Komatsu GD535-6 Motor Grader Shop Manual SEN06943-02 PDF

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Komatsu GD535-6 Motor Grader Shop Manual SEN06943-02 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GD535-6 Motor Grader Shop Manual SEN06943-02 – PDF DOWNLOAD 

Language : English
Pages : 2374
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu GD535-6 Motor Grader Shop Manual SEN06943-02 – PDF DOWNLOAD 

SERIAL NUMBERS 3002 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword, safety, basic information 23
How to read the shop manual 23
Safety notice for operation 25
Precautions to prevent fire 31
Actions if fire occurs 32
Precautions for removal of dangerous materials 32
Steps necessary to meet exhaust gas regulations 33
Precautions for handling hydraulic equipment 36
Precautions for disconnection and connection of pipings 38
Precautions for handling electrical equipment 45
Precautions for handling fuel system equipment 47
Precautions for handling intake system equipment 48
Practical use of KOMTRAX 49
Disconnect and connect push-pull type coupler 50
Precautions for disconnection and connection of connectors 54
Method for disconnecting and connecting Deutsch connector 58
Method for disconnecting and connecting slide lock type connector 59
Method for disconnecting and connecting connector with lock to pull 60
Method for disconnecting and connecting connector with lock to push 61
Method for disconnecting and connecting connector with housing to rotate 63
How to read electrical wire code 64
Explanation of terms for maintenance standard 68
Standard tightening torque table 70
Conversion table 77
Abbreviation list 82
01 Specification 85
Contents 86
Specifications 87
Specification drawing 87
Specifications 89
Weight table 95
Fuel, coolant, and lubricant 96
10 Structure and function 99
Contents 100
Urea SCR system 103
Layout drawing of Urea SCR system 103
Urea SCR system diagram 105
Function of Urea SCR system 106
Component parts of Urea SCR system 115
Boot-up system 123
Layout drawing of boot-up system 123
System operating lamp system 125
Battery disconnect switch 126
Preheating system 127
Engine shutdown secondary switch 129
Engine system 130
Layout drawing of engine system 130
Engine control system 132
Engine power mode selector system 135
Component parts of engine system 136
Cooling system 146
Layout drawing of cooling system 146
Cooling fan control system 148
Component parts of cooling system 151
Power train system 159
Power train system drawing 159
Power train piping drawing 160
Transmission control 161
Component parts of power train system 162
Steering system 205
Steering piping drawing 205
Component parts of steering system 206
Brake system 220
Hydraulic piping drawing of brake system 220
Component parts of brake system 221
Undercarriage and frame 236
Frame 236
Tire 237
Hydraulic system 238
Hydraulic system 238
Hydraulic piping drawing of work equipment 240
Work equipment control 242
Component parts of hydraulic system 243
Work equipment system 260
Circle and drawbar 260
Blade 262
Lifter 264
Circle rotation motor 266
Circle rotation gear 268
Cab and its attachments 270
ROPS canopy 270
Electrical system 271
Automatic gear shift control system 271
KOMTRAX system 276
Component parts of electrical system 277
20 Standard value table 309
Contents 310
Standard value table 311
Standard value table for engine 311
Standard value table for machine 314
30 Testing and adjusting 325
Contents 326
Tools for testing, adjusting, and troubleshooting 329
Tools for testing, adjusting, and troubleshooting 329
Engine and cooling system 338
Testing engine speed 338
Testing boost pressure 340
Testing exhaust gas color 342
Testing and adjusting valve clearance 345
Testing compression pressure 347
Testing blowby pressure 351
Testing engine oil pressure 353
Handling fuel system devices 354
Releasing remaining pressure from fuel system 355
Testing fuel pressure 356
Bleeding air from fuel system 360
Testing fuel circuit for leakage 361
Handling cylinder cutout mode operation 362
Handling no-injection cranking operation 363
