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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.
SEBM020906 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual.pdf
SEBM020909 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual.pdf
SEBM020911 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual.pdf
KEAM037900 – Motor Grader GALEO GD655-3C Operation & Maintenance Manual.pdf
KEAM038000 – Motor Grader GALEO GD675-3C Operation & Maintenance Manual.pdf
KEAM038100 – Motor Grader GALEO GD555-3C Operation & Maintenance Manual.pdf
SEAM037902T – Motor Grader GD655-3C Operation & Maintenance Manual.pdf
SEAM038002 – Motor Grader GD675-3C Operation & Maintenance Manual.pdf
SEAM038003 – Motor Grader GD675-3C Operation & Maintenance Manual.pdf
SEAM038102T – Motor Grader GD555-3C Operation & Maintenance Manual.pdf
TEN00095-01 – Motor Grader GALEO GD655-3C Operation & Maintenance Manual.pdf
TEN00178-02 – Motor Grader GD555-3C Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,513 pages
File Format: PDF
Language: English
MAIN SECTIONS
KEAM037900 – Motor Grader GALEO GD655-3C Operation & Maintenance Manual….2
COVER….2
FOREWORD….3
FOREWORD….4
SAFETY INFORMATION….7
INTENDED USE….9
DIRECTIONS OF MACHINE….9
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….10
MACHINE SERIAL NO. PLATE POSITION….10
ENGINE SERIAL NO. PLATE POSITION….10
SERVICE METER POSITION….11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….11
CONTENTS….12
SAFETY….15
SAFETY INFORMATION….16
SAFETY LABELS….18
POSITION FOR ATTACHING SAFETY LABELS….19
SAFETY LABELS….20
GENERAL PRECAUTIONS….26
SAFETY RULES….26
IF ABNORMALITIES ARE FOUND….26
CLOTHING AND PERSONAL PROTECTIVE ITEMS….26
FIRE EXTINGUISHER AND FIRST AID KIT….26
SAFETY FEATURES….26
KEEP MACHINE CLEAN….27
INSIDE OPERATOR'S COMPARTMENT….27
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….27
HANDRAILS AND STEPS….28
MOUNTING AND DISMOUNTING….28
DO NOT GET CAUGHT IN ARTICULATED PORTION….28
PREVENTION OF BURNS….29
FIRE PREVENTION….29
ACTION IF FIRE OCCURS….30
WINDOW WASHER LIQUID….30
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)….30
PRECAUTIONS FOR ATTACHMENTS….31
UNAUTHORIZED MODIFICATION….31
SAFETY AT WORKSITE….31
WORKING ON LOOSE GROUND….31
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….32
ENSURE GOOD VISIBILITY….32
VENTILATION FOR ENCLOSED AREAS….32
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….33
EMERGENCY ESCAPE FROM OPERATOR'S CAB….33
ASBESTOS DUST HAZARD PREVENTION….33
PRECAUTIONS DURING OPERATION….34
STARTING ENGINE….34
CHECKS BEFORE STARTING ENGINE, ADJUST….34
PRECAUTIONS WHEN STARTING….34
PRECAUTIONS IN COLD AREAS….35
OPERATION….35
CHECKS BEFORE STARTING OPERATION….35
PRECAUTIONS BEFORE MOVING OFF….35
PRECAUTIONS WHEN TRAVELING….36
PRECAUTIONS WHEN TRAVELING ON SLOPES….37
PRECAUTIONS WHEN OPERATIONS ON SLOPES….37
PROHIBITED OPERATIONS….37
PRECAUTIONS WHEN OPERATING….37
OPERATE CAREFULLY ON SNOW….38
PARKING MACHINE….38
TRANSPORTATION….39
LOADING AND UNLOADING….39
SHIPPING….39
BATTERY….40
BATTERY HAZARD PREVENTION….40
STARTING WITH BOOSTER CABLES….41
TOWING….42
WHEN TOWING….42
PRECAUTIONS FOR MAINTENANCE….43
WARNING TAG….43
KEEP WORK PLACE CLEAN AND TIDY….43
APPOINT LEADER WHEN WORKING WITH OTHERS….43
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….44
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….45
PROPER TOOLS….45
ACCUMULATOR….46
PERSONNEL….46
ATTACHMENTS….46
WORK UNDER THE MACHINE….46
NOISE….46
PRECAUTIONS WHEN USING HAMMER….47
REPAIR WELDING….47
REMOVING BATTERY TERMINAL….47
PRECAUTIONS WITH HIGH-PRESSURE OIL….47
PRECAUTIONS WITH HIGH-PRESSURE FUEL….47
HANDLING HIGH-PRESSURE HOSES….48
WASTE MATERIALS….48
MAINTENANCE OF AIR CONDITIONER….48
COMPRESSED AIR….48
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….48
PRECAUTIONS WITH TIRES….49
HANDLING TIRES….49
PRECAUTIONS WHEN STORING TIRE….49
OPERATION….51
GENERAL VIEW….52
GENERAL VIEW OF MACHINE….52
GENERAL VIEW OF CONTROLS AND GAUGES….53
EXPLANATION OF COMPONENTS….56
METERS AND LAMPS….56
SWITCHES….63
CONTROL LEVERS, PEDALS….74
ARTICULATE LOCK PIN….83
FUSE BOX….83
OPERATION….85
CHECK BEFORE STARTING ENGINE….85
STARTING ENGINE….97
OPERATIONS, CHECKS AFTER STARTING ENGINE….101
STOPPING ENGINE….103
CHECK AFTER STOPPING ENGINE….103
TRAVELING POSTURE FOR MACHINE….104
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….105
TURNING MACHINE….109
OPERATING WORK EQUIPMENT….112
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….118
PRECAUTIONS WHEN OPERATION….139
ADJUSTING WORK EQUIPMENT POSTURE….143
PARKING MACHINE….153
CHECKS AFTER COMPLETION OF OPERATION….154
LOCKING….155
HANDLING THE TIRES….155
TRANSPORTATION….156
LOADING, UNLOADING WORK….156
PRECAUTIONS FOR LOADING….157
COLD WEATHER OPERATION….158
PRECAUTIONS FOR LOW TEMPERATURE….158
CAUTIONS AFTER COMPLETION OF WORK….159
AFTER COLD WEATHER….159
LONG-TERM STORAGE….160
BEFORE STORAGE….160
DURING STORAGE….160
AFTER STORAGE….160
TROUBLESHOOTING….161
AFTER RUNNING OUT OF FUEL….161
WHEN LEANING PIPING IS DAMAGED….162
TOWING THE MACHINE….163
IF BATTERY IS DISCHARGED….165
OTHER TROUBLE….168
MAINTENANCE….175
GUIDES TO MAINTENANCE….176
OUTLINES OF SERVICE….178
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….178
RELATING TO ELECTRIC SYSTEM….180
WEAR PARTS….181
WEAR PARTS LIST….181
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….182
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….186
TORQUE LIST….186
PERIODIC REPLACEMENT OF CRITICAL PARTS….188
CRITICAL PARTS….188
MAINTENANCE SCHEDULE CHART….189
MAINTENANCE SCHEDULE CHART….189
SERVICE PROCEDURE….191
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….191
REPLACE FUEL FILTER CARTRIDGE….222
CHANGE OIL IN TRANSMISSION CASE….230
CHANGE OIL IN FINAL DRIVE CASE….231
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….236
CHANGE OIL IN HYDRAULIC TANK….235
REPLACE HYDRAULIC TANK FILTER ELEMENT….231
CHANGE OIL IN TANDEM DRIVE CASE….237
CHECK ENGINE VALVE CLEARANCE, ADJUST….239
WHEN REQUIRED….192
CLEAN INSIDE OF COOLING SYSTEM….192
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….195
CLEAN, CHECK WATER SEPARATOR….199
CHECK ELECTRICAL INTAKE AIR HEATER….200
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….200
CHECK INCHING PEDAL….200
CLEAN AIR CONDITIONER AIR FILTER….201
CHECK REFRIGERANT (GAS) LEVEL….202
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….202
SELECTION AND INSPECTION OF TIRES….203
CHECK BEFORE STARTING….205
EVERY 50 HOURS SERVICE….206
LUBRICATING….206
EVERY 250 HOURS SERVICE….207
LUBRICATING….207
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….213
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….214
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….215
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….216
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….216
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….217
CHECK LEVEL OF BATTERY ELECTROLYTE….218
CHECK BALL JOINT CLEARANCE, ADJUST….220
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….220
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….220
CHECK FAN BELT TENSION, ADJUST….221
EVERY 500 HOURS SERVICE….222
REPLACE FUEL FILTER CARTRIDGE….222
CLEAN, CHECK RADIATOR FINS….224
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….225
EVERY 1000 HOURS SERVICE….228
LUBRICATING….228
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….229
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….230
CHANGE OIL IN FINAL DRIVE CASE….231
REPLACE HYDRAULIC TANK FILTER ELEMENT….231
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….232
CHECK TOE-IN, ADJUST….232
CHECK FRONT WHEEL BEARING PLAY, ADJUST….233
REPLACE CORROSION RESISTOR CARTRIDGE….234
EVERY 2000 HOURS SERVICE….235
CHANGE OIL IN HYDRAULIC TANK….235
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….236
CHANGE OIL IN TANDEM DRIVE CASE….237
CHECK DISC BRAKE….238
CHECK ALTERNATOR, STARTING MOTOR….239
CHECK ENGINE VALVE CLEARANCE, ADJUST….239
CHECK VIBRATION DAMPER….239
CLEAN, CHECK TURBOCHARGER….239
CHECK ACCUMULATOR GAS PRESSURE….239
CHANGE GREASE IN FRONT WHEEL BEARING….239
EVERY 4000 HOURS SERVICE….240
CHECK WATER PUMP….240
CHECK AND ADJUST AIR COMPRESSOR….240
CHECK FAN PULLEY….240
CHECK INJECTOR….240
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….240
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….241
EVERY 8000 HOURS SERVICE….242
REPLACE INJECTOR NOZZLE TIP….242
REPLACE HIGH-PRESSURE PIPING CLAMP….242
REPLACE FUEL SPRAY PREVENTION CAP….242
SPECIFICATIONS….243
SPECIFICATIONS….244
ATTACHMENTS, OPTIONS….247
HANDLING BLADE ACCUMULATOR….248
FEATURES OF BLADE ACCUMULATOR….248
METHOD OF OPERATING BLADE ACCUMULATOR….249
AM/FM RADIO-CASSETTE STEREO….250
EXPLANATION OF COMPONENTS….250
METHOD OF OPERATION….255
PRECAUTIONS WHEN USING….258
AIR CONDITIONER….259
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….259
METHOD OF OPERATION….261
PRECAUTIONS WHEN USING….261
TESTING AND MAINTENANCE….261
HANDLING AIR-SUSPENSION SEAT….262
ADJUST OPERATOR'S SEAT….262
INDEX….265
KEAM038000 – Motor Grader GALEO GD675-3C Operation & Maintenance Manual….269
COVER….269
FOREWORD….270
FOREWORD….271
SAFETY INFORMATION….274
INTENDED USE….276
DIRECTIONS OF MACHINE….276
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….277
MACHINE SERIAL NO. PLATE POSITION….277
ENGINE SERIAL NO. PLATE POSITION….277
SERVICE METER POSITION….278
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….278
