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Komatsu GD655-3E0, GD675-3E0 Motor Grader Shop Manual 51501, 51301 and up – PDF DOWNLOAD
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Komatsu GD655-3E0, GD675-3E0 Motor Grader Shop Manual
Book Code: SEN01775-05
SERIAL NUMBERS : GD655- 51501 and up GD675- 51301
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Description
Komatsu GD655-3E0, GD675-3E0 Motor Grader Shop Manual
FILE DETAILS:
Komatsu GD655-3E0, GD675-3E0 Motor Grader Shop Manual
Brands: Komatsu
Equipment Type: Motor Grader
Manuals Type: Shop Manual
Machine Model: GD655-3E0, GD675-3E0
Serial Number: 51501 and up, 51301 and up
Book Code: SEN01775-05
Language: English
Pages: 1035
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu GD655-3E0, GD675-3E0 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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
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 instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by 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.
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 reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu GD655-3E0, GD675-3E0 Motor Grader Shop Manual
COVER .................................................................................................................. 1 00 Index and foreword................................................................................................... 0 Index............................................................................................................... 2 Composition of shop manual...................................................................................... 3 Table of contents............................................................................................... 5 Foreword and general information.................................................................................... 16 Safety notice................................................................................................... 17 How to read the shop manual..................................................................................... 22 Explanation of terms for maintenance standard................................................................... 24 Handling electric equipment and hydraulic component............................................................. 26 How to read electric wire code.................................................................................. 38 Precautions when carrying out operation......................................................................... 41 Method of disassembling and connecting push-pull type coupler................................................... 44 Standard tightening torque table................................................................................ 47 Conversion table................................................................................................ 51 01 Specification........................................................................................................ 0 Specification and technical data.................................................................................... 57 Specification and technical data................................................................................ 58 General assembly drawing.................................................................................... 58 Specifications.............................................................................................. 59 Weight table................................................................................................ 67 Fuel, coolant, and lubricant selection...................................................................... 68 10 Structure, function and maintenance standard......................................................................... 0 Engine and cooling system........................................................................................... 71 Engine and cooling system....................................................................................... 72 Cooling line................................................................................................ 72 Fan drive................................................................................................... 73 Power train......................................................................................................... 75 Power train..................................................................................................... 76 Power train diagram......................................................................................... 76 Transmission hydraulic piping............................................................................... 77 Transmission control........................................................................................ 78 Torque converter............................................................................................ 79 Torque converter control valve.............................................................................. 84 Transmission................................................................................................ 85 Transmission control valve.................................................................................. 105 ECMV........................................................................................................ 107 Main relief valve and torque converter relief valve......................................................... 113 Final drive................................................................................................. 115 Steering system..................................................................................................... 122 Steering system................................................................................................. 123 Steering hydraulic piping drawing........................................................................... 123 Steering valve (Q/Amp manual Orbit-roll type)............................................................... 124 Priority valve.............................................................................................. 131 Accumulator pressure governor valve......................................................................... 139 Front axle.................................................................................................. 141 Brake system........................................................................................................ 146 Brake system.................................................................................................... 147 Blake hydraulic piping...................................................................................... 147 Brake valve................................................................................................. 149 Wheel brake................................................................................................. 153 Slack adjuster.............................................................................................. 154 Accumulator................................................................................................. 156 Parking brake............................................................................................... 157 Parking brake and bank control valve........................................................................ 158 Undercarriage and frame............................................................................................. 160 Undercarriage and frame......................................................................................... 161 Tandem drive................................................................................................ 161 Main frame.................................................................................................. 164 Hydraulic system.................................................................................................... 166 Hydraulic system................................................................................................ 167 Work equipment hydraulic piping drawing..................................................................... 167 Hydraulic pump.............................................................................................. 174 Main control valve.......................................................................................... 