Komatsu GD555-3C GD655-3C GD675-3C Motor Grader Shop Manual SEBM020908 – PDF Download

Description

Komatsu GD555-3C, GD655-3C & GD675-3C Motor Grader Shop Manual — SEBM020908

This is the complete Komatsu shop manual for the GD555-3C, GD655-3C, and GD675-3C motor graders, covering machines from serial number 50001 and up. Issued under document number SEBM020908, this 713-page PDF gives you the full service information for all three grader models in a single, printable file. Whether you are working on the SA6D102E-1 or SAA6D102E-2 engine in the GD555-3C, or the S6D114E-1, SA6D114E-1, or SAA6D114E-2 engine in the GD655-3C and GD675-3C, this manual covers the procedures, specifications, and values you need.

Komatsu shop manuals are written for technicians, not for show. The text is direct, the illustrations are tied to the procedures, and the specifications are printed where you need them. This manual follows that pattern across every major system on these graders: torque converter and transmission, final drive and tandem drive, steering and brakes, hydraulic pump and control valve, work equipment, circle and drawbar, and the electrical systems that tie it all together.

File Details

• Manual type: Shop Manual
• Brand: Komatsu
• Models covered: GD555-3C, GD655-3C, GD675-3C
• Serial number: 50001 and up
• Document number: SEBM020908
• Language: English
• Page count: 713
• File format: PDF

The engine section in this manual is limited. Komatsu notes in the foreword that full engine details are found in the 102 Series Engine Shop Manual and the 114 Series Engine Shop Manual. What you get here for the engines is the surrounding installation, control linkage, starting circuit, stop circuit, preheat circuit, and sensor information — the material that ties the engine into the grader’s chassis and hydraulic systems.

Chapters Covered

• 01 GENERAL
• 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 20 TESTING AND ADJUSTING
• 30 DISASSEMBLY AND ASSEMBLY
• 90 OTHERS

01 General

The general section gives you the machine overview, including the general assembly drawing with overall length, height, and width dimensions for each model. You get the full specifications tables for the GD555-3C, GD655-3C, and GD675-3C — machine weights on front and rear axles, travel speeds for all eight forward and four reverse ranges, maximum drawbar pull, gradeability, minimum turning radius, and static stability. Engine data includes flywheel horsepower, maximum torque, displacement, and fuel consumption. The section also covers the weight table for individual components, fuel/coolant/lubricant selection by ambient temperature, standard tightening torques, conversion tables, and the electric wire code.

10 Structure, Function and Maintenance Standard

This is the largest chapter in the manual, running from the accelerator control linkage all the way through to the air conditioner and sensors. Each system gets a clear explanation of how it works, what it looks like inside, and what the maintenance standards are. You get the power train diagram, torque converter operation with lock-up clutch, transmission clutch operation for all eight forward and four reverse ranges, and the ECMV valve function. The hydraulic sections cover the steering valve, priority valve, accumulator pressure governor valve, brake valve, slack adjuster, wheel brake, parking brake, and the full CLSS hydraulic pump and main control valve. Work equipment coverage includes the blade, circle, drawbar, scarifier, ripper, and the circle rotation motor. The electrical section covers the engine starting circuit, stop circuit, preheat circuit, automatic shift control system, transmission controller, monitor, and all the sensors on the machine.

20 Testing and Adjusting

This chapter gives you the standard value tables for engine, chassis, and electrical system — all the measurement conditions, standard values, and permissible limits in one place. Then it walks through the actual testing and adjusting procedures: measuring exhaust color, blowby pressure, engine oil pressure, and engine speed; testing fan belt and air conditioner compressor belt tension; measuring torque converter stall speed; checking clutch and torque converter oil pressure; adjusting the speed sensors, accelerator control linkage, parking brake pad clearance, and circle guide clearance; testing the brake disc, accumulator charge pressure, work equipment oil pressure, and LS differential pressure; adjusting the PC valve and LS relief valve; bleeding air from the hydraulic and brake circuits; charging nitrogen gas for the brake and work equipment accumulators; and the initial learning method for the transmission controller. Troubleshooting sections for the electrical system, transmission controller system, and hydraulic/mechanical system are also included, with error code tables and diagnostic flow charts.

30 Disassembly and Assembly

The disassembly and assembly chapter covers the major components: engine hood, radiator, fuel tank and hydraulic tank, engine assembly, transmission assembly, torque converter, final drive, final brake case, side case, differential gear, bevel gear and bevel pinion, operator’s cab, cab floor, steering valve, blade assembly, circle drawbar, blade circle gear, and the circle rotation gear in both shear-pin and slip-clutch configurations. Each procedure includes the special tools required, the tightening torques, the inspection points, and the assembly notes that keep you from damaging seals, bearings, or machined surfaces. This is the chapter you use when a component comes out of the machine and needs to be rebuilt.

90 Others

The final chapter contains the hydraulic circuit diagrams and electrical circuit diagrams. The transmission hydraulic circuits are shown for both serial number ranges (50001–51000 and 51001 and up). The hydraulic circuit diagrams cover the steering, brake, work equipment, and transmission systems. The electrical circuit diagrams are split across six pages for each serial number range, covering the engine start/stop/preheat/charge circuits, transmission control system, and main monitor system. These diagrams are essential when you are tracing a fault through the wiring harness or hydraulic piping.

Who This Manual Is For

This shop manual is for the technician, shop owner, or serious owner-operator who needs the real Komatsu procedures and specifications for these graders. It is not a generic overview. It is the document you open when you need to know the clutch pressure for the FL circuit, the preload on a bevel pinion bearing, the clearance between the circle and circle guide, or the correct sequence for disassembling the transmission cover. The 713 pages are dense with the kind of information that keeps a machine running correctly and prevents damage during repair.

The GD555-3C, GD655-3C, and GD675-3C are production motor graders used in road construction, mining, and heavy earthmoving. When one goes down, the cost is measured in lost production. Having the correct manual on hand means you can diagnose the problem, order the right parts, and carry out the repair without guesswork. The testing and adjusting chapter alone can save hours of trial-and-error when a transmission is not shifting correctly or a hydraulic function is slow.

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Instant PDF Delivery

This is a digital download. You get the PDF immediately after payment — no shipping, no waiting for a physical book to arrive. The file works on any device: laptop, tablet, or smartphone. You can print the pages you need for the shop floor, or keep the whole manual on a computer for quick reference. The PDF format means you can zoom in on the detailed illustrations and circuit diagrams without losing clarity. Whether you are servicing the GD555-3C with its SA6D102E engine, the GD655-3C with the S6D114E or SA6D114E, or the GD675-3C with the SA6D114E or SAA6D114E, this manual gives you the full factory service information in one complete file.