Handling voltage circuit of engine controller 364
Testing KDPF, SCR and muffler stack for looseness and damage 365
Testing installed condition of cylinder heads and manifolds 366
Testing engine piping for damage and looseness 367
Testing fuel discharge, return and leakage 368
Testing alternator belt 373
Testing automatic tensioner 374
Writing ash in soot accumulation correction to engine controller 376
Testing SCR related functions 377
Cleaning DEF tank 404
Cleaning DEF pump 408
Power train 413
Testing power train oil pressure 413
Adjusting transmission speed sensor 430
Retrieval of disabled machine due to transmission valve failure 433
Flushing for torque converter and transmission circuits 436
Testing and adjusting toe-in 438
Adjusting bearing preload 440
Steering system 441
Testing and adjusting steering oil pressure 441
Testing oil leakage of steering cylinder 442
Bleeding air from steering circuit 443
Brake system 444
Releasing remaining pressure from brake circuit 444
Testing and adjusting brake oil pressure 445
Bleeding air from brake circuit 448
Testing wear of wheel brake disc 449
Testing and adjusting parking brake pad 450
Releasing parking brake manually 453
Charging brake accumulator with gas 454
Hydraulic system 456
Testing work equipment oil pressure 456
Testing lifter lock pin circuit pressure 458
Testing cooling fan speed 460
Testing cooling fan circuit oil pressure 461
Testing oil leakage of work equipment cylinder 463
Bleeding air from work equipment circuit 466
Work equipment 467
Adjusting drawbar ball joint clearance 467
Testing and adjusting circle guide clearance 468
Testing and adjusting slip clutch type circle drive 470
Electrical system 472
Setting and adjusting various equipment 472
Special functions of machine monitor 473
Handling high-voltage circuit of engine controller 532
KOMTRAX terminal start-up procedure 533
Handling battery disconnect switch 537
Testing diodes 538
Preparatory work for troubleshooting of electrical system failure 539
Pm Clinic 541
Pm Clinic 541
40 Troubleshooting 551
Contents 552
Information related to troubleshooting 562
Points to remember when troubleshooting 562
Troubleshooting points for Urea SCR system 563
How to proceed in troubleshooting 574
Checks before troubleshooting 575
Inspection procedure before troubleshooting 577
Troubleshooting procedure 594
Symptom and troubleshooting numbers 596
Information described in troubleshooting table 599
Diagnosis of open harness in pressure sensor system 601
Connector list and layout 603
Connector pin layout 618
T-box and T-adapter list 665
Locations of fuses 671
Precautions for cleaning and replacing KDPF (KCSF and KDOC) 674
Precaution of short circuit electrical connector (for failure code [CA1883] and [CA3135]) 678
Failure code list 680
Troubleshooting by failure code (display of code) 697
Failure code [1500L0] 697
Failure code [15G0MW] 698
Failure code [15H0MW] 699
Failure code [15J0MW] 700
Failure code [15K0MW] 701
Failure code [15L0MW] 702
Failure code [15M0MW] 703
Failure code [15N0MW] 704
Failure code [15SBL1] 705
Failure code [15SBMA] 707
Failure code [15SCL1] 709
Failure code [15SCMA] 711
Failure code [15SDL1] 713
Failure code [15SDMA] 715
Failure code [15SEL1] 717
Failure code [15SEMA] 719
Failure code [15SFL1] 721
Failure code [15SFMA] 723
Failure code [15SGL1] 725
Failure code [15SGMA] 727
Failure code [15SHL1] 729
Failure code [15SHMA] 731
Failure code [15SJMA] 733
Failure code [15U0NT] 734
Failure code [2G42ZG] 735
Failure code [2G43ZG] 737
Failure code [989L00] 739
Failure code [989M00] 740
Failure code [989N00] 741
Failure code [A1U0N3] 742
Failure code [A1U0N4] 744
Failure code [AB00KE] 746
Failure code [AB00KY] 747
Failure code [AQ10MB] 748
Failure code [AS00R2] 750
Failure code [AS00R3] 751
Failure code [AS00R4] 752
Failure code [AS00R5] 753
Failure code [AS00R6] 754
Failure code [AS00ZK] 755
Failure code [AS10KM] 756
Failure code [AS10NR] 757
Failure code [AS10NT] 758
Failure code [B@BAZG] 759
Failure code [B@BCNS] 760
Failure code [B@BCQA] 761
Failure code [B@BCZK] 763
Failure code [B@CENS] 765
Failure code [B@HANS] 766
Failure code [CA115] 768