195 CLSS........................................................................................................ 204 Work equipment...................................................................................................... 217 Work equipment.................................................................................................. 219 Work equipment control...................................................................................... 219 Hydraulic system............................................................................................ 221 Hydraulic tank.............................................................................................. 224 Swivel joint................................................................................................ 225 Pilot check valve........................................................................................... 226 Blade accumulator, float valve.............................................................................. 230 Blade float device.......................................................................................... 233 Circle rotation motor....................................................................................... 235 Hydraulic cylinder.......................................................................................... 237 Circle, drawbar............................................................................................. 239 Blade....................................................................................................... 241 Circle rotation gear........................................................................................ 243 Scarifier................................................................................................... 246 Ripper...................................................................................................... 248 Cab and its attachments............................................................................................. 250 Cab and its attachments......................................................................................... 251 Air conditioner (If equipped)............................................................................... 251 Electrical system................................................................................................... 254 Electrical system............................................................................................... 255 Engine starting circuit..................................................................................... 255 Engine stop circuit......................................................................................... 257 Preheat circuit............................................................................................. 258 Automatic shift control system.............................................................................. 259 Transmission controller..................................................................................... 260 Monitor..................................................................................................... 266 Sensors..................................................................................................... 269 Communication controller.................................................................................... 275 KOMTRAX terminal system (if equipped)....................................................................... 276 20 Standard value table................................................................................................. 0 Standard service value table........................................................................................ 279 Standard service value table.................................................................................... 280 Standard value table for engine............................................................................. 280 Standard value table for chassis............................................................................ 281 30 Testing and adjusting................................................................................................ 0 Testing and adjusting, Part 1....................................................................................... 288 Testing and adjusting, Part 1................................................................................... 290 Tools for testing, adjusting and troubleshooting............................................................ 290 Measuring exhaust color..................................................................................... 293 Measuring exhaust temperature............................................................................... 294 Measuring intake air pressure (boost pressure).............................................................. 296 Measuring blowby pressure................................................................................... 298 Measuring engine oil pressure............................................................................... 299 Measuring engine speed...................................................................................... 300 Testing fan belt tension.................................................................................... 300 Testing air conditioner compressor belt tension............................................................. 301 Measuring torque converter stall speed...................................................................... 302 Checking clutch oil pressure................................................................................ 303 Checking torque converter oil pressure...................................................................... 304 Adjusting speed sensor...................................................................................... 305 Flushing torque converter and transmission circuit.......................................................... 307 Testing brake disc.......................................................................................... 308 Testing and adjusting parking brake......................................................................... 309 Method for emergency release of parking brake............................................................... 311 Testing and adjusting parking brake pad clearance........................................................... 312 Testing accumulator charge pressure......................................................................... 313 Testing and adjusting work equipment oil pressure........................................................... 314 Testing and adjusting LS differential pressure.............................................................. 315 Adjusting PC valve.......................................................................................... 317 Bleeding air from hydraulic circuit......................................................................... 318 Measuring internal cylinder leakage......................................................................... 319 Testing and adjusting differential lock oil pressure [Differential lock specification]...................... 321 Measuring steering and brake oil pressure................................................................... 323 Bleeding air from brake piping.............................................................................. 324 Charging nitrogen gas for brake, work equipment accumulator................................................. 325 Testing and adjusting circle guide clearance................................................................ 327 Testing and adjusting slip clutch type rotary device........................................................ 329 Memorizing idle and full position procedure................................................................. 331 Initial learning method for transmission controller......................................................... 332 Inspection procedure of diode............................................................................... 334 Testing and adjusting, Part 2....................................................................................... 336 Testing and adjusting, Part 2................................................................................... 