Komatsu GD555-3A GD655-3A GD675-3A Motor Grader Workshop Repair Service Manual + Operation Maintenance PDF - MKTMSGD555A675A.zip
This complete workshop service repair manual, complete with Electrical Wiring Diagrams, covers the Komatsu GD555-3A, GD655-3A and GD675-3A Motor Graders. It delivers every piece of technical data needed to service, troubleshoot, overhaul and rebuild these machines the way professional technicians do.
The workshop service repair manual for Komatsu GD555-3A, GD655-3A and GD675-3A Motor Graders contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,723 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English / Spanish
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MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...26
GENERAL ASSEMBLY DRAWING...27
SPECIFICATIONS...28
WEIGHT TABLE...40
FUEL, COOLANT, AND LUBRICANT ...42
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...44
ACCELERATOR CONTROL LINKAGE...45
ACCELERATOR PEDAL...46
FAN DRIVE...47
POWER TRAIN DIAGRAM...48
TRANSMISSION HYDRAULIC PIPING...49
TRANSMISSION CONTROL...53
TORQUE CONVERTER...54
TORQUE CONVERTER LOCK-UP VALVE (ECMV)...59
TRANSMISSION...62
TRANSMISSION VALVE...84
ECMV (ELECTRONIC CONTROL MODULATION VALVE)...85
MAIN RELIEF VALVE...89
TRANSMISSION PUMP...92
TRANSMISSION AND DIFFERENTIAL LOCK PUMP...93
FINAL DRIVE...94
TANDEM DRIVE...99
STEERING HYDRAULIC PIPING DRAWING...102
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)...103
PRIORITY VALVE...110
ACCUMULATOR PRESSURE GOVERNOR VALVE...117
FRONT AXLE...119
BRAKE HYDRAULIC PIPING...123
BRAKE VALVE...125
SLACK ADJUSTER...129
ACCUMULATOR...132
WHEEL BRAKE...133
PARKING BRAKE...134
PARKING BRAKE AND BANK CONTROL VALVE...135
WORK EQUIPMENT HYDRAULIC PIPING DRAWING...136
HYDRAULIC PUMP...143
MAIN CONTROL VALVE...164
CLSS...179
WORK EQUIPMENT CONTROL...191
HYDRAULIC SYSTEM...193
HYDRAULIC TANK...196
SWIVEL JOINT...197
PILOT CHECK VALVE...198
BLADE ACCUMULATOR, FLOAT VALVE...203
ACCUMULATOR...205
BLADE FLOAT DEVICE...206
CIRCLE ROTATION MOTOR...208
HYDRAULIC CYLINDER...210
CIRCLE, DRAWBAR...216
LIFTER BRACKET LOCK PIN...218
BLADE...219
CIRCLE ROTATION GEAR...221
SCARIFIER...224
RIPPER...226
MAIN FRAME...228
AIR CONDITIONER (IF EQUIPPED)...229
ENGINE STARTING CIRCUIT...233
ENGINE STOP CIRCUIT...238
PREHEAT CIRCUIT...240
AUTOMATIC SHIFT CONTROL SYSTEM...242
TRANSMISSION CONTROLLER...243
MONITOR...248
SENSORS...252
20 TESTING AND ADJUSTING...257
STANDARD VALUE TABLE...258
STANDARD VALUE TABLE FOR ENGINE...258
STANDARD VALUE TABLE FOR CHASSIS...260
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...267
TESTING AND ADJUSTING...276
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...277
MEASURING EXHAUST COLOR...278
MEASURING BLOWBY PRESSURE...279
MEASURING ENGINE OIL PRESSURE ...280
MEASURING ENGINE SPEED...280
TESTING FAN BELT TENSION...281
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION...282
MEASURING TORQUE CONVERTER STALL SPEED...282
CHECKING CLUTCH OIL PRESSURE...283
CHECKING TORQUE CONVERTER OIL PRESSURE...284
ADJUSTING SPEED SENSOR...285
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT...287
ADJUSTING ACCELERATOR CONTROL LINKAGE...288
TESTING BRAKE DISC...289
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE...290
TESTING ACCUMULATOR CHARGE PRESSURE...291
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE...291
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE...292
ADJUSTING PC VALVE...294
BLEEDING AIR FROM HYDRAULIC CIRCUIT...294
MEASURING INTERNAL CYLINDER LEAKAGE...295
MEASURING STEERING, BRAKE OIL PRESSURE...297
BLEEDING AIR FROM THE BRAKE PIPING...298
CHARGING BRAKE, WORK EQUIPMENT ACCUMULATOR...299
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE...300