Failure code [CA122] 769
Failure code [CA123] 771
Failure code [CA131] 773
Failure code [CA132] 775
Failure code [CA144] 778
Failure code [CA145] 780
Failure code [CA153] 782
Failure code [CA154] 784
Failure code [CA187] 786
Failure code [CA227] 788
Failure code [CA234] 790
Failure code [CA238] 791
Failure code [CA239] 792
Failure code [CA249] 793
Failure code [CA256] 795
Failure code [CA271] 797
Failure code [CA272] 799
Failure code [CA322] 800
Failure code [CA324] 802
Failure code [CA331] 804
Failure code [CA332] 806
Failure code [CA351] 808
Failure code [CA352] 809
Failure code [CA386] 811
Failure code [CA428] 812
Failure code [CA429] 814
Failure code [CA431] 816
Failure code [CA432] 819
Failure code [CA435] 823
Failure code [CA441] 825
Failure code [CA442] 827
Failure code [CA451] 828
Failure code [CA452] 830
Failure code [CA488] 832
Failure code [CA515] 833
Failure code [CA516] 835
Failure code [CA553] 837
Failure code [CA555] 838
Failure code [CA556] 839
Failure code [CA559] 840
Failure code [CA689] 843
Failure code [CA691] 846
Failure code [CA692] 848
Failure code [CA697] 850
Failure code [CA698] 851
Failure code [CA731] 852
Failure code [CA741] 854
Failure code [CA742] 856
Failure code [CA743] 858
Failure code [CA778] 859
Failure code [CA1117] 864
Failure code [CA1664] 866
Failure code [CA1669] 869
Failure code [CA1673] 870
Failure code [CA1677] 871
Failure code [CA1678] 872
Failure code [CA1682] 873
Failure code [CA1683] 878
Failure code [CA1684] 880
Failure code [CA1686] 882
Failure code [CA1695] 883
Failure code [CA1696] 884
Failure code [CA1712] 887
Failure code [CA1713] 890
Failure code [CA1714] 893
Failure code [CA1715] 894
Failure code [CA1776] 895
Failure code [CA1777] 898
Failure code [CA1843] 901
Failure code [CA1844] 903
Failure code [CA1879] 906
Failure code [CA1881] 908
Failure code [CA1883] 910
Failure code [CA1885] 913
Failure code [CA1887] 915
Failure code [CA1921] 917
Failure code [CA1922] 920
Failure code [CA1942] 925
Failure code [CA1993] 926
Failure code [CA2185] 929
Failure code [CA2186] 931
Failure code [CA2311] 933
Failure code [CA2373] 934
Failure code [CA2374] 936
Failure code [CA2554] 938
Failure code [CA2555] 940
Failure code [CA2556] 942
Failure code [CA2639] 944
Failure code [CA2771] 946
Failure code [CA2973] 950
Failure code [CA2976] 951
Failure code [CA3133] 953
Failure code [CA3134] 955
Failure code [CA3135] 957
Failure code [CA3142] 961
Failure code [CA3143] 962
Failure code [CA3144] 963
Failure code [CA3146] 966
Failure code [CA3147] 967
Failure code [CA3148] 968
Failure code [CA3151] 971
Failure code [CA3165] 979
Failure code [CA3229] 981
Failure code [CA3231] 983
Failure code [CA3232] 985
Failure code [CA3235] 989
Failure code [CA3239] 991
Failure code [CA3241] 994
Failure code [CA3242] 997
Failure code [CA3251] 1000
Failure code [CA3253] 1002
Failure code [CA3254] 1005
Failure code [CA3255] 1007
Failure code [CA3256] 1011
Failure code [CA3311] 1013
Failure code [CA3312] 1015
Failure code [CA3313] 1018
Failure code [CA3314] 1019
Failure code [CA3315] 1020
Failure code [CA3316] 1023
Failure code [CA3317] 1024
Failure code [CA3318] 1025
Failure code [CA3319] 1028
Failure code [CA3321] 1029
Failure code [CA3322] 1031
Failure code [CA3497] 1034
Failure code [CA3498] 1035
Failure code [CA3545] 1036
Failure code [CA3547] 1038
Failure code [CA3558] 1039
Failure code [CA3559] 1041
Failure code [CA3562] 1043
Failure code [CA3563] 1045
Failure code [CA3567] 1048
Failure code [CA3568] 1052
Failure code [CA3571] 1058
Failure code [CA3572] 1060
Failure code [CA3574] 1062
Failure code [CA3575] 1065
Failure code [CA3577] 1067
Failure code [CA3578] 1069
Failure code [CA3583] 1071
Failure code [CA3596] 1073
Failure code [CA3649] 1077
Failure code [CA3681] 1079
Failure code [CA3682] 1084
Failure code [CA3713] 1089
Failure code [CA3717] 1092
Failure code [CA3718] 1093
Failure code [CA3725] 1094
Failure code [CA3741] 1097
Failure code [CA3748] 1098
Failure code [CA3866] 1100
Failure code [CA3867] 1104
Failure code [CA3868] 1107
Failure code [CA4151] 1111
Failure code [CA4152] 1115
Failure code [CA4155] 1119
