Komatsu MOTOR GRADER GD535-5 Hydraulic drive fan Shop Manual PDF

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Komatsu MOTOR GRADER GD535-5 Hydraulic drive fan specification Shop Manual KEBM665002 – PDF DOWNLOAD

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Komatsu MOTOR GRADER GD535-5 Hydraulic drive fan specification Shop Manual KEBM665002 – PDF DOWNLOAD

Language : English
Pages : 1550
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu MOTOR GRADER GD535-5 Hydraulic drive fan specification Shop Manual KEBM665002 – PDF DOWNLOAD

• SERIAL NUMBERS B10001 and up

Notice of revision 3
00 Index and foreword . 11
00 Index and foreword . 11
Table of contents . 12
Acronyms 24
Foreword and general information 29
Safety notice . 29
How to read the shop manual . 34
Explanation of terms for maintenance standard . 36
Handling of electric equipment and hydraulic components . 38
Handling of connectors newly used for engines . 47
How to read electric wire code 50
Precautions when carrying out work 53
Method of disassembling and connecting push-pull type coupler . 56
Standard tightening torque table 59
Conversion table 63
01 Specification 69
01 Specification 69
Contents 70
Acronyms 71
Specifications 76
Specification drawing . 76
Specifications 78
Weight table 84
Table of fuel, coolant, and lubricants 85
10 Structure and function . 87
10 Structure and function . 87
Contents 88
Acronyms 90
Engine and cooling system . 95
Cooling system 95
Cooling fan motor . 97
Power train system 105
Power train system drawing 105
Power train piping drawing 106
Transmission control 107
Torque converter 108
Transmission 111
Transmission control valve 130
ECMV 132
Main relief valve and torque converter relief valve . 139
Front axle 141
Rear axle . 144
Differential (Non-differential specification) . 145
Differential (Differential lock specification) 147
Differential lock solenoid valve 150
Final drive . 151
Tandem drive 153
Steering system . 155
Steering piping drawing . 155
Priority valve 156
Steering valve 161
Brake system 168
Hydraulic piping drawing of brake system 168
Brake valve . 169
Brake circuit accumulator . 174
Brake circuit accumulator charge valve 175
Wheel brake . 181
Parking brake solenoid valve and lifter lock pin solenoid valve . 182
Parking brake . 183
Undercarriage and frame . 184
Frame . 184
Tire 185
Hydraulic system 186
Hydraulic system 186
Hydraulic piping drawing of work equipment 188
Work equipment control 190
Hydraulic tank 191
Work equipment pump and steering pump . 192
Power train pump 193
Power train pump and differential lock pump . 194
Brake and cooling fan pump 195
Control valve . 196
Functions and valve operations 198
Hydraulic cylinder 199
Swivel joint 200
Pilot check valve . 201
Work equipment system . 210
Circle and drawbar 210
Blade . 212
Lifter 214
Circle rotation motor . 216
Circle rotation gear 218
Ripper 220
Cab and its attachments . 221
ROPS cab 221
Electrical system . 222
Layout drawing of electrical system . 222
System operating lamp system 224
Battery disconnect switch . 225
Machine monitor . 226
Automatic gear shift control system . 237
Transmission controller . 242
Engine controller . 245
KOMTRAX system 248
KOMTRAX terminal 249
Rearview monitor system . 251
Rearview monitor 252
Rearview camera . 253
Engine starting circuit . 254
Engine stop circuit . 256
Preheating circuit 257
Sensors . 258
Engine power mode selector circuit 267
Cooling fan control system 268
20 Standard value table . 271
20 Standard value table . 271
Contents 272
Acronyms 273
Standard value table 278
Standard value table for engine . 278
Standard value table for machine 280
30 Testing and adjusting 291
30 Testing and adjusting 291
Contents 292
Acronyms 294
Tools for testing, adjusting, and troubleshooting . 299
Tools for testing, adjusting, and troubleshooting . 299
Engine and cooling system . 306
Testing engine speed 306
Testing boost pressure 308
Testing exhaust gas temperature . 310
Testing exhaust gas color . 312
Adjusting valve clearance . 314
Testing compression pressure 316
Testing blowby pressure . 319
Testing engine oil pressure . 320
Handling fuel system devices 321
Releasing remaining pressure from fuel system . 322
Testing fuel pressure . 323
Bleeding air from fuel circuit 324
Testing fuel circuit for leakage 325