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE...302
MEMORIZING IDLE AND FULL POSITION PROCEDURE...304
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER...305
DIODE CHECKING PROCEDURE...307
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...308
ADJUSTING CAB STOPPER BOLT (IF EQUIPPED WITH CAB)...310
TROUBLESHOOTING...312
TROUBLESHOOTING POINTS TO REMEMBER...313
TROUBLESHOOTING SEQUENCE...314
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE...315
CHECKS BEFORE TROUBLESHOOTING...323
CONNECTOR TYPES AND MOUNTING LOCATIONS (SERIAL NO. 10001-11000)...324
CONNECTOR TYPES AND MOUNTING LOCATIONS (SERIAL NO. 11001 AND UP)...330
CONNECTOR ARRANGEMENT DIAGRAM (SERIAL NO. 10001-11000)...336
CONNECTOR ARRANGEMENT DIAGRAM (SERIAL NO. 11001 AND UP)...340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...344
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES...367
USING TROUBLESHOOTING CHARTS...371
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...372
ELECTRICAL CIRCUIT DIAGRAM...373
E-1 ENGINE DOES NOT START...377
E-2 ENGINE DOES NOT STOP...387
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW...389
E-4 ELECTRICAL COMPONENTS DO NOT WORK...391
TROUBLESHOOTING THE TRANSMISSION CONTROLLER SYSTEM (T MODE)...393
TRANSMISSION CONTROLLER SYSTEM JUDGEMENT TABLE...394
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH MACHINE...399
ELECTRICAL CIRCUIT DIAGRAM...421
T-1 ERROR CODE [A1] (HOT SHORT, GROUND, OR FL SOLENOID SYSTEM)...425
T-2 ERROR CODE [A2] (HOT SHORT, GROUND, OR FH SOLENOID SYSTEM)...426
T-3 ERROR CODE [A3] (HOT SHORT, GROUND, OR R SOLENOID CIRCUIT)...427
T-4 ERROR CODE [A4] (HOT SHORT, 1ST OR 3RD SOLENOID CIRCUIT, OR GROUND)...428
T-5 ERROR CODE [A5] (HOT SHORT, 2ND OR 4TH SOLENOID SYSTEM, OR GROUND)...430
T-6 ERROR CODE [A8] (HOT SHORT, LOCK-UP SOLENOID SYSTEM, OR GROUND)...432
T-7 ERROR CODE [B1] (OPEN FL SOLENOID CIRCUIT)...433
T-8 ERROR CODE [B2] (OPEN FH SOLENOID CIRCUIT)...434
T-9 ERROR CODE [B3] (OPEN R SOLENOID CIRCUIT)...435
T-10 ERROR CODE [B4] (OPEN 1ST SOLENOID CIRCUIT)...436
T-11 ERROR CODE [B5] (OPEN 2ND SOLENOID CIRCUIT)...437
T-12 ERROR CODE [B6] (OPEN 3RD SOLENOID CIRCUIT)...438
T-13 ERROR CODE [B7] (OPEN 4TH SOLENOID CIRCUIT)...439
T-14 ERROR CODE [B8] (OPEN LOCK-UP SOLENOID CIRCUIT)...440
T-15 ERROR CODE [C0] (POWER SUPPLY VOLTAGE REDUCED)...441
T-16 ERROR CODE [C1] (OPEN ENGINE SPEED SENSOR CIRCUIT)...442
T-17 ERROR CODE [C3] (HOT SHORT OR OPEN ACCELERATOR POTENTIOMETER CIRCUIT)...443
T-18 ERROR CODE [C4] (HOT SHORT OR OPEN INCHING POTENTIOMETER CIRCUIT)...445
T-19 ERROR CODE [C5] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE SENSOR CIRCUIT)...447
T-20 ERROR CODE [C6] (HOT SHORT OR OPEN CIRCUIT IN THE TORQUE CONVERTER OUTLET OIL TEMPERATURE SENSOR CIRCUIT)...449
T-21 ERROR CODE [C7] (HOT SHORT OR OPEN CIRCUIT IN THE HYDRAULIC OIL TEMPERATURE SENSOR CIRCUIT)...451
T-22 ERROR CODE [C8] (OPEN CIRCUIT IN THE TRANSMISSION INPUT SHAFT SPEED SENSOR CIRCUIT)...453
T-23 ERROR CODE [C9] (OPEN CIRCUIT IN THE TRANSMISSION OUTPUT SHAFT SPEED SENSOR CIRCUIT)...454
T-24 ERROR CODE [D1] (HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL OIL TEMPERATURE WARNING LAMP CIRCUIT)...455
T-25 ERROR CODE [D2] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION OIL TEMPERATURE WARNING LAMP CIRCUIT)...456
T-26 ERROR CODE [D4] (HOT SHORT OR OPEN CIRCUIT IN THE BUZZER ALARM SYSTEM)...457
T-27 ERROR CODE [D5] (HOT SHORT OR OPEN CIRCUIT IN THE TRANSMISSION CONTROL WARNING LAMP SYSTEM)...459
T-28 ERROR CODE [D6] (HOT SHORT OR OPEN CIRCUIT IN THE DIFFERENTIAL CONTROL RELAY SYSTEM)...460
T-29 ERROR CODE [D7] (HOT SHORT OR OPEN CIRCUIT IN THE VHP RELAY SYSTEM)...461
T-30 ERROR CODE [E1] (HOT SHORT OR OPEN CIRCUIT IN THE F (FORWARD), R (REVERSE) SYSTEM)...462
