Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual SEN05215-06 – PDF DOWNLOAD
Original price was: $65.95.$26.95Current price is: $26.95.
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual
SERIAL NUMBERS:
GD555-55001 and up
GD655-55001 and up
GD675-55001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual SEN05215-06
FILE DETAILS:
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual
Brands: Komatsu
Equipment Type: Motor Grader
Manuals Type: Shop Manual
Machine Model: GD555-5, GD655-5, GD675-5
Serial Number: 55001 and up
Book Code: SEN05215-06
Language: English
Pages: 1476
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual
COVER ................................................................................................................................................. 1 Notice of revision..................................................................................................................................... 3 00 Index and foreword.................................................................................................................................. 11 Table of contents.................................................................................................................................. 12 Table of contents.............................................................................................................................. 12 Foreword and general information................................................................................................................... 23 Safety notice.................................................................................................................................. 23 How to read the shop manual.................................................................................................................... 28 Explanation of terms for maintenance standard.................................................................................................. 30 Handling of electric equipment and hydraulic components........................................................................................ 32 Handling of connectors newly used for engines.................................................................................................. 41 How to read electric wire code................................................................................................................. 44 Precautions when carrying out work............................................................................................................. 47 Method of disassembling and connecting push-pull type coupler.................................................................................. 50 Standard tightening torque table............................................................................................................... 53 List of Abbreviation........................................................................................................................... 57 Conversion table............................................................................................................................... 61 01 Specification....................................................................................................................................... 67 Specification drawing.............................................................................................................................. 69 Specifications..................................................................................................................................... 70 Weight table....................................................................................................................................... 76 Table of fuel, coolant and lubricants.............................................................................................................. 77 10 Structure, function and maintenance standard........................................................................................................ 79 Engine and Cooling................................................................................................................................. 82 Cooling system................................................................................................................................. 82 Cooling fan pump............................................................................................................................... 84 Power train system................................................................................................................................. 92 Power train system drawing..................................................................................................................... 92 Power train piping drawing..................................................................................................................... 94 Transmission control........................................................................................................................... 96 Torque converter............................................................................................................................... 98 Transmission................................................................................................................................... 102 Transmission control valve..................................................................................................................... 124 ECMV........................................................................................................................................... 128 Main relief and torque converter relief valve.................................................................................................. 136 Front axle..................................................................................................................................... 138 Final drive (no differential specification).................................................................................................... 142 Final drive (differential/ differential lock specification).................................................................................... 144 Differential lock solenoid valve............................................................................................................... 146 Tandem drive................................................................................................................................... 148 Steering system.................................................................................................................................... 150 Steering piping diagram........................................................................................................................ 150 Priority valve................................................................................................................................. 152 Steering valve................................................................................................................................. 158 Brake system....................................................................................................................................... 166 Brake hydraulic piping diagram................................................................................................................. 166 Brake valve.................................................................................................................................... 167 Slack adjuster................................................................................................................................. 174 Accumulator (for brake)........................................................................................................................ 176 Charge valve................................................................................................................................... 177 Wheel brake.................................................................................................................................... 184 Parking brake and bank control valve........................................................................................................... 186 Parking brake.................................................................................................................................. 188 Undercarriage frame................................................................................................................................ 190 Frame.......................................................................................................................................... 190 Tire........................................................................................................................................... 192 Hydraulic system................................................................................................................................... 194 Hydraulic system............................................................................................................................... 194 Work equipment hydraulic piping diagram........................................................................................................ 198 Work equipment control......................................................................................................................... 202 Hydraulic tank................................................................................................................................. 204 Main pump...................................................................................................................................... 206 Power train pump............................................................................................................................... 218 Control valve.................................................................................................................................. 