337 Special functions of machine monitor (EMMS)................................................................. 337 Self-diagnosis display of gear shift lever.................................................................. 362 Handling of high-voltage circuit of engine controller....................................................... 363 Preparatory work for troubleshooting for electrical equipment system........................................ 364 Moving machine when transmission valve fails................................................................ 365 Adjusting cab stopper bolt.................................................................................. 367 How to start operation of KOMTRAX terminal.................................................................. 369 Lamp display of KOMTRAX terminal............................................................................ 372 Pm-clinic................................................................................................... 375 40 Troubleshooting...................................................................................................... 0 Failure code table and fuse locations............................................................................... 383 Failure code table and fuse locations........................................................................... 384 Failure code table.......................................................................................... 384 Fuse locations.............................................................................................. 388 General information on troubleshooting.............................................................................. 393 General information on troubleshooting.......................................................................... 394 Points to remember when troubleshooting..................................................................... 394 Sequence of events in troubleshooting....................................................................... 395 Testing before troubleshooting.............................................................................. 396 Classification and procedures of troubleshooting............................................................ 397 Connection table for connector pin numbers.................................................................. 398 T- branch box and T- branch adapter table................................................................... 434 Troubleshooting by failure code, Part 1............................................................................. 439 Troubleshooting by failure code, Part 1......................................................................... 441 Failure code [(DF1000)] Neutral safety...................................................................... 441 Failure code [2G42ZG] Decrease of accumulator oil pressure (Front).......................................... 442 Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear)........................................... 443 Failure code [AB00L6] Signal of alternator disagrees with operating state of engine......................... 444 Failure code [AB00MA] Malfunction of alternator............................................................. 446 Failure code [B@BAZG] Engine oil pressure too low........................................................... 448 Failure code [B@BCNS] Engine overheat....................................................................... 449 Failure code [B@CENS] Torque converter oil temperature too high............................................. 450 Failure code [B@CKNS] Differential oil overheat............................................................. 451 Failure code [CA111] Abnormality in controller.............................................................. 452 Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors........................................ 453 Failure code [CA122] Charge pressure sensor too high........................................................ 454 Failure code [CA123] Charge pressure sensor too low......................................................... 456 Failure code [CA131] Throttle sensor too high............................................................... 458 Failure code [CA132] Throttle sensor too low................................................................ 460 Failure code [CA144] Coolant temperature sensor too high.................................................... 462 Failure code [CA145] Coolant temperature sensor too low..................................................... 464 Failure code [CA153] Charge temperature sensor too high..................................................... 466 Failure code [CA154] Charge temperature sensor too low...................................................... 468 Failure code [CA155] Charge temperature too high and engine speed derated................................... 470 Failure code [CA187] Sensor power source 2 too low.......................................................... 471 Failure code [CA221] Atmospheric pressure sensor too high................................................... 473 Failure code [CA222] Atmospheric pressure sensor too low.................................................... 475 Failure code [CA227] Sensor power source 2 too high......................................................... 477 Failure code [CA234] Engine over speed...................................................................... 479 Failure code [CA238] Abnormal power source for Ne speed sensor.............................................. 480 Failure code [CA271] Short circuit in fuel pump actuator.................................................... 481 Failure code [CA272] Disconnection in fuel pump actuator.................................................... 483 Failure code [CA281] Abnormal supply pump pressure balance.................................................. 485 Failure code [CA322] Disconnection or short circuit in injector No.1........................................ 486 Failure code [CA323] Disconnection or short circuit in injector No.5........................................ 488 Failure code [CA324] Disconnection or short circuit in injector No.3........................................ 490 Failure code [CA325] Disconnection or short circuit in injector No.6........................................ 492 Failure code [CA331] Disconnection or short circuit in injector No.2........................................ 494 Failure code [CA332] Disconnection or short circuit in injector No.4........................................ 496 Troubleshooting by failure code, Part 2............................................................................. 499 Troubleshooting by failure code, Part 2......................................................................... 501 Failure code [CA342] Abnormality in engine controller data consistency...................................... 501 Failure code [CA351] Abnormality in injector drive circuit.................................................. 502 Failure code [CA352] Sensor power source 1 too low.......................................................... 504 Failure code [CA386] Sensor power source 1 too high......................................................... 506 Failure code [CA428] Water detection sensor too high........................................................ 508 Failure code [CA429] Water detection sensor too low......................................................... 510 Failure code [CA435] Abnormality in engine oil pressure switch.............................................. 512 Failure code [CA441] Power supply voltage too low........................................................... 514 Failure code [CA442] Power supply voltage too high.......................................................... 516 Failure code [CA449] Common rail pressure too high (2)...................................................... 518 Failure code [CA451] Common rail pressure sensor too high................................................... 522 Failure code [CA452] Common rail pressure sensor too low.................................................... 524 Failure code [CA488] Charge temperature too high and torque derated......................................... 526 Failure code [CA553] Common rail pressure too high (1)...................................................... 527 Failure code [CA559] Supply pump no pressure (1)............................................................ 