Komatsu Motor Grader GD655-3E0 GD675-3E0 Shop Manual SEN01775-05 PDF

Description

Komatsu Motor Grader GD655-3E0 GD675-3E0 Shop Manual SEN01775-05  – PDF DOWNLOAD

FILE DETAILS:

Komatsu Motor Grader GD655-3E0 GD675-3E0 Shop Manual SEN01775-05  – PDF DOWNLOAD

Language : English
Pages :1074
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Motor Grader GD655-3E0 GD675-3E0 Shop Manual SEN01775-05  – PDF DOWNLOAD

SERIAL NUMBERS GD655-3E0-51501
GD675-3E0-51301 and up

1. General precautions

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

TABLE OF CONTENTS:

Komatsu Motor Grader GD655-3E0 GD675-3E0 Shop Manual SEN01775-05  – PDF DOWNLOAD

SERIAL NUMBERS GD655-3E0-51501
GD675-3E0-51301 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling electric equipment and hydraulic component 27
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 Specification 59
Specification and technical data 59
Specification and technical data 1General assembly drawing 60
Weight table 69
Fuel, coolant, and lubricant selection 70
10 Structure, function andmaintenance standard 73
Engine and cooling system 73
Cooling line 74
Fan drive 75
Power train 77
Power train diagram 78
Transmission hydraulic piping 79
Transmission control 80
Torque converter 81
Torque converter control valve 86
Transmission 87
Transmission control valve 108
ECMV 110
Main relief valve and torque converter relief valve 116
Final drive 118
Steering system 125
Steering system 126
Steering hydraulic piping drawing 126
Steering valve (Q/Amp manual Orbit-roll type) 127
Priority valve 134
Accumulator pressure governor valve 142
Front axle 144
Brake system 149
Brake system 150
Blake hydraulic piping 150
Brake valve 152
Wheel brake 156
Slack adjuster 157
Accumulator 159
Parking brake 160
Parking brake and bank control valve 161
Undercarriage and frame 163
Undercarriage and frame 164
Tandem drive 164
Main frame 167
Hydraulic system 169
Hydraulic system 170
Work equipment hydraulic piping drawing 170
Hydraulic pump 178
Main control valve 201
CLSS 212
Work equipment 225
Work equipment 228
Work equipment control 228
Hydraulic system 230
Hydraulic tank 233
Swivel joint 234
Pilot check valve 235
Blade accumulator, float valve 239
Blade float device 242
Circle rotation motor 244
Hydraulic cylinder 246
Circle, drawbar 248
Blade 250
Circle rotation gear 252
Cab and its attachments 261
Cab and its attachments 262
Air conditioner (If equipped) 262
Electrical system 265
Electrical system 266
Engine starting circuit 266
Engine stop circuit 268
Preheat circuit 269
Automatic shift control system 270
Transmission controller 272
Transmission controller 272
Monitor 278
Sensors 281
Communication controller 287
KOMTRAX terminal system (if equipped) 288
20 Standard value table 291
Standard service value table 292
Standard value table for engine 292
Standard value table for chassis 293
30 Testing and adjusting 301
Testing and adjusting, Part 1 301
Testing and adjusting, Part 1 303
Tools for testing, adjusting and troubleshooting 303
Measuring exhaust color 306
Measuring exhaust temperature 307
Measuring intake air pressure(boost pressure) 309
Measuring blowby pressure 311
Measuring engine oil pressure 312
Measuring engine speed 313
Testing fan belt tension 313
Testing air conditioner compressor belt tension 314
Measuring torque converter stallspeed 315
Checking clutch oil pressure 316
Checking torque converter oilpressure 317
Adjusting speed sensor 318
Flushing torque converter and transmission circuit 320
Testing brake disc 321
Testing and adjusting parking brake 322
Method for emergency release of parking brake 324
Testing and adjusting parking brake pad clearance 325
Testing accumulator charge pressure 326
Testing and adjusting work equipment oil pressure 327
Testing and adjusting LS differential pressure 328
Adjusting PC valve 330
Bleeding air from hydraulic circuit 331
Measuring internal cylinder leakage 332
Testing and adjusting differential lock oil pressure [Differential lock specification] 334
Measuring steering and brake oil pressure 336
Bleeding air from brake piping 337
Charging nitrogen gas for brake, work equipment accumulator 338
Testing and adjusting circle guide clearance 340