Handling cylinder cutout mode operation . 326
Handling no-injection cranking operation 327
Handling voltage circuit of engine controller . 328
Testing muffler (main body) and stacked muffler for looseness and damage 329
Testing muffler function 330
Testing installed condition of cylinder heads and manifolds . 331
Testing of engine piping for damage and looseness . 332
Testing fuel discharge, return rate, and leakage 333
Testing and adjusting air conditioner compressor belt tension . 337
Checking and replacing alternator belt 339
Checking and replacing auto-tensioner . 341
Power train . 344
Testing power train oil pressure 344
Adjusting transmission speed sensor . 358
Retrieval of disabled machine due to transmission valve failure . 361
Flushing procedure for torque converter and transmission circuits . 364
Testing and adjusting toe-in 366
Testing and adjusting differential lock oil pressure (differential lock specification) 368
Steering system . 370
Testing and adjusting steering oil pressure . 370
Testing oil leakage of steering cylinder 371
Bleeding air from steering circuit 372
Brake system 373
Releasing remaining pressure from brake circuit . 373
Testing and adjusting brake oil pressure 374
Bleeding air from brake circuit . 377
Testing wear of wheel brake disc 378
Testing and adjusting parking brake pad . 379
Releasing parking brake manually 382
Charging brake accumulator with gas . 383
Hydraulic system 385
Testing work equipment oil pressure . 385
Testing lifter lock pin circuit pressure 387
Testing cooling fan speed . 389
Testing cooling fan circuit oil pressure 390
Testing oil leakage of work equipment cylinder 392
Bleeding air from work equipment circuit 395
Work equipment 396
Adjusting drawbar ball joint clearance 396
Testing and adjusting circle guide clearance 397
Testing and adjusting slip clutch type circle drive . 399
Electrical system . 401
Procedure for testing diodes 401
Special functions of machine monitor 403
Handling high-voltage circuit of engine controller 452
KOMTRAX terminal start-up procedure . 453
Adjusting rearview camera angle . 457
Handle battery disconnect switch 459
Preparatory work for troubleshooting of electrical system failure . 460
Pm Clinic . 462
Pm Clinic . 462
40 Troubleshooting 473
40 Troubleshooting 473
Contents 474
Acronyms 480
Information related to troubleshooting 485
Points to remember when troubleshooting . 485
How to proceed in troubleshooting . 486
Checks before troubleshooting . 487
Inspection procedure before troubleshooting . 489
Troubleshooting procedure . 504
Failure code list . 506
Symptoms and troubleshooting numbers 514
Information described in troubleshooting table 517
Diagnosis of open harness in pressure sensor system . 519
Connector list and layout . 521
Connector pin layout 535
T-box and T-adapter list 571
Locations of fuses 576
Troubleshooting by failure code (display of code) . 579
Failure code [1500L0] Double Engagement of T/M Clutches . 579
Failure code [15G0MW] Failure of R-Clutch System 580
Failure code [15H0MW] Failure of Clutch System (FH) . 581
Failure code [15J0MW] Failure of Clutch System (FL) . 582
Failure code [15K0MW] Failure of Clutch System (1st) 583
Failure code [15L0MW] Failure of Clutch System (2nd) 584
Failure code [15M0MW] Failure of Clutch System (3rd) 585
Failure code [15N0MW] Failure of Clutch System (4th) 586
Failure code [15SBL1] Release Trouble of ECMV (R) . 587
Failure code [15SBMA] Malfunction of ECMV (R) . 589
Failure code [15SCL1] Release Trouble of ECMV (FH) 591
Failure code [15SCMA] Malfunction of ECMV (FH) 593
Failure code [15SDL1] Release Trouble of ECMV (FL) 595
Failure code [15SDMA] Malfunction of ECMV (FL) 597
Failure code [15SEL1] Release Trouble of ECMV (1st) . 599
Failure code [15SEMA] Malfunction of ECMV (1st) . 601
Failure code [15SFL1] Release Trouble of ECMV (2nd) . 603
Failure code [15SFMA] Malfunction of ECMV (2nd) . 605
Failure code [15SGL1] Release Trouble of ECMV (3rd) . 607
Failure code [15SGMA] Malfunction of ECMV (3rd) . 609
Failure code [15SHL1] Release Trouble of ECMV (4th) . 611
Failure code [15SHMA] Malfunction of ECMV (4th) . 613
Failure code [15SJMA] Malfunction of ECMV (L/U) . 615
Failure code [15U0NT] Overload of Inching Clutch 616
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 617
