Komatsu GD555-3C GD655-3C GD675-3C Shop Manual SEBM020911 PDF

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Komatsu Motor Grader GD555-3C GD655-3C GD675-3C Shop Manual SEBM020911 – PDF DOWNLOAD

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Komatsu Motor Grader GD555-3C GD655-3C GD675-3C Shop Manual SEBM020911 – PDF DOWNLOAD

Language : English
Pages :743
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Motor Grader GD555-3C GD655-3C GD675-3C Shop Manual SEBM020911 – PDF DOWNLOAD

MACHINE MODEL    SERIAL NUMBER
GD555-3C                   50001 and up
GD655-3C                   50001 and up
GD675-3C                   50001 and up

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 GD555-3C GD655-3C GD675-3C Shop Manual SEBM020911 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 27
GENERAL ASSEMBLY DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 41
FUEL, COOLANT, AND LUBRICANT SELECTION 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 92
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 93
MAIN RELIEF VALVE 98
TRANSMISSION PUMP101
TRANSMISSION AND DIFFERENTIAL LOCK PUMP (WITH DIFFERENTIAL LOCK)102
FINAL DRIVE104
TANDEM DRIVE110
STEERING HYDRAULIC PIPING DRAWING114
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)117
PRIORITY ACC GOVERNOR VALVE (SERIAL NO50001-51000)124
PRIORITY VALVE (SERIAL NO51001 AND UP)131
ACCUMULATOR PRESSURE GOVERNOR VALVE (SERIAL NO51001 AND UP)138
FRONT AXLE140
BRAKE HYDRAULIC PIPING 144
BRAKE VALVE148
WHEEL BRAKE152
SLACK ADJUSTER153
ACCUMULATOR156
PARKING BRAKE157
PARKING BRAKE AND BANK CONTROL VALVE158
WORK EQUIPMENT HYDRAULIC PIPING DRAWING160
HYDRAULIC PUMP (SERIAL NO50001-51000)170
HYDRAULIC PUMP (SERIAL NO51001 AND UP)192
MAIN CONTROL VALVE215
CLSS234
WORK EQUIPMENT CONTROL246
HYDRAULIC SYSTEM248
HYDRAULIC TANK254
SWIVEL JOINT255
PILOT CHECK VALVE258
BLADE ACCUMULATOR, FLOAT VALVE263
SHUT-OFF VALVE267
BLADE FLOAT DEVICE268
CIRCLE ROTATION MOTOR270
HYDRAULIC CYLINDER272
CIRCLE, DRAWBAR278
LIFTER BRACKET LOCK PIN280
BLADE282
CIRCLE ROTATION GEAR284
SCARIFIER288
RIPPER290
MAIN FRAME293
AIR CONDITIONER (IF EQUIPPED)294
ENGINE STARTING CIRCUIT298
ENGINE STOP CIRCUIT302
PREHEAT CIRCUIT304
AUTOMATIC SHIFT CONTROL SYSTEM306
TRANSMISSION CONTROLLER307
MONITOR311
SENSORS314
20 TESTING AND ADJUSTING321
STANDARD VALUE TABLE322
STANDARD VALUE TABLE FOR ENGINE322
STANDARD VALUE TABLE FOR CHASSIS326
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM333
TESTING AND ADJUSTING343
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING344
MEASURING EXHAUST COLOR345
MEASURING BLOWBY PRESSURE346
MEASURING ENGINE OIL PRESSURE347
MEASURING ENGINE SPEED347
TESTING FAN BELT TENSION348
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION349
MEASURING TORQUE CONVERTER STALL SPEED349
CHECKING CLUTCH OIL PRESSURE350
CHECKING TORQUE CONVERTER OIL PRESSURE351
ADJUSTING SPEED SENSOR352
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT354
ADJUSTING ACCELERATOR CONTROL LINKAGE355
TESTING BRAKE DISC356
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE357
TESTING ACCUMULATOR CHARGE PRESSURE358
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE358
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE359
ADJUSTING PC VALVE361
BLEEDING AIR FROM HYDRAULIC CIRCUIT361
MEASURING INTERNAL CYLINDER LEAKAGE362
MEASURING STEERING, BRAKE OIL PRESSURE364
BLEEDING AIR FROM BRAKE PIPING365
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR366
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE367
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE369
MEMORIZING IDLE AND FULL POSITION PROCEDURE371
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER372
DIODE CHECKING PROCEDURE374
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS375
ADJUSTING CAB STOPPER BOLT377
TROUBLESHOOTING379
TROUBLESHOOTING POINTS TO REMEMBER380
TROUBLESHOOTING SEQUENCE381
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE382
CHECKS BEFORE TROUBLESHOOTING390
CONNECTOR TYPES AND MOUNTING LOCATIONS391
CONNECTOR ARRANGEMENT DIAGRAM400
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS408
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES429
USING THE TROUBLESHOOTING CHARTS433