CONTENTS….279
SAFETY….282
SAFETY INFORMATION….283
SAFETY LABELS….285
POSITION FOR ATTACHING SAFETY LABELS….286
SAFETY LABELS….287
GENERAL PRECAUTIONS….292
SAFETY RULES….292
IF ABNORMALITIES ARE FOUND….292
CLOTHING AND PERSONAL PROTECTIVE ITEMS….292
FIRE EXTINGUISHER AND FIRST AID KIT….292
SAFETY FEATURES….292
KEEP MACHINE CLEAN….293
INSIDE OPERATOR'S COMPARTMENT….293
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….293
HANDRAILS AND STEPS….294
MOUNTING AND DISMOUNTING….294
DO NOT GET CAUGHT IN ARTICULATED PORTION….294
PREVENTION OF BURNS….295
FIRE PREVENTION….295
ACTION IF FIRE OCCURS….296
WINDOW WASHER LIQUID….296
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)….296
PRECAUTIONS FOR ATTACHMENTS….297
UNAUTHORIZED MODIFICATION….297
SAFETY AT WORKSITE….297
WORKING ON LOOSE GROUND….297
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….298
ENSURE GOOD VISIBILITY….298
VENTILATION FOR ENCLOSED AREAS….298
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….299
EMERGENCY ESCAPE FROM OPERATOR'S CAB….299
ASBESTOS DUST HAZARD PREVENTION….299
PRECAUTIONS DURING OPERATION….300
STARTING ENGINE….300
CHECKS BEFORE STARTING ENGINE, ADJUST….300
PRECAUTIONS WHEN STARTING….300
PRECAUTIONS IN COLD AREAS….301
OPERATION….302
CHECKS BEFORE STARTING OPERATION….302
PRECAUTIONS BEFORE MOVING OFF….302
PRECAUTIONS WHEN TRAVELING….303
PRECAUTIONS WHEN TRAVELING ON SLOPES….304
PRECAUTIONS WHEN OPERATIONS ON SLOPES….304
PROHIBITED OPERATIONS….304
PRECAUTIONS WHEN OPERATING….304
OPERATE CAREFULLY ON SNOW….304
PARKING MACHINE….305
TRANSPORTATION….306
LOADING AND UNLOADING….306
SHIPPING….306
BATTERY….307
BATTERY HAZARD PREVENTION….307
STARTING WITH BOOSTER CABLES….308
TOWING….309
WHEN TOWING….309
PRECAUTIONS FOR MAINTENANCE….310
WARNING TAG….310
KEEP WORK PLACE CLEAN AND TIDY….310
APPOINT LEADER WHEN WORKING WITH OTHERS….310
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….311
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….312
PROPER TOOLS….312
ACCUMULATOR….313
PERSONNEL….313
ATTACHMENTS….313
WORK UNDER THE MACHINE….313
NOISE….313
PRECAUTIONS WHEN USING HAMMER….314
REPAIR WELDING….314
REMOVING BATTERY TERMINAL….314
PRECAUTIONS WITH HIGH-PRESSURE OIL….314
HANDLING HIGH-PRESSURE HOSES….315
WASTE MATERIALS….315
MAINTENANCE OF AIR CONDITIONER….315
COMPRESSED AIR….315
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….315
PRECAUTIONS WITH TIRES….316
HANDLING TIRES….316
PRECAUTIONS WHEN STORING TIRE….316
OPERATION….318
GENERAL VIEW….319
GENERAL VIEW OF MACHINE….319
GENERAL VIEW OF CONTROLS AND GAUGES….320
EXPLANATION OF COMPONENTS….323
METERS AND LAMPS….323
SWITCHES….330
CONTROL LEVERS, PEDALS….341
DUST INDICATOR….350
ARTICULATE LOCK PIN….350
FUSE BOX….350
OPERATION….352
CHECK BEFORE STARTING ENGINE….352
STARTING ENGINE….364
OPERATIONS, CHECKS AFTER STARTING ENGINE….368
STOPPING ENGINE….370
CHECK AFTER STOPPING ENGINE….370
TRAVELING POSTURE FOR MACHINE….371
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….372
TURNING MACHINE….376
OPERATING WORK EQUIPMENT….379
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….385
PRECAUTIONS WHEN OPERATION….406
ADJUSTING WORK EQUIPMENT POSTURE….410
PARKING MACHINE….419
CHECKS AFTER COMPLETION OF OPERATION….420
LOCKING….421
HANDLING THE TIRES….421
TRANSPORTATION….422
LOADING, UNLOADING WORK….422
PRECAUTIONS FOR LOADING….423
COLD WEATHER OPERATION….424
PRECAUTIONS FOR LOW TEMPERATURE….424
CAUTIONS AFTER COMPLETION OF WORK….425
AFTER COLD WEATHER….425
LONG-TERM STORAGE….426
BEFORE STORAGE….426
DURING STORAGE….426
AFTER STORAGE….426
TROUBLESHOOTING….427
AFTER RUNNING OUT OF FUEL….427
WHEN LEANING PIPING IS DAMAGED….428
TOWING THE MACHINE….429
IF BATTERY IS DISCHARGED….431
OTHER TROUBLE….434
MAINTENANCE….442
GUIDES TO MAINTENANCE….443
OUTLINES OF SERVICE….445
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….445
RELATING TO ELECTRIC SYSTEM….447
WEAR PARTS….448
WEAR PARTS LIST….448
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….449
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….453
TORQUE LIST….453
PERIODIC REPLACEMENT OF CRITICAL PARTS….455
CRITICAL PARTS….455
MAINTENANCE SCHEDULE CHART….456
MAINTENANCE SCHEDULE CHART….456
SERVICE PROCEDURE….458
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….458
REPLACE FUEL FILTER CARTRIDGE….489
CHANGE OIL IN TRANSMISSION CASE….497
CHANGE OIL IN FINAL DRIVE CASE….498
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….503
CHANGE OIL IN HYDRAULIC TANK….502
REPLACE HYDRAULIC TANK FILTER ELEMENT….498
CHANGE OIL IN TANDEM DRIVE CASE….504
CHECK ENGINE VALVE CLEARANCE, ADJUST….506
WHEN REQUIRED….459
CLEAN INSIDE OF COOLING SYSTEM….459
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….462
CLEAN, CHECK WATER SEPARATOR….466
CHECK ELECTRICAL INTAKE AIR HEATER….467
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….467
CHECK INCHING PEDAL….467
CLEAN AIR CONDITIONER AIR FILTER….468
CHECK REFRIGERANT (GAS) LEVEL….469
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….469
SELECTION AND INSPECTION OF TIRES….470
CHECK BEFORE STARTING….472
EVERY 50 HOURS SERVICE….473
LUBRICATING….473
EVERY 250 HOURS SERVICE….474
LUBRICATING….474
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….480
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….481
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….482
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….483
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….483
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….484
CHECK LEVEL OF BATTERY ELECTROLYTE….485
CHECK BALL JOINT CLEARANCE, ADJUST….487
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….487
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….487
CHECK FAN BELT TENSION, ADJUST….488
EVERY 500 HOURS SERVICE….489
REPLACE FUEL FILTER CARTRIDGE….489
CLEAN, CHECK RADIATOR FINS….491
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….492
EVERY 1000 HOURS SERVICE….495
LUBRICATING….495
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….496
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….497
CHANGE OIL IN FINAL DRIVE CASE….498
REPLACE HYDRAULIC TANK FILTER ELEMENT….498
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….499
CHECK TOE-IN, ADJUST….500
CHECK FRONT WHEEL BEARING PLAY, ADJUST….501
REPLACE CORROSION RESISTOR CARTRIDGE….501
EVERY 2000 HOURS SERVICE….502
CHANGE OIL IN HYDRAULIC TANK….502
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….503
CHANGE OIL IN TANDEM DRIVE CASE….504
CHECK DISC BRAKE….505
CHECK ALTERNATOR, STARTING MOTOR….506
CHECK ENGINE VALVE CLEARANCE, ADJUST….506
CHECK VIBRATION DAMPER….506
CLEAN, CHECK TURBOCHARGER….506
CHECK ACCUMULATOR GAS PRESSURE….506
CHANGE GREASE IN FRONT WHEEL BEARING….506
EVERY 4000 HOURS SERVICE….507
CHECK WATER PUMP….507
CHECK AND ADJUST AIR COMPRESSOR….507
CHECK FAN PULLEY….507
CHECK INJECTOR….507
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….507
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….508
EVERY 8000 HOURS SERVICE….509
REPLACE INJECTOR NOZZLE TIP….509
REPLACE HIGH-PRESSURE PIPING CLAMP….509
REPLACE FUEL SPRAY PREVENTION CAP….509
SPECIFICATIONS….510
SPECIFICATIONS….511
ATTACHMENTS, OPTIONS….512
HANDLING BLADE ACCUMULATOR….513
FEATURES OF BLADE ACCUMULATOR….513
METHOD OF OPERATING BLADE ACCUMULATOR….514
AM/FM RADIO-CASSETTE STEREO….515
EXPLANATION OF COMPONENTS….515
METHOD OF OPERATION….520
PRECAUTIONS WHEN USING….523
AIR CONDITIONER….524
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….524
METHOD OF OPERATION….526
PRECAUTIONS WHEN USING….526
TESTING AND MAINTENANCE….526
HANDLING AIR-SUSPENSION SEAT….527
ADJUST OPERATOR'S SEAT….527
INDEX….530
KEAM038100 – Motor Grader GALEO GD555-3C Operation & Maintenance Manual….534
COVER….534
FOREWORD….535
FOREWORD….536
SAFETY INFORMATION….539
INTENDED USE….541
DIRECTIONS OF MACHINE….541
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….542
MACHINE SERIAL NO. PLATE POSITION….542
ENGINE SERIAL NO. PLATE POSITION….542
SERVICE METER POSITION….543
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….543
CONTENTS….544
SAFETY….547
SAFETY INFORMATION….548
SAFETY LABELS….550
POSITION FOR ATTACHING SAFETY LABELS….551
SAFETY LABELS….552
GENERAL PRECAUTIONS….557
SAFETY RULES….557
IF ABNORMALITIES ARE FOUND….557
CLOTHING AND PERSONAL PROTECTIVE ITEMS….557
FIRE EXTINGUISHER AND FIRST AID KIT….557
SAFETY FEATURES….557
KEEP MACHINE CLEAN….558
INSIDE OPERATOR'S COMPARTMENT….558
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….558
HANDRAILS AND STEPS….559
MOUNTING AND DISMOUNTING….559
DO NOT GET CAUGHT IN ARTICULATED PORTION….559
PREVENTION OF BURNS….560
FIRE PREVENTION….560
ACTION IF FIRE OCCURS….561
WINDOW WASHER LIQUID….561
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)….561
PRECAUTIONS FOR ATTACHMENTS….562
UNAUTHORIZED MODIFICATION….562
SAFETY AT WORKSITE….562
WORKING ON LOOSE GROUND….562
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….563
ENSURE GOOD VISIBILITY….563
VENTILATION FOR ENCLOSED AREAS….563
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….564
EMERGENCY ESCAPE FROM OPERATOR'S CAB….564
ASBESTOS DUST HAZARD PREVENTION….564
PRECAUTIONS DURING OPERATION….565
STARTING ENGINE….565
CHECKS BEFORE STARTING ENGINE, ADJUST….565
PRECAUTIONS WHEN STARTING….565
PRECAUTIONS IN COLD AREAS….566
OPERATION….567
CHECKS BEFORE STARTING OPERATION….567
PRECAUTIONS BEFORE MOVING OFF….567
PRECAUTIONS WHEN TRAVELING….567
