Komatsu GD555-5 GD655-5 GD675-5 Motor Grader Workshop Repair Service Manual PDF - MKMTSGD555GD675.zip
A full workshop service and repair manual featuring Electrical Wiring Diagrams for the Komatsu Motor Grader GD555-5, GD655-5, and GD675-5, containing the technical data needed to service, troubleshoot, fix, and rebuild these machines just as expert technicians would.
The workshop service and repair manual for the Komatsu Motor Grader GD555-5, GD655-5, and GD675-5 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: 3,174 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN05215-06 - Motor Grader GD555-5, GD655-5, GD675-5 Shop Manual.pdf
TEN00368-01 - Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00369-01 - Motor Grader GD675-5 Operation & Maintenance Manual.pdf
TEN00445-02 - Motor Grader GD555-5 Operation & Maintenance Manual.pdf
TEN00446-02 - Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00447-02 - Motor Grader GD675-5 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
Notice of revision...3
00 Index and foreword...11
Table of contents...12
Table of contents...12
Foreword and general information...23
Safety notice...23
How to read the shop manual...28
Explanation of terms for maintenance standard...30
Handling of electric equipment and hydraulic components...32
Handling of connectors newly used for engines...41
How to read electric wire code...44
Precautions when carrying out work...47
Method of disassembling and connecting push-pull type coupler...50
Standard tightening torque table...53
List of Abbreviation...57
Conversion table...61
01 Specification...67
Specification drawing...69
Specifications...70
Weight table...76
Table of fuel, coolant and lubricants...77
10 Structure, function and maintenance standard...79
Engine and Cooling...82
Cooling system...82
Cooling fan pump...84
Power train system...92
Power train system drawing...92
Power train piping drawing...94
Transmission control...96
Torque converter...98
Transmission...102
Transmission control valve...124
ECMV...128
Main relief and torque converter relief valve...136
Front axle...138
Final drive (no differential specification)...142
Final drive (differential/ differential lock specification)...144
Differential lock solenoid valve...146
Tandem drive...148
Steering system...150
Steering piping diagram...150
Priority valve...152
Steering valve...158
Brake system...166
Brake hydraulic piping diagram...166
Brake valve...167
Slack adjuster...174
Accumulator (for brake)...176
Charge valve...177
Wheel brake...184
Parking brake and bank control valve...186
Parking brake...188
Undercarriage frame...190
Frame...190
Tire...192
Hydraulic system...194
Hydraulic system...194
Work equipment hydraulic piping diagram...198
Work equipment control...202
Hydraulic tank...204
Main pump...206
Power train pump...218
Control valve...220
CLSS...230
Functions and operation by valve...234
Hydraulic cylinder...244
Swivel joint...246
Pilot check valve...248
Accumulator (for blade)...256
Work equipment...258
Circle and drawbar...258
Blade...260
Lifter...262
Circle rotation motor...264
Circle rotation gear...266
Cab...268
Cab...268
Electrical system...270
Machine monitor...270
Automatic shift control system...274
Transmission controller...282
Engine controller...286
KOMTRAX system...290
Starting engine circuit...294
Stopping engine circuit...296
Preheating circuit...298
Sensor...300
Engine power mode select circuit...312
Cooling fan control function...314
20 Standard value table...319
Standard value table...321
Standard value table for engine...321
Standard value table for machine...323
30 Testing and adjusting...331
Tools for testing, adjusting, and troubleshooting...334
Tools for testing, adjusting, and troubleshooting...334
Engine and cooling system...340
Testing engine speed...340
Testing intake air pressure (boost pressure)...342
Testing exhaust gas temperature...344
Testing exhaust gas color...346
Adjusting valve clearance...348
Testing compression pressure...350
Testing blowby pressure...353
Testing engine oil pressure...355
Handling fuel system device...356
Releasing remaining pressure from fuel system...357
Testing fuel pressure...358
Bleeding air from fuel circuit...359
Testing fuel circuit for leakage...360
Cylinder cut-out test mode...361
No injection cranking...362
Handling voltage circuit of engine controller...363
Checking muffler body and muffler stack for looseness and damage...364
Checking muffler function...365