T-31 ERROR CODE [E2] (HOT SHORT OR OPEN CIRCUIT IN THE NEUTRAL SIGNAL CIRCUIT)...463
T-32 ERROR CODE [E3] (HOT SHORT OR OPEN CIRCUIT IN THE PARKING SIGNAL CIRCUIT)...464
T-33 ERROR CODE [E4] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC A SIGNAL CIRCUIT)...466
T-34 ERROR CODE [E5] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC B SIGNAL CIRCUIT)...467
T-35 ERROR CODE [E6] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC C SIGNAL CIRCUIT)...468
T-36 ERROR CODE [E7] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC D SIGNAL CIRCUIT)...469
T-37 ERROR CODE [E8] (HOT SHORT OR OPEN CIRCUIT IN THE LOGIC E SIGNAL CIRCUIT)...470
T-38 ERROR CODE [F1] (SHORT CIRCUIT WITH GROUND IN THE FL CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...471
T-39 ERROR CODE [F2] (SHORT CIRCUIT WITH GROUND IN THE FH CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...471
T-40 ERROR CODE [F3] (SHORT CIRCUIT WITH GROUND IN THE R CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...472
T-41 ERROR CODE [F4] (SHORT CIRCUIT WITH GROUND IN THE 1ST CLUTCH PRESSURE SWITCH CIRCUIT)...473
T-42 ERROR CODE [F5] (SHORT CIRCUIT WITH GROUND IN THE 2ND CLUTCH PRESSURE SWITCH CIRCUIT)...473
T-43 ERROR CODE [F6] (SHORT CIRCUIT WITH GROUND IN THE 3RD CLUTCH PRESSURE SWITCH CIRCUIT)...474
T-44 ERROR CODE [F7] (SHORT CIRCUIT WITH GROUND IN THE 4TH CLUTCH PRESSURE SWITCH CIRCUIT)...474
T-45 ERROR CODE [F8] (SHORT CIRCUIT WITH GROUND IN THE LOCK-UP CLUTCH PRESSURE SWITCH SIGNAL CIRCUIT)...475
T-46 ERROR CODE [91] (OPEN CIRCUIT IN THE FL CLUTCH PRESSURE SWITCH CIRCUIT)...476
T-47 ERROR CODE [92] (OPEN CIRCUIT IN THE FH CLUTCH PRESSURE SWITCH CIRCUIT)...476
T-48 ERROR CODE [93] (OPEN CIRCUIT IN THE R CLUTCH PRESSURE SWITCH CIRCUIT)...477
T-49 ERROR CODE [94] (OPEN CIRCUIT IN THE 1ST CLUTCH PRESSURE SWITCH CIRCUIT)...478
T-50 ERROR CODE [95] (OPEN CIRCUIT IN THE 2ND CLUTCH PRESSURE SWITCH CIRCUIT)...478
T-51 ERROR CODE [96] (OPEN CIRCUIT IN THE 3RD CLUTCH PRESSURE SWITCH CIRCUIT)...479
T-52 ERROR CODE [97] (OPEN CIRCUIT IN THE 4TH CLUTCH PRESSURE SWITCH CIRCUIT)...479
T-53 ERROR CODE [98] (OPEN CIRCUIT IN THE LOCK-UP CLUTCH PRESSURE SWITCH CIRCUIT)...480
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...481
FAILURE TABLE: MODES AND CAUSES...482
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER...484
H-2 NO WORK EQUIPMENT MOVES...485
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...485
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP...486
H-5 EXCESSIVE BLADE DRIFT...486
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE...487
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING, DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT CYLINDERS (LEFT, RIGHT)...487
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)...488
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE...488
H-10 EXCESSIVE SCARIFIER DRIFT...489
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE...490
H-12 TRANSMISSION DOES NOT UPSHIFT OR DOWNSHIFT...491
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELLING...491
H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION...492
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR...492
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...493
H-17 BRAKING FORCE IS INSUFFICIENT...494
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...495
FAILURE TABLE: MODES AND CAUSES...496
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM...498
M-1 ENGINE OIL PRESSURE CAUTION LAMP GLOWS...502
M-2 TRANSMISSION CONTROLLER CAUTION LAMP GLOWS...503
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP GLOWS...503
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP GLOWS (OPT)...504
M-5 BANK PIN CAUTION LAMP GLOWS...505