PRECAUTIONS WHEN TRAVELING ON SLOPES….568
PRECAUTIONS WHEN OPERATIONS ON SLOPES….569
PROHIBITED OPERATIONS….569
PRECAUTIONS WHEN OPERATING….569
OPERATE CAREFULLY ON SNOW….569
PARKING MACHINE….570
TRANSPORTATION….571
LOADING AND UNLOADING….571
SHIPPING….571
BATTERY….572
BATTERY HAZARD PREVENTION….572
STARTING WITH BOOSTER CABLES….573
TOWING….574
WHEN TOWING….574
PRECAUTIONS FOR MAINTENANCE….575
WARNING TAG….575
KEEP WORK PLACE CLEAN AND TIDY….575
APPOINT LEADER WHEN WORKING WITH OTHERS….575
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….576
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….577
PROPER TOOLS….577
ACCUMULATOR….578
PERSONNEL….578
ATTACHMENTS….578
WORK UNDER THE MACHINE….578
NOISE….578
PRECAUTIONS WHEN USING HAMMER….579
REPAIR WELDING….579
REMOVING BATTERY TERMINAL….579
PRECAUTIONS WITH HIGH-PRESSURE FUEL….579
HANDLING HIGH-PRESSURE HOSES….580
WASTE MATERIALS….580
MAINTENANCE OF AIR CONDITIONER….580
COMPRESSED AIR….580
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….580
PRECAUTIONS WITH TIRES….581
PRECAUTIONS WITH TIRES….581
HANDLING TIRES….581
PRECAUTIONS WHEN STORING TIRE….581
OPERATION….583
GENERAL VIEW….584
GENERAL VIEW OF MACHINE….584
GENERAL VIEW OF CONTROLS AND GAUGES….585
EXPLANATION OF COMPONENTS….588
METERS AND LAMPS….588
SWITCHES….595
CONTROL LEVERS, PEDALS….606
DUST INDICATOR….615
ARTICULATE LOCK PIN….615
FUSE BOX….615
OPERATION….617
CHECK BEFORE STARTING ENGINE….617
STARTING ENGINE….629
OPERATIONS, CHECKS AFTER STARTING ENGINE….633
STOPPING ENGINE….635
CHECK AFTER STOPPING ENGINE….635
TRAVELING POSTURE FOR MACHINE….636
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….637
TURNING MACHINE….641
OPERATING WORK EQUIPMENT….644
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….650
PRECAUTIONS WHEN OPERATION….671
ADJUSTING WORK EQUIPMENT POSTURE….675
PARKING MACHINE….686
CHECKS AFTER COMPLETION OF OPERATION….687
LOCKING….688
HANDLING THE TIRES….688
TRANSPORTATION….689
LOADING, UNLOADING WORK….689
PRECAUTIONS FOR LOADING….690
COLD WEATHER OPERATION….691
PRECAUTIONS FOR LOW TEMPERATURE….691
CAUTIONS AFTER COMPLETION OF WORK….692
AFTER COLD WEATHER….692
LONG-TERM STORAGE….693
BEFORE STORAGE….693
DURING STORAGE….693
AFTER STORAGE….693
TROUBLESHOOTING….694
AFTER RUNNING OUT OF FUEL….694
WHEN LEANING PIPING IS DAMAGED….695
TOWING THE MACHINE….696
IF BATTERY IS DISCHARGED….698
OTHER TROUBLE….701
MAINTENANCE….709
GUIDES TO MAINTENANCE….710
OUTLINES OF SERVICE….712
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….712
RELATING TO ELECTRIC SYSTEM….714
WEAR PARTS….715
WEAR PARTS LIST….715
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….716
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….720
TORQUE LIST….720
PERIODIC REPLACEMENT OF CRITICAL PARTS….722
CRITICAL PARTS….722
MAINTENANCE SCHEDULE CHART….723
MAINTENANCE SCHEDULE CHART….723
SERVICE PROCEDURE….725
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….725
REPLACE FUEL FILTER CARTRIDGE….755
CHANGE OIL IN TRANSMISSION CASE….763
CHANGE OIL IN FINAL DRIVE CASE….764
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….768
CHANGE OIL IN HYDRUALIC TANK….764
REPLACE HYDRAULIC TANK FILTER ELEMENT….725
CHANGE OIL IN TANDEM DRIVE CASE….769
CHECK ENGINE VALVE CLEARANCE, ADJUST….771
WHEN REQUIRED….726
CLEAN INSIDE OF COOLING SYSTEM….726
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….729
CLEAN, CHECK WATER SEPARATOR….732
CHECK ELECTRICAL INTAKE AIR HEATER….733
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….733
CHECK INCHING PEDAL….733
CLEAN AIR CONDITIONER AIR FILTER….734
CHECK REFRIGERANT (GAS) LEVEL….735
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….735
SELECTION AND INSPECTION OF TIRES….736
CHECK BEFORE STARTING….738
EVERY 50 HOURS SERVICE….739
LUBRICATING….739
EVERY 250 HOURS SERVICE….740
LUBRICATING….740
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….746
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….747
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….748
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….749
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….749
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….750
CHECK LEVEL OF BATTERY ELECTROLYTE….751
CHECK BALL JOINT CLEARANCE, ADJUST….753
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….753
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….753
CHECK FAN BELT TENSION, ADJUST….754
EVERY 500 HOURS SERVICE….755
REPLACE FUEL FILTER CARTRIDGE….755
CLEAN, CHECK RADIATOR FINS….757
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….758
EVERY 1000 HOURS SERVICE….761
LUBRICATING….761
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….762
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….763
CHANGE OIL IN FINAL DRIVE CASE….764
REPLACE HYDRAULIC TANK FILTER ELEMENT….764
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….765
CHECK TOE-IN, ADJUST….765
CHECK FRONT WHEEL BEARING PLAY, ADJUST….766
EVERY 2000 HOURS SERVICE….767
CHANGE OIL IN HYDRAULIC TANK….767
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….768
CHANGE OIL IN TANDEM DRIVE CASE….769
CHECK DISC BRAKE….770
CHECK ALTERNATOR, STARTING MOTOR….771
CHECK ENGINE VALVE CLEARANCE, ADJUST….771
CHECK VIBRATION DAMPER….771
CLEAN, CHECK TURBOCHARGER….771
CHECK ACCUMULATOR GAS PRESSURE….771
CHANGE GREASE IN FRONT WHEEL BEARING….771
EVERY 4000 HOURS SERVICE….772
CHECK WATER PUMP….772
CHECK AND ADJUST AIR COMPRESSOR….772
CHECK FAN PULLEY….772
SPECIFICATIONS….773
SPECIFICATIONS….774
ATTACHMENTS, OPTIONS….777
HANDLING BLADE ACCUMULATOR….778
FEATURES OF BLADE ACCUMULATOR….778
METHOD OF OPERATING BLADE ACCUMULATOR….779
AM/FM RADIO-CASSETTE STEREO….780
EXPLANATION OF COMPONENTS….780
METHOD OF OPERATION….785
PRECAUTIONS WHEN USING….787
AIR CONDITIONER….788
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….788
METHOD OF OPERATION….790
PRECAUTIONS WHEN USING….790
TESTING AND MAINTENANCE….790
HANDLING AIR-SUSPENSION SEAT….791
ADJUST OPERATOR'S SEAT….791
INDEX….793
SEAM037902T – Motor Grader GD655-3C Operation & Maintenance Manual….797
COVER….797
FOREWORD….798
FOREWORD….799
SAFETY INFORMATION….802
INTENDED USE….804
DIRECTIONS OF MACHINE….804
LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR….805
MACHINE SERIAL NO.PLATE POSITION….805
ENGINE SERIAL NO.PLATE POSITION….805
SERVICE METER POSITION….806
TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR….806
CONTENTS….807
SAFETY….810
SAFETY INFORMATION….811
SAFETY LABELS….813
POSITION FOR ATTACHING SAFETY LABELS….813
SAFETY LABELS….814
GENERAL PRECAUTIONS….819
SAFETY RULES….819
IF ABNORMALITIES ARE FOUND….819
CLOTHING AND PERSONAL PROTECTIVE ITEMS….819
FIRE EXTINGUISHER AND FIRST AID KIT….819
SAFETY FEATURES….819
KEEP MACHINE CLEAN….820
INSIDE OPERATOR'S COMPARTMENT….820
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….820
HANDRAILS AND STEPS….821
MOUNTING AND DISMOUNTING….821
DO NOT GET CAUGHT IN ARTICULATED PORTION….821
PREVENTION OF BURNS….822
FIRE PREVENTION….822
ACTION IF FIRE OCCURS….823
WINDOW WASHER LIQUID….823
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….823
PRECAUTIONS FOR ATTACHMENTS….824
UNAUTHORIZED MODIFICATION….824
SAFETY AT WORKSITE….824
WORKING ON LOOSE GROUND….824
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….825
ENSURE GOOD VISIBILITY….825
VENTILATION FOR ENCLOSED AREAS….825
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….826
EMERGENCY ESCAPE FROM OPERATOR’S CAB….826
ASBESTOS DUST HAZARD PREVENTION….826
PRECAUTIONS DURING OPERATION….827
STARTING ENGINE….827
CHECKS BEFORE STARTING ENGINE,ADJUST….827
PRECAUTIONS WHEN STARTING….827
PRECAUTIONS IN COLD AREAS….828
OPERATION….828
CHECKS BEFORE STARTING OPERATION….828
PRECAUTIONS BEFORE MOVING OFF….828
PRECAUTIONS WHEN TRAVELING….829
PRECAUTIONS WHEN TRAVELING ON SLOPES….830
PRECAUTIONS WHEN OPERATIONS ON SLOPES….830
PROHIBITED OPERATIONS….830
PRECAUTIONS WHEN OPERATING….830
OPERATE CAREFULLY ON SNOW….830
PARKING MACHINE….831
TRANSPORTATION….832
LOADING AND UNLOADING….832
SHIPPING….832
BATTERY….833
BATTERY HAZARD PREVENTION….833
STARTING WITH BOOSTER CABLES….834
TOWING….835
WHEN TOWING….835
PRECAUTIONS FOR MAINTENENCE….836
WARNING TAG….836
KEEP WORK PLACE CLEAN AND TIDY….836
APPOINT LEADER WHEN WORKING WITH OTHERS….836
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….837
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….838
PROPER TOOLS….838
ACCUMULATOR….839
PERSONNEL….839
ATTACHMENTS….839
WORK UNDER THE MACHINE….839
NOISE….839
PRECAUTIONS WHEN USIN HAMMER….840
REPAIR WELDING….840
REMOVING BATTERY TERMINAL….840
PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN….840
PRECAUTIONS WITH HIGH-PRESSURE OIL….840
HANDLING HIGH-PRESSURE HOSES….841
WASTE MATERIALS….841
MAINTENANCE OF AIR CONDITIONER….841
COMPRESSED AIR….841
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….841
PRECAUTIONS WITH TIRES….842
HANDLING TIRES….842
PRECAUTIONS WHEN STORING TIRE….842
OPERATION….843
GENERAL VIEW….844
GENERAL VIEW OF MACHINE….844
GENERAL VIEW OF CONTROLS AND GAUGES….845
EXPLANATION OF COMPONENTS….847
METERS AND LAMPS….847
SWITCHES….854
CONTROL LEVERS,PEDALS….863
DUST INDICATOR….872
ARTICULATE LOCK PIN….872
FUSE BOX….872
CAR STEREO….874
AIR CONDITIONER….883
OPERATION….886
CHECK BEFORE STARTING ENGINE….886
STARTING ENGINE….899
OPERATIONS,CHECKS AFTER STARTING ENGINE….902
STOPPING ENGINE….904
CHECK AFTER STOPPING ENGINE….904
TRAVELING POSTURE FOR MACHINE….905