Testing and adjusting slip clutch type rotary device 342
Memorizing idle and full position procedure 344
Initial learning method for transmission controller 345
Inspection procedure of diode 347
Testing and adjusting, Part 2 349
Testing and adjusting, Part 2 350
Special functions of machine monitor (EMMS) 350
Self-diagnosis display of gear shift lever 375
Handling of high-voltage circuit of engine controller 376
Preparatory work for troubleshooting for electrical equipment system 377
Moving machine when transmission valve fails 378
Adjusting cab stopper bolt 380
How to start operation of KOMTRAX terminal 382
Lamp display of KOMTRAX terminal 385
Pm-clinic 388
40 Troubleshooting 397
Failure code table and fuse locations 397
Failure code table and fuse locations 398
Failure code table 398
Fuse locations 402
General information on troubleshooting 407
General information on troubleshooting 408
Points to remember when troubleshooting 408
Sequence of events in troubleshooting 409
Testing before troubleshooting 410
Classification and procedures of troubleshooting 411
Connection table for connector pin numbers 412
T- branch box and T- branch adapter table 448
Troubleshooting by failure code, Part 1 453
Troubleshooting by failure code, Part 1 455
Failure code [(DF1000)] Neutral safety 455
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front) 456
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear) 457
Failure code [AB00L6] Signal of alternator disagrees with operating state of engine 458
Failure code [AB00MA] Malfunction of alternator 460
Failure code [B@BAZG] Engine oil pressure too low 462
Failure code [B@BCNS] Engine overheat 463
Failure code [B@CENS] Torque converter oil temperature too high 464
Failure code [B@CKNS] Differential oil overheat 465
Failure code [CA111] Abnormality in controller 466
Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors 467
Failure code [CA122] Charge pressure sensor too high 468
Failure code [CA123] Charge pressure sensor too low 470
Failure code [CA131] Throttle sensor too high 472
Failure code [CA132] Throttle sensor too low 474
Failure code [CA144] Coolant temperature sensor too high 476
Failure code [CA145] Coolant temperature sensor too low 478
Failure code [CA153] Charge temperature sensor too high 480
Failure code [CA154] Charge temperature sensor too low 482
Failure code [CA155] Charge temperature too high and engine speed derated 484
Failure code [CA187] Sensor power source 2 too low 486
Failure code [CA221] Atmospheric pressure sensor too high 488
Failure code [CA222] Atmospheric pressure sensor too low 490
Failure code [CA227] Sensor power source 2 too high 492
Failure code [CA234] Engine over speed 494
Failure code [CA238] Abnormal power source for Ne speed sensor 495
Failure code [CA271] Short circuit in fuel pump actuator 496
Failure code [CA272] Disconnection in fuel pump actuator 498
Failure code [CA281] Abnormal supply pump pressure balance 500
Failure code [CA322] Disconnection or short circuit in injector No1 502
Failure code [CA323] Disconnection or short circuit in injector No5 504
Failure code [CA324] Disconnection or short circuit in injector No3 506
Failure code [CA325] Disconnection or short circuit in injector No6 508
Failure code [CA331] Disconnection or short circuit in injector No2 510
Failure code [CA332] Disconnection or short circuit in injector No4 512
Troubleshooting by failure code, Part 2 515
Troubleshooting by failure code, Part 2 517
Failure code [CA342] Abnormality in engine controller data consistency 517
Failure code [CA351] Abnormality in injector drive circuit 518
Failure code [CA352] Sensor power source 1 too low 520
Failure code [CA386] Sensor power source 1 too high 522
Failure code [CA428] Water detection sensor too high 524
Failure code [CA429] Water detection sensor too low 526
Failure code [CA435] Abnormality in engine oil pressure switch 528
Failure code [CA441] Power supply voltage too low 530
Failure code [CA442] Power supply voltage too high 532
Failure code [CA449] Common rail pressure too high (2) 534
Failure code [CA451] Common rail pressure sensor too high 538
Failure code [CA452] Common rail pressure sensor too low 540
Failure code [CA488] Charge temperature too high and torque derated 542