220 CLSS........................................................................................................................................... 230 Functions and operation by valve............................................................................................................... 234 Hydraulic cylinder............................................................................................................................. 244 Swivel joint................................................................................................................................... 246 Pilot check valve.............................................................................................................................. 248 Accumulator (for blade)........................................................................................................................ 256 Work equipment..................................................................................................................................... 258 Circle and drawbar............................................................................................................................. 258 Blade.......................................................................................................................................... 260 Lifter......................................................................................................................................... 262 Circle rotation motor.......................................................................................................................... 264 Circle rotation gear........................................................................................................................... 266 Cab................................................................................................................................................ 268 Cab............................................................................................................................................ 268 Electrical system.................................................................................................................................. 270 Machine monitor................................................................................................................................ 270 Automatic shift control system................................................................................................................. 274 Transmission controller........................................................................................................................ 282 Engine controller.............................................................................................................................. 286 KOMTRAX system................................................................................................................................. 290 Starting engine circuit........................................................................................................................ 294 Stopping engine circuit........................................................................................................................ 296 Preheating circuit............................................................................................................................. 298 Sensor......................................................................................................................................... 300 Engine power mode select circuit............................................................................................................... 312 Cooling fan control function................................................................................................................... 314 20 Standard value table................................................................................................................................ 319 Standard value table............................................................................................................................... 321 Standard value table for engine................................................................................................................ 321 Standard value table for machine............................................................................................................... 323 30 Testing and adjusting............................................................................................................................... 331 Tools for testing, adjusting, and troubleshooting.................................................................................................. 334 Tools for testing, adjusting, and troubleshooting.............................................................................................. 334 Engine and cooling system.......................................................................................................................... 340 Testing engine speed........................................................................................................................... 340 Testing intake air pressure (boost pressure)................................................................................................... 342 Testing exhaust gas temperature................................................................................................................ 344 Testing exhaust gas color...................................................................................................................... 346 Adjusting valve clearance...................................................................................................................... 348 Testing compression pressure................................................................................................................... 350 Testing blowby pressure........................................................................................................................ 353 Testing engine oil pressure.................................................................................................................... 355 Handling fuel system device.................................................................................................................... 356 Releasing remaining pressure from fuel system.................................................................................................. 357 Testing fuel pressure.......................................................................................................................... 358 Bleeding air from fuel circuit................................................................................................................. 359 Testing fuel circuit for leakage............................................................................................................... 360 Cylinder cut-out test mode..................................................................................................................... 361 No injection cranking.......................................................................................................................... 362 Handling voltage circuit of engine controller.................................................................................................. 363 Checking muffler body and muffler stack for looseness and damage............................................................................... 364 Checking muffler function...................................................................................................................... 365 Checking cylinder head and manifolds for looseness............................................................................................. 366 Checking engine piping for damage and looseness................................................................................................ 367 Checking fuel delivery, return rate and leakage................................................................................................ 368 Replacing fan belt............................................................................................................................. 371 Testing and adjusting air conditioner compressor belt tension [machines with air conditioner].................................................. 372 Power train........................................................................................................................................ 374 Testing power train oil pressure............................................................................................................... 374 Adjusting transmission speed sensor............................................................................................................ 386 Emergency escape method in case of transmission valve failure.................................................................................. 390 Flushing torque converter and trasmission circuits............................................................................................. 394 Testing and adjusting toe-in................................................................................................................... 396 Testing and adjusting differential lock-up oil pressure [machine with differential lock-up].................................................... 398 Steering system.................................................................................................................................... 400 Testing and adjusting steering oil pressure.................................................................................................... 