MOVING MACHINE OFF (FORWARD,REVERSE,SHIFTING GEAR),STOPPING….906
TURNING MACHINE….910
OPERATING WORK EQUIPMENT….913
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….919
PRECAUTIONS WHEN OPERATION….940
ADJUSTING WORK EQUIPMENT POSTURE….944
PARKING MACHINE….954
CHECKS AFTER COMPLETION OF OPERATION….955
LOCKING….956
HANDLING THE TIRES….956
TRANSPORTATION….957
LOADING, UNLOADING WORK….957
PRECAUTIONS FOR LOADING….957
COLD WEATHER OPERATION….958
PRECAUTIONS FOR LOW TEMPERATURE….958
CAUTIONS AFTER COMPLETION OF WORK….959
AFTER COLD WEATHER….959
LONG-TERM STORAGE….960
BEFORE STORAGE….960
DURING STORAGE….960
AFTER STORAGE….960
TROUBLESHOOTING….961
AFTER RUNNING OUT OF FUEL….961
WHEN LEANING PIPING IS DAMAGED….961
TOWING THE MACHINE….962
IF BATTERY IS DISCHARGED….964
OTHER TROUBLE….967
MAINTENANCE….974
GUIDE TO MAINTENANCE….975
OUTLINE OF SERVICE….977
HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC….977
RELATING TO ELECTRIC SYSTEM….979
WEAR PARTS….980
WEAR PARTS LIST….980
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….981
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….985
TORQUE LIST….985
PERIODIC REPLACEMENT OF CRITICAL PARTS….986
CRITICAL PARTS….986
MAINTENANCE SCHEDULE CHART….987
MAINTENANCE SCHEDULE CHART….987
SERVICE PROCEDURE….989
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….989
WHEN REQUIRED….990
CLEAN INSIDE OF COOLING SYSTEM….990
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT….993
DRAIN WATER,SEDIMENT FROM WATER SEPARATOR….995
CHECK ELECTRICAL INTAKE AIR HEATER….995
REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT….995
CHECK INCHING PEDAL….995
CLEAN AIR CONDITIONER AIR FILTER….996
CHECK REFRIGERANT (GAS) LEVEL….997
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….997
SELECTION AND INSPECTION OF TIRES….998
CHECK BEFORE STARTING….1000
EVERY 50 HOURS SERVICE….1001
LUBRICATING….1001
EVERY 250 HOURS SERVICE….1002
LUBRICATING….1002
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1007
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….1008
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1009
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….1010
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL….1010
CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL….1011
CHECK LEVEL OF BATTERY ELECTROLYTE….1012
CHECK BALL JOINT CLEARANCE,ADJUST….1012
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….1013
CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR….1013
CHECK FAN BELT TENSION,ADJUST….1013
EVERY 500 HOURS SERVICE….1014
REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE….1014
CLEAN,CHECK RADIATOR FINS….1015
CHECK CIRCLE GUIDE CLEARANCE,ADJUST….1015
EVERY 1000 HOURS SERVICE….1018
GREASE DRIVE SHAFT….1018
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….1018
CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER….1019
CHANGE OIL IN FINAL DRIVE CASE….1020
REPLACE HYDRAULIC TANK FILTER ELEMENT….1020
CHECK LOOSENESS,PLAY OF BALL JOINT AT FRONT OF DRAWBAR….1021
CHECK TOE-IN,ADJUST….1021
REPLACE CORROSION RESISTOR CARTRIDGE….1022
CHECK FRONT WHEEL BEARING PLAY,ADJUST….1022
EVERY 2000 HOURS SERVICE….1023
CHANGE OIL IN HYDRAULIC TANK….1023
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1024
CHANGE OIL IN TANDEM DRIVE CASE….1025
CHECK DISC BRAKE….1026
CHECK ALTERNATOR,STARTING MOTOR….1027
CHECK ENGINE VALVE CLEARANCE,ADJUST….1027
CHECK VIBRATION DAMPER….1027
CLEAN,CHECK TURBOCHARGER….1027
CHECK ACCUMULATOR GAS PRESSURE….1027
CHANGE GREASE IN FRONT WHEEL BEARING….1027
EVERY 4000 HOURS SERVICE….1028
CHECK WATER PUMP….1028
CHECK AND ADJUST AIR COMPRESSOR….1028
CHECK FAN PULLEY….1028
SPECIFICATIONS….1029
SPECIFICATIONS….1030
ATTACHMENTS,OPTIONS….1032
HANDLING BLADE ACCUMULATOR….1033
FEATURES OF BLADE ACCUMULATOR….1033
METHOD OF OPERATING BLADE ACCUMULATOR….1034
INDEX….1035
SEAM038002 – Motor Grader GD675-3C Operation & Maintenance Manual….1038
COVER….1038
FOREWARD….1039
FOREWARD….1040
SAFETY INFORMATION….1043
INTENDED USE….1045
DIRECTIONS OF MACHINE….1045
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1046
MACHINE SERIAL NO. PLATE POSITION….1046
ENGINE SERIAL NO. PLATE POSITION….1046
SERVICE METER POSITION….1047
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1047
CONTENTS….1048
SAFETY….1051
SAFETY INFORMATION….1052
SAFETY LABELS….1054
POSITION FOR ATTACHING SAFETY LABELS….1054
SAFETY LABELS….1055
GENERAL PRECAUTIONS….1060
SAFETY RULES….1060
IF ABNORMALITIES ARE FOUND….1060
CLOTHING AND PERSONAL PROTECTIVE ITEMS….1060
FIRE EXTINGUISHER AND FIRST AID KIT….1060
SAFETY FEATURES….1060
KEEP MACHINE CLEAN….1061
INSIDE OPERATOR'S COMPARTMENT….1061
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….1061
HANDRAILS AND STEPS….1062
MOUNTING AND DISMOUNTING….1062
DO NOT GET CAUGHT IN ARTICULATED PORTION….1062
PREVENTION OF BURNS….1063
FIRE PREVENTION….1063
ACTION IF FIRE OCCURS….1064
WINDOW WASHER LIQUID….1064
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….1064
PRECAUTIONS FOR ATTACHMENTS….1065
UNAUTHORIZED MODIFICATION….1065
SAFETY AT WORKSITE….1065
WORKING ON LOOSE GROUND….1065
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES….1066
ENSURE GOOD VISIBILITY….1066
VENTILATION FOR ENCLOSED AREAS….1066
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….1067
EMERGENCY ESCAPE FROM OPERATOR'S CAB….1067
ASBESTOS DUST HAZARD PREVENTION….1067
PRECAUTIONS DURING OPERATION….1068
STARTING ENGINE….1068
CHECKS BEFORE STARTING ENGINE, ADJUST….1068
PRECAUTIONS WHEN STARTING….1068
PRECAUTIONS IN COLD AREAS….1069
OPERATION….1069
CHECKS BEFORE STARTING OPERATION….1069
PRECAUTIONS BEFORE MOVING OFF….1069
PRECAUTIONS WHEN TRAVELING….1070
PRECAUTIONS WHEN TRAVELING ON SLOPES….1071
PRECAUTIONS WHEN OPERATIONS ON SLOPES….1071
PROHIBITED OPERATIONS….1071
PRECAUTIONS WHEN OPERATING….1071
OPERATE CAREFULLY ON SNOW….1071
PARKING MACHINE….1072
TRANSPORTATION….1073
LOADING AND UNLOADING….1073
SHIPPING….1073
BATTERY….1074
BATTERY HAZARD PREVENTION….1074
STARTING WITH BOOSTER CABLES….1075
TOWING….1076
WHEN TOWING….1076
PRECAUTIONS FOR MAINTENANCE….1077
WARNING TAG….1077
KEEP WORK PLACE CLEAN AND TIDY….1077
APPOINT LEADER WHEN WORKING WITH OTHERS….1077
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….1078
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1079
PROPER TOOLS….1079
ACCUMULATOR….1080
PERSONNEL….1080
ATTACHMENTS….1080
WORK UNDER THE MACHINE….1080
NOISE….1080
PRECAUTIONS WHEN USING HAMMER….1081
REPAIR WELDING….1081
REMOVING BATTERY TERMINAL….1081
PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN….1081
PRECAUTIONS WITH HIGH PRESSURE OIL….1081
HANDLING HIGH PRESSURE HOSES….1082
WASTE MATERIALS….1082
MAINTENANCE OF AIR CONDITIONER….1082
COMPRESSED AIR….1082
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1082
PRECAUTIONS WITH TIRES….1083
HANDLING TIRES….1083
PRECAUTIONS WHEN STORING TIRE….1083
OPERATION….1085
GENERAL VIEW….1086
GENERAL VIEW OF MACHINE….1086
GENERAL VIEW OF CONTROLS AND GAUGES….1087
EXPLANATION OF COMPONENTS….1089
METERS AND LAMPS….1089
SWITCHES….1096
CONTROL LEVERS, PEDALS….1105
DUST INDICATOR….1114
ARTICULATE LOCK PIN….1114
FUSE BOX….1114
CAR STEREO….1116
AIR CONDITIONER….1125
OPERATION….1128
CHECK BEFORE STARTING ENGINE….1128
STARTING ENGINE….1141
OPERATIONS AND CHECKS AFTER STARTING ENGINE….1144
STOPPING ENGINE….1146
CHECK AFTER STOPPING ENGINE….1146
TRAVELING POSTURE FOR MACHINE….1147
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1148
TURNING MACHINE….1152
OPERATING WORK EQUIPMENT….1155
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1161
PRECAUTIONS WHEN OPERATION….1182
ADJUSTING WORK EQUIPMENT POSTURE….1186
PARKING MACHINE….1196
CHECKS AFTER COMPLETION OF OPERATION….1197
LOCKING….1198
HANDLING THE TIRES….1198
TRANSPORTATION….1199
LOADING, UNLOADING WORK….1199
PRECAUTIONS FOR LOADING….1199
COLD WEATHER OPERATION….1200
PRECAUTIONS FOR LOW TEMPERATURE….1200
CAUTIONS AFTER COMPLETION OF WORK….1201
AFTER COLD WEATHER….1201
LONG TERM STORAGE….1202
BEFORE STORAGE….1202
DURING STORAGE….1202
AFTER STORAGE….1202
TROUBLESHOOTING….1203
AFTER RUNNING OUT OF FUEL….1203
WHEN LEANING PIPING IS DAMAGED….1203
TOWING THE MACHINE….1204
IF BATTERY IS DISCHARGED….1206
OTHER TROUBLE….1209
MAINTENANCE….1217
GUIDES TO MAINTENANCE….1218
OUTLINES OF SERVICE….1220
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1220
RELATING TO ELECTRIC SYSTEM….1222
WEAR PARTS….1223
WEAR PARTS LIST….1223
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1224
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1228
TORQUE LIST….1228
PERIODIC REPLACEMENT OF CRITICAL PARTS….1229
CRITICAL PARTS….1229
MAINTENANCE SCHEDULE CHART….1230
MAINTENANCE SCHEDULE CHART….1230
SERVICE PROCEDURE….1232
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….1232
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1251
REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE….1258
CHANGE OIL IN TRANSMISSION CASE….1263
CHANGE OIL IN FINAL DRIVE CASE….1264
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1268
CHANGE OIL IN HYDRAULIC TANK….1267
REPLACE HYDRAULIC TANK FILTER ELEMENT….1264
CHANGE OIL IN TANDEM DRIVE CASE….1269
CHECK ENGINE VALVE CLEARANCE, ADJUST….1271
WHEN REQUIRED….1233
CLEAN INSIDE OF COOLING SYSTEM….1233
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1236
DRAIN WATER, SEDIMENT FROM WATER SEPARATOR ….1238
CHECK ELECTRICAL INTAKE AIR HEATER….1238
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….1238