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) . 619
Failure code [989L00] Engine Controller Lock Caution 1 621
Failure code [989M00] Engine Controller Lock Caution 2 622
Failure code [989N00] Engine Controller Lock Caution 3 623
Failure code [AB00KE] Charge Voltage Low 624
Failure code [AB00KY] Hot Short of Alternator R Terminal 625
Failure code [B@BAZG] Derating in speed due to engine oil pressure drop . 626
Failure code [B@BCNS] Engine Overheat . 627
Failure code [B@CENS] T/C Oil Temp. Overheat 628
Failure code [B@CKNS] DIFF Oil Temp. Overheat . 629
Failure code [B@HANS] HYD Oil Temp. Overheat 631
Failure code [CA111] Engine NE, controller internal error . 633
Failure code [CA115] Engine NE, Bkup speed sensor error . 634
Failure code [CA122] Charge pressure sensor high error 635
Failure code [CA123] Charge pressure sensor low error . 637
Failure code [CA131] Throttle sensor high error . 639
Failure code [CA132] Throttle sensor low error 641
Failure code [CA144] Coolant sensor high error 644
Failure code [CA145] Coolant sensor low error . 646
Failure code [CA153] Charge temperature sensor high error . 648
Failure code [CA154] Charge temperature sensor low error 650
Failure code [CA155] Speed derating error by high charge temperature 652
Failure code [CA187] Sensor power supply 2 low error 653
Failure code [CA221] Atmospheric pressure sensor high error . 655
Failure code [CA222] Atmospheric pressure sensor low error 657
Failure code [CA227] Sensor power supply 2 high error . 659
Failure code [CA234] Engine overspeed . 660
Failure code [CA238] Ne speed sensor power supply error . 661
Failure code [CA271] IMV short-circuit error 662
Failure code [CA272] IMV open circuit . 664
Failure code [CA322] Injector #1 (L/B #1) open/short 666
Failure code [CA323] Injector #5 (L/B #5) open/short 668
Failure code [CA324] Injector #3 (L/B #3) open/short 670
Failure code [CA325] Injector #6 (L/B #6) open/short 672
Failure code [CA331] Injector #2 (L/B #2) open/short 674
Failure code [CA332] Injector #4 (L/B #4) open/short 676
Failure code [CA342] Data compatibility error in engine controller 678
Failure code [CA351] Injector drive circuit error . 679
Failure code [CA352] Sensor power supply 1 low error 680
Failure code [CA386] Sensor power supply 1 high error . 682
Failure code [CA428] Water-in-fuel sensor high error 683
Failure code [CA429] Water-in-fuel sensor low error . 685
Failure code [CA431] Idle validation switch error . 687
Failure code [CA432] Idle validation action error . 691
Failure code [CA435] Engine oil pressure switch error . 694
Failure code [CA441] Power supply voltage low error . 695
Failure code [CA442] Power supply voltage high error 697
Failure code [CA449] Common rail pressure high error 2 698
Failure code [CA451] Common rail pressure sensor high error . 699
Failure code [CA452] Common rail pressure sensor low error 701
Failure code [CA488] Torque derating error by high charge temperature . 703
Failure code [CA553] Common rail pressure high error 1 704
Failure code [CA559] Supply pump pressure low error 1 . 705
Failure code [CA689] Engine Ne speed sensor error . 707
Failure code [CA731] Engine Bkup speed sensor phase error . 709
Failure code [CA757] All continuous data lost error . 711
Failure code [CA778] Engine Bkup speed sensor error . 712
Failure code [CA1633] KOMNET (CAN communication) error 716
Failure code [CA2185] Throttle sensor power supply high error . 720
Failure code [CA2186] Throttle sensor power supply low error 722
Failure code [CA2249] Supply pump pressure low error 2 724
Failure code [CA2311] Abnormality in IMV (IMA) solenoid . 725
Failure code [CA2555] Intake heater relay open circuit 726
Failure code [CA2556] Intake heater relay short circuit . 728
Failure code [D160KA] Disconnection of Backup Light Relay . 730
Failure code [D160KB] Ground Fault of Backup Light Relay 732
Failure code [D160KY] Hot Short of Back Lamp Relay Output . 734
Failure code [D19JKZ] Personal Code Relay Abnormality . 736
Failure code [D19KKZ] Failure of Diff Control Relay . 738
Failure code [D1EHKA] Disconnection of Engine Start Relay . 740
Failure code [D1EHKB] Ground Fault of Engine Start Relay 741
Failure code [D1EHKY] Hot Short of Engine Start Relay . 742
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay . 743