528 Failure code [CA689] Abnormality in engine Ne speed sensor.................................................. 530 Failure code [CA731] Abnormality in engine Bkup speed sensor phase1......................................... 532 Failure code [CA757] Loss of all engine controller data..................................................... 534 Failure code [CA778] Abnormality in engine Bkup speed sensor................................................ 536 Failure code [CA1633] Abnormality in KOMNET................................................................. 538 Failure code [CA2185] Accelerator pedal sensor power source too high........................................ 540 Failure code [CA2186] Accelerator pedal sensor power source too low......................................... 542 Failure code [CA2249] Supply pump no pressure (2)........................................................... 544 Failure code [CA2265] Disconnection in electric lift pump................................................... 546 Failure code [CA2266] Short circuit in electric lift pump................................................... 548 Failure code [CA2311] Abnormal resistance in IMV solenoid................................................... 550 Failure code [CA2555] Disconnection in air intake heater relay.............................................. 552 Failure code [CA2556] Short circuit in air intake heater relay.............................................. 554 Troubleshooting by failure code, Part 3............................................................................. 557 Troubleshooting by failure code, Part 3......................................................................... 560 Failure code [D19CKZ] Disconnection or short circuit in differential control relay.......................... 560 Failure code [D19KKZ] Differential lock-up relay : Disconnection............................................ 562 Failure code [DAQ0KK] Power source voltage of transmission controller too low............................... 566 Failure code [DAQSKR] Communication controller cannot recognize S-NET....................................... 567 Failure code [DB2RKR] Communication lost engine controller.................................................. 568 Failure code [DBF0KK] Power source voltage of communication controller too low.............................. 570 Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low.................................. 572 Failure code [DBFRKR] Communication lost communication controller........................................... 574 Failure code [DD1PKB] Power supply line short in RPM set switch............................................. 576 Failure code [DD1QKB] Short circuit in RPM set mode switch.................................................. 578 Failure code [DDTGKA] Disconnection in lock-up clutch fill switch........................................... 580 Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch)............ 581 Failure code [DDTHKA] Disconnection in FH clutch fill switch................................................ 582 Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch)................. 583 Failure code [DDTJKA] Disconnection in FL clutch fill switch................................................ 584 Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch)................. 585 Failure code [DDTKKA] Disconnection in 1st clutch fill switch............................................... 586 Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)................ 588 Failure code [DDTLKA] Disconnection in 2nd clutch fill switch............................................... 590 Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch)................ 592 Failure code [DDTMKA] Disconnection in 3rd clutch fill switch............................................... 594 Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch)................ 596 Failure code [DDTNKA] Disconnection in R clutch fill switch................................................. 598 Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch).................. 599 Failure code [DDTPKA] Disconnection in 4th clutch fill switch............................................... 600 Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch)................ 602 Failure code [DF10KA] Disconnection in transmission shift lever switch...................................... 604 Failure code [DF10KB] Short circuit in transmission shift lever switch...................................... 608 Failure code [DGF1KX] Transmission oil temperature out of range............................................. 612 Failure code [DGT1KX] Torque converter oil temperature out of range......................................... 614 Failure code [DJF1KA] Disconnection in fuel level sensor.................................................... 616 Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range.......................... 618 Failure code [DK70KX] Input of inching pedal potentiometer out of normal range.............................. 620 Failure code [DKD0KA] Disconnection in articulate sensor.................................................... 622 Failure code [DLE2KA] Disconnection in engine speed sensor.................................................. 624 Failure code [DLF1KA] Disconnection in transmission input speed sensor...................................... 625 Failure code [DLT3KA] Disconnection in transmission output speed sensor..................................... 626 Failure code [DV00KB] Short circuit in caution buzzer....................................................... 627 Failure code [DW4BKA] Disconnection in parking brake relay.................................................. 628 Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid................................................ 630 Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid...................................... 631 Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid.............................................. 632 Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid.................................... 634 Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid.............................................. 636 Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid.................................... 638 Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid............................................. 640 Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid.............................. 641 Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid............................................. 642 Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid.............................. 643 Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid............................................. 644 Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid............................................... 645 Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid..................................... 646 Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid............................................. 648 Troubleshooting of electrical system (E-mode)....................................................................... 651 Troubleshooting of electrical system (E-mode)................................................................... 653 Contents of troubleshooting table........................................................................... 653 E-1 Engine does not start at all or does not start easily................................................... 654 E-2 Transmission mode does not change....................................................................... 661 E-3 Differential lock function does not work or is not reset [Differential lock specification].............. 663 E-4 Wheel brake does not work normally...................................................................... 666 E-5 Parking brake does not work or is not reset............................................................. 668 E-6 Lift arm lock pin is not locked or reset [Lift arm specification]....................................... 670 E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification].... 673 E-8 Blade float function does not work or is not reset [Blade accumulator and float specification].......... 676 E-9 When starting switch is turned ON, machine monitor does not operate normally............................ 