CHECK INCHING PEDAL….1238
CLEAN AIR CONDITIONER AIR FILTER….1239
CHECK REFRIGERANT (GAS) LEVEL….1240
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….1240
SELECTION AND INSPECTION OF TIRES….1241
CHECK BEFORE STARTING….1243
EVERY 50 HOURS SERVICE….1244
LUBRICATING….1244
EVERY 250 HOURS SERVICE….1245
LUBRICATING….1245
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1251
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….1252
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1253
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….1254
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….1254
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….1255
CHECK LEVEL OF BATTERY ELECTROLYTE….1256
CHECK BALL JOINT CLEARANCE, ADJUST….1256
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT ….1257
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….1257
CHECK FAN BELT TENSION, ADJUST….1257
EVERY 500 HOURS SERVICE….1258
REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE….1258
CLEAN, CHECK RADIATOR FINS….1259
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….1259
EVERY 1000 HOURS SERVICE….1262
GREASE DRIVE SHAFT….1262
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….1262
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….1263
CHANGE OIL IN FINAL DRIVE CASE….1264
REPLACE HYDRAULIC TANK FILTER ELEMENT….1264
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….1265
CHECK TOE-IN, ADJUST….1265
REPLACE CORROSION RESISTOR CARTRIDGE….1266
CHECK FRONT WHEEL BEARING PLAY, ADJUST….1266
EVERY 2000 HOURS SERVICE….1267
CHANGE OIL IN HYDRAULIC TANK….1267
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1268
CHANGE OIL IN TANDEM DRIVE CASE….1269
CHECK DISC BRAKE….1270
CHECK ALTERNATOR, STARTING MOTOR….1271
CHECK VALVE CLEARANCE, ADJUST….1271
CHECK VIBRATION DAMPER….1271
CLEAN, CHECK TURBOCHARGER….1271
CHECK ACCUMULATOR GAS PRESSURE….1271
CHNAGE GREASE IN FRONT WHEEL BEARING….1271
EVERY 4000 HOURS SERVICE….1272
CHECK WATER PUMP….1272
CHECK AND ADJUST AIR COMPRESSOR….1272
CHECK FAN PULLEY….1272
SPECIFICATIONS….1273
SPECIFICATIONS….1274
ATTACHMENTS, OPTIONS….1277
HANDLING BLADE ACCUMULATOR….1278
FEATURES OF BLADE ACCUMULATOR….1278
METHOD OF OPERATING BLADE ACCUMULATOR….1279
INDEX….1281
SEAM038003 – Motor Grader GD675-3C Operation & Maintenance Manual….1285
COVER….1285
FOREWARD….1286
FOREWARD….1288
SAFETY INFORMATION….1290
INTENDED USE….1292
DIRECTIONS OF MACHINE….1292
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1293
MACHINE SERIAL NO. PLATE POSITION….1293
ENGINE SERIAL NO. PLATE POSITION….1293
SERVICE METER POSITION….1294
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1294
CONTENTS….1295
SAFETY….1298
SAFETY INFORMATION….1299
SAFETY LABELS….1301
POSITION FOR ATTACHING SAFETY LABELS….1302
SAFETY LABELS….1303
GENERAL PRECAUTIONS….1308
SAFETY RULES….1308
IF ABNORMALITIES ARE FOUND….1308
CLOTHING AND PERSONAL PROTECTIVE ITEMS….1308
FIRE EXTINGUISHER AND FIRST AID KIT….1308
SAFETY FEATURES….1308
KEEP MACHINE CLEAN….1309
INSIDE OPERATOR'S COMPARTMENT….1309
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….1309
HANDRAILS AND STEPS….1310
MOUNTING AND DISMOUNTING….1310
DO NOT GET CAUGHT IN ARTICULATED PORTION….1310
PREVENTION OF BURNS….1311
FIRE PREVENTION….1311
ACTION IF FIRE OCCURS….1312
WINDOW WASHER LIQUID….1312
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….1312
PRECAUTIONS FOR ATTACHMENTS….1313
UNAUTHORIZED MODIFICATION….1313
SAFETY AT WORKSITE….1313
WORKING ON LOOSE GROUND….1313
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES….1314
ENSURE GOOD VISIBILITY….1314
VENTILATION FOR ENCLOSED AREAS….1314
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….1315
EMERGENCY ESCAPE FROM OPERATOR'S CAB….1315
ASBESTOS DUST HAZARD PREVENTION….1315
PRECAUTIONS DURING OPERATION….1316
STARTING ENGINE….1316
CHECKS BEFORE STARTING ENGINE, ADJUST….1316
PRECAUTIONS WHEN STARTING….1316
PRECAUTIONS IN COLD AREAS….1317
OPERATION….1318
CHECKS BEFORE STARTING OPERATION….1318
PRECAUTIONS BEFORE MOVING OFF….1318
PRECAUTIONS WHEN TRAVELING….1319
PRECAUTIONS WHEN TRAVELING ON SLOPES….1320
PRECAUTIONS WHEN OPERATIONS ON SLOPES….1320
PROHIBITED OPERATIONS….1320
PRECAUTIONS WHEN OPERATING….1320
OPERATE CAREFULLY ON SNOW….1320
PARKING MACHINE….1321
TRANSPORTATION….1322
LOADING AND UNLOADING….1322
SHIPPING….1322
BATTERY….1323
BATTERY HAZARD PREVENTION….1323
STARTING WITH BOOSTER CABLES….1324
TOWING….1325
WHEN TOWING….1325
PRECAUTIONS FOR MAINTENANCE….1326
WARNING TAG….1326
KEEP WORK PLACE CLEAN AND TIDY….1326
APPOINT LEADER WHEN WORKING WITH OTHERS….1326
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….1327
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1328
PROPER TOOLS….1328
ACCUMULATOR….1329
PERSONNEL….1329
ATTACHMENTS….1329
WORK UNDER THE MACHINE….1329
NOISE….1329
PRECAUTIONS WHEN USING HAMMER….1330
REPAIR WELDING ….1330
REMOVING BATTERY TERMINAL….1330
PRECAUTIONS WITH HIGH PRESSURE OIL….1330
PRECAUTIONS WITH HIGH PRESSURE FUEL….1330
HANDLING HIGH PRESSURE HOSES….1331
WASTE MATERIALS….1331
MAINTENANCE OF AIR CONDITIONER….1331
COMPRESSED AIR….1331
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1331
PRECAUTIONS WITH TIRES….1332
HANDLING TIRES….1332
PRECAUTIONS WHEN STORING TIRE….1332
OPERATION….1334
GENERAL VIEW….1335
GENERAL VIEW OF MACHINE….1335
GENERAL VIEW OF CONTROLS AND GAUGES….1336
EXPLANATION OF COMPONENTS….1339
METERS AND LAMPS….1339
SWITCHES….1346
CONTROL LEVERS, PEDALS….1357
DUST INDICATOR….1366
ARTICULATE LOCK PIN….1366
FUSE BOX….1366
OPERATION….1368
CHECK BEFORE STARTING ENGINE….1368
STARTING ENGINE….1380
OPERATIONS, CHECKS AFTER STARTING ENGINE….1384
STOPPING ENGINE….1386
CHECK AFTER STOPPING ENGINE….1386
TRAVELING POSTURE FOR MACHINE….1387
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1388
TURNING MACHINE….1392
OPERATING WORK EQUIPMENT….1395
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1401
PRECAUTIONS WHEN OPERATION….1422
ADJUSTING WORK EQUIPMENT POSTURE….1426
PARKING MACHINE….1435
CHECKS AFTER COMPLETION OF OPERATION….1436
LOCKING….1437
HANDLING THE TIRES….1437
TRANSPORTATION….1438
LOADING, UNLOADING WORK….1438
PRECAUTIONS FOR LOADING….1439
COLD WEATHER OPERATION….1440
PRECAUTIONS FOR LOW TEMPERATURE….1440
CAUTIONS AFTER COMPLETION OF WORK….1441
AFTER COLD WEATHER ….1441
LONG TERM STORAGE….1442
BEFORE STORAGE….1442
DURING STORAGE….1442
AFTER STORAGE….1442
TROUBLESHOOTING….1443
AFTER RUNNING OUT OF FUEL….1443
WHEN LEANING PIPING IS DAMAGED….1444
TOWING THE MACHINE….1445
IF BATTERY IS DISCHARGED….1447
OTHER TROUBLE….1450
MAINTENANCE….1458
GUIDES TO MAINTENANCE….1459
OUTLINES OF SERVICE….1461
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1461
RELATING TO ELECTRIC SYSTEM….1463
WEAR PARTS….1464
WEAR PARTS LIST….1464
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1465
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1469
TORQUE LIST….1469
PERIODIC REPLACEMENT OF CRITICAL PARTS….1471
CRITICAL PARTS….1471
MAINTENANCE SCHEDULE CHART….1472
MAINTENANCE SCHEDULE CHART….1472
SERVICE PROCEDURE….1474
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….1474
REPLACE FUEL FILTER CARTRIDGE….1505
CHANGE OIL IN TRANSMISSION CASE….1513
CHANGE OIL IN FINAL DRIVE CASE….1514
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1519
CHANGE OIL IN HYDRAULIC TANK….1518
REPLACE HYDRAULIC TANK FILTER ELEMENT….1514
CHANGE OIL IN TANDEM DRIVE CASE….1520
CHECK ENGINE VALVE CLEARANCE, ADJUST….1522
WHEN REQUIRED….1475
CLEAN INSIDE OF COOLING SYSTEM….1475
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1478
CLEAN, CHECK WATER SEPARATOR….1482
CHECK ELECTRICAL INTAKE AIR HEATER….1483
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….1483
CHECK INCHING PEDAL….1483
CLEAN AIR CONDITIONER AIR FILTER….1484
CHECK REFRIGERANT (GAS) LEVEL….1485
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….1485
SELECTION AND INSPECTION OF TIRES….1486
CHECK BEFORE STARTING….1488
EVERY 50 HOURS SERVICE….1489
LUBRICATING….1489
EVERY 250 HOURS SERVICE….1490
LUBRICATING….1490
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1496
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….1497
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1498
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….1499
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….1499
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….1500
CHECK LEVEL OF BATTERY ELECTROLYTE….1501
CHECK BALL JOINT CLEARANCE, ADJUST….1503
CHECK AND TIGHTEN WHEEL HUB NIT AND HUB BOLT….1503
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….1503
CHECK FAN BELT TENSION, ADJUST….1504
EVERY 500 HOURS SERVICE….1505
REPLACE FUEL FILTER CARTRIDGE….1505
CLEAN, CHECK RADIATOR FINS….1507
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….1508
EVERY 1000 HOURS SERVICE….1511
LUBRICATING….1511
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….1512
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….1513
CHANGE OIL IN FINAL DRIVE CASE….1514
REPLACE HYDRAULIC TANK FILTER ELEMENT….1514
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….1515
CHECK TOE-IN, ADJUST….1516
CHECK FRONT WHEEL BEARING PLAY, ADJUST….1517
REPLACE CORROSION RESISTOR CARTRIDGE….1517
EVERY 2000 HOURS SERVICE….1518
CHANGE OIL IN HYDRAULIC TANK….1518
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1519
CHANGE OIL IN TANDEM DRIVE CASE….1520
CHECK BRAKE DISC….1521