400 Testing steering cylinder oil leakage.......................................................................................................... 401 Bleeding air from steering circuit............................................................................................................. 402 Brake system....................................................................................................................................... 404 Testing and adjusting brake oil pressure....................................................................................................... 404 Releasing remaining pressure from brake circuit................................................................................................ 408 Bleeding air from brake circuit................................................................................................................ 409 Testing wheel brake disc wear.................................................................................................................. 410 Testing and adjusting parking brake............................................................................................................ 412 Emergency release method of parking brake...................................................................................................... 414 Filling gas into brake accumulator............................................................................................................. 416 Hydraulic system................................................................................................................................... 418 Testing and adjusting work equipment oil pressure.............................................................................................. 418 Testing and adjusting pump LS differential pressure............................................................................................ 421 Testing lift arm lock cylinder circuit oil pressure [machine with bank cut].................................................................... 423 Testing work equipment cylinder oil leakage amount............................................................................................. 424 Bleeding air from work equipment circuit....................................................................................................... 427 Work equipment..................................................................................................................................... 428 Clearance adjustment of drawbar ball joint..................................................................................................... 428 Testing and adjusting circle guide clearance................................................................................................... 429 Testing and adjusting slip clutch type circle rotator.......................................................................................... 431 Filling gas into blade accumulator [machine with blade accumulator]............................................................................ 433 Electrical system.................................................................................................................................. 434 Procedure for testing diodes................................................................................................................... 434 Special functions of machine monitor (EMMS).................................................................................................... 435 Handling high voltage circuit of engine controller............................................................................................. 484 How to start KOMTRAX terminal operations....................................................................................................... 486 Indicator lamps of KOMTRAX terminal............................................................................................................ 495 Preparation work for troubleshooting of electrical system...................................................................................... 502 Pm clinic.......................................................................................................................................... 504 40 Troubleshooting..................................................................................................................................... 513 General information on troubleshooting............................................................................................................. 519 Points to remember when troubleshooting........................................................................................................ 519 Sequence of events in troubleshooting.......................................................................................................... 520 Checks before troubleshooting.................................................................................................................. 521 Classification and procedures for troubleshooting.............................................................................................. 541 Failure codes table............................................................................................................................ 542 Failure and troubleshooting numbers............................................................................................................ 549 Information in troubleshooting table........................................................................................................... 551 Troubleshooting method for open circuit in wiring harness of pressure sensor system............................................................ 553 Connector list and layout...................................................................................................................... 555 Connection table for connector pin numbers..................................................................................................... 570 T- branch box and T- branch adapter table...................................................................................................... 606 Locations of fuses............................................................................................................................. 609 Troubleshooting by failurecode..................................................................................................................... 611 Failure code [1500LO] TORQUEFLOW transmission: Double engagement............................................................................... 611 Failure code [15G0MW] Transmission R clutch: Slip.............................................................................................. 612 Failure code [15H0MW] Transmission FH clutch: Slip............................................................................................. 613 Failure code [15J0MW] Transmission FL clutch: Slip............................................................................................. 613 Failure code [15K0MW] Transmission 1st clutch: Slip............................................................................................ 614 Failure code [15L0MW] Transmission 2nd clutch: Slip............................................................................................ 615 Failure code [15M0MW] Transmission 3rd speed clutch: Slip...................................................................................... 616 Failure code [15N0MW] Transmission 4th clutch: Slip............................................................................................ 617 Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF.............................................................. 618 Failure code [15SBMA] ECMV R clutch: Malfunction............................................................................................... 620 Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF............................................................. 622 Failure code [15SCMA] ECMV FH clutch: Malfunction.............................................................................................. 624 Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF............................................................. 626 Failure code [15SDMA] ECMV FL clutch: Malfunction.............................................................................................. 628 Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF............................................................ 630 Failure code [15SEMA] ECMV 1st clutch: Malfunction............................................................................................. 632 Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF............................................................ 634 Failure code [15SFMA] ECMV 2nd clutch: Malfunction............................................................................................. 636 Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF............................................................ 638 Failure code [15SGMA] ECMV 3rd clutch: Malfunction............................................................................................. 640 Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF............................................................ 642 Failure code [15SHMA] ECMV 4th clutch: Malfunction............................................................................................. 644 Failure code [15SJMA] ECMV lockup clutch: Malfunction.......................................................................................... 646 Failure code [15UONT] Inching clutch: Overheating.............................................................................................. 