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 . 745
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) . 746
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 748
Failure code [DAF0MB] Monitor ROM Abnormality . 749
Failure code [DAF0MC] Monitor Error . 750
Failure code [DAF3KK] Controller Power Source Low (MON) . 751
Failure code [DAFLKA] Op Lamp Open Cir (Mon) 753
Failure code [DAFLKB] Op Lamp Shrt Cir (Mon) 755
Failure code [DAQ0KK] Controller Power Source Low (T/M) . 757
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 759
Failure code [DAQ0MC] T/M Con Error . 760
Failure code [DAQ1KA] Disconnection of Key SW ACC . 761
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) . 763
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 765
Failure code [DAQLKA] Op Lamp Open Cir (T/M Cont) . 766
Failure code [DAQLKB] Op Lamp Shrt Cir (T/M Cont) . 768
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 770
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) . 771
Failure code [DB2QKR] CAN2 Discon (Engine Con) 772
Failure code [DD1PKB] Abnormality of RPM Switch . 776
Failure code [DD1QKB] Abnormality of RPM Set Mode Switch 778
Failure code [DDB6L4] Parking brake signal error 780
Failure code [DDTHKA] Disconnection of Fill Switch (FH) . 782
Failure code [DDTJKA] Disconnection of Fill Switch (FL) . 783
Failure code [DDTKKA] Disconnection of Fill Switch (1st) 784
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) 785
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) 786
Failure code [DDTNKA] Disconnection of Fill Switch (R) 787
Failure code [DDTPKA] Disconnection of Fill Switch (4th) 788
Failure code [DF10KA] Disconnection of Shift Lever Input 789
Failure code [DF10L4] Gear Speed/Travel Direction Signal Error 793
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor 796
Failure code [DGH2KB] Ground Fault of Hydraulic Oil Temp. S . 798
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor 800
Failure code [DGT7KB] Ground Fault of Diff Oil Temp. S.(C) 802
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor . 803
Failure code [DHT5L6] Failure of T/C Oil Press Sensor . 805
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 807
Failure code [DK70KX] Out of Range of Inching Potentio 809
Failure code [DKD0KX] Out of Range of Articulated Angle Sensor 811
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor . 813
Failure code [DLF1LC] Failure of T/M Input Speed Sensor . 815
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor 817
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 819
Failure code [DLM3KA] Rad Fan Spd Sen Opn/Shrt Cir 821
Failure code [DLM3LC] Rad Fan Spd Sen Sig Error . 823
Failure code [DLM3MB] Rad Fan Spd Sen Error . 824
Failure code [DLT3KA] Disconnection of T/M output Speed Sensor 825
Failure code [DW4BKA] Disconnection of Parking Brake Valve 827
Failure code [DW4BKB] Ground Fault of Parking Brake Valve . 829
Failure code [DW4BKY] Hot Short of Parking Brake Solenoid . 831
Failure code [DW7BKA] Rad Fan R Sol Opn Cir . 833
Failure code [DW7BKB] Rad Fan R Sol Gnd Flt . 835
Failure code [DW7BKY] Rad Fan R Sol Shrt Cir 837
Failure code [DX16KA] Rad Fan Pump EPC Sol Opn Cir 839
Failure code [DX16KB] Rad Fan Pump EPC Sol Gnd Flt 841
Failure code [DX16KY] Rad Fan Pmp EPC Sol Shrt Cir 843
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) . 845
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 847
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) . 849
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) . 851
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 853
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) . 855
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 857
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) . 859
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 861
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 863
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) . 865
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 867
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 869
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) . 871
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 873
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 875
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) . 877