Failure code [CA4156] 1122
Failure code [CA4157] 1125
Failure code [CA4158] 1127
Failure code [CA4159] 1128
Failure code [CA4161] 1129
Failure code [CA4162] 1132
Failure code [CA4163] 1135
Failure code [CA4164] 1137
Failure code [CA4165] 1139
Failure code [CA4166] 1141
Failure code [CA4168] 1142
Failure code [CA4169] 1145
Failure code [CA4171] 1147
Failure code [CA4249] 1149
Failure code [CA4251] 1151
Failure code [CA4259] 1153
Failure code [CA4261] 1156
Failure code [CA4277] 1159
Failure code [CA4459] 1163
Failure code [CA4461] 1165
Failure code [CA4731] 1168
Failure code [CA4732] 1169
Failure code [CA4739] 1170
Failure code [CA4768] 1171
Failure code [CA4769] 1173
Failure code [CA4842] 1176
Failure code [CA4952] 1179
Failure code [CA5115] 1181
Failure code [CA5179] 1184
Failure code [CA5181] 1186
Failure code [CA5271] 1188
Failure code [CA5272] 1190
Failure code [CA5273] 1192
Failure code [CA5274] 1193
Failure code [CA5275] 1195
Failure code [CA5276] 1197
Failure code [CA5383] 1199
Failure code [CA5631] 1201
Failure code [CA5632] 1203
Failure code [CA5655] 1205
Failure code [CA5689] 1211
Failure code [CA5715] 1213
Failure code [CA5716] 1216
Failure code [CA5838] 1219
Failure code [CA5864] 1221
Failure code [CA5865] 1223
Failure code [CA5938] 1225
Failure code [CA6771] 1227
Failure code [D160KA] 1232
Failure code [D160KB] 1234
Failure code [D160KY] 1236
Failure code [D19JKZ] 1238
Failure code [D1EHKA] 1240
Failure code [D1EHKB] 1241
Failure code [D1EHKY] 1242
Failure code [D1FBKB] 1243
Failure code [D811MC] 1245
Failure code [D862KA] 1246
Failure code [D8ALKA] (Machine with gateway function controller) 1247
Failure code [D8ALKB] (Machine with gateway function controller) 1249
Failure code [D8AQK4] 1251
Failure code [D8AQKR] 1255
Failure code [D8G1KT] 1259
Failure code [D8G6KT] 1260
Failure code [DAF0KT] 1261
Failure code [DAF0MB] 1262
Failure code [DAF0MC] 1263
Failure code [DAF3KK] 1264
Failure code [DAFGMC] 1266
Failure code [DAFLKA] 1267
Failure code [DAFLKB] 1269
Failure code [DAFQKR] 1271
Failure code [DAQ0KK] 1277
Failure code [DAQ0KT] 1279
Failure code [DAQ0MC] 1280
Failure code [DAQ1KA] 1281
Failure code [DAQ2KK] 1283
Failure code [DAQ9KQ] 1286
Failure code [DAQLKA] 1287
Failure code [DAQLKB] 1289
Failure code [DAQQKR] 1291
Failure code [DAQRMA] 1299
Failure code [DB2QKR] 1300
Failure code [DB2RKR] 1309
Failure code [DD1PKB] 1318
Failure code [DD1QKB] 1320
Failure code [DDAAL6] 1322
Failure code [DDB6L4] 1324
Failure code [DDTHKA] 1327
Failure code [DDTJKA] 1328
Failure code [DDTKKA] 1329
Failure code [DDTLKA] 1330
Failure code [DDTMKA] 1331
Failure code [DDTNKA] 1332
Failure code [DDTPKA] 1333
Failure code [DF10KA] 1334
Failure code [DF10L4] 1338
Failure code [DGF1KX] 1341
Failure code [DGH2KB] 1343
Failure code [DGT1KX] 1345
Failure code [DHAAMA] 1347
Failure code [DHACMA] 1349
Failure code [DHT5KX] 1351
Failure code [DHT5L6] 1353
Failure code [DHT8KA] 1355
Failure code [DHT8KB] 1357
Failure code [DHT8ZG] 1359
Failure code [DJF1KA] 1360
Failure code [DK70KX] 1362
Failure code [DKD0KX] 1364
Failure code [DLF1KA] 1366
Failure code [DLF1LC] 1368
Failure code [DLF2KA] 1370
Failure code [DLF2LC] 1372
Failure code [DLM3KA] 1374
Failure code [DLM3LC] 1376
Failure code [DLM3MB] 1378
Failure code [DLT3KA] 1379
Failure code [DV00KB] 1381
Failure code [DW4BKA] 1383
Failure code [DW4BKB] 1385
Failure code [DW4BKY] 1387
Failure code [DW7BKA] 1389
Failure code [DW7BKB] 1391
Failure code [DW7BKY] 1393
Failure code [DX16KA] 1395
Failure code [DX16KB] 1397
Failure code [DX16KY] 1399
Failure code [DXH1KA] 1401
Failure code [DXH1KB] 1403
Failure code [DXH1KY] 1405
Failure code [DXH2KA] 1407
Failure code [DXH2KB] 1409
Failure code [DXH2KY] 1411
Failure code [DXH3KA] 1413
Failure code [DXH3KB] 1415
Failure code [DXH3KY] 1417
Failure code [DXH4KA] 1419
Failure code [DXH4KB] 1421
Failure code [DXH4KY] 1423
Failure code [DXH5KA] 1425
Failure code [DXH5KB] 1427
Failure code [DXH5KY] 1429
Failure code [DXH6KA] 1431
Failure code [DXH6KB] 1433
Failure code [DXH6KY] 1435
Failure code [DXH7KA] 1437
Failure code [DXH7KB] 1439
Failure code [DXH7KY] 1441
