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Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual SEBM021008 – PDF DOWNLOAD
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Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual
MACHINE MODEL SERIAL NUMBER
GD555-3A 10001 and up
GD655-3A 10001 and up
GD675-3A 10001 and up
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Description
Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual
FILE DETAILS:
Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual
Brands: Komatsu
Equipment Type: Motor Grader
Manuals Type: Shop Manual
Machine Model: GD555-3A, GD655-3A, GD675-3A
Serial Number: 10001 and up
Book Code: SEBM021008
Language: English
Pages: 681
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu GD555-3A, GD655-3A, GD675-3A Motor Grader Shop Manual
COVER...................................................................................................................................... 1 CONTENTS................................................................................................................................... 2 01 GENERAL................................................................................................................................. 27 GENERAL ASSEMBLY DRAWING............................................................................................................... 28 SPECIFICATIONS......................................................................................................................... 29 WEIGHT TABLE........................................................................................................................... 41 FUEL, COOLANT, AND LUBRICANT .......................................................................................................... 43 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................................................................ 45 ACCELERATOR CONTROL LINKAGE............................................................................................................ 46 ACCELERATOR PEDAL...................................................................................................................... 47 FAN DRIVE.............................................................................................................................. 48 POWER TRAIN DIAGRAM.................................................................................................................... 49 TRANSMISSION HYDRAULIC PIPING.......................................................................................................... 50 TRANSMISSION CONTROL................................................................................................................... 54 TORQUE CONVERTER....................................................................................................................... 55 TORQUE CONVERTER LOCK-UP VALVE (ECMV).................................................................................................. 60 TRANSMISSION........................................................................................................................... 63 TRANSMISSION VALVE..................................................................................................................... 85 ECMV (ELECTRONIC CONTROL MODULATION VALVE)............................................................................................. 86 MAIN RELIEF VALVE...................................................................................................................... 90 TRANSMISSION PUMP...................................................................................................................... 93 TRANSMISSION AND DIFFERENTIAL LOCK PUMP................................................................................................ 94 FINAL DRIVE............................................................................................................................ 95 TANDEM DRIVE...........................................................................................................................100 STEERING HYDRAULIC PIPING DRAWING......................................................................................................103 STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)..........................................................................................104 PRIORITY VALVE.........................................................................................................................111 ACCUMULATOR PRESSURE GOVERNOR VALVE....................................................................................................118 FRONT AXLE.............................................................................................................................120 BRAKE HYDRAULIC PIPING.................................................................................................................124 BRAKE VALVE............................................................................................................................126 SLACK ADJUSTER.........................................................................................................................130 ACCUMULATOR............................................................................................................................133 WHEEL BRAKE............................................................................................................................134 PARKING BRAKE..........................................................................................................................135 PARKING BRAKE AND BANK CONTROL VALVE...................................................................................................136 WORK EQUIPMENT HYDRAULIC PIPING DRAWING................................................................................................137 HYDRAULIC PUMP.........................................................................................................................144 MAIN CONTROL VALVE.....................................................................................................................165 CLSS...................................................................................................................................180 WORK EQUIPMENT CONTROL.................................................................................................................192 HYDRAULIC SYSTEM.......................................................................................................................194 HYDRAULIC TANK.........................................................................................................................197 SWIVEL JOINT...........................................................................................................................198 PILOT CHECK