Komatsu Motor Graders GD555-3C, GD655-3C, GD675-3C Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD555-3C, GD655-3C, GD675-3C, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD555-3C, GD655-3C, GD675-3C 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: 4,513 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
FOREWORD...6
SAFETY...6
GENERAL...8
HOW TO READ THE SHOP MANUAL...9
HOIST INSTRUCTIONS...10
PUSH-PULL TYPE COUPLERS...11
COATING MATERIALS...13
STANDARD TIGHTENING TORQUE...15
ELECTRIC WIRE CODE...18
CONVERSION TABLES...19
UNITS...25
01 GENERAL...26
GENERAL ASSEMBLY DRAWING...27
SPECIFICATIONS...28
WEIGHT TABLE...40
FUEL, COOLANT, AND LUBRICANT SELECTION...42
10 STRUCTURE AND FUNCTION...45
ACCELERATOR CONTROL LINKAGE...46
ACCELERATOR PEDAL...47
FAN DRIVE...48
POWER TRAIN DIAGRAM...49
TRANSMISSION HYDRAULIC PIPING...50
TRANSMISSION CONTROL...54
TORQUE CONVERTER...55
TORQUE CONVERTER LOCK-UP VALVE (ECMV)...60
TRANSMISSION...63
TRANSMISSION VALVE...92
ECMV (ELECTRONIC CONTROL MODULATION VALVE)...93
MAIN RELIEF VALVE...98
TRANSMISSION PUMP...101
TRANSMISSION AND DIFFERENTIAL LOCK PUMP...102
FINAL DRIVE...103
TANDEM DRIVE...108
STEERING HYDRAULIC PIPING DRAWING...112
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)...115
PRIORITY ACC GOVERNOR VALVE SERIAL NO. 50001-51000...122
PRIORITY VALVE SERIAL NO. 51001 AND UP...129
ACCUMULATOR CHARGE VALVE...136
FRONT AXLE...138
BRAKE HYDRAULIC PIPING...142
BRAKE VALVE...146
WHEEL BRAKE...150
SLACK ADJUSTER...151
ACCUMULATOR...154
PARKING BRAKE...155
PARKING AND BANK CONTROL VALVE ...156
WORK EQUIPMENT HYDRAULIC PIPING DRAWING...158
HYDRAULIC PUMP SERIAL NO. 50001-51000...168
HYDRAULIC PUMP SERIAL NO. 51001 AND UP...190
MAIN CONTROL VALVE...213
CLSS...232
WORK EQUIPMENT CONTROL...244
HYDRAULIC SYSTEM...246
HYDRAULIC TANK...252
SWIVEL JOINT...253
PILOT CHECK VALVE...256
BLADE ACCUMULATOR, FLOAT VALVE...261
SHUT-OFF VALVE...265
BLADE FLOAT DEVICE...266
CIRCLE ROTATION MOTOR...268
HYDRAULIC CYCLINDER...270
CIRCLE DRAWBAR...276
LIFTER BRACKET LOCK PIN...278
BLADE...280
CIRCLE ROTATION GEAR...282
SCARIFIER...286
RIPPER...288
MAIN FRAME...291
AIR CONDITIONER...292
ENGINE STARTING CIRCUIT...296
ENGINE STOP CIRCUIT...300
PREHEAT CIRCUIT...302
AUTOMATIC SHIFT CONTROL SYSTEM...304
TRANSMISSION CONTROLLER...305
MONITOR...309
SENSORS...312
20 TESTING AND ADJUSTING...319
STANDARD VALUE TABLES...320
STANDARD VALUE TABLE FOR ENGINE...320
STANDARD VALUE TABLE FOR CHASSIS...324
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...331
TESTING AND ADJUSTING...341
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...342
MEASURING EXHAUST COLOR...343
MEASURING BLOWBY PRESSURE...344
MEASURING ENGINE OIL PRESSURE...345
MEASURING ENGINE SPEED...345
TESTING FAN BELT TENSION...346
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION ...347
MEASURING TORQUE COVERTER STALL SPEED...347
CHECKING CLUTCH OIL PRESSURE ...348
CHECKING TORQUE CONVERTER OIL PRESSURE...349
ADJUSTING SPEED SENSOR ...350
FLUSHING THE TORQUE CONVETER, TRANSMISSION CIRCUIT...352
ADJUSTING ACCELERATOR CONTROL LINKAGE ...353
TESTING THE BRAKE DISC...354
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE ...355
TESTING ACCUMULATOR CHARGE PRESSURE...356
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE...356
TESTING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE...357
ADJUSTING THE PC VALVE ...359
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT...359
MEASURING INTERNAL CYLINDER LEAKAGE...360
MEASURING STEERING, BRAKE OIL PRESSURE...362
BLEEDING AIR FROM THE BRAKE PIPING...363
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR...364
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE...365
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE...367
MEMORIZING IDLE AND FULL POSITION PROCEDURE ...369
INITIAL LEARNING METHOD FOR THE TRANSMISSION CONTROLLER...370
DIODE CHECKING PROCEDURE...372
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...373
ADJUSTING CAB STOPPER BOLT...375
TROUBLESHOOTING...377
TROUBLESHOOTING POINTS TO REMEMBER...378
TROUBLESHOOTING SEQUENCE...379
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE...380
CHECKS BEFORE TROUBLESHOOTING...388
CONNECTOR TYPES AND MOUNTING LOCATIONS...389
CONNECTOR ARRANGEMENT DIAGRAM...398
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...406