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 879
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 881
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) . 883
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 885
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 887
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) . 889
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 891
Troubleshooting of electrical system (E-mode) . 893
E-1 Engine does not start (Starting motor does not rotate) 893
E-2 Manual preheating system does not work 897
E-3 When starting switch is turned ON, machine monitor displays nothing . 903
E-4 LCD panel backlight of machine monitor fails (goes out or flickers) . 906
E-5 LCD display failure of machine monitor 907
E-6 The switch of machine monitor switch panel does not work 908
E-7 Two-switch operation of switch panel on machine monitor does not function . 909
E-8 Machine monitor buzzer does not sound . 910
E-9 Some gauges or caution lamps of machine monitor do not work normally 911
E-10 Rearview monitor does not light up or backlight flickers . 912
E-11 Rearview monitor images are not displayed clearly 914
E-12 Rearview monitor brightness cannot be adjusted . 916
E-13 Night lighting lamp of rearview monitor is abnormal 919
E-14 Speedometer or engine speed display is abnormal 921
E-15 Engine coolant temperature is displayed abnormally . 922
E-16 Articulated meter display is abnormal 924
E-17 Torque converter oil temperature is displayed abnormally . 926
E-18 Fuel gauge is displayed abnormally . 928
E-19 Centralized warning lamps do not light or do not go out 930
E-20 Alarm buzzer does not sound or does not stop sounding 931
E-21 Transmission mode cannot be switched . 933
E-22 Engine mode cannot be switched . 935
E-23 Differential gear lock function does not operate or is not canceled (for differential gear lock model) . 937
E-24 Cannot be locked or canceled by the lifter lock pin 939
E-25 Horn does not sound or does not stop sounding 941
E-26 Backup alarm does not sound or does not stop sounding 943
E-27 Headlamps, clearance lamps, and tail lamps do not light up or go out . 946
E-28 Working lamps do not light up or go out 954
E-29 Turn indicator light or emergency flashing light does not flash 959
E-30 Stop lamp does not light up or does not go out . 968
E-31 Backup lamp does not light up or does not go out . 970
E-32 All wipers do not operate 972
E-33 Front wiper does not operate . 974
E-34 Rear wiper does not operate 978
E-35 Left and right door wiper does not operate . 981
E-36 Left door wiper does not operate . 984
E-37 Right door wiper does not operate 986
E-38 Front or door washer does not operate 988
E-39 Rear washer does not operate . 990
E-40 KOMTRAX system does not operate normally . 992
Troubleshooting of hydraulic and mechanical system (H-mode) . 994
How to use troubleshooting table 994
H-1 Engine speed drops significantly or engine stalls .1000
H-2 Machine does not move off .1001
H-3 Gear speed does not shift .1002
H-4 Travel speed or power is low 1003
H-5 Torque converter lockup does not operate or is not canceled .1006
H-6 Machine starts or gear speed shifts with long time lag 1007
H-7 Torque converter oil temperature is high 1010
H-8 Differential gear lock function does not operate or is not canceled .1013
H-9 Steering speed or power is insufficient .1014
H-10 Steering wheel does not move .1015
H-11 Wheel brakes do not work or are weak .1016
H-12 Wheel brakes are not released or drag 1017
H-13 Parking brake does not work or it is weak 1018
H-14 Parking brake (including emergency release system) is not released or drags 1019
H-15 All work equipment operates slowly or lacks power 1020
H-16 Work equipment does not operate 1021
H-17 Unusual noise is heard from around hydraulic pump 1022
H-18 Blade lift speed or power is low .1023
H-19 Hydraulic drift of lifted blade is large .1024
H-20 Drawbar side shift speed or power is low .1025
H-21 Blade side shift speed or power is low .1026
H-22 Power tilt speed or power is low .1027
H-23 Articulate speed or power is low .1028
H-24 Leaning speed or power is insufficient .1029
H-25 Hydraulic drift (tilting) of leaning is large 1030
H-26 Blade does not rotate 1031