Checking cylinder head and manifolds for looseness...366
Checking engine piping for damage and looseness...367
Checking fuel delivery, return rate and leakage...368
Replacing fan belt...371
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]...372
Power train...374
Testing power train oil pressure...374
Adjusting transmission speed sensor...386
Emergency escape method in case of transmission valve failure...390
Flushing torque converter and trasmission circuits...394
Testing and adjusting toe-in...396
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]...398
Steering system...400
Testing and adjusting steering oil pressure...400
Testing steering cylinder oil leakage...401
Bleeding air from steering circuit...402
Brake system...404
Testing and adjusting brake oil pressure...404
Releasing remaining pressure from brake circuit...408
Bleeding air from brake circuit...409
Testing wheel brake disc wear...410
Testing and adjusting parking brake...412
Emergency release method of parking brake...414
Filling gas into brake accumulator...416
Hydraulic system...418
Testing and adjusting work equipment oil pressure...418
Testing and adjusting pump LS differential pressure...421
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut]...423
Testing work equipment cylinder oil leakage amount...424
Bleeding air from work equipment circuit...427
Work equipment...428
Clearance adjustment of drawbar ball joint...428
Testing and adjusting circle guide clearance...429
Testing and adjusting slip clutch type circle rotator...431
Filling gas into blade accumulator [machine with blade accumulator]...433
Electrical system...434
Procedure for testing diodes...434
Special functions of machine monitor (EMMS)...435
Handling high voltage circuit of engine controller...484
How to start KOMTRAX terminal operations...486
Indicator lamps of KOMTRAX terminal...495
Preparation work for troubleshooting of electrical system...502
Pm clinic...504
40 Troubleshooting...513
General information on troubleshooting...519
Points to remember when troubleshooting...519
Sequence of events in troubleshooting...520
Checks before troubleshooting...521
Classification and procedures for troubleshooting...541
Failure codes table...542
Failure and troubleshooting numbers...549
Information in troubleshooting table...551
Troubleshooting method for open circuit in wiring harness of pressure sensor system...553
Connector list and layout...555
Connection table for connector pin numbers...570
T- branch box and T- branch adapter table...606
Locations of fuses...609
Troubleshooting by failurecode...611
Failure code [1500LO] TORQUEFLOW transmission: Double engagement...611
Failure code [15G0MW] Transmission R clutch: Slip...612
Failure code [15H0MW] Transmission FH clutch: Slip...613
Failure code [15J0MW] Transmission FL clutch: Slip...613
Failure code [15K0MW] Transmission 1st clutch: Slip...614
Failure code [15L0MW] Transmission 2nd clutch: Slip...615
Failure code [15M0MW] Transmission 3rd speed clutch: Slip...616
Failure code [15N0MW] Transmission 4th clutch: Slip...617
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF...618
Failure code [15SBMA] ECMV R clutch: Malfunction...620
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF...622
Failure code [15SCMA] ECMV FH clutch: Malfunction...624
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF...626
Failure code [15SDMA] ECMV FL clutch: Malfunction...628
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF...630
Failure code [15SEMA] ECMV 1st clutch: Malfunction...632
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF...634
Failure code [15SFMA] ECMV 2nd clutch: Malfunction...636
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF...638
Failure code [15SGMA] ECMV 3rd clutch: Malfunction...640
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF...642
Failure code [15SHMA] ECMV 4th clutch: Malfunction...644
Failure code [15SJMA] ECMV lockup clutch: Malfunction...646
Failure code [15UONT] Inching clutch: Overheating...646
Failure code [2G42ZG] Front accumulater: Oil pressure drop...647
Failure code [2G43ZG] Rear accumulater: Pressure drop...647
Failure code [AA1ANX] Air cleaner: Clogging...648
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched...650
Failure code [AB00MA] Alternator: Malfunction...652
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop...654
Failure code: [B@BCNS] Engine coolant overheat...654
Failure code: [B@CENS] Torque converter oil overheat...655
Failure code: [B@CKNS] Differential case: Overheat...656