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES...427
USING THE TROUBLESHOOTING CHARTS...431
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...433
ELECTRICAL CIRCUIT DIAGRAM...434
E-1 ENGINE DOES NOT START...438
E-2 ENGINE DOES NOT STOP...448
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW...450
E-4 ELECTRICAL COMPONENTS DO NOT WORK...452
TROUBLESHOOTING THE TRANSMISSION CONTROLLER SYSTEM (T MODE)...454
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE...457
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE...461
ELECTRICAL CIRCUIT DIAGRAM...481
T-1 FAILURE CODE [A1]...485
T-2 FAILURE CODE [A2]...486
T-3 FAILURE CODE [A-3]...487
T-4 FAILURE CODE [A4]...488
T-5 FAILURE CODE [A5]...489
T-6 FAILURE CODE [A8]...490
T-7 FAILURE CODE [B1]...491
T-8 FAILURE CODE [B2]...492
T-9 FAILURE CODE [B3]...493
T-10 FAILURE CODE [B4]...494
T-11 FAILURE CODE [B5]...495
T-12 FAILURE CODE [B6]...496
T-13 FAILURE CODE [B7]...497
T-14 FAILURE CODE [B8]...498
T-15 FAILURE CODE [C0]...499
T-16 FAILURE CODE [C1]...500
T-17 FAILURE CODE [C3]...501
T-18 FAILURE CODE [C4]...503
T-19 FAILURE CODE [C5]...505
T-20 FAILURE CODE [C6]...506
T-21 FAILURE CODE [C7]...507
T-22 FAILURE CODE [C8]...508
T-23 FAILURE CODE [C9]...509
T-24 FAILURE CODE [D1]...510
T-25 FAILURE CODE [D2]...511
T-26 FAILURE CODE [D4]...512
T-27 FAILURE CODE [D5]...513
T-28 FAILURE CODE [D6]...514
T-29 FAILURE CODE [D7]...515
T-30 FAILURE CODE [E1]...516
T-31 FAILURE CODE [E2]...517
T-32 FAILURE CODE [E3]...518
T-33 FAILURE CODE [E4]...520
T-34 FAILURE CODE [E5]...520
T-35 FAILURE CODE [E6]...521
T-36 FAILURE CODE [E7]...522
T-37 FAILURE CODE [E8]...522
T-38 FAILURE CODE [F1]...524
T-39 FAILURE CODE [F2]...524
T-40 FAILURE CODE [F3]...525
T-41 FAILURE CODE [F4]...526
T-42 FAILURE CODE [F5]...526
T-43 FAILURE CODE [F6]...527
T-44 FAILURE CODE [F7]...527
T-45 FAILURE CODE [F8]...528
T-46 FAILURE CODE [91]...529
T-47 FAILURE CODE [92]...529
T-48 FAILURE CODE [93]...530
T-49 FAILURE CODE [94]...531
T-50 FAILURE CODE [95]...531
T-51 FAILURE CODE [96]...532
T-52 FAILURE CODE [97]...532
T-53 FAILURE CODE [98]...534
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...535
FAILURE TABLE: MODES AND CAUSES...536
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER...538
H-2 NO WORK EQUIPMENT MOVES...539
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...539
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP...540
H-5 EXCESSIVE BLADE DRIFT...540
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE...541
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIM CYLINDERS (LEFT,RIGHT)...541
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)...542
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE...542
H-10 EXCESSIVE SCARIFIER DRIFT...543
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE...543
H-12 TRANSMISSION DOES NOT UPSHIFT OR DOWNSHIFT...544
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING...544
H-14 TORQUE COVERTER LOCK-UP MALFUNCTION...545
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR...545
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...546
H-17 BRAKING FORCE IS INSUFFICIENT...547
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...549
FAILURE TABLE: MODES AND CAUSES...550
ELECTRICAL CIRCUIT DIAGRAM FOR THE MAIN MONITOR SYSTEM...552
M-1 ENGINE OIL PRESSURE CAUTION LAMP GLOWS...556
M-2 TRANSMISSION CONTROLLER CAUTION LAMP GLOWS...557
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP GLOWS...557
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP GLOWS (OPT)...558
M-5 BANK PIN CAUTION LAMP GLOWS...559
M-6 BRAKE OIL PRESSURE CAUTION LAMP GLOWS...560
M-7 BATTERY CHARGE CAUTION LAMP GLOWS...561
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP...562
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP...563
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)...564
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)...565
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP...566
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP...566
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP...568
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH...569
M-16 ARTICULATION GAUGE DOES NOT WORK...570
M-17 FUEL GAUGE DOES NOT WORK...572
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK...574