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)435
ELECTRICAL CIRCUIT DIAGRAM436
E-1 ENGINE DOES NOT START440
E-2 ENGINE DOES NOT STOP450
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW452
E-4 ELECTRICAL COMPONENTS DO NOT WORK454
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)457
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE460
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE464
ELECTRICAL CIRCUIT DIAGRAM484
T-1 FAILURE CODE [A1]488
T-2 FAILURE CODE [A2]489
T-3 FAILURE CODE [A3]490
T-4 FAILURE CODE [A4]491
T-5 FAILURE CODE [A5]492
T-6 FAILURE CODE [A8]493
T-7 FAILURE CODE [b1]494
T-8 FAILURE CODE [b2]495
T-9 FAILURE CODE [b3]496
T-10 FAILURE CODE [b4]497
T-11 FAILURE CODE [b5]498
T-12 FAILURE CODE [b6]499
T-13 FAILURE CODE [b7]500
T-14 FAILURE CODE [b8]501
T-15 FAILURE CODE [C0]502
T-16 FAILURE CODE [C1]503
T-17 FAILURE CODE [C3]504
T-18 FAILURE CODE [C4]506
T-19 FAILURE CODE [C5]508
T-20 FAILURE CODE [C6]509
T-21 FAILURE CODE [C7]510
T-22 FAILURE CODE [C8]511
T-23 FAILURE CODE [C9]512
T-24 FAILURE CODE [d1]513
T-25 FAILURE CODE [d2]514
T-26 FAILURE CODE [d4]515
T-27 FAILURE CODE [d5]516
T-28 FAILURE CODE [d6]517
T-29 FAILURE CODE [d7]518
T-30 FAILURE CODE [E1]519
T-31 FAILURE CODE [E2]520
T-32 FAILURE CODE [E3]521
T-33 FAILURE CODE [E4]523
T-34 FAILURE CODE [E5]523
T-35 FAILURE CODE [E6]524
T-36 FAILURE CODE [E7]525
T-37 FAILURE CODE [E8]525
T-38 FAILURE CODE [F1]527
T-39 FAILURE CODE [F2]527
T-40 FAILURE CODE [F3]528
T-41 FAILURE CODE [F4]529
T-42 FAILURE CODE [F5]529
T-43 FAILURE CODE [F6]530
T-44 FAILURE CODE [F7]530
T-45 FAILURE CODE [F8]531
T-46 FAILURE CODE [91]532
T-47 FAILURE CODE [92]532
T-48 FAILURE CODE [93]533
T-49 FAILURE CODE [94]534
T-50 FAILURE CODE [95]534
T-51 FAILURE CODE [96]535
T-52 FAILURE CODE [97]535
T-53 FAILURE CODE [98]537
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)539
FAILURE TABLE: MODES AND CAUSES540
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER542
H-2 NO WORK EQUIPMENT MOVES543
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS543
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP544
H-5 EXCESSIVE BLADE DRIFT544
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE545
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING, DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT CYLINDERS (LEFT, RIGHT)545
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)546
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE546
H-10 EXCESSIVE SCARIFIER DRIFT547
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE547
H-12 TRANSMISSION DOES NOT SHIFT-UP OR SHIFT-DOWN548
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING548
H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION,CANNOT BE ACTUATED OR CANCELED549
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR549
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH550
H-17 BRAKING FORCE IS INSUFFICIENT551
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)553
FAILURE TABLE: MODES AND CAUSES554
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM556
M-1 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP560
M-2 TRANSMISSION CONTROLLER CAUTION LAMP LIGHTS UP561
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP LIGHTS UP561
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP LIGHTS UP (OPT)562
M-5 BANK PIN CAUTION LAMP LIGHTS UP563
M-6 BRAKE OIL PRESSURE CAUTION LAMP LIGHTS UP564
M-7 BATTERY CHANGE CAUTION LAMP LIGHTS UP565
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP566
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP567
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)568
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)569
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP570
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP570
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP 572
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH573
M-16 ARTICULATION GAUGE DOES NOT WORK574
M-17 FUEL GAUGE DOES NOT WORK576
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK578
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)579
M-20 MESSAGE CENTER DOES NOT WORK580
M-21 SERVICE METER DOES NOT WORK581
30 DISASSEMBLY AND ASSEMBLY583
METHOD OF USING MANUAL585