Failure code [DXHHKA] 1443
Failure code [DXHHKB] 1445
Failure code [DXHHKY] 1447
Failure code [F313KA] 1449
Failure code [F313KB] 1451
Failure code [F314KA] 1452
Failure code [F314KB] 1454
Failure code [F315KB] 1456
Failure code [F315KY] 1458
Failure code [F316KB] 1460
Failure code [F316KY] 1462
Failure code [F318KB] 1464
Failure code [F318KY] 1466
Failure code [F31AKB] 1467
Failure code [F31AKY] 1469
Failure code [F31BKB] 1471
Failure code [F31BKY] 1473
Failure code [F31CKB] 1475
Failure code [F31CKY] 1477
Failure code [F31DKB] 1479
Failure code [F31DKY] 1481
Failure code [F31EKB] 1483
Failure code [F31EKY] 1485
Failure code [FS10ZE] 1487
Troubleshooting of electrical system (E-mode) 1488
E-1 Engine does not start (Starting motor does not rotate) 1488
E-2 Manual preheating system does not work 1492
E-3 When starting switch is turned ON, machine monitor displays nothing 1498
E-4 LCD panel backlight of machine monitor fails (goes out or flickers) 1501
E-5 LCD display failure of machine monitor 1502
E-6 The switch of machine monitor switch panel does not work 1503
E-7 Two-switch operation of switch panel on machine monitor does not function 1504
E-8 Machine monitor buzzer does not sound 1505
E-9 Some gauges or caution lamps of machine monitor do not work normally 1506
E-10 DEF level is not displayed properly 1507
E-11 Radiator coolant level caution lamp does not light up 1510
E-12 Speedometer or engine speed display is abnormal 1512
E-13 Engine coolant temperature is displayed abnormally 1513
E-14 Articulated meter display is abnormal 1515
E-15 Torque converter oil temperature is displayed abnormally 1517
E-16 Fuel gauge is displayed abnormally 1519
E-17 Centralized warning lamps do not light or do not go out 1521
E-18 Seatbelt caution lamp does not show normally 1522
E-19 Alarm buzzer does not sound or does not stop sounding 1524
E-20 Transmission mode cannot be switched 1525
E-21 Engine mode cannot be switched 1527
E-22 Cannot be locked or canceled by the lifter lock pin 1529
E-23 Horn does not sound or does not stop sounding 1531
E-24 Backup alarm does not sound or does not stop sounding 1533
E-25 Headlamps, clearance lamps, and tail lamps do not light up or go out 1536
E-26 Working lamps do not light up or go out 1544
E-27 Turn indicator light or emergency flashing light does not flash 1549
E-28 Stop lamp does not light up or does not go out 1558
E-29 Backup lamp does not light up or does not go out 1560
E-30 KOMTRAX system does not operate normally 1562
Troubleshooting of hydraulic and mechanical system (H-mode) 1564
How to use troubleshooting table 1564
H-1 Engine speed drops significantly or engine stalls 1570
H-2 Machine does not move off 1571
H-3 Gear speed does not shift 1572
H-4 Travel speed or power is low 1573
H-5 Torque converter lockup does not operate or is not canceled 1576
H-6 Machine starts or gear speed shifts with long time lag 1577
H-7 Torque converter oil temperature is high 1580
H-8 Steering speed or power is insufficient 1583
H-9 Steering wheel does not move 1584
H-10 Wheel brakes do not work or are weak 1585
H-11 Wheel brakes are not released or drag 1586
H-12 Parking brake does not work or it is weak 1587
H-13 Parking brake (including emergency release system) is not released or drags 1588
H-14 All work equipment operates slowly or lacks power 1589
H-15 Work equipment does not operate 1590
H-16 Unusual noise is heard from around hydraulic pump 1591
H-17 Blade lift speed or power is low 1592
H-18 Hydraulic drift of lifted blade is large 1593
H-19 Drawbar side shift speed or power is low 1594
H-20 Blade side shift speed or power is low 1595
H-21 Power tilt speed or power is low 1596
H-22 Articulate speed or power is low 1597
H-23 Leaning speed or power is insufficient 1598
H-24 Hydraulic drift (tilting) of leaning is large 1599
H-25 Blade does not rotate 1600
H-26 Lifter lock pin is not locked or is not canceled 1601
H-27 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 1602
Troubleshooting of engine (S-mode) 1603
Information mentioned in troubleshooting table (S-mode) 1603