646 Failure code [2G42ZG] Front accumulater: Oil pressure drop..................................................................................... 647 Failure code [2G43ZG] Rear accumulater: Pressure drop.......................................................................................... 647 Failure code [AA1ANX] Air cleaner: Clogging.................................................................................................... 648 Failure code [AB00L6] Alternator; Engine start and stop signals are not matched................................................................ 650 Failure code [AB00MA] Alternator: Malfunction.................................................................................................. 652 Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop....................................................................... 654 Failure code: [B@BCNS] Engine coolant overheat................................................................................................. 654 Failure code: [B@CENS] Torque converter oil overheat........................................................................................... 655 Failure code: [B@CKNS] Differential case: Overheat............................................................................................. 656 Failure code: [B@HANS] Hydraulic oil: Overheating.............................................................................................. 658 Failure code [CA111] Engine controller internal error.......................................................................................... 660 Failure code [CA115] Engine Ne, Bkup speed sensor error........................................................................................ 661 Failure code [CA122] Charge pressure sensor high error......................................................................................... 662 Failure code [CA123] Charge pressure sensor low error.......................................................................................... 664 Failure code [CA131] Throttle sensor high error................................................................................................ 666 Failure code [CA132] Throttle sensor low error................................................................................................. 668 Failure code [CA144] Coolant sensor high error................................................................................................. 670 Failure code [CA145] Coolant sensor low error.................................................................................................. 672 Failure code [CA153] Charge temperature sensor high error...................................................................................... 674 Failure code [CA154] Charge temperature sensor low error....................................................................................... 676 Failure code [CA155] Speed derating error by high charge temperature........................................................................... 678 Failure code [CA187] Sensor power supply 2 low error........................................................................................... 680 Failure code [CA221] Atmospheric pressure sensor high error.................................................................................... 682 Failure code [CA222] Atmospheric pressure sensor low error..................................................................................... 684 Failure code [CA227] Sensor power supply 2 high error.......................................................................................... 686 Failure code [CA234] Engine overspeed.......................................................................................................... 686 Failure code [CA238] Ne speed sensor power supply error........................................................................................ 687 Failure code [CA271] IMV/IMA: Short circuit.................................................................................................... 688 Failure code [CA272] IMV/IMA open circuit...................................................................................................... 690 Failure code [CA322] Injector #1 (L#1) open/short.............................................................................................. 692 Failure code [CA323] Injector #5 (L#5) open/short.............................................................................................. 694 Failure code [CA324] Injector #3 (L#3) open/short.............................................................................................. 696 Failure code [CA325] Injector #6 (L#6) open/short.............................................................................................. 698 Failure code [CA331] Injector #2 (L#2) open/short.............................................................................................. 700 Failure code [CA332] Injector #4 (L#4) open/short.............................................................................................. 702 Failure code [CA342] Data compatibility error in engine controller............................................................................. 704 Failure code [CA351] Injector drive circuit error.............................................................................................. 705 Failure code [CA352] Sensor power supply 1 low error........................................................................................... 706 Failure code [CA386] Sensor power supply 1 high error.......................................................................................... 707 Failure code [CA428] Water-in-fuel sensor high error........................................................................................... 708 Failure code [CA429] Water-in-fuel sensor low error............................................................................................ 710 Failure code [CA431] Idle validation switch error.............................................................................................. 712 Failure code [CA432] Idle validation action error.............................................................................................. 716 Failure code [CA435] Engine oil pressure switch error.......................................................................................... 719 Failure code [CA441] Power supply voltage low error............................................................................................ 720 Failure code [CA442] Power supply voltage high error........................................................................................... 722 Failure code [CA449] Common rail pressure high error 2......................................................................................... 723 Failure code [CA451] Common rail pressure sensor high error.................................................................................... 724 Failure code [CA452] Common rail pressure sensor low error..................................................................................... 726 Failure code [CA488] Torque derating error by high charge temperature.......................................................................... 728 Failure code [CA553] Common rail pressure high error 1......................................................................................... 729 Failure code [CA559] Supply pump pressure low error 1.......................................................................................... 730 Failure code [CA689] Engine Ne speed sensor error.............................................................................................. 731 Failure code [CA731] Engine Bkup speed sensor phase error...................................................................................... 733 Failure code [CA757] All continuous data lost error............................................................................................ 734 Failure code [CA778] Engine Bkup speed sensor error............................................................................................ 735 Failure code [CA1633] KOMNET (CAN communication) error......................................................................................... 738 Failure code [CA2185] Throttle sensor power supply high error.................................................................................. 740 Failure code [CA2186] Throttle sensor power supply low error................................................................................... 742 Failure code [CA2249] Supply pump pressure low error 2......................................................................................... 744 Failure code [CA2311] Abnormality in IMV (IMA) solenoid........................................................................................ 745 Failure code [CA2555] Intake heater relay open circuit......................................................................................... 746 Failure code [CA2556] Intake heater relay short circuit........................................................................................ 748 Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness..................................................... 750 Failure code [D160KB] Backup lamp relay: Ground fault.......................................................................................... 752 Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault...................................................................... 754 Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state.......................................................... 756 Failure code [DAFRKR] CAN communication failure (monitor panel)................................................................................ 758 Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input).......................................................... 