H-27 Lifter lock pin is not locked or is not canceled .1032
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) .1033
Troubleshooting of engine (S-mode) 1035
How to read matrix 1035
S-1 Engine startability is poor .1038
S-2 Engine does not start .1039
S-3 Engine does not pick-up smoothly 1042
S-4 Engine stops during operation .1043
S-5 Engine runs rough or is unstable 1044
S-6 Engine lacks power 1045
S-7 Exhaust smoke is black (Incomplete combustion) 1046
S-8 Large oil consumption (or blue exhaust gas) .1047
S-9 Oil becomes contaminated early 1048
S-10 Fuel consumption is excessive 1049
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1050
S-12 Oil pressure drops .1051
S-13 Oil amount increases (due to water or fuel mixing) .1052
S-14 Coolant temperature rises too high (overheating) .1053
S-15 Unusual noise is heard .1054
S-16 Vibration is excessive .1055
50 Disassembly and assembly .1057
Contents 1058
Acronyms 1060
Related information on disassembly and assembly .1065
How to read this manual .1065
Coating materials list 1067
Special tool list .1071
Sketches of special tools .1081
Engine and cooling system .1109
Removal and installation of supply pump assembly 1109
Removal and installation of injector assembly .1113
Removal and installation of cylinder head assembly 1122
Removal and installation of air conditioner compressor belt .1140
Removal and installation of alternator belt .1141
Removal and installation of engine front oil seal .1143
Removal and installation of engine rear oil seal 1146
Removal and installation of cooling fan pump assembly .1149
Removal and installation of cooling fan and fan motor assembly 1151
Removal and installation of radiator assembly .1155
Removal and installation of aftercooler assembly 1159
Removal and installation of power train oil cooler assembly .1163
Removal and installation of fuel tank assembly 1166
Removal and installation of engine hood assembly 1170
Removal and installation of air conditioner compressor assembly .1172
Power train .1174
Removal and installation of engine, transmission, and torque converter assembly .1174
Disconnection and connection of engine, transmission, and torque converter assembly .1182
Disassembly and assembly of torque converter assembly .1184
Disassembly and assembly of transmission assembly .1195
Removal and installation of tandem drive and final drive assembly .1230
Disassembly and assembly of tandem drive assembly .1233
Disassembly and assembly of differential assembly .1239
Disassembly and assembly of final drive assembly 1252
Steering system .1261
Removal and installation of Orbitrol valve assembly .1261
Brake system 1266
Disassembly and assembly of wheel brake assembly 1266
Undercarriage and frame .1274
Removal and installation of center hinge pin 1274
Hydraulic system 1285
Removal and installation of hydraulic tank, battery, and frame assembly .1285
Removal and installation of hydraulic tank assembly .1292
Removal and installation of control valve assembly 1296
Disassembly and assembly of hydraulic cylinder assembly .1301
Work equipment 1305
Removal and installation of blade assembly 1305
Removal and installation of circle drawbar assembly .1306
Removal and installation of circle rotation gear assembly .1308
Disassembly and assembly of circle rotation gear assembly .1310
Cab and its attachments .1315
Removal and installation of operator’s cab assembly .1315
Removal and installation of operator cab glass (adhered glass) 1324
Removal and installation of floor frame assembly 1334
Removal and installation of operator’s cab and floor frame assembly .1338
Removal and installation of air conditioner unit assembly .1345
Removal and installation operator’s seat 1351
Removal and installation seat belt 1352
Electrical system .1354
Removal and installation of engine controller assembly 1354
Removal and installation of machine monitor assembly 1356
Removal and installation of transmission controller assembly 1357
Removal and installation of rearview camera .1359
Removal and installation of KOMTRAX terminal assembly .1361
50 Disassembly and assembly .1057
60 Maintenance standard .1365
60 Maintenance standard .1365
Contents 1366
Acronyms 1367
Engine and cooling system .1372
Engine mount and transmission mount .1372
Cooling system 1373
Cooling fan motor .1374
Power train system 1376