VALVE......................................................................................................................199 BLADE ACCUMULATOR, FLOAT VALVE.........................................................................................................204 ACCUMULATOR............................................................................................................................206 BLADE FLOAT DEVICE.....................................................................................................................207 CIRCLE ROTATION MOTOR..................................................................................................................209 HYDRAULIC CYLINDER.....................................................................................................................211 CIRCLE, DRAWBAR........................................................................................................................217 LIFTER BRACKET LOCK PIN................................................................................................................219 BLADE..................................................................................................................................220 CIRCLE ROTATION GEAR...................................................................................................................222 SCARIFIER..............................................................................................................................225 RIPPER.................................................................................................................................227 MAIN FRAME.............................................................................................................................229 AIR CONDITIONER (IF EQUIPPED)..........................................................................................................230 ENGINE STARTING CIRCUIT................................................................................................................234 ENGINE STOP CIRCUIT....................................................................................................................239 PREHEAT CIRCUIT........................................................................................................................241 AUTOMATIC SHIFT CONTROL SYSTEM.........................................................................................................243 TRANSMISSION CONTROLLER................................................................................................................244 MONITOR................................................................................................................................249 SENSORS................................................................................................................................253 20 TESTING AND ADJUSTING...................................................................................................................258 STANDARD VALUE TABLE...................................................................................................................259 STANDARD VALUE TABLE FOR ENGINE....................................................................................................259 STANDARD VALUE TABLE FOR CHASSIS...................................................................................................261 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.........................................................................................268 TESTING AND ADJUSTING..................................................................................................................277 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................................................278 MEASURING EXHAUST COLOR............................................................................................................279 MEASURING BLOWBY PRESSURE..........................................................................................................280 MEASURING ENGINE OIL PRESSURE .....................................................................................................281 MEASURING ENGINE SPEED.............................................................................................................281 TESTING FAN BELT TENSION...........................................................................................................282 TESTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................283 MEASURING TORQUE CONVERTER STALL SPEED.............................................................................................283 CHECKING CLUTCH OIL PRESSURE.......................................................................................................284 CHECKING TORQUE CONVERTER OIL PRESSURE.............................................................................................285 ADJUSTING SPEED SENSOR.............................................................................................................286 FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT....................................................................................288 ADJUSTING ACCELERATOR CONTROL LINKAGE..............................................................................................289 TESTING BRAKE DISC.................................................................................................................290 TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE..................................................................................291 TESTING ACCUMULATOR CHARGE PRESSURE................................................................................................292 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE..................................................................................292 TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE.....................................................................................293 ADJUSTING PC VALVE.................................................................................................................295 BLEEDING AIR FROM HYDRAULIC CIRCUIT................................................................................................295 MEASURING INTERNAL CYLINDER LEAKAGE................................................................................................296 MEASURING STEERING, BRAKE OIL PRESSURE.............................................................................................298 BLEEDING AIR FROM THE BRAKE PIPING.................................................................................................299 CHARGING BRAKE, WORK EQUIPMENT ACCUMULATOR.........................................................................................300 TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE.......................................................................................301 TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE...............................................................................303 MEMORIZING IDLE AND FULL POSITION PROCEDURE........................................................................................305 INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER................................................................................306 DIODE CHECKING PROCEDURE...........................................................................................................308 MOVING MACHINE WHEN TRANSMISSION VALVE FAILS.......................................................................................309 ADJUSTING CAB STOPPER BOLT (IF EQUIPPED WITH CAB)..................................................................................311 TROUBLESHOOTING........................................................................................................................313 TROUBLESHOOTING POINTS TO REMEMBER.................................................................................................314 TROUBLESHOOTING SEQUENCE...........................................................................................................315 POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE.....................................................................................316 CHECKS BEFORE TROUBLESHOOTING......................................................................................................324 CONNECTOR TYPES AND MOUNTING LOCATIONS (SERIAL NO. 10001-11000)....................................................................325 CONNECTOR TYPES AND MOUNTING LOCATIONS (SERIAL NO. 11001 AND UP)...................................................................331 CONNECTOR ARRANGEMENT DIAGRAM (SERIAL NO. 10001-11000).............................................................................337 CONNECTOR ARRANGEMENT DIAGRAM (SERIAL NO. 11001 AND UP)............................................................................341 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................345 MESSAGE CENTER DISPLAY AND TABLE ERROR CODES.......................................................................................368 USING TROUBLESHOOTING CHARTS.......................................................................................................372 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)......................................................................................373 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................374 E-1 ENGINE DOES NOT START......................................................................................................378 E-2 ENGINE DOES NOT STOP.......................................................................................................388 E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW.................................................................................390 E-4 ELECTRICAL COMPONENTS DO NOT WORK..........................................................................................392 TROUBLESHOOTING THE TRANSMISSION CONTROLLER SYSTEM (T MODE)........................................................................394 TRANSMISSION CONTROLLER SYSTEM JUDGEMENT TABLE.................................................................................395 CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH MACHINE.............................................................................400 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................422 T-1 ERROR CODE [A1] (HOT SHORT, GROUND, OR FL SOLENOID SYSTEM).................................................................426 T-2 ERROR CODE [A2] (HOT SHORT, GROUND, OR FH SOLENOID SYSTEM).................................................................427 T-3 ERROR CODE [A3] (HOT SHORT, GROUND, OR R SOLENOID CIRCUIT).................................................................428 T-4 ERROR CODE [A4] (HOT SHORT, 1ST OR 3RD SOLENOID CIRCUIT, OR GROUND)........................................................429 T-5 ERROR CODE [A5] (HOT SHORT, 2ND OR 4TH SOLENOID SYSTEM, OR GROUND).........................................................431 T-6 ERROR CODE [A8] (HOT SHORT, LOCK-UP SOLENOID SYSTEM, OR GROUND)............................................................433 T-7 ERROR CODE [B1] (OPEN FL SOLENOID CIRCUIT).................................................................................434 T-8 ERROR CODE [B2] (OPEN FH SOLENOID CIRCUIT).................................................................................435 T-9 ERROR CODE [B3] (OPEN R SOLENOID CIRCUIT)..................................................................................436 T-10 ERROR CODE [B4] (OPEN 1ST SOLENOID CIRCUIT)...............................................................................437 T-11 ERROR CODE [B5] (OPEN 2ND SOLENOID CIRCUIT)...............................................................................438 T-12 ERROR CODE [B6] (OPEN 3RD SOLENOID CIRCUIT)...............................................................................439 T-13 ERROR CODE [B7] (OPEN 4TH SOLENOID CIRCUIT)...............................................................................440 T-14 ERROR CODE [B8] (OPEN LOCK-UP SOLENOID CIRCUIT)...........................................................................441 T-15 ERROR CODE [C0] (POWER SUPPLY VOLTAGE REDUCED)............................................................................442 T-16 ERROR CODE [C1] (OPEN ENGINE SPEED SENSOR CIRCUIT)........................................................................443 T-17 ERROR CODE [C3] (HOT SHORT OR OPEN ACCELERATOR POTENTIOMETER CIRCUIT).....................................................444 T-18 ERROR CODE [C4] (HOT SHORT OR OPEN INCHING POTENTIOMETER CIRCUIT).........................................................446 T-19 ERROR CODE [C5] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE SENSOR CIRCUIT)............................448 T-20 ERROR CODE [C6] (HOT SHORT OR OPEN CIRCUIT IN THE TORQUE CONVERTER OUTLET OIL TEMPERATURE SENSOR CIRCUIT).................450 T-21 ERROR CODE [C7] (HOT SHORT OR OPEN CIRCUIT IN THE HYDRAULIC OIL TEMPERATURE SENSOR CIRCUIT)...............................452 T-22 ERROR CODE [C8] (OPEN CIRCUIT IN THE TRANSMISSION INPUT SHAFT SPEED SENSOR CIRCUIT).......................................454 T-23 ERROR CODE [C9] (OPEN CIRCUIT IN THE TRANSMISSION OUTPUT SHAFT SPEED SENSOR CIRCUIT)......................................455 T-24 ERROR CODE [D1] (HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL OIL TEMPERATURE WARNING LAMP CIRCUIT)......................456 T-25 ERROR CODE [D2] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE WARNING LAMP CIRCUIT)......................457 T-26 ERROR CODE [D4] (HOT SHORT OR OPEN CIRCUIT IN THE BUZZER ALARM SYSTEM)....................................................458 T-27 ERROR CODE [D5] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION CONTROL WARNING LAMP SYSTEM)...............................460 T-28 ERROR CODE [D6] (HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL CONTROL RELAY SYSTEM)......................................461 T-29 ERROR CODE [D7] (HOT SHORT OR OPEN CIRCUIT IN THE VHP RELAY SYSTEM).......................................................462 T-30 ERROR CODE [E1] (HOT SHORT OR OPEN CIRCUIT IN THE F (FORWARD), R (REVERSE) SYSTEM)........................................463 T-31 ERROR CODE [E2] (HOT SHORT OR OPEN CIRCUIT IN THE NEUTRAL SIGNAL CIRCUIT).................................................464 T-32 ERROR CODE [E3] (HOT SHORT OR OPEN CIRCUIT IN THE PARKING SIGNAL CIRCUIT).................................................465 T-33 ERROR CODE [E4] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC A SIGNAL CIRCUIT).................................................467 T-34 ERROR CODE [E5] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC B SIGNAL CIRCUIT).................................................468 T-35 ERROR CODE [E6] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC C SIGNAL CIRCUIT).................................................469 T-36 ERROR CODE [E7] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC D SIGNAL CIRCUIT).................................................470 T-37 ERROR CODE [E8] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC E SIGNAL CIRCUIT).................................................471 T-38 ERROR CODE [F1] (SHORT CIRCUIT WITH GROUND IN THE FL CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...............................472 T-39 ERROR CODE [F2] (SHORT CIRCUIT WITH GROUND IN THE FH CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...............................472 T-40 ERROR CODE [F3] (SHORT CIRCUIT WITH GROUND IN THE R CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)................................473 T-41 ERROR CODE [F4] (SHORT CIRCUIT WITH GROUND IN THE 1ST CLUTCH PRESSURE SWITCH CIRCUIT).....................................474 T-42 ERROR CODE [F5] (SHORT CIRCUIT WITH GROUND IN THE 2ND CLUTCH PRESSURE SWITCH CIRCUIT).....................................474 T-43 ERROR CODE [F6] (SHORT CIRCUIT WITH GROUND IN THE 3RD CLUTCH PRESSURE SWITCH CIRCUIT).....................................475 T-44 ERROR CODE [F7] (SHORT CIRCUIT WITH GROUND IN THE 4TH CLUTCH PRESSURE SWITCH CIRCUIT).....................................475 T-45 ERROR CODE [F8] (SHORT CIRCUIT WITH GROUND IN THE LOCK-UP CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)..........................476 T-46 ERROR CODE [91] (OPEN CIRCUIT IN THE FL CLUTCH PRESSURE SWITCH CIRCUIT)...................................................477 T-47 ERROR CODE [92] (OPEN CIRCUIT IN THE FH CLUTCH PRESSURE SWITCH CIRCUIT)...................................................477 T-48 ERROR CODE [93] (OPEN CIRCUIT IN THE R CLUTCH PRESSURE SWITCH CIRCUIT)....................................................478 T-49 ERROR CODE [94] (OPEN CIRCUIT IN THE 1ST CLUTCH PRESSURE SWITCH CIRCUIT)..................................................479 T-50 ERROR CODE [95] (OPEN CIRCUIT IN THE 2ND CLUTCH PRESSURE SWITCH CIRCUIT)..................................................479 T-51 ERROR CODE [96] (OPEN CIRCUIT IN THE 3RD CLUTCH PRESSURE SWITCH CIRCUIT)..................................................480 T-52 ERROR CODE [97] (OPEN CIRCUIT IN THE 4TH CLUTCH PRESSURE SWITCH CIRCUIT)..................................................480 T-53 ERROR CODE [98] (OPEN CIRCUIT IN THE LOCK-UP CLUTCH PRESSURE SWITCH CIRCUIT)..............................................481 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)........................................................................482 FAILURE TABLE: MODES AND CAUSES................................................................................................483 H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER..................................................................................485 H-2 NO WORK EQUIPMENT MOVES....................................................................................................486 H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...........................................................................486 H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP...................................................................................487 H-5 EXCESSIVE BLADE DRIFT......................................................................................................487 H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE.......................................................................488 H-7 LACK OF ACTUATING POWER IN THE ARTICULATING, DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT CYLINDERS (LEFT, RIGHT)....488 H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)..............................................................................489 H-9 IMPOSSIBLE TO ROTATE THE CIRCLE............................................................................................489 H-10 EXCESSIVE SCARIFIER DRIFT.................................................................................................490 H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE........................................................................491 H-12 TRANSMISSION DOES NOT UPSHIFT OR DOWNSHIFT................................................................................492 H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELLING............................................................................492 H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION......................................................................................493 H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR.........................................................................493 H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..................................................................................494 H-17 BRAKING FORCE IS INSUFFICIENT.............................................................................................495 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)....................................................................................496 FAILURE TABLE: MODES AND CAUSES................................................................................................497 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM.............................................................................499 M-1 ENGINE OIL PRESSURE CAUTION LAMP GLOWS.....................................................................................503 M-2 TRANSMISSION CONTROLLER CAUTION LAMP GLOWS.................................................................................504 M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP GLOWS............................................................................504 