760 Failure code [DAQOKT] Transmission controller: Non-volatile memory error....................................................................... 762 Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)............................................... 764 Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement............................................. 766 Failure code [DAQRKR] Transmission controller CAN communication: Communication error........................................................... 768 Failure code [DAQRMA] Transmission controller option setting: Malfunction...................................................................... 772 Failure code [DB2RKR] Engine controller CAN communication: Communication error................................................................. 773 Failure code [DD1NLD] Fan reverse switch signal: Short circuit................................................................................. 780 Failure code [DD1PKB] RPM set switch power supply short circuit................................................................................ 782 Failure code [DD1QKB] RPM set mode switch short circuit........................................................................................ 784 Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error................................................................. 786 Failure code [DDTHKA] Fill switch for FH clutch: Open circuit.................................................................................. 788 Failure code [DDTJKA] Fill switch for FL clutch: Open circuit.................................................................................. 788 Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit................................................................................. 789 Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit................................................................................. 789 Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit................................................................................. 790 Failure code [DDTNKA] Fill switch for R clutch: Open circuit................................................................................... 791 Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit................................................................................. 792 Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input.............................................................. 793 Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error................................................... 797 Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range........................................................... 800 Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault........................................................................... 802 Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range....................................................... 804 Failure code [DGT7KB] Differential oil temperature sensor: Ground fault........................................................................ 806 Failure code [DJF1KA] Fuel level sensor: Open circuit.......................................................................................... 808 Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range.................................................................... 810 Failure code [DKD0KX] Articulation angle sensor: Input signal out of range..................................................................... 812 Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit...................................................................... 814 Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match....................................................... 815 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit............................................................... 816 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match................................................ 817 Failure code [DLM3KA] Fan speed sensor: Open circuit........................................................................................... 818 Failure code [DLM3LC] Fan speed sensor: Short circuit.......................................................................................... 819 Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit..................................................................... 820 Failure code [DV00KB] Buzzer: Short circuit.................................................................................................... 822 Failure code [DW4BKA] Parking brake solenoid valve: Open circuit............................................................................... 824 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.............................................................................. 826 Failure code [DW7BKA] Fan reverse solenoid: Open circuit....................................................................................... 827 Failure code [DW7BKB] Fan reverse solenoid: Short circuit...................................................................................... 828 Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line................................................................. 830 Failure code [DX16KA] Fan motor EPC solenoid: Open circuit..................................................................................... 832 Failure code [DX16KB] Fan motor EPC solenoid: Short circuit.................................................................................... 833 Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line............................................................... 834 Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit....................................................................................... 836 Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit...................................................................................... 837 Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line................................................................. 838 Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit.................................................................................... 840 Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit................................................................................... 841 Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line.............................................................. 842 Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit.................................................................................... 844 Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit................................................................................... 846 Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line.............................................................. 848 Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit................................................................................... 850 Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit.................................................................................. 852 Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line............................................................. 854 Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit................................................................................... 856 Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.................................................................................. 858 Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line............................................................. 860 Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit................................................................................... 862 Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit.................................................................................. 864 Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line............................................................. 866 Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit..................................................................................... 868 Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit.................................................................................... 869 Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line............................................................... 870 Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit................................................................................... 872 Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.................................................................................. 874 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line............................................................. 876 Troubleshooting of electrical system (E-mode)...................................................................................................... 878 E-1 Engine does not start (starting motor does not turn)....................................................................................... 878 E-2 Preheating does not work................................................................................................................... 884 E-3 When starting switch is turned to ON position, machine monitor displays nothing............................................................ 889 E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen.............................................. 892 E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen.... 892 E-6 Emergency stop monitor lights up while engine is running................................................................................... 