S-1 Engine does not crank when starting switch is turned to start position 1604
S-2 Engine cranks but no exhaust gas comes out 1605
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1606
S-4 Engine startability is poor 1608
S-5 Engine does not pick up smoothly 1610
S-6 Engine stops during operation 1612
S-7 Engine running is not stable 1614
S-8 Output is not sufficient (power is low) 1615
S-9 Exhaust is black (KDPF gets clogged in a short time) 1617
S-10 Engine oil consumption is excessive 1619
S-11 Engine oil becomes contaminated quickly 1620
S-12 Fuel consumption is excessive 1621
S-13 Oil is in coolant (or coolant spurts back or coolant level goes down) 1622
S-14 Oil pressure drops 1623
S-15 Fuel mixes into engine oil 1625
S-16 Water mixes into engine oil (milky) 1626
S-17 Coolant temperature rises too high (overheating) 1627
S-18 There is an unusual noise 1628
S-19 Vibration is excessive 1629
S-20 Air cannot be bled from fuel circuit 1630
S-21 Active regeneration is executed frequently 1631
S-22 Active regeneration takes long 1632
S-23 White smoke is exhausted during active regeneration 1633
S-24 DEF consumption is excessive 1634
S-25 There is an unusual smell (irritating odor) 1636
S-26 Foreign material mixes into DEF (DEF level increases) 1637
50 Disassembly and assembly 1639
Contents 1640
Related information on disassembly and assembly 1644
How to read this manual 1644
Coating materials list 1646
Special tools list 1651
Sketches of special tools 1671
Preparation 1702
Drain and add coolant 1702
Drain coolant 1702
Add coolant 1704
Drain and add hydraulic oil 1706
Drain hydraulic oil 1706
Add hydraulic oil 1708
Drain and add fuel 1710
Drain fuel 1710
Add fuel 1711
Engine and cooling system 1712
Remove and install supply pump assembly 1712
Remove supply pump assembly 1712
Install supply pump assembly 1717
Remove and install injector assembly 1722
Remove injector assembly 1722
Install injector assembly 1730
Remove and install cylinder head assembly 1739
Remove cylinder head assembly 1739
Install cylinder head assembly 1757
Remove and install starting motor assembly 1779
Remove starting motor assembly 1779
Install starting motor assembly 1781
Remove and install alternator belt 1785
Remove alternator belt 1785
Install alternator belt 1787
Remove and install alternator assembly 1790
Remove alternator assembly 1790
Install alternator assembly 1791
Remove and install auto-tensioner 1793
Remove auto-tensioner 1793
Install auto-tensioner 1793
Remove and install engine front oil seal 1794
Remove engine front oil seal 1794
Install engine front oil seal 1795
Remove and install engine rear oil seal 1797
Remove engine rear oil seal 1797
Install engine rear oil seal 1798
Remove and install steering and work equipment, brake and cooling fan pump assembly 1801
Remove steering and work equipment, brake and cooling fan pump assembly 1801
Install steering and work equipment, brake and cooling fan pump assembly 1805
Remove and install cooling fan and fan motor assembly 1806
Remove cooling fan and fan motor assembly 1806
Install cooling fan and fan motor assembly 1810
Remove and install radiator assembly 1811
Remove radiator assembly 1811
Install radiator assembly 1821
Remove and install aftercooler assembly 1823
Remove aftercooler assembly 1823
Install aftercooler assembly 1831
Remove and install power train oil cooler assembly 1833
Remove power train oil cooler assembly 1833
Install power train oil cooler assembly 1841
Remove and install fuel tank assembly 1843
Remove fuel tank assembly 1844
Install fuel tank assembly 1849
Remove and install engine hood assembly 1850
Remove engine hood assembly 1850
Install engine hood assembly 1853
Remove and install grille assembly 1854
Remove grille assembly 1854
Install grille assembly 1858
Remove and install bellows pipe assembly 1859
Remove bellows pipe assembly 1859
Install bellows pipe assembly 1863
Remove and install DEF tank assembly 1867
Remove DEF tank assembly 1868
Install DEF tank assembly 1877
Remove and install DEF tank sensor flange assembly 1878
Remove DEF tank sensor flange assembly 1878
Install DEF tank sensor flange assembly 1883