M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP GLOWS (OPT)......................................................................505 M-5 BANK PIN CAUTION LAMP GLOWS................................................................................................506 M-6 BRAKE OIL PRESSURE CAUTION LAMP GLOWS......................................................................................507 M-7 BATTERY CHARGE CAUTION LAMP GLOWS..........................................................................................508 M-8 PREHEATING DISPLAY DOES NOT LIGHT UP.......................................................................................509 M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP........................................................................................510 M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)..............................................................................511 M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)...............................................................512 M-12 ACCUMULATOR ACTUATION DISPLAY DEOS NOT LIGHT UP...........................................................................513 M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP.................................................................................513 M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP...................................................................................515 M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH...................................................................................516 M-16 ARTICULATION GAUGE DOES NOT WORK..........................................................................................517 M-17 FUEL GAUGE DOES NOT WORK..................................................................................................519 M-18 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT WORK............................................................................521 M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)....................................................................522 M-20 MESSAGE CENTER DOES NOT WORK..............................................................................................523 M-21 SERVICE METER DOES NOT WORK...............................................................................................524 30 DISASSEMBLY AND ASSEMBLY................................................................................................................525 METHOD OF USING MANUAL.................................................................................................................527 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................529 SPECIAL TOOL LIST......................................................................................................................531 SKETCHES OF SPECIAL TOOLS..............................................................................................................534 REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO. 10001-11000)...............................................................................539 INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO. 10001-11000)..........................................................................539 REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO. 11001 AND UP)..............................................................................540 INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO. 11001 AND UP).........................................................................540 REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO. 10001-11000)..................................................................................541 INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO. 10001-11000).............................................................................542 REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO. 11001 AND UP).................................................................................543 INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO. 11001 AND UP)............................................................................544 REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 10001-11000)....................................................545 INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 10001-11000)...............................................547 REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 11001 AND UP)...................................................549 INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 11001 AND UP)..............................................551 REMOVAL OF ENGINE ASSEMBLY.............................................................................................................552 INSTALLATION OF ENGINE ASSEMBLY........................................................................................................554 REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT..........................................................................555 INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT.....................................................................555 REMOVAL OF TRANSMISSION ASSEMBLY.......................................................................................................557 INSTALLATION OF TRANSMISSION ASSEMBLY..................................................................................................559 DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...............................................................................................561 ASSEMBLY OF TORQUE CONVERTER ASSEMBLY..................................................................................................563 DISASSEMBLY OF TRANSMISSION ASSEMBLY...................................................................................................566 ASSEMBLY OF TRANSMISSION ASSEMBLY......................................................................................................580 REMOVAL OF FINAL DRIVE ASSEMBLY........................................................................................................600 INSTALLATION OF FINAL DRIVE ASSEMBLY...................................................................................................603 DISASSEMBLY OF FINAL DRIVE ASSEMBLY....................................................................................................605 ASSEMBLY OF FINAL DRIVE ASSEMBLY.......................................................................................................606 DISASSEMBLY OF FINAL BRAKE CASE........................................................................................................609 ASSEMBLY OF FINAL BRAKE CASE...........................................................................................................609 DISASSEMBLY OF SIDE CASE ASSEMBLY (FOR STANDARD