Komatsu Motor Graders GD655-3E0, GD675-3E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD655-3E0, GD675-3E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD655-3E0, GD675-3E0 workshop service repair manual includes:
* 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: 2,261 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN01775-05 - Motor Grader GD655-3E0, GD675-3E0 Shop Manual.pdf
TEN00149-05 - Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00150-05 - Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf
TEN00448-00 - Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00449-01 - Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf
MAIN SECTIONS
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