M-6 BRAKE OIL PRESSURE CAUTION LAMP GLOWS...506
M-7 BATTERY CHARGE CAUTION LAMP GLOWS...507
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP...508
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP...509
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)...510
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)...511
M-12 ACCUMULATOR ACTUATION DISPLAY DEOS NOT LIGHT UP...512
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP...512
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP...514
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH...515
M-16 ARTICULATION GAUGE DOES NOT WORK...516
M-17 FUEL GAUGE DOES NOT WORK...518
M-18 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT WORK...520
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)...521
M-20 MESSAGE CENTER DOES NOT WORK...522
M-21 SERVICE METER DOES NOT WORK...523
30 DISASSEMBLY AND ASSEMBLY...524
METHOD OF USING MANUAL...526
PRECAUTIONS WHEN CARRYING OUT OPERATION...528
SPECIAL TOOL LIST...530
SKETCHES OF SPECIAL TOOLS...533
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO. 10001-11000)...538
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO. 10001-11000)...538
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO. 11001 AND UP)...539
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO. 11001 AND UP)...539
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO. 10001-11000)...540
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO. 10001-11000)...541
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO. 11001 AND UP)...542
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO. 11001 AND UP)...543
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 10001-11000)...544
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 10001-11000)...546
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 11001 AND UP)...548
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLANT SUB TANK (SERIAL NO. 11001 AND UP)...550
REMOVAL OF ENGINE ASSEMBLY...551
INSTALLATION OF ENGINE ASSEMBLY...553
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT...554
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT...554
REMOVAL OF TRANSMISSION ASSEMBLY...556
INSTALLATION OF TRANSMISSION ASSEMBLY...558
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...560
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...562
DISASSEMBLY OF TRANSMISSION ASSEMBLY...565
ASSEMBLY OF TRANSMISSION ASSEMBLY...579
REMOVAL OF FINAL DRIVE ASSEMBLY...599
INSTALLATION OF FINAL DRIVE ASSEMBLY...602
DISASSEMBLY OF FINAL DRIVE ASSEMBLY...604
ASSEMBLY OF FINAL DRIVE ASSEMBLY...605
DISASSEMBLY OF FINAL BRAKE CASE...608
ASSEMBLY OF FINAL BRAKE CASE...608
DISASSEMBLY OF SIDE CASE ASSEMBLY (FOR STANDARD FINAL DRIVER)...611
ASSEMBLY OF SIDE CASE ASSEMBLY (FOR STANDARD FINAL DRIVER)...612
DISASSEMBLY OF SIDE CASE (FOR PLANETRY FINAL DRIVER)...614
ASSEMBLY OF SIDE CASE (FOR PLANETRY FINAL DRIVER)...616
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)...618
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY (IF EQUIPPED)...619
DISASSEMBLY OF BEVEL GEAR ASSEMBLY (FOR STANDARD FINAL DRIVER)...622
ASSEMBLY OF BEVEL GEAR ASSEMBLY (FOR STANDARD FINAL DRIVER)...622
DISASSEMBLY OF BEVEL GEAR (FOR PLANETRY FINAL DRIVER)...626
ASSEMBLY OF BEVEL GEAR (FOR PLANETRY FINAL DRIVER)...627
DISASSEMBLY OF BEVEL PINION ASSEMBLY...629
ASSEMBLY OF BEVEL PINION ASSEMBLY...630
REMOVAL OF OPERATOR'S CAB ASSEMBLY...631
INSTALLATION OF OPERATOR'S CAB ASSEMBLY...632
REMOVAL OF OPERATOR'S CAB FLOOR...634
INSTALLATION OF OPERATOR'S CAB FLOOR...635
REMOVAL OF STEERING VALVE (ORBIT-ROLL)...637
INSTALLATION OF STEERING VALVE(ORBIT-ROLL)...637
STANDARD INTEGRAL ORBIT-ROLL...638
DISASSEMBLY OF STEERING VALVE...640
ASSEMBLY OF STEERING VALVE...642