CHECK ALTERNATOR, STARTING MOTOR….1522
CHECK ENGINE VALVE CLEARANCE, ADJUST….1522
CHECK VIBRATION DAMPER….1522
CLEAN, CHECK TURBOCHARGER….1522
CHECK ACCUMULATOR GAS PRESSURE….1522
CHANGE GREASE IN FRONT WHEEL BEARING….1522
EVERY 4000 HOURS SERVICE….1523
CHECK WATER PUMP….1523
CHECK AND ADJUST AIR COMPRESSOR….1523
CHECK FAN PULLEY….1523
CHECK INJECTOR….1523
CHECKING FOR LOOSENESS OF HIGH PRESSURE CLAMP, HARDENING OF RUBBER….1523
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….1524
EVERY 8000 HOURS SERVICE….1525
REPLACE INJECTOR NOZZLE TIP….1525
REPLACE HIGH PRESSURE PIPING CLAMP….1525
REPLACE FUEL SPRAY PREVENTION CAP….1525
SPECIFICATIONS….1526
SPECIFICATIONS….1527
ATTACHMENTS, OPTIONS….1528
HANDLING BLADE ACCUMULATOR….1529
FEATURES OF BLADE ACCUMULATOR….1529
METHOD OF OPERATING BLADE ACCUMULATOR….1530
AM/FM RADIO CASSETTE STEREO….1531
EXPLANATION OF COMPONENTS….1531
METHOD OF OPERATION….1536
PRECAUTIONS WHEN USING….1539
AIR CONDITIONER….1540
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1540
METHOD OF OPERATION….1542
PRECAUTIONS WHEN USING….1542
TESTING AND MAINTENANCE….1542
HANDLING AIR SUSPENSION SEAT….1543
ADJUST OPERATOR'S SEAT….1543
INDEX….1546
SEAM038102T – Motor Grader GD555-3C Operation & Maintenance Manual….1550
COVER….1550
FOREWORD….1551
FOREWORD….1552
SAFETY INFORMATION….1555
INTENDED USE….1557
DIRECTIONS OF MACHINE….1557
LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR….1558
MACHINE SERIAL NO.PLATE POSITION….1558
ENGINE SERIAL NO.PLATE POSITION….1558
SERVICE METER POSITION….1559
TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR….1559
CONTENTS….1560
SAFETY….1563
SAFETY INFORMATION….1564
SAFETY LABELS….1566
POSITION FOR ATTACHING SAFETY LABELS….1566
SAFETY LABELS….1567
GENERAL PRECAUTIONS….1572
SAFETY RULES….1572
IF ABNORMALITIES ARE FOUND….1572
CLOTHING AND PERSONAL PROTECTIVE ITEMS….1572
FIRE EXTINGUISHER AND FIRST AID KIT….1572
SAFETY FEATURES….1572
KEEP MACHINE CLEAN….1573
INSIDE OPERATOR'S COMPARTMENT….1573
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….1573
HANDRAILS AND STEPS….1574
MOUNTING AND DISMOUNTING….1574
DO NOT GET CAUGHT IN ARTICULATED PORTION….1574
PREVENTION OF BURNS….1575
FIRE PREVENTION….1575
ACTION IF FIRE OCCURS….1576
WINDOW WASHER LIQUID….1576
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….1576
PRECAUTIONS FOR ATTACHMENTS….1577
UNAUTHORIZED MODIFICATION….1577
SAFETY AT WORKSITE….1577
WORKING ON LOOSE GROUND….1577
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….1578
ENSURE GOOD VISIBILITY….1578
VENTILATION FOR ENCLOSED AREAS….1578
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….1579
EMERGENCY ESCAPE FROM OPERATOR’S CAB….1579
ASBESTOS DUST HAZARD PREVENTION….1579
PRECAUTIONS DURING OPERATION….1580
STARTING ENGINE….1580
CHECKS BEFORE STARTING ENGINE,ADJUST….1580
PRECAUTIONS WHEN STARTING….1580
PRECAUTIONS IN COLD AREAS….1581
OPERATION….1582
CHECKS BEFORE STARTING OPERATION….1582
PRECAUTIONS BEFORE MOVING OFF….1582
PRECAUTIONS WHEN TRAVELING….1582
PRECAUTIONS WHEN TRAVELING ON SLOPES….1583
PRECAUTIONS WHEN OPERATIONS ON SLOPES….1584
PROHIBITED OPERATIONS….1584
PRECAUTIONS WHEN OPERATING….1584
OPERATE CAREFULLY ON SNOW….1584
PARKING MACHINE….1585
TRANSPORTATION….1586
LOADING AND UNLOADING….1586
SHIPPING….1586
BATTERY….1587
BATTERY HAZARD PREVENTION….1587
STARTING WITH BOOSTER CABLES….1588
TOWING….1589
WHEN TOWING….1589
PRECAUTIONS FOR MAINTENENCE….1590
WARNING TAG….1590
KEEP WORK PLACE CLEAN AND TIDY….1590
APPOINT LEADER WHEN WORKING WITH OTHERS….1590
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….1591
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1592
PROPER TOOLS….1592
ACCUMULATOR….1593
PERSONNEL….1593
ATTACHMENTS….1593
WORK UNDER THE MACHINE….1593
NOISE….1593
PRECAUTIONS WHEN USING HAMMER….1594
REPAIR WELDING….1594
REMOVING BATTERY TERMINAL….1594
PRECAUTIONS WITH HIGH-PRESSURE OIL….1594
HANDLING HIGH-PRESSURE HOSES….1595
WASTE MATERIALS….1595
MAINTENANCE OF AIR CONDITIONER….1595
COMPRESSED AIR….1595
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….1595
PRECAUTIONS WITH TIRES….1596
HANDLING TIRES….1596
PRECAUTIONS WHEN STORING TIRE….1596
OPERATION….1597
GENERAL VIEW….1598
GENERAL VIEW OF MACHINE….1598
GENERAL VIEW OF CONTROLS AND GAUGES….1599
EXPLANATION OF COMPONENTS….1601
METERS AND LAMPS….1601
SWITCHES….1608
CONTROL LEVERS,PEDALS….1617
DUST INDICATOR….1626
ARTICULATE LOCK PIN….1626
FUSE BOX….1626
CAR STEREO….1628
AIR CONDITIONER….1637
OPERATION….1640
CHECK BEFORE STARTING ENGINE….1640
STARTING ENGINE….1653
OPERATIONS,CHECKS AFTER STARTING ENGINE….1656
STOPPING ENGINE….1658
CHECK AFTER STOPPING ENGINE….1658
TRAVELING POSTURE FOR MACHINE….1659
MOVING MACHINE OFF (FORWARD,REVERSE,SHIFTING GEAR),STOPPING….1660
TURNING MACHINE….1664
OPERATING WORK EQUIPMENT….1667
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1673
PRECAUTIONS WHEN OPERATION….1694
ADJUSTING WORK EQUIPMENT POSTURE….1698
PARKING MACHINE….1709
CHECKS AFTER COMPLETION OF OPERATION….1710
LOCKING….1711
HANDLING THE TIRES….1711
TRANSPORTATION….1712
LOADING, UNLOADING WORK….1712
PRECAUTIONS FOR LOADING….1712
COLD WEATHER OPERATION….1713
PRECAUTIONS FOR LOW TEMPERATURE….1713
CAUTIONS AFTER COMPLETION OF WORK….1714
AFTER COLD WEATHER….1714
LONG-TERM STORAGE….1715
BEFORE STORAGE….1715
DURING STORAGE….1715
AFTER STORAGE….1715
TROUBLESHOOTING….1716
AFTER RUNNING OUT OF FUEL….1716
WHEN LEANING PIPING IS DAMAGED….1716
TOWING THE MACHINE….1717
IF BATTERY IS DISCHARGED….1719
OTHER TROUBLE….1722
MAINTENANCE….1729
GUIDE TO MAINTENANCE….1730
OUTLINES OF SERVICE….1732
HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC….1732
RELATING TO ELECTRIC SYSTEM….1734
WEAR PARTS….1735
WEAR PARTS LIST….1735
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1736
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1740
TORQUE LIST….1740
PERIODIC REPLACEMENT OF CRITICAL PARTS….1741
CRITICAL PARTS….1741
MAINTENANCE SCHEDULE CHART….1742
MAINTENANCE SCHEDULE CHART….1742
SERVICE PROCEDURE….1744
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….1744
WHEN REQUIRED….1745
CLEAN INSIDE OF COOLING SYSTEM….1745
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT….1748
DRAIN WATER,SEDIMENT FROM WATER SEPARATOR….1750
CHECK ELECTRICAL INTAKE AIR HEATER….1750
REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT….1750
CHECK INCHING PEDAL….1750
CLEAN AIR CONDITIONER AIR FILTER….1751
CHECK REFRIGERANT (GAS) LEVEL….1752
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….1752
SELECTION AND INSPECTION OF TIRES….1753
CHECK BEFORE STARTING….1755
EVERY 50 HOURS SERVICE….1756
LUBRICATING….1756
EVERY 250 HOURS SERVICE….1757
LUBRICATING….1757
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1763
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….1764
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1765
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….1766
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL….1766
CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL….1767
CHECK LEVEL OF BATTERY ELECTROLYTE….1768
CHECK BALL JOINT CLEARANCE,ADJUST….1770
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….1770
CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR….1770
CHECK FAN BELT TENSION,ADJUST….1771
EVERY 500 HOURS SERVICE….1772
REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE….1772
CLEAN,CHECK RADIATOR FINS….1773
CHECK CIRCLE GUIDE CLEARANCE,ADJUST….1773
EVERY 1000 HOURS SERVICE….1776
GREASE DRIVE SHAFT….1776
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….1776
CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER….1777
CHANGE OIL IN FINAL DRIVE CASE….1778
REPLACE HYDRAULIC TANK FILTER ELEMENT….1778
CHECK LOOSENESS,PLAY OF BALL JOINT AT FRONT OF DRAWBAR….1779
CHECK TOE-IN,ADJUST….1779
CHECK FRONT WHEEL BEARING PLAY,ADJUST….1780
EVERY 2000 HOURS SERVICE….1781
CHANGE OIL IN HYDRAULIC TANK….1781
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….1782
CHANGE OIL IN TANDEM DRIVE CASE….1783
CHECK DISC BRAKE….1784
CHECK ALTERNATOR,STARTING MOTOR….1785
CHECK ENGINE VALVE CLEARANCE,ADJUST….1785
CHECK VIBRATION DAMPER….1785
CLEAN,CHECK TURBOCHARGER….1785
CHECK ACCUMULATOR GAS PRESSURE….1785
CHANGE GREASE IN FRONT WHEEL BEARING….1785
EVERY 4000 HOURS SERVICE….1786
CHECK WATER PUMP….1786
CHECK AND ADJUST AIR COMPRESSOR….1786
CHECK FAN PULLEY….1786
SPECIFICATIONS….1787
SPECIFICATIONS….1788
ATTACHMENTS,OPTIONS….1790
HANDLING BLADE ACCUMULATOR….1791
FEATURES OF BLADE ACCUMULATOR….1791
METHOD OF OPERATING BLADE ACCUMULATOR….1792
INDEX….1793
SEBM020906 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual….1796
COVER….1796
CONTENTS….1797
FOREWORD….1801
SAFETY….1801
GENERAL….1803
HOW TO READ THE SHOP MANUAL….1804
HOIST INSTRUCTIONS….1805
PUSH-PULL TYPE COUPLERS….1806
COATING MATERIALS….1808
STANDARD TIGHTENING TORQUE….1810
ELECTRIC WIRE CODE….1813
CONVERSION TABLES….1814
UNITS….1820
01 GENERAL….1821
GENERAL ASSEMBLY DRAWING….1822
SPECIFICATIONS….1823
WEIGHT TABLE….1835
FUEL, COOLANT, AND LUBRICANT SELECTION….1837
10 STRUCTURE AND FUNCTION….1840
ACCELERATOR CONTROL LINKAGE….1841
ACCELERATOR PEDAL….1842
FAN DRIVE….1843
POWER TRAIN DIAGRAM….1844
TRANSMISSION HYDRAULIC PIPING….1845
TRANSMISSION CONTROL….1849
TORQUE CONVERTER….1850
TORQUE CONVERTER LOCK-UP VALVE (ECMV)….1855
TRANSMISSION….1858
TRANSMISSION VALVE….1887
ECMV (ELECTRONIC CONTROL MODULATION VALVE)….1888
MAIN RELIEF VALVE….1893
TRANSMISSION PUMP….1896
