................................................1534 Hydraulic circuit diagram.......................................................................................1537 Power train hydraulic circuit diagram...........................................................................1541 Electrical diagrams and drawings....................................................................................1543 Symbols used in electric circuit diagrams.......................................................................1543 Chassis electric circuit diagram................................................................................1547 Floor electric circuit diagram..................................................................................1557 Index...................................................................................................................1571
DESCRIPTION:
KOMATSU GD535-5 MOTOR GRADER SHOP MANUAL SEN06650-07 – 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.
Take rests in specified safe places.
S.S 30/12/24