Failure code [CA553] Common rail pressure too high (1) 543
Failure code [CA559] Supply pump no pressure (1) 544
Failure code [CA689] Abnormality in engine Ne speed sensor 546
Failure code [CA731] Abnormality in engine Bkup speed sensor phase 548
Failure code [CA757] Loss of all engine controller data 550
Failure code [CA778] Abnormality in engine Bkup speed sensor 552
Failure code [CA1633] Abnormality in KOMNET 554
Failure code [CA2185] Accelerator pedal sensor power source too high 556
Failure code [CA2186] Accelerator pedal sensor power source too low 558
Failure code [CA2249] Supply pump no pressure (2) 560
Failure code [CA2265] Disconnection in electric lift pump 562
Failure code [CA2266] Short circuit in electric lift pump 564
Failure code [CA2311] Abnormal resistance in IMV solenoid 566
Failure code [CA2555] Disconnection in air intake heater relay 568
Failure code [CA2556] Short circuit in air intake heater relay 570
Troubleshooting by failure code, Part 3 573
Troubleshooting by failure code, Part 3 576
Failure code [D19CKZ] Disconnection or short circuit in differential control relay 576
Failure code [D19KKZ] Differential lock-up relay : Disconnection 578
Failure code [D5ZHL6] Terminal C signal does not match state of engine 580
Failure code [DAQ0KK] Power source voltage of transmission controller too low 582
Failure code [DAQSKR] Communication controller cannot recognize S-NET 583
Failure code [DB2RKR] Communication lost engine controller 584
Failure code [DBF0KK] Power source voltage of communication controller too low 586
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low 588
Failure code [DBFRKR] Communication lost communication controller 590
Failure code [DD1PKB] Power supply line short in RPM set switch 592
Failure code [DD1QKB] Short circuit in RPM set mode switch 594
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch 596
Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch) 597
Failure code [DDTHKA] Disconnection in FH clutch fill switch 598
Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch) 599
Failure code [DDTJKA] Disconnection in FL clutch fill switch 600
Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch) 601
Failure code [DDTKKA] Disconnection in 1st clutch fill switch 602
Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch) 604
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch 606
Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch) 608
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch 610
Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch) 612
Failure code [DDTNKA] Disconnection in R clutch fill switch 614
Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch) 615
Failure code [DDTPKA] Disconnection in 4th clutch fill switch 616
Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch) 618
Failure code [DF10KA] Disconnection in transmission shift lever switch 620
Failure code [DF10KB] Short circuit in transmission shift lever switch 624
Failure code [DGF1KX] Transmission oil temperature out of range 628
Failure code [DGT1KX] Torque converter oil temperature out of range 630
Failure code [DJF1KA] Disconnection in fuel level sensor 632
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range 634
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range 636
Failure code [DKD0KA] Disconnection in articulate sensor 638
Failure code [DLE2KA] Disconnection in engine speed sensor 640
Failure code [DLF1KA] Disconnection in transmission input speed sensor 641
Failure code [DLT3KA] Disconnection in transmission output speed sensor 642
Failure code [DV00KB] Short circuit in caution buzzer 643
Failure code [DW4BKA] Disconnection in parking brake relay 644
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid 646
Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid 647
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid 648
Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid 650
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid 652
Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid 654
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid 656
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid 657