683 E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display.................... 685 E-11 When starting switch is turned ON, caution item lights up.............................................. 686 E-12 While engine is running, emergency stop item lights up................................................. 687 E-13 Indication of speedometer and engine tachometer is abnormal............................................ 696 E-14 Indication of engine coolant temperature gauge is abnormal............................................. 697 E-15 Indication of articulate gauge is abnormal............................................................. 699 E-16 Indication of torque converter oil temperature gauge is abnormal....................................... 700 E-17 Indication of fuel level gauge is abnormal............................................................. 701 E-18 Display of character display is abnormal............................................................... 703 E-19 Centralized warning lamp does not light up or go off................................................... 704 E-20 Alarm buzzer does not sound or stop.................................................................... 705 E-21 Machine monitor mode selector switch does not function................................................. 707 E-22 Headlamp, clearance lamp and tail lamp do not light up or go off....................................... 710 E-23 Working lamp does not light up or go off............................................................... 715 E-24 Turn signal lamp and hazard lamp do not blink or go off................................................ 719 E-25 Brake lamp does not light up or go off................................................................. 724 E-26 Backup lamp does not light up or go off................................................................ 726 E-27 Backup buzzer does not sound or stop................................................................... 727 E-28 Air conditioner does not work or stop.................................................................. 728 E-29 KOMTRAX system does not operate normally............................................................... 731 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................... 734 Troubleshooting of hydraulic and mechanical system (H-mode)..................................................... 736 Contents of troubleshooting table........................................................................... 736 H-1 Excessive drop in engine speed, or engine stalls........................................................ 737 H-2 Machine does not move in either forward or reverse direction............................................ 738 H-3 Transmission does not shift up or shift down............................................................ 739 H-4 Machine is slow or lacks power when traveling........................................................... 740 H-5 Torque converter lockup function cannot be actuated or canceled......................................... 742 H-6 Excessive time lag when starting or shifting gear....................................................... 743 H-7 Torque converter oil temperature is high................................................................ 744 H-8 Differential lock function is not operated or reset [Differential lock specification]................... 746 H-9 Machine is slow or lacks power when steering............................................................ 747 H-10 Wheel brake does not work normally..................................................................... 748 H-11 Parking brake is not applied or released............................................................... 749 H-12 All work equipment is slow or lacks power.............................................................. 750 H-13 No work equipment moves................................................................................ 751 H-14 Abnormal noise generated around pump................................................................... 752 H-15 Blade is slow or lacks power in lifting................................................................ 753 H-16 Excessive blade drift.................................................................................. 754 H-17 Drawbar side shift operation is slow or lacks power.................................................... 755 H-18 Blade side shift operation is slow or lacks power...................................................... 756 H-19 Power tilt operation is slow or lacks power............................................................ 757 H-20 Articulate operation is slow or lacks power............................................................ 758 H-21 Leaning operation is slow or lacks power............................................................... 759 H-22 Excessive drift of leaning............................................................................. 760 H-23 Blade does not rotate.................................................................................. 761 H-24 Lift arm lock pin is not locked or reset [Lift arm specification]...................................... 762 H-25 Blade accumulator function is not operated or reset [Blade accumulator and float specification]........ 763 H-26 Blade float function is not operated or reset [Blade accumulator and float specification].............. 764 Troubleshooting of engine (S-mode).................................................................................. 766 Troubleshooting of engine (S-mode).............................................................................. 768 Method of using troubleshooting charts...................................................................... 768 S-1 Starting performance is poor............................................................................ 771 S-2 Engine does not start................................................................................... 772 S-3 Engine does not pick up smoothly........................................................................ 775 S-4 Engine stops during operations.......................................................................... 776 S-5 Engine does not rotate smoothly......................................................................... 777 S-6 Engine lacks output (or lacks power).................................................................... 778 S-7 Exhaust smoke is black (incomplete combustion).......................................................... 779 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 780 S-9 Oil becomes contaminated quickly........................................................................ 781 S-10 Fuel consumption is excessive.......................................................................... 782 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................. 783 S-12 Oil pressure drops..................................................................................... 784 S-13 Oil level rises (water, fuel in oil)................................................................... 785 S-14 Coolant temperature becomes too high (overheating)..................................................... 786 S-15 Abnormal noise is made................................................................................. 787 S-16 Vibration is excessive................................................................................. 788 50 Disassembly and assembly............................................................................................. 0 General information on disassembly and assembly..................................................................... 790 How to read this manual......................................................................................... 791 How to read this manual..................................................................................... 791 Coating materials list...................................................................................... 793 Special tool list........................................................................................... 796 Sketches of special tools................................................................................... 801 Engine and cooling system........................................................................................... 