Remove and install DEF tank sensor 1886
Remove DEF tank sensor 1886
Install DEF tank sensor 1887
Remove and install DEF tank strainer 1894
Remove DEF tank strainer 1894
Install DEF tank strainer 1894
Remove and install KDPF assembly 1896
Remove KDPF assembly 1896
Install KDPF assembly 1903
Disassemble and assemble KDPF assembly 1908
Disassemble KDPF assembly 1908
Assemble KDPF assembly 1912
Remove and install SCR assembly 1918
Remove SCR assembly 1918
Install SCR assembly 1926
Remove and install KDPF and SCR assembly 1933
Remove KDPF and SCR assembly 1933
Install KDPF and SCR assembly 1946
Remove and install exhaust throttle valve 1950
Remove exhaust throttle valve 1950
Install exhaust throttle valve 1955
Remove and install DEF injector 1962
Remove DEF injector 1962
Install DEF injector 1966
Remove and install DEF pump 1969
Remove DEF pump 1969
Install DEF pump 1973
Remove and install DEF hose 1974
Remove DEF hose 1974
Install DEF hose 1985
Remove and install air cleaner assembly 1986
Remove air cleaner assembly 1986
Install air cleaner assembly 1988
Remove and install exhaust pipe cover 1989
Remove exhaust pipe cover 1989
Install exhaust pipe cover 1994
Power train 1995
Remove and install engine, torque converter, and transmission assembly 1995
Remove engine, torque converter, and transmission assembly 1996
Install engine, torque converter, and transmission assembly 2005
Disconnect and connect engine, torque converter, and transmission assembly 2007
Disconnect engine, torque converter, and transmission assembly 2007
Connect engine, torque converter, and transmission assembly 2009
Disassemble and assemble torque converter assembly 2011
Disassemble torque converter assembly 2011
Assemble torque converter assembly 2018
Disassemble and assemble transmission assembly 2027
Disassemble transmission assembly 2029
Assemble transmission assembly 2050
Remove and install tandem drive and final drive assembly 2080
Remove tandem drive and final drive assembly 2080
Install tandem drive and final drive assembly 2084
Disassemble and assemble tandem drive assembly 2085
Disassemble tandem drive assembly 2085
Assemble tandem drive assembly 2088
Disassemble and assemble bevel gear assembly 2095
Disassemble bevel gear assembly 2095
Assemble bevel gear assembly 2098
Disassemble and assemble final drive assembly 2106
Disassemble final drive assembly 2106
Assemble final drive assembly 2111
Steering system 2119
Remove and install orbitrol valve assembly 2119
Remove orbitrol valve assembly 2119
Install orbitrol valve assembly 2127
Brake system 2128
Disassemble and assemble wheel brake assembly 2128
Disassemble wheel brake assembly 2129
Assemble wheel brake assembly 2132
Undercarriage and frame 2140
Remove and install center hinge pin 2140
Remove center hinge pin 2140
Install center hinge pin 2149
Hydraulic system 2154
Remove and install hydraulic tank, battery, and frame assembly 2154
Remove hydraulic tank, battery, and frame assembly 2154
Install hydraulic tank, battery, and frame assembly 2166
Remove and install hydraulic tank assembly 2167
Remove hydraulic tank assembly 2167
Install hydraulic tank assembly 2172
Remove and install control valve assembly 2173
Remove control valve assembly 2173
Install control valve assembly 2178
Disassemble and assemble hydraulic cylinder assembly 2181
Disassemble hydraulic cylinder assembly 2182
Assemble hydraulic cylinder assembly 2185
Work equipment 2190
Remove and install blade assembly 2190
Remove blade assembly 2190
Install blade assembly 2190
Remove and install circle and drawbar assembly 2192
Remove circle and drawbar assembly 2192
Install circle and drawbar assembly 2193
Remove and install circle rotation gear assembly 2195
Remove circle rotation gear assembly 2195
Install circle rotation gear assembly 2196
Disassemble and assemble circle rotation gear assembly 2198
Disassemble circle rotation gear assembly 2198
Assemble circle rotation gear assembly 2200
Cab related parts 2205
Remove and install canopy assembly 2205
Remove canopy assembly 2205
Install canopy assembly 2211
Remove and install floor frame assembly 2213