FINAL DRIVER)..........................................................................612 ASSEMBLY OF SIDE CASE ASSEMBLY (FOR STANDARD FINAL DRIVER).............................................................................613 DISASSEMBLY OF SIDE CASE (FOR PLANETRY FINAL DRIVER)...................................................................................615 ASSEMBLY OF SIDE CASE (FOR PLANETRY FINAL DRIVER)......................................................................................617 DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)................................................................................619 ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)...................................................................................620 DISASSEMBLY OF BEVEL GEAR ASSEMBLY (FOR STANDARD FINAL DRIVER).........................................................................623 ASSEMBLY OF BEVEL GEAR ASSEMBLY (FOR STANDARD FINAL DRIVER)............................................................................623 DISASSEMBLY OF BEVEL GEAR (FOR PLANETRY FINAL DRIVER)..................................................................................627 ASSEMBLY OF BEVEL GEAR (FOR PLANETRY FINAL DRIVER).....................................................................................628 DISASSEMBLY OF BEVEL PINION ASSEMBLY...................................................................................................630 ASSEMBLY OF BEVEL PINION ASSEMBLY......................................................................................................631 REMOVAL OF OPERATOR'S CAB ASSEMBLY.....................................................................................................632 INSTALLATION OF OPERATOR'S CAB ASSEMBLY................................................................................................633 REMOVAL OF OPERATOR'S CAB FLOOR........................................................................................................635 INSTALLATION OF OPERATOR'S CAB FLOOR...................................................................................................636 REMOVAL OF STEERING VALVE (ORBIT-ROLL).................................................................................................638 INSTALLATION OF STEERING VALVE(ORBIT-ROLL).............................................................................................638 STANDARD INTEGRAL ORBIT-ROLL...........................................................................................................639 DISASSEMBLY OF STEERING VALVE..........................................................................................................641 ASSEMBLY OF STEERING VALVE.............................................................................................................643 REMOVAL OF BLADE ASSEMBLY .............................................................................................................648 INSTALLATION OF BLADE ASSEMBLY.........................................................................................................648 REMOVAL OF CIRCLE DRAWBAR ASSEMBLY.....................................................................................................649 INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY................................................................................................650 REMOVAL OF BLADE CIRCLE ROTATION GEAR..................................................................................................651 INSTALLATION OF BLADE CIRCLE ROTATION GEAR.............................................................................................652 REMOVAL OF BLADE CIRCLE ROTATION GEAR (WITH SHEAR PIN).................................................................................653 INSTALLATION OF BLADE CIRCLE ROTATION GEAR (WITH SHEAR PIN)............................................................................654 DISASSEMBLY OF CIRCLE ROTATION GEAR (WITH SHEAR PIN)...................................................................................655 ASSEMBLY OF CIRCLE ROTATION GEAR (WITH SHEAR PIN)......................................................................................657 DISASSEMBLY OF CIRCLE ROTATION GEAR (WITH SLIP CLUTCH).................................................................................659 ASSEMBLY OF CIRCLE ROTATION GEAR (WITH SLIP CLUTCH)....................................................................................661 90 OTHERS..................................................................................................................................664 TRANSMISSION HYDRAULIC CIRCUIT.........................................................................................................665 BRAKE OIL CIRCUIT......................................................................................................................667 HYDRAULIC CIRCUIT DIAGRAM(1/2).........................................................................................................668 HYDRAULIC CIRCUIT DIAGRAM(2/2).........................................................................................................669 ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:10001-11000)..............................................................................670 ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:10001-11000)..............................................................................671 ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:10001-11000)..............................................................................672 ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:10001-11000)..............................................................................673 ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:10001-11000)..............................................................................674 ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO.:10001-11000)..............................................................................675 ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:11001 AND UP).............................................................................677 ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:11001 AND UP).............................................................................678 ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:11001 AND UP).............................................................................679 ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:11001 AND UP).............................................................................680 ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:11001 AND UP).............................................................................681
KOMATSU GD555-3A, GD655-3A, GD675-3A MOTOR GRADER SHOP MANUAL SEBM021008 – PDF DOWNLOAD:
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