893 E-7 Speedometer or engine tachometer does not indicate correctly............................................................................... 897 E-8 Engine coolant temperature gauge does not indicate correctly............................................................................... 898 E-9 Articulation angle indicator does not indicate correctly................................................................................... 900 E-10 Torque converter oil temperature gauge does not indicate correctly........................................................................ 902 E-11 Fuel level gauge does not indicate correctly.............................................................................................. 904 E-12 Character display does not display correctly.............................................................................................. 906 E-13 Centralized warning lamp does not light up or does not go off............................................................................. 908 E-14 Alarm buzzer does not sound or does not stop sounding..................................................................................... 910 E-15 Machine monitor mode selector switch does not work........................................................................................ 912 E-16 Transmission mode does not switch......................................................................................................... 916 E-17 Engine mode does not switch............................................................................................................... 918 E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]............................ 920 E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification].................................. 924 E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]............................... 926 E-21 Horn does not sound or does not stop sounding............................................................................................. 930 E-22 Backup alarm does not sound or does not stop sounding..................................................................................... 932 E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off................................................................... 935 E-24 Working lamp does not light up or does not go off......................................................................................... 942 E-25 Turn signal lamp and hazard lamp do not flash............................................................................................. 948 E-26 Stop lamp does not light up or does not go off............................................................................................ 954 E-27 Backup lamp does not light up or does not go off.......................................................................................... 956 E-28 Windshield wiper does not operate......................................................................................................... 958 E-29 Window washer does not operate............................................................................................................ 966 E-30 KOMTRAX system does not operate correctly................................................................................................. 970 Troubleshooting of hydraulic and mechanical system (H-mode)........................................................................................ 974 How to read troubleshooting matrix............................................................................................................. 974 H-1 Engine speed lowers significantly or engine stalls......................................................................................... 980 H-2 Machine does not start..................................................................................................................... 981 H-3Gear is not shifted......................................................................................................................... 982 H-4 Travel lacks speed or power................................................................................................................ 983 H-5 Torque converter lockup does not work or is not released................................................................................... 988 H-6 A large time lag results at start or in gear shift......................................................................................... 989 H-7 Oil temperature of torque converter is high................................................................................................ 994 H-8 Differential lock-up function does not work or is not released............................................................................. 999 H-9 Steering lacks speed or power..............................................................................................................1000 H-10 Steering wheel does not move..............................................................................................................1001 H-11 Wheel brake does not work at all or sufficiently..........................................................................................1002 H-12 Wheel brake cannot be released or drags...................................................................................................1003 H-13 Parking brake does not work at all or insufficiently......................................................................................1004 H-14 Parking brake (including emergency release system) cannot be released or drags............................................................1005 H-15 All work equipment operation lacks speed or power.........................................................................................1006 H-16 Work equipment does not work at all.......................................................................................................1007 H-17 Unusual noise comes out from around hydraulic pump........................................................................................1008 H-18 Blade lift operation lacks speed or power.................................................................................................1009 H-19 Hydraulic drift of blade lift cylinders is large..........................................................................................1010 H-20 Drawbar side shift operation lacks speed or power.........................................................................................1011 H-21 Blade side shift operation lacks speed or power...........................................................................................1012 H-22 Power tilt operation lacks speed or power.................................................................................................1013 H-23 Articulate operation lacks speed or power.................................................................................................1014 H-24 Leaning operation lacks speed or power....................................................................................................1015 H-25 Hydraulic drift of leaning cylinders (leaning) is large...................................................................................1016 H-26 Blade does not rotate.....................................................................................................................1017 H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)..................................1018 H-28 Blade accumulator function does not work or cannot be released(for machine with blade accumulator float specification)....................1019 H-29 Blade float function does not work or cannot be released..................................................................................1020 H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)..................................................1021 Troubleshooting of engine (S-mode).................................................................................................................1022 Method of using troubleshooting chart..........................................................................................................1022 S-1 Startability is poor.......................................................................................................................1026 S-2 Engine does not start......................................................................................................................1027 S-3 Engine does not pick up smoothly...........................................................................................................1030 S-4 Engine stops during operation..............................................................................................................1031 S-5 Engine runs rough or is unstable...........................................................................................................1032 S-6 Engine lacks power.........................................................................................................................1033 S-7 Exhaust smoke is black (incomplete combustion).............................................................................................1034 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................................1035 S-9 Oil becomes contaminated early.............................................................................................................1036 S-10 Fuel consumption is excessive.............................................................................................................1037 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)..........................................................................1038 S-12 Oil pressure drops........................................................................................................................1039 S-13 Oil level rises (coolant or fuel in