PRECAUTIONS WHEN CARRYING OUT OPERATION587
SPECIAL TOOL LIST590
SKETCHES OF SPECIAL TOOLS593
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO:50001-51000)598
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO:50001-51000)599
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO:51001 AND UP)599
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO:5101 AND UP)600
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO:50001-51000)601
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO:50001-51000)602
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO:51001 AND UP)603
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO:51001 AND UP)605
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO:50001-51000)606
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO:50001-51000)608
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSMBLY (SERIAL NO:51001 AND UP)610
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB ATNK ASSEMBLY (SERIAL NO:51001 AND UP)612
REMOVAL OF ENGINE ASSEMBLY613
INSTALLATION OF ENGINE ASSEMBLY614
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT616
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT617
REMOVAL OF TRANSMISSION ASSEMBLY618
INSTALLATION OF TRANSMISSION ASSEMBLY620
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY623
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY625
DISASSEMBLY OF TRANSMISSION ASSEMBLY629
ASSEMBLY OF TRANSMISSION ASSEMBLY645
REMOVAL OF FINAL DRIVE ASSEMBLY666
INSTALLATION OF FINAL DRIVE ASSEMBLY669
DISASSEMBLY OF FINAL DRIVE ASSEMBLY671
ASSEMBLY OF FINAL DRIVE ASSEMBLY672
DISASSEMBLY OF FINAL BRAKE CASE675
ASSEMBLY OF FINAL BRAKE CASE676
DISASSEMBLY OF SIDE CASE678
ASSEMBLY OF SIDE CASE679
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY681
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY682
DISASSEMBLY OF BEVEL GEAR685
ASSEMBLY OF BEVEL GEAR686
DISASSEMBLY OF BEVEL PINION ASSEMBLY687
ASSEMBLY OF BEVEL PINION ASSEMBLY688
REMOVAL OF OPERATOR’S CAB ASSEMBLY689
INSTALLATION OF OPERATOR’S CAB ASSEMBLY691
REMOVAL OF OPERATOR’S CAB FLOOR693
INSTALLATION OF OPERATOR’S CAB FLOOR695
REMOVAL OF STEERING VALVE (ORBIT-ROLL)697
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)697
STANDARD INTEGRAL ORBIT-ROLL698
DISASSEMBLY OF STEERING VALVE700
ASSEMBLY OF STEERING VALVE703
REMOVAL OF BLADE ASSEMBLY708
INSTALLATION OF BLADE ASSEMBLY708
REMOVAL OF CIRCLE DRAWBAR ASSEMBLY709
INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY710
REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY711
INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY712
REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)713
INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)714
DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)715
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)717
DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)719
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)721
90 OTHERS725
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO:50001-51000)727
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO:51001 AND UP)728
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO:50001-51000)729
HYDRAULIC CIRCUIT DIAGRAM (1/2) (SERIAL NO:51001 AND UP)730
HYDRAULIC CIRCUIT DIAGRAM (2/2) (SERIAL NO:51001 AND UP)731
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO:50001-51000)732
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO:50001-51000)733
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO:50001-51000)734
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO:50001-51000)735
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO:50001-51000)736
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO:50001-51000)737
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO:51001 AND UP)738
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO:51001 AND UP)739
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO:51001 AND UP)740
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO:51001 AND UP)741
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO:51001 AND UP)742
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO:51001 AND UP)743

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24