Torque converter 1376
Transmission 1378
Main relief valve and torque converter relief valve .1387
Front axle 1388
Rear axle .1390
Differential (Non-differential specification) .1391
Differential (Differential lock specification) 1392
Final drive .1394
Differential lock solenoid valve 1395
Tandem drive 1396
Steering system .1397
Steering cylinder .1397
Brake system 1398
Wheel brake .1398
Parking brake .1399
Undercarriage and frame .1400
Frame and center hinge pin 1400
Hydraulic system 1401
Hydraulic tank 1401
Work equipment pump and steering pump .1402
Power train pump 1403
Power train pump and differential lock pump .1404
Parking brake solenoid valve and lifter lock pin solenoid valve .1405
Leaning cylinder 1406
Articulate cylinder .1407
Blade lift cylinder .1408
Drawbar shift cylinder 1409
Blade side shift cylinder .1410
Power tilt cylinder .1411
Scarifier cylinder 1412
Ripper cylinder .1413
Work equipment 1414
Circle and drawbar 1414
Blade .1416
Lifter 1418
Circle rotation gear 1419
Ripper 1421
80 Appendix .1423
80 Appendix .1423
Contents 1424
Acronyms 1425
Air conditioner system 1430
Precautions for refrigerant .1430
Air conditioner component .1431
Specifications of air conditioner .1434
Configuration and function of refrigeration cycle .1435
Outline of refrigeration cycle 1436
Component parts of air conditioner system .1438
Air conditioner unit 1438
Component parts of air conditioner unit .1441
Compressor 1443
Condenser .1444
Receiver drier 1445
Explanation of procedure for testing and troubleshooting of air conditioner .1446
Circuit diagram and arrangement of connector pins for air conditioner .1448
Air conditioner system diagram 1450
Input and output signals of air conditioner control panel .1451
Installation locations of air conditioner parts and arrangement of connectors .1454
Testing air leakage (duct) 1459
Method for testing air leakage (duct) .1459
Testing air conditioner using self-diagnosis function .1461
Check temperature control function 1462
Method for checking temperature control function 1462
Testing fresh/recirc air changeover .1463
Method for testing fresh/recirc air changeover 1463
Test evaporator temperature sensor 1464
Method for checking evaporator temperature sensor .1464
Test relays .1465
Method for testing relays .1465
Check blower AMP 1466
Method for checking blower AMP 1466
Air conditioner troubleshooting chart 1 .1468
Air conditioner troubleshooting chart 2 .1470
Information described in troubleshooting table 1473
A-1 Troubleshooting for power supply system (air conditioner does not operate) 1474
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) .1476
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) 1479
A-4 Troubleshooting for temperature control function 1482
A-5 Troubleshooting for fresh/recirc air changeover .1485
A-6 Troubleshooting for hot water cut valve .1488
Troubleshooting using gauge pressure 1490
Connection of service tool 1492
Method for connecting service tool 1493
Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings .1494
Handle compressor oil .1496
90 Diagrams and drawings 1499
Contents 1500
Acronyms 1501
Hydraulic diagrams and drawings .1506
Symbols used in hydraulic circuit diagrams 1506
Hydraulic circuit diagram . 0
Hydraulic circuit diagram (1/2) . 0
Hydraulic circuit diagram (2/2) . 0
Power train hydraulic circuit diagram .1513
Power train hydraulic circuit diagram . 0
Electrical diagrams and drawings 1515
Symbols used in electric circuit diagrams .1515
Chassis electric circuit diagram 0
Floor electric circuit diagram 0
Chassis electric circuit diagram .1519
Chassis electric circuit diagram (1/5) 0
Chassis electric circuit diagram (2/5) 0
Chassis electric circuit diagram (3/5) 0
Chassis electric circuit diagram (4/5) 0
Chassis electric circuit diagram (5/5) 0
Floor electric circuit diagram (1/7) 0
Floor electric circuit diagram (2/7) 0
Floor electric circuit diagram (3/7) 0
Floor electric circuit diagram (4/7) 0
Floor electric circuit diagram (5/7) 0
Floor electric circuit diagram (6/7) 0
Floor electric circuit diagram (7/7) 0
Index .1543
Colophon 1550
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DESCRIPTION:

Komatsu MOTOR GRADER GD535-5 Hydraulic drive fan specification Shop Manual KEBM665002 – PDF DOWNLOAD

• SERIAL NUMBERS B10001 and up