Remove floor frame assembly 2213
Install floor frame assembly 2218
Remove and install canopy and floor frame assembly 2219
Remove canopy and floor frame assembly 2219
Install canopy and floor frame assembly 2226
Remove and install operator seat assembly 2227
Remove operator seat assembly 2227
Install operator seat assembly 2228
Remove and install seatbelt 2229
Remove seatbelt 2229
Install seatbelt 2230
Electrical system 2231
Remove and install engine controller assembly 2231
Remove engine controller assembly 2231
Install engine controller assembly 2236
Remove and install machine monitor assembly 2241
Remove machine monitor assembly 2241
Install machine monitor assembly 2242
Remove and install transmission controller assembly 2243
Remove transmission controller assembly 2243
Install transmission controller assembly 2244
Remove and install intake manifold pressure and temperature sensor 2245
Remove intake manifold pressure and temperature sensor 2245
Install intake manifold pressure and temperature sensor 2246
Remove and install KDPF temperature sensor 2248
Remove KDPF temperature sensor 2248
Install KDPF temperature sensor 2252
Remove and install KDPF differential pressure sensor 2257
Remove KDPF differential pressure sensor 2257
Install KDPF differential pressure sensor 2259
Remove and install SCR temperature sensor 2261
Remove SCR temperature sensor 2261
Install SCR temperature sensor 2266
Remove and install SCR outlet NOx sensor 2271
Remove SCR outlet NOx sensor 2271
Install SCR outlet NOx sensor 2275
Remove and install gateway function controller 2278
Remove gateway function controller 2278
Install gateway function controller 2279
60 Maintenance standard 2281
Contents 2282
Engine and cooling system 2283
Engine mount and transmission mount 2283
Cooling system 2284
Cooling fan motor 2285
Power train system 2287
Torque converter 2287
Transmission 2289
Main relief valve and torque converter relief valve 2298
Front axle 2299
Rear axle 2301
Bevel gear 2302
Final drive 2304
Tandem drive 2306
Steering system 2307
Steering cylinder 2307
Brake system 2308
Wheel brake 2308
Parking brake 2310
Undercarriage and frame 2311
Frame and center hinge pin 2311
Hydraulic system 2312
Hydraulic tank 2312
Steering and work equipment and brake and cooling fan pump 2313
Power train pump 2314
Parking brake solenoid valve and lifter lock pin solenoid valve 2315
Leaning cylinder 2316
Articulate cylinder 2317
Blade lift cylinder 2318
Drawbar shift cylinder 2319
Blade side shift cylinder 2320
Power tilt cylinder 2321
Scarifier cylinder 2322
Work equipment 2323
Circle and drawbar 2323
Blade 2325
Lifter 2327
Circle rotation gear 2328
90 Diagrams and drawings 2331
Contents 2332
Hydraulic diagrams and drawings 2333
Symbols used in hydraulic circuit diagrams 2333
Hydraulic circuit diagram 2335
Power train hydraulic circuit diagram 2337
Electrical diagrams and drawings 2339
Symbols used in electric circuit diagrams 2339
Chassis electric circuit diagram 2343
Floor electric circuit diagram 2355
Index 2367

DESCRIPTION:

Komatsu GD535-6 Motor Grader Shop Manual SEN06943-02 – PDF DOWNLOAD 

SERIAL NUMBERS 3002 and up

Foreword, safety, basic information
How to read the shop manual
q Some of the attachments and options described in this shop manual may not be available in some areas. If they are required,consult your Komatsu distributor.
q The materials and specifications are subject to change without notice.
q Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
q Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION”
is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting.
Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TEST AND ADJUST
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method
of each part. The standard values and repair limit for TEST AND ADJUST are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of
troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly,
and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials,
lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and
remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 28/12/24