oil)..................................................................................................1040 S-14 Coolant temperature rises too high (overheating)..........................................................................................1041 S-15 Unusual noise is made.....................................................................................................................1042 S-16 Vibration is excessive....................................................................................................................1043 50 Disassembly and assembly............................................................................................................................1045 General information on disassembly and assembly....................................................................................................1048 How to read this manual........................................................................................................................1048 Coating materials list.........................................................................................................................1050 Special tools list.............................................................................................................................1053 Sketches of special tools......................................................................................................................1057 Engine and cooling system..........................................................................................................................1061 Removal and installation of fuel supply pump assembly..........................................................................................1061 Removal and installation of fuel injector assembly.............................................................................................1066 Removal and installation of cylinder head assembly.............................................................................................1076 Removal and installation of engine front oil seal..............................................................................................1094 Removal and installation of engine rear oil seal...............................................................................................1097 Removal and installation of cooling fan pump assembly..........................................................................................1101 Removal and installation of cooling fan and fan motor assembly.................................................................................1103 Removal and installation of radiator assembly..................................................................................................1107 Removal and installation of aftercooler assembly...............................................................................................1111 Removal and installation of power train oil cooler assembly....................................................................................1114 Removal and installation of fuel tank assembly.................................................................................................1117 Removal and installation of engine hood assembly...............................................................................................1121 Power train........................................................................................................................................1123 Removal and installation of engine and transmission/torque converter assembly..................................................................1123 Disassembly and assembly of engine and transmission/torque converter assembly..................................................................1131 Disassembly and assembly of torque converter assembly..........................................................................................1133 Disassembly and assembly of transmission assembly..............................................................................................1141 Removal and installation of tandem drive and final drive assembly..............................................................................1179 Disassembly and assembly of tandem drive assembly..............................................................................................1183 Disassembly and assembly of final drive assembly...............................................................................................1188 Steering system....................................................................................................................................1207 Removal and installation of steering valve (orbit-roll) assembly...............................................................................1207 Disassembly and assembly of steering valve (orbit-roll) assembly...............................................................................1213 Brake system.......................................................................................................................................1224 Disassembly and assembly of wheel brake assembly...............................................................................................1224 Undercarriage and frame............................................................................................................................1229 Removal and installation of center hinge pin...................................................................................................1229 Hydraulic system...................................................................................................................................1242 Removal and installation of hydraulic tank, battery and frame assembly ........................................................................1242 Removal and installation of hydraulic tank assembly............................................................................................1249 Removal and installation of control valve assembly.............................................................................................1256 Disassembly and assembly of control valve assembly.............................................................................................1262 Disassembly and assembly of hydraulic cylinder assembly........................................................................................1265 Work equipment.....................................................................................................................................1270 Removal and installation of blade assembly.....................................................................................................1270 Removal and installation of circle drawbar assembly............................................................................................1272 Removal and installation of circle rotation gear assembly......................................................................................1275 Disassembly and assembly of circle rotation gear assembly......................................................................................1277 Removal and installation of ripper assembly....................................................................................................1282 Cab and its attachments............................................................................................................................1285 Removal and installation of operator cab assembly..............................................................................................1285 Removal and installation of floor frame assembly...............................................................................................1297 Removal and installation of operator cab glass (adhered glass).................................................................................1301 Removal and installation of air conditioner unit assembly......................................................................................1311 Electrical system..................................................................................................................................1317 Removal and installation of engine controller assembly.........................................................................................1317 Removal and installation of machine monitor assembly...........................................................................................1319 Removal and installation of transmission controller assembly...................................................................................1321 Removal and installation of KOMTRAX terminal assembly..........................................................................................1323 60 Maintenance standard................................................................................................................................1325 Engine and Cooling.................................................................................................................................1328 Engine mount and transmission mount............................................................................................................1328 Cooling system.................................................................................................................................1330 Cooling fan motor..............................................................................................................................1332 Power train system.................................................................................................................................1336 Transmission control...........................................................................................................................1336 Torque