Failure code: [B@HANS] Hydraulic oil: Overheating...658
Failure code [CA111] Engine controller internal error...660
Failure code [CA115] Engine Ne, Bkup speed sensor error...661
Failure code [CA122] Charge pressure sensor high error...662
Failure code [CA123] Charge pressure sensor low error...664
Failure code [CA131] Throttle sensor high error...666
Failure code [CA132] Throttle sensor low error...668
Failure code [CA144] Coolant sensor high error...670
Failure code [CA145] Coolant sensor low error...672
Failure code [CA153] Charge temperature sensor high error...674
Failure code [CA154] Charge temperature sensor low error...676
Failure code [CA155] Speed derating error by high charge temperature...678
Failure code [CA187] Sensor power supply 2 low error...680
Failure code [CA221] Atmospheric pressure sensor high error...682
Failure code [CA222] Atmospheric pressure sensor low error...684
Failure code [CA227] Sensor power supply 2 high error...686
Failure code [CA234] Engine overspeed...686
Failure code [CA238] Ne speed sensor power supply error...687
Failure code [CA271] IMV/IMA: Short circuit...688
Failure code [CA272] IMV/IMA open circuit...690
Failure code [CA322] Injector #1 (L#1) open/short...692
Failure code [CA323] Injector #5 (L#5) open/short...694
Failure code [CA324] Injector #3 (L#3) open/short...696
Failure code [CA325] Injector #6 (L#6) open/short...698
Failure code [CA331] Injector #2 (L#2) open/short...700
Failure code [CA332] Injector #4 (L#4) open/short...702
Failure code [CA342] Data compatibility error in engine controller...704
Failure code [CA351] Injector drive circuit error...705
Failure code [CA352] Sensor power supply 1 low error...706
Failure code [CA386] Sensor power supply 1 high error...707
Failure code [CA428] Water-in-fuel sensor high error...708
Failure code [CA429] Water-in-fuel sensor low error...710
Failure code [CA431] Idle validation switch error...712
Failure code [CA432] Idle validation action error...716
Failure code [CA435] Engine oil pressure switch error...719
Failure code [CA441] Power supply voltage low error...720
Failure code [CA442] Power supply voltage high error...722
Failure code [CA449] Common rail pressure high error 2...723
Failure code [CA451] Common rail pressure sensor high error...724
Failure code [CA452] Common rail pressure sensor low error...726
Failure code [CA488] Torque derating error by high charge temperature...728
Failure code [CA553] Common rail pressure high error 1...729
Failure code [CA559] Supply pump pressure low error 1...730
Failure code [CA689] Engine Ne speed sensor error...731
Failure code [CA731] Engine Bkup speed sensor phase error...733
Failure code [CA757] All continuous data lost error...734
Failure code [CA778] Engine Bkup speed sensor error...735
Failure code [CA1633] KOMNET (CAN communication) error...738
Failure code [CA2185] Throttle sensor power supply high error...740
Failure code [CA2186] Throttle sensor power supply low error...742
Failure code [CA2249] Supply pump pressure low error 2...744
Failure code [CA2311] Abnormality in IMV (IMA) solenoid...745
Failure code [CA2555] Intake heater relay open circuit...746
Failure code [CA2556] Intake heater relay short circuit...748
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness...750
Failure code [D160KB] Backup lamp relay: Ground fault...752
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault...754
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state...756
Failure code [DAFRKR] CAN communication failure (monitor panel)...758
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)...760
Failure code [DAQOKT] Transmission controller: Non-volatile memory error...762
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)...764
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement...766
Failure code [DAQRKR] Transmission controller CAN communication: Communication error...768
Failure code [DAQRMA] Transmission controller option setting: Malfunction...772
Failure code [DB2RKR] Engine controller CAN communication: Communication error...773
Failure code [DD1NLD] Fan reverse switch signal: Short circuit...780
Failure code [DD1PKB] RPM set switch power supply short circuit...782
Failure code [DD1QKB] RPM set mode switch short circuit...784
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error...786
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit...788
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit...788