TRANSMISSION AND DIFFERENTIAL LOCK PUMP….1897
FINAL DRIVE….1898
TANDEM DRIVE….1903
STEERING HYDRAULIC PIPING DRAWING….1907
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)….1910
PRIORITY ACC GOVERNOR VALVE SERIAL NO. 50001-51000….1917
PRIORITY VALVE SERIAL NO. 51001 AND UP….1924
ACCUMULATOR CHARGE VALVE….1931
FRONT AXLE….1933
BRAKE HYDRAULIC PIPING….1937
BRAKE VALVE….1941
WHEEL BRAKE….1945
SLACK ADJUSTER….1946
ACCUMULATOR….1949
PARKING BRAKE….1950
PARKING AND BANK CONTROL VALVE ….1951
WORK EQUIPMENT HYDRAULIC PIPING DRAWING….1953
HYDRAULIC PUMP SERIAL NO. 50001-51000….1963
HYDRAULIC PUMP SERIAL NO. 51001 AND UP….1985
MAIN CONTROL VALVE….2008
CLSS….2027
WORK EQUIPMENT CONTROL….2039
HYDRAULIC SYSTEM….2041
HYDRAULIC TANK….2047
SWIVEL JOINT….2048
PILOT CHECK VALVE….2051
BLADE ACCUMULATOR, FLOAT VALVE….2056
SHUT-OFF VALVE….2060
BLADE FLOAT DEVICE….2061
CIRCLE ROTATION MOTOR….2063
HYDRAULIC CYCLINDER….2065
CIRCLE DRAWBAR….2071
LIFTER BRACKET LOCK PIN….2073
BLADE….2075
CIRCLE ROTATION GEAR….2077
SCARIFIER….2081
RIPPER….2083
MAIN FRAME….2086
AIR CONDITIONER….2087
ENGINE STARTING CIRCUIT….2091
ENGINE STOP CIRCUIT….2095
PREHEAT CIRCUIT….2097
AUTOMATIC SHIFT CONTROL SYSTEM….2099
TRANSMISSION CONTROLLER….2100
MONITOR….2104
SENSORS….2107
20 TESTING AND ADJUSTING….2114
STANDARD VALUE TABLES….2115
STANDARD VALUE TABLE FOR ENGINE….2115
STANDARD VALUE TABLE FOR CHASSIS….2119
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM….2126
TESTING AND ADJUSTING….2136
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING….2137
MEASURING EXHAUST COLOR….2138
MEASURING BLOWBY PRESSURE….2139
MEASURING ENGINE OIL PRESSURE….2140
MEASURING ENGINE SPEED….2140
TESTING FAN BELT TENSION….2141
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION ….2142
MEASURING TORQUE COVERTER STALL SPEED….2142
CHECKING CLUTCH OIL PRESSURE ….2143
CHECKING TORQUE CONVERTER OIL PRESSURE….2144
ADJUSTING SPEED SENSOR ….2145
FLUSHING THE TORQUE CONVETER, TRANSMISSION CIRCUIT….2147
ADJUSTING ACCELERATOR CONTROL LINKAGE ….2148
TESTING THE BRAKE DISC….2149
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE ….2150
TESTING ACCUMULATOR CHARGE PRESSURE….2151
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE….2151
TESTING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE….2152
ADJUSTING THE PC VALVE ….2154
BLEEDING AIR FROM THE HYDRAULIC CIRCUIT….2154
MEASURING INTERNAL CYLINDER LEAKAGE….2155
MEASURING STEERING, BRAKE OIL PRESSURE….2157
BLEEDING AIR FROM THE BRAKE PIPING….2158
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR….2159
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE….2160
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE….2162
MEMORIZING IDLE AND FULL POSITION PROCEDURE ….2164
INITIAL LEARNING METHOD FOR THE TRANSMISSION CONTROLLER….2165
DIODE CHECKING PROCEDURE….2167
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS….2168
ADJUSTING CAB STOPPER BOLT….2170
TROUBLESHOOTING….2172
TROUBLESHOOTING POINTS TO REMEMBER….2173
TROUBLESHOOTING SEQUENCE….2174
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE….2175
CHECKS BEFORE TROUBLESHOOTING….2183
CONNECTOR TYPES AND MOUNTING LOCATIONS….2184
CONNECTOR ARRANGEMENT DIAGRAM….2193
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….2201
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES….2222
USING THE TROUBLESHOOTING CHARTS….2226
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….2228
ELECTRICAL CIRCUIT DIAGRAM….2229
E-1 ENGINE DOES NOT START….2233
E-2 ENGINE DOES NOT STOP….2243
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW….2245
E-4 ELECTRICAL COMPONENTS DO NOT WORK….2247
TROUBLESHOOTING THE TRANSMISSION CONTROLLER SYSTEM (T MODE)….2249
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE….2252
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE….2256
ELECTRICAL CIRCUIT DIAGRAM….2276
T-1 FAILURE CODE [A1]….2280
T-2 FAILURE CODE [A2]….2281
T-3 FAILURE CODE [A-3]….2282
T-4 FAILURE CODE [A4]….2283
T-5 FAILURE CODE [A5]….2284
T-6 FAILURE CODE [A8]….2285
T-7 FAILURE CODE [B1]….2286
T-8 FAILURE CODE [B2]….2287
T-9 FAILURE CODE [B3]….2288
T-10 FAILURE CODE [B4]….2289
T-11 FAILURE CODE [B5]….2290
T-12 FAILURE CODE [B6]….2291
T-13 FAILURE CODE [B7]….2292
T-14 FAILURE CODE [B8]….2293
T-15 FAILURE CODE [C0]….2294
T-16 FAILURE CODE [C1]….2295
T-17 FAILURE CODE [C3]….2296
T-18 FAILURE CODE [C4]….2298
T-19 FAILURE CODE [C5]….2300
T-20 FAILURE CODE [C6]….2301
T-21 FAILURE CODE [C7]….2302
T-22 FAILURE CODE [C8]….2303
T-23 FAILURE CODE [C9]….2304
T-24 FAILURE CODE [D1]….2305
T-25 FAILURE CODE [D2]….2306
T-26 FAILURE CODE [D4]….2307
T-27 FAILURE CODE [D5]….2308
T-28 FAILURE CODE [D6]….2309
T-29 FAILURE CODE [D7]….2310
T-30 FAILURE CODE [E1]….2311
T-31 FAILURE CODE [E2]….2312
T-32 FAILURE CODE [E3]….2313
T-33 FAILURE CODE [E4]….2315
T-34 FAILURE CODE [E5]….2315
T-35 FAILURE CODE [E6]….2316
T-36 FAILURE CODE [E7]….2317
T-37 FAILURE CODE [E8]….2317
T-38 FAILURE CODE [F1]….2319
T-39 FAILURE CODE [F2]….2319
T-40 FAILURE CODE [F3]….2320
T-41 FAILURE CODE [F4]….2321
T-42 FAILURE CODE [F5]….2321
T-43 FAILURE CODE [F6]….2322
T-44 FAILURE CODE [F7]….2322
T-45 FAILURE CODE [F8]….2323
T-46 FAILURE CODE [91]….2324
T-47 FAILURE CODE [92]….2324
T-48 FAILURE CODE [93]….2325
T-49 FAILURE CODE [94]….2326
T-50 FAILURE CODE [95]….2326
T-51 FAILURE CODE [96]….2327
T-52 FAILURE CODE [97]….2327
T-53 FAILURE CODE [98]….2329
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….2330
FAILURE TABLE: MODES AND CAUSES….2331
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER….2333
H-2 NO WORK EQUIPMENT MOVES….2334
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS….2334
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP….2335
H-5 EXCESSIVE BLADE DRIFT….2335
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE….2336
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIM CYLINDERS (LEFT,RIGHT)….2336
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)….2337
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE….2337
H-10 EXCESSIVE SCARIFIER DRIFT….2338
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE….2338
H-12 TRANSMISSION DOES NOT UPSHIFT OR DOWNSHIFT….2339
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING….2339
H-14 TORQUE COVERTER LOCK-UP MALFUNCTION….2340
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR….2340
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH….2341
H-17 BRAKING FORCE IS INSUFFICIENT….2342
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)….2344
FAILURE TABLE: MODES AND CAUSES….2345
ELECTRICAL CIRCUIT DIAGRAM FOR THE MAIN MONITOR SYSTEM….2347
M-1 ENGINE OIL PRESSURE CAUTION LAMP GLOWS….2351
M-2 TRANSMISSION CONTROLLER CAUTION LAMP GLOWS….2352
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP GLOWS….2352
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP GLOWS (OPT)….2353
M-5 BANK PIN CAUTION LAMP GLOWS….2354
M-6 BRAKE OIL PRESSURE CAUTION LAMP GLOWS….2355
M-7 BATTERY CHARGE CAUTION LAMP GLOWS….2356
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP….2357
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP….2358
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)….2359
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)….2360
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP….2361
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP….2361
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP….2363
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH….2364
M-16 ARTICULATION GAUGE DOES NOT WORK….2365
M-17 FUEL GAUGE DOES NOT WORK….2367
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK….2369
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)….2370
M-20 MESSAGE CENTER DOES NOT WORK….2371
M-21 SERVICE METER DOES NOT WORK….2372
30 DISASSEMBLY AND ASSEMBLY….2373
METHOD OF USING MANUAL….2375
PRECAUTIONS WHEN CARRYING OUT OPERATION….2377
SPECIAL TOOL LIST….2380
SKETCHES OF SPECIAL TOOLS….2383
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001-51000)….2388
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001-51000)….2389
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001-UP)….2389
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001-UP)….2390
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)….2391
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 50001-51000)….2392
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.: 51001-UP)….2393
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 51001-UP)….2395
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001-51000)….2396
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001-51000)….2398
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001-UP)….2400
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001-UP)….2402
REMOVAL OF ENGINE ASSEMBLY….2403
INSTALLATION OF ENGINE ASSEMBLY….2404
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….2406
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….2407
REMOVAL OF TRANSMISSION ASSEMBLY….2408
INSTALLATION OF TRANSMISSION ASSEMBLY….2410
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY….2413
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY….2415
DISASSEMBLY OF TRANSMISSION ASSEMBLY….2419
ASSEMBLY OF TRANSMISSION ASSEMBLY….2435
REMOVAL OF FINAL DRIVE ASSEMBLY….2456
INSTALLATION OF FINAL DRIVE ASSEMBLY….2459
DISASSEMBLY OF FINAL DRIVE ASSEMBLY….2461
ASSEMBLY OF FINAL DRIVE ASSEMBLY….2462
DISASSEMBLY OF FINAL BRAKE CASE….2465
ASSEMBLY OF FINAL BRAKE CASE….2466