converter...............................................................................................................................1338 Transmission...................................................................................................................................1340 Main relief valve and torque converter relief valve............................................................................................1348 Front axle.....................................................................................................................................1350 Final drive (no differential specification)....................................................................................................1354 Final drive (differential/ differential lock specification)....................................................................................1356 Differential lock solenoid valve...............................................................................................................1358 Tandem drive...................................................................................................................................1360 Brake system.......................................................................................................................................1362 Slack adjuster.................................................................................................................................1362 Wheel brake....................................................................................................................................1364 Parking brake..................................................................................................................................1366 Hydraulic system...................................................................................................................................1368 Power train pump...............................................................................................................................1368 Control valve..................................................................................................................................1370 Hydraulic cylinder.............................................................................................................................1378 Work equipment.....................................................................................................................................1380 Circle and drawbar.............................................................................................................................1380 Blade..........................................................................................................................................1382 Lifter.........................................................................................................................................1384 Circle rotation gear...........................................................................................................................1386 80 Appendix............................................................................................................................................1389 Air conditioner....................................................................................................................................1391 Precautions for refrigerant....................................................................................................................1391 Air Conditioner Components.....................................................................................................................1392 Structure and Function of Refrigeration System.................................................................................................1394 Overview of Refrigeration System...............................................................................................................1395 Air Conditioner Unit...........................................................................................................................1396 Compressor.....................................................................................................................................1399 Condenser......................................................................................................................................1400 Receiver drier.................................................................................................................................1401 Air conditioner control panel..................................................................................................................1402 Procedure for check and troubleshooting........................................................................................................1404 Circuit diagram and layout of connector pins...................................................................................................1406 System diagram.................................................................................................................................1408 Detail of air conditioner unit.................................................................................................................1410 Parts and connectors layout....................................................................................................................1412 Testing air leakage (ducts)....................................................................................................................1414 Check with self-diagnosis (control panel display)..............................................................................................1415 Testing temperature control....................................................................................................................1416 Testing Fresh/Recirc air changeover............................................................................................................1417 Testing evaporator temperature sensor..........................................................................................................1418 Testing relays.................................................................................................................................1419 Testing blower amp.............................................................................................................................1420 Troubleshooting Chart 1........................................................................................................................1421 Troubleshooting Chart 2........................................................................................................................1423 Information in troubleshooting table...........................................................................................................1425 Troubleshooting for power supply system (Air conditioner does not operate).....................................................................1426 Troubleshooting of compressor and refrigerant system (Air is not cooled).......................................................................1428 Troubleshooting for blower motor system (Air does not come out or air flow is improper)........................................................1432 Troubleshooting for temperature control........................................................................................................1434 Troubleshooting for FRESH/RECIRC air changeover................................................................................................1436 Troubleshooting with gauge pressure............................................................................................................1438 Connection of service tool.....................................................................................................................1440 Precautions for disconnecting and connecting air conditioner piping............................................................................1442 Handling compressor oil........................................................................................................................1444 90 Diagrams and drawings...............................................................................................................................1447 Hydraulic diagrams and drawings....................................................................................................................1449 Symbols used in hydraulic circuit diagrams.....................................................................................................1449 Hydraulic circuit diagram......................................................................................................................1451 Power train hydraulic circuit diagram..........................................................................................................1453 Differential hydraulic circuit diagram.........................................................................................................1454 Electrical diagrams and drawings...................................................................................................................1455 Symbols used in electric circuit diagrams......................................................................................................1455 Electrical circuit diagram.....................................................................................................................1459 Index..................................................................................................................................................1469
KOMATSU GD555-5, GD655-5, GD675-5 MOTOR GRADER SHOP MANUAL SEN05215-06 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
1 review for Komatsu GD555-5, GD655-5, GD675-5 Motor Grader Shop Manual SEN05215-06 – PDF DOWNLOAD
Add a review
Kiaan –
Fast and secure