808 Engine and cooling system....................................................................................... 809 Removal and installation of fuel supply pump assembly....................................................... 809 Removal and installation of fuel injector assembly.......................................................... 812 Removal and installation of cylinder head assembly.......................................................... 817 Removal and installation of engine front seal............................................................... 830 Removal and installation of engine rear seal................................................................ 834 Removal and installation of engine assembly................................................................. 840 Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly......................... 844 Removal and installation of air conditioner condenser....................................................... 848 Removal and installation of oil cooler assembly............................................................. 851 Removal and installation of aftercooler assembly............................................................ 853 Removal and installation of radiator assembly............................................................... 856 Removal and installation of engine hood..................................................................... 859 Power train, Part 1................................................................................................. 864 Power train, Part 1............................................................................................. 865 Removal and installation of engine and transmission assembly................................................ 865 Removal and installation of transmission assembly........................................................... 871 Disassembly and assembly of torque converter assembly....................................................... 877 Disassembly and assembly of transmission assembly........................................................... 884 Power train, Part 2................................................................................................. 922 Power train, Part 2............................................................................................. 923 Removal and installation of final drive assembly............................................................ 923 Disassembly and assembly of final drive assembly............................................................ 928 Disassembly and assembly of final brake case assembly....................................................... 933 Disassembly and assembly of side case assembly (For standard final drive)................................... 937 Disassembly and assembly of bevel gear assembly............................................................. 940 Disassembly and assembly of bevel gear shaft................................................................ 944 Disassembly and assembly of bevel pinion assembly........................................................... 946 Steering system..................................................................................................... 949 Steering system................................................................................................. 950 Removal and installation of steering valve (Orbit-roll)..................................................... 950 Disassembly and assembly of steering valve.................................................................. 951 Hydraulic system.................................................................................................... 962 Hydraulic system................................................................................................ 963 Disassembly and assembly of work equipment control valve assembly........................................... 963 Disassembly and assembly of hydraulic cylinder assembly..................................................... 966 Work equipment...................................................................................................... 971 Work equipment.................................................................................................. 972 Removal and installation of blade assembly.................................................................. 972 Removal and installation of circle drawbar assembly......................................................... 973 Removal and installation of blade circle gear assembly...................................................... 975 Removal and installation of blade circle rotation gear assembly (with shear pin)............................ 977 Disassembly and assembly of blade circle rotation gear assembly (with shear pin)............................ 979 Disassembly and assembly of circle rotation gear assembly (with slip clutch)................................ 983 Cab and its attachments............................................................................................. 989 Cab and its attachments......................................................................................... 990 Removal and installation of operator's cab assembly......................................................... 990 Removal and installation of floor frame assembly............................................................ 992 Disassembly and assembly of operator’s seat assembly........................................................ 995 Removal and installation of operator's cab glass (stuck glass)..............................................1004 Removal and installation of air conditioner unit assembly...................................................1010 Electrical system...................................................................................................1013 Electrical system...............................................................................................1014 Removal and installation of machine monitor assembly........................................................1014 Removal and installation of engine controller assembly......................................................1015 Removal and installation of transmission controller assembly................................................1016 Removal and installation of KOMTRAX controller assembly.....................................................1017 Removal and installation of COMMUNICATION controller assembly...............................................1018 90 Diagrams and drawings................................................................................................ 0 Hydraulic diagrams and drawings.....................................................................................1020 Hydraulic diagrams and drawings.................................................................................1021 Power train hydraulic circuit diagram.......................................................................1021 Brake hydraulic circuit.....................................................................................1023 Hydraulic circuit diagram (1/2).............................................................................1024 Hydraulic circuit diagram (2/2).............................................................................1025 Electrical diagrams and drawings....................................................................................1027 Electrical diagrams and drawings................................................................................1028 Electrical circuit diagram (1/6)............................................................................1028 Electrical circuit diagram (2/6)............................................................................1029 Electrical circuit diagram (3/6)............................................................................1030 Electrical circuit diagram (4/6)............................................................................1031 Electrical circuit diagram (5/6)............................................................................1032 Electrical circuit diagram (6/6)............................................................................1033 Connector arrangement diagram...............................................................................1034
KOMATSU GD655-3E0, GD675-3E0 MOTOR GRADER SHOP MANUAL 51501, 51301 AND UP – PDF DOWNLOAD:
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