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid 658
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid 659
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid 660
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid 661
Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid 662
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid 664
Troubleshooting of electrical system (E-mode) 667
Troubleshooting of electrical system (E-mode) 669
Contents of troubleshooting table 669
E-1 Engine does not start at all or does not start easily 670
E-2 Transmission mode does not change 678
E-3 Differential lock function does not work or is not reset [Differential lock specification] 680
E-4 Wheel brake does not work normally 684
E-5 Parking brake does not work or is not reset 686
E-6 Lift arm lock pin is not locked or reset [Lift arm specification] 688
E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification] 691
E-8 Blade float function does not work or is not reset [Blade accumulator and float specification] 694
E-9 When starting switch is turned ON, machine monitor does not operate normally 702
E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display 704
E-11 When starting switch is turned ON, caution item lights up 705
E-12 While engine is running, emergency stop item lights up 706
E-13 Indication of speedometer and engine tachometer is abnormal 715
E-14 Indication of engine coolant temperature gauge is abnormal 716
E-15 Indication of articulate gauge is abnormal 718
E-16 Indication of torque converter oil temperature gauge is abnormal 719
E-17 Indication of fuel level gauge is abnormal 720
E-18 Display of character display is abnormal 722
E-19 Centralized warning lamp does not light up or go off 723
E-20 Alarm buzzer does not sound or stop 724
E-21 Machine monitor mode selector switch does not function 726
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off 729
E-23 Working lamp does not light up or go off 734
E-24 Turn signal lamp and hazard lamp do not blink or go off 738
E-25 Brake lamp does not light up or go off 744
E-26 Backup lamp does not light up or go off 746
E-27 Backup buzzer does not sound or stop 747
E-28 Air conditioner does not work or stop 748
E-29 KOMTRAX system does not operate normally 752
Troubleshooting of hydraulic and mechanical system (H-mode) 755
Troubleshooting of hydraulic and mechanical system (H-mode) 757
Contents of troubleshooting table 757
H-1 Excessive drop in engine speed, or engine stalls 758
H-2 Machine does not move in either forward or reverse direction 759
H-3 Transmission does not shift up or shift down 760
H-4 Machine is slow or lacks power when traveling 761
H-5 Torque converter lockup function cannot be actuated or canceled 763
H-6 Excessive time lag when starting or shifting gear 764
H-7 Torque converter oil temperature is high 765
H-8 Differential lock function is not operated or reset [Differential lock specification] 767
H-9 Machine is slow or lacks power when steering 768
H-10 Wheel brake does not work normally 769
H-11 Parking brake is not applied or released 770
H-12 All work equipment is slow or lacks power 771
H-13 No work equipment moves 772
H-14 Abnormal noise generated around pump 773
H-15 Blade is slow or lacks power in lifting 774
H-16 Excessive blade drift 775
H-17 Drawbar side shift operation is slow or lacks power 776
H-18 Blade side shift operation is slow or lacks power 777
H-19 Power tilt operation is slow or lacks power 778
H-20 Articulate operation is slow or lacks power 779
H-21 Leaning operation is slow or lacks power 780
H-22 Excessive drift of leaning 781
H-23 Blade does not rotate 782
H-24 Lift arm lock pin is not locked or reset [Lift arm specification] 783
H-25 Blade accumulator function is not operated or reset [Blade accumulator and float specification] 784
H-26 Blade float function is not operated or reset [Blade accumulator and float specification] 785
Troubleshooting of engine (S-mode) 787
Troubleshooting of engine (S-mode) 789
Method of using troubleshooting charts 789
S-1 Starting performance is poor 792
S-2 Engine does not start 793
S-3 Engine does not pick up smoothly 796
S-4 Engine stops during operations 797
S-5 Engine does not rotate smoothly 798