DISASSEMBLY OF SIDE CASE….2468
ASSEMBLY OF SIDE CASE….2469
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….2471
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….2472
DISASSEMBLY OF BEVEL GEAR….2475
ASSEMBLY OF BEVEL GEAR….2476
DISASSEMBLY OF BEVEL PINION ASSEMBLY….2477
ASSEMBLY OF BEVEL PINION ASSEMBLY….2478
REMOVAL OF OPERATOR'S CAB ASSEMBLY….2479
INSTALLATION OF OPERATOR'S CAB ASSEMBLY….2481
REMOVAL OF OPERATOR'S CAB FLOOR….2483
INSTALLATION OF OPERATOR'S CAB FLOOR….2485
REMOVAL OF STEERING VALVE (ORBIT-ROLL)….2487
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)….2487
STANDARD INTEGRAL ORBIT-ROLL….2488
DISASSEMBLY OF STEERING VALVE….2490
ASSEMBLY OF STEERING VALVE….2493
REMOVAL OF BLADE ASSEMBLY….2498
INSTALLATION OF BLADE ASSEMBLY….2498
REMOVAL OF CIRCLE DRAWBAR ASSEMBLY….2499
INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY….2500
REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY….2501
INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY….2502
REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMLBY (WITH SHEAR PIN)….2503
INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….2504
DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….2505
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….2507
DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….2509
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….2511
90 OTHERS….2515
TRANSMISSION HYDRAULIC CIRCUIT SERIAL NO.: 50001-51000….2516
TRANSMISSION HYDRAULIC CIRCUIT SERIAL NO.: 51001 AND UP….2517
HYDRAULIC CIRCUIT DIAGRAM SERIAL NO.:50001-51000….2518
HYDRAULIC CIRCUIT DIAGRAM (1/2) SERIAL NO.:51001 AND UP….2519
HYDRAULIC CIRCUIT DIAGRAM (2/2) SERIAL NO.:51001 AND UP….2520
ELECTRICAL CIRCUIT DIAGRAM (1/6) SERIAL NO.: 50001-51000….2521
ELECTRICAL CIRCUIT DIAGRAM (2/6) SERIAL NO.: 50001-51000….2522
ELECTRICAL CIRCUIT DIAGRAM (3/6) SERIAL NO.: 50001-51000….2523
ELECTRICAL CIRCUIT DIAGRAM (4/6) SERIAL NO.: 50001-51000….2524
ELECTRICAL CIRCUIT DIAGRAM (5/6) SERIAL NO.: 50001-51000….2525
ELECTRICAL CIRCUIT DIAGRAM (6/6) SERIAL NO.: 50001-51000….2526
ELECTRICAL CIRCUIT DIAGRAM (1/6) SERIAL NO.: 51001 AND UP….2527
ELECTRICAL CIRCUIT DIAGRAM (2/6) SERIAL NO.: 51001 AND UP….2528
ELECTRICAL CIRCUIT DIAGRAM (3/6) SERIAL NO.: 51001 AND UP….2529
ELECTRICAL CIRCUIT DIAGRAM (4/6) SERIAL NO.: 51001 AND UP….2530
ELECTRICAL CIRCUIT DIAGRAM (5/6) SERIAL NO.: 51001 AND UP….2531
ELECTRICAL CIRCUIT DIAGRAM (6/6) SERIAL NO.: 51001 AND UP….2532
SEBM020909 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual….2533
COVER….2533
CONTENTS….2534
01 GENERAL….2559
GENERAL ASSEMBLY DRAWING….2560
SPECIFICATIONS….2561
WEIGHT TABLE….2573
FUEL, COOLANT, AND LUBRICANT SELECTION….2575
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….2577
ACCELERATOR CONTROL LINKAGE….2578
ACCELERATOR PEDAL….2579
FAN DRIVE….2580
POWER TRAIN DIAGRAM….2581
TRANSMISSION HYDRAULIC PIPING….2582
TRANSMISSION CONTROL….2586
TORQUE CONVERTER….2587
TORQUE CONVERTER LOCK-UP VALVE (ECMV)….2592
TRANSMISSION….2595
TRANSMISSION VALVE….2624
ECMV (ELECTRONIC CONTROL MODULATION VALVE)….2625
MAIN RELIEF VALVE….2629
TRANSMISSION PUMP….2632
TRANSMISSION AND DIFFERENTIAL LOCK PUMP (WITH DIFFERENTIAL LOCK)….2633
FINAL DRIVE….2634
TANDEM DRIVE….2639
STEERING HYDRAULIC PIPING DRAWING….2642
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)….2644
PRIORITY ACC GOVERNOR VALVE (SERIAL NO.50001-51000)….2651
PRIORITY VALVE (SERIAL NO.51001 AND UP)….2658
ACCUMULATOR PRESSURE GOVERNOR VALVE (SERIAL NO.51001 AND UP)….2665
FRONT AXLE….2667
BRAKE HYDRAULIC PIPING ….2671
BRAKE VALVE….2675
WHEEL BRAKE….2679
SLACK ADJUSTER….2680
ACCUMULATOR….2682
PARKING BRAKE….2683
PARKING BRAKE AND BANK CONTROL VALVE….2684
WORK EQUIPMENT HYDRAULIC PIPING DRAWING….2686
HYDRAULIC PUMP (SERIAL NO.50001-51000)….2696
HYDRAULIC PUMP (SERIAL NO.51001 AND UP)….2717
MAIN CONTROL VALVE….2738
CLSS….2753
WORK EQUIPMENT CONTROL….2765
HYDRAULIC SYSTEM….2767
HYDRAULIC TANK….2773
SWIVEL JOINT….2774
PILOT CHECK VALVE….2776
BLADE ACCUMULATOR, FLOAT VALVE….2781
SHUT-OFF VALVE….2784
BLADE FLOAT DEVICE….2785
CIRCLE ROTATION MOTOR….2787
HYDRAULIC CYLINDER….2789
CIRCLE, DRAWBAR….2795
LIFTER BRACKET LOCK PIN….2797
BLADE….2798
CIRCLE ROTATION GEAR….2800
SCARIFIER….2803
RIPPER….2805
MAIN FRAME….2807
AIR CONDITIONER (IF EQUIPPED)….2808
ENGINE STARTING CIRCUIT….2812
ENGINE STOP CIRCUIT….2816
PREHEAT CIRCUIT….2818
AUTOMATIC SHIFT CONTROL SYSTEM….2820
TRANSMISSION CONTROLLER….2821
MONITOR….2825
SENSORS….2828
20 TESTING AND ADJUSTING….2835
STANDARD VALUE TABLE….2836
STANDARD VALUE TABLE FOR ENGINE….2836
STANDARD VALUE TABLE FOR CHASSIS….2840
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM….2847
TESTING AND ADJUSTING….2856
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….2857
MEASURING EXHAUST COLOR….2858
MEASURING BLOWBY PRESSURE….2859
MEASURING ENGINE OIL PRESSURE….2860
MEASURING ENGINE SPEED….2860
TESTING FAN BELT TENSION….2861
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION….2862
MEASURING TORQUE CONVERTER STALL SPEED….2862
CHECKING CLUTCH OIL PRESSURE….2863
CHECKING TORQUE CONVERTER OIL PRESSURE….2864
ADJUSTING SPEED SENSOR….2865
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT….2867
ADJUSTING ACCELERATOR CONTROL LINKAGE….2868
TESTING BRAKE DISC….2869
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE….2870
TESTING ACCUMULATOR CHARGE PRESSURE….2871
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE….2871
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE….2872
ADJUSTING PC VALVE….2874
BLEEDING AIR FROM HYDRAULIC CIRCUIT….2874
MEASURING INTERNAL CYLINDER LEAKAGE….2875
MEASURING STEERING, BRAKE OIL PRESSURE….2877
BLEEDING AIR FROM BRAKE PIPING….2878
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR….2879
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE….2880
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE….2882
MEMORIZING IDLE AND FULL POSITION PROCEDURE….2884
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER….2885
DIODE CHECKING PROCEDURE….2887
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS….2888
ADJUSTING CAB STOPPER BOLT….2890
TROUBLESHOOTING….2892
TROUBLESHOOTING POINTS TO REMEMBER….2893
TROUBLESHOOTING SEQUENCE….2894
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE….2895
CHECKS BEFORE TROUBLESHOOTING….2903
CONNECTOR TYPES AND MOUNTING LOCATIONS….2904
CONNECTOR ARRANGEMENT DIAGRAM….2912
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….2920
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES….2941
USING THE TROUBLESHOOTING CHARTS….2945
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….2946
ELECTRICAL CIRCUIT DIAGRAM….2947
E-1 ENGINE DOES NOT START….2951
E-2 ENGINE DOES NOT STOP….2961
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW….2963
E-4 ELECTRICAL COMPONENTS DO NOT WORK….2965
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)….2967
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE….2969
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE….2973
ELECTRICAL CIRCUIT DIAGRAM….2993
T-1 FAILURE CODE [A1]….2997
T-2 FAILURE CODE [A2]….2998
T-3 FAILURE CODE [A3]….2999
T-4 FAILURE CODE [A4]….3000
T-5 FAILURE CODE [A5]….3001
T-6 FAILURE CODE [A8]….3002
T-7 FAILURE CODE [b1]….3003
T-8 FAILURE CODE [b2]….3004
T-9 FAILURE CODE [b3]….3005
T-10 FAILURE CODE [b4]….3006
T-11 FAILURE CODE [b5]….3007
T-12 FAILURE CODE [b6]….3008
T-13 FAILURE CODE [b7]….3009
T-14 FAILURE CODE [b8]….3010
T-15 FAILURE CODE [C0]….3011
T-16 FAILURE CODE [C1]….3012
T-17 FAILURE CODE [C3]….3013
T-18 FAILURE CODE [C4]….3015
T-19 FAILURE CODE [C5]….3017
T-20 FAILURE CODE [C6]….3018
T-21 FAILURE CODE [C7]….3019
T-22 FAILURE CODE [C8]….3020
T-23 FAILURE CODE [C9]….3021
T-24 FAILURE CODE [d1]….3022
T-25 FAILURE CODE [d2]….3023
T-26 FAILURE CODE [d4]….3024
T-27 FAILURE CODE [d5]….3025
T-28 FAILURE CODE [d6]….3026
T-29 FAILURE CODE [d7]….3027
T-30 FAILURE CODE [E1]….3028
T-31 FAILURE CODE [E2]….3029
T-32 FAILURE CODE [E3]….3030
T-33 FAILURE CODE [E4]….3032
T-34 FAILURE CODE [E5]….3032
T-35 FAILURE CODE [E6]….3033
T-36 FAILURE CODE [E7]….3034
T-37 FAILURE CODE [E8]….3034
T-38 FAILURE CODE [F1]….3036
T-39 FAILURE CODE [F2]….3036
T-40 FAILURE CODE [F3]….3037
T-41 FAILURE CODE [F4]….3038
T-42 FAILURE CODE [F5]….3038
T-43 FAILURE CODE [F6]….3039
T-44 FAILURE CODE [F7]….3039
T-45 FAILURE CODE [F8]….3040
T-46 FAILURE CODE [91]….3041
T-47 FAILURE CODE [92]….3041
T-48 FAILURE CODE [93]….3042
T-49 FAILURE CODE [94]….3043
T-50 FAILURE CODE [95]….3043
T-51 FAILURE CODE [96]….3044
T-52 FAILURE CODE [97]….3044
T-53 FAILURE CODE [98]….3046
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….3047
FAILURE TABLE: MODES AND CAUSES….3048
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER….3050
H-2 NO WORK EQUIPMENT MOVES….3051
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS….3051
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP….3052
H-5 EXCESSIVE BLADE DRIFT….3052
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE….3053
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING, DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT CYLINDERS (LEFT, RIGHT)….3053
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)….3054
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE….3054
H-10 EXCESSIVE SCARIFIER DRIFT….3055
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE….3055
H-12 TRANSMISSION DOES NOT SHIFT-UP OR SHIFT-DOWN….3