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)...575
M-20 MESSAGE CENTER DOES NOT WORK...576
M-21 SERVICE METER DOES NOT WORK...577
30 DISASSEMBLY AND ASSEMBLY...578
METHOD OF USING MANUAL...580
PRECAUTIONS WHEN CARRYING OUT OPERATION...582
SPECIAL TOOL LIST...585
SKETCHES OF SPECIAL TOOLS...588
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001-51000)...593
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001-51000)...594
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001-UP)...594
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001-UP)...595
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)...596
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 50001-51000)...597
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.: 51001-UP)...598
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 51001-UP)...600
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001-51000)...601
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001-51000)...603
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001-UP)...605
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001-UP)...607
REMOVAL OF ENGINE ASSEMBLY...608
INSTALLATION OF ENGINE ASSEMBLY...609
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT...611
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT...612
REMOVAL OF TRANSMISSION ASSEMBLY...613
INSTALLATION OF TRANSMISSION ASSEMBLY...615
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...618
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...620
DISASSEMBLY OF TRANSMISSION ASSEMBLY...624
ASSEMBLY OF TRANSMISSION ASSEMBLY...640
REMOVAL OF FINAL DRIVE ASSEMBLY...661
INSTALLATION OF FINAL DRIVE ASSEMBLY...664
DISASSEMBLY OF FINAL DRIVE ASSEMBLY...666
ASSEMBLY OF FINAL DRIVE ASSEMBLY...667
DISASSEMBLY OF FINAL BRAKE CASE...670
ASSEMBLY OF FINAL BRAKE CASE...671
DISASSEMBLY OF SIDE CASE...673
ASSEMBLY OF SIDE CASE...674
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...676
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...677
DISASSEMBLY OF BEVEL GEAR...680
ASSEMBLY OF BEVEL GEAR...681
DISASSEMBLY OF BEVEL PINION ASSEMBLY...682
ASSEMBLY OF BEVEL PINION ASSEMBLY...683
REMOVAL OF OPERATOR'S CAB ASSEMBLY...684
INSTALLATION OF OPERATOR'S CAB ASSEMBLY...686
REMOVAL OF OPERATOR'S CAB FLOOR...688
INSTALLATION OF OPERATOR'S CAB FLOOR...690
REMOVAL OF STEERING VALVE (ORBIT-ROLL)...692
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)...692
STANDARD INTEGRAL ORBIT-ROLL...693
DISASSEMBLY OF STEERING VALVE...695
ASSEMBLY OF STEERING VALVE...698
REMOVAL OF BLADE ASSEMBLY...703
INSTALLATION OF BLADE ASSEMBLY...703
REMOVAL OF CIRCLE DRAWBAR ASSEMBLY...704
INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY...705
REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY...706
INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY...707
REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMLBY (WITH SHEAR PIN)...708
INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)...709
DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)...710
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)...712
DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)...714
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)...716
90 OTHERS...720
TRANSMISSION HYDRAULIC CIRCUIT SERIAL NO.: 50001-51000...721
TRANSMISSION HYDRAULIC CIRCUIT SERIAL NO.: 51001 AND UP...722
HYDRAULIC CIRCUIT DIAGRAM SERIAL NO.:50001-51000...723
HYDRAULIC CIRCUIT DIAGRAM (1/2) SERIAL NO.:51001 AND UP...724
HYDRAULIC CIRCUIT DIAGRAM (2/2) SERIAL NO.:51001 AND UP...725
ELECTRICAL CIRCUIT DIAGRAM (1/6) SERIAL NO.: 50001-51000...726
ELECTRICAL CIRCUIT DIAGRAM (2/6) SERIAL NO.: 50001-51000...727
ELECTRICAL CIRCUIT DIAGRAM (3/6) SERIAL NO.: 50001-51000...728
ELECTRICAL CIRCUIT DIAGRAM (4/6) SERIAL NO.: 50001-51000...729
ELECTRICAL CIRCUIT DIAGRAM (5/6) SERIAL NO.: 50001-51000...730
ELECTRICAL CIRCUIT DIAGRAM (6/6) SERIAL NO.: 50001-51000...731
ELECTRICAL CIRCUIT DIAGRAM (1/6) SERIAL NO.: 51001 AND UP...732
ELECTRICAL CIRCUIT DIAGRAM (2/6) SERIAL NO.: 51001 AND UP...733
ELECTRICAL CIRCUIT DIAGRAM (3/6) SERIAL NO.: 51001 AND UP...734
ELECTRICAL CIRCUIT DIAGRAM (4/6) SERIAL NO.: 51001 AND UP...735
ELECTRICAL CIRCUIT DIAGRAM (5/6) SERIAL NO.: 51001 AND UP...736
ELECTRICAL CIRCUIT DIAGRAM (6/6) SERIAL NO.: 51001 AND UP...737