S-6 Engine lacks output (or lacks power) 799
S-7 Exhaust smoke is black (incomplete combustion) 800
S-8 Oil consumption is excessive (or exhaust smoke is blue) 801
S-9 Oil becomes contaminated quickly 802
S-10 Fuel consumption is excessive 803
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 804
S-12 Oil pressure drops 805
S-13 Oil level rises (water, fuel in oil) 806
S-14 Coolant temperature becomes too high (overheating) 807
S-15 Abnormal noise is made 808
S-16 Vibration is excessive 809
50 Disassembly and assembly 811
General information on disassembly andassembly 811
How to read this manual 812
Coating materials list 814
Special tool list 817
Sketches of special tools 822
Engine and cooling system 829
Engine and cooling system 830
Removal and installation of fuel supply pump assembly 830
Removal and installation of fuel injector assembly 833
Removal and installation of cylinder head assembly 838
Removal and installation of engine front seal 851
Removal and installation of engine rear seal 855
Removal and installation of engine assembly 861
Removal and installation of fuel tank, hydraulic tank and coolantsub tank assembly 865
Removal and installation of air conditioner condenser 869
Removal and installation of oil cooler assembly 872
Removal and installation of aftercooler assembly 874
Removal and installation of radiator assembly 877
Removal and installation of engine hood 880
Power train, Part 1 885
Power train, Part 1 886
Removal and installation of engine and transmission assembly 886
Removal and installation of transmission assembly 892
Disassembly and assembly of torque converter assembly 898
Disassembly and assembly of transmission assembly 905
Power train, Part 2 945
Power train, Part 2 946
Removal and installation of final drive assembly 946
Disassembly and assembly of final drive assembly 951
Disassembly and assembly of final brake case assembly 956
Disassembly and assembly of
side case assembly
(For standard final drive) 960
Disassembly and assembly of bevel gear assembly 963
Disassembly and assembly of bevel gear shaft 967
Disassembly and assembly of bevel pinion assembly 969
Steering system 973
Steering system 974
Removal and installation of steering valve (Orbit-roll) 974
Disassembly and assembly of steering valve 976
Hydraulic system 987
Hydraulic system 988
Disassembly and assembly of work equipment control valve assembly 988
Disassembly and assembly of hydraulic cylinder assembly 991
Work equipment 997
Work equipment 998
Removal and installation of blade assembly 998
Removal and installation of circle drawbar assembly 999
Removal and installation of blade circle gear assembly1001
Removal and installation of blade circle rotation gear assembly (with shear pin)1003
Disassembly and assembly of blade circle rotation gear assembly (with shear pin)1005
Disassembly and assembly of circle rotation gear assembly (with slip clutch)1009
Cab and its attachments1015
Cab and its attachments1016
Removal and installation of operator’s cab assembly1016
Removal and installation of floor frame assembly1018
Disassembly and assembly of operator’s seat assembly1021
Removal and installation of operator’s cab glass (stuck glass)1030
Removal and installation of air conditioner unit assembly1036
Electrical system1039
Electrical system1040
Removal and installation of machine monitor assembly1040
Removal and installation of engine controller assembly1041
Removal and installation of transmission controller assembly1042
Removal and installation of KOMTRAX controller assembly1043
Removal and installation of COMMUNICATION controller assembly1044
90 Diagrams and drawings1047
Hydraulic diagrams and drawings1047
Hydraulic diagrams and drawings1048
Power train hydraulic circuit diagram1048
Brake hydraulic circuit1050
Hydraulic circuit diagram (1/2)1051
Hydraulic circuit diagram (2/2)1053
Electrical diagrams and drawings1057
Electrical circuit diagram (1/6)1059
Electrical circuit diagram (2/6)1061
Electrical circuit diagram (3/6)1063
Electrical circuit diagram (4/6) 11065
Electrical circuit diagram (5/6) 11067
Electrical circuit diagram (6/6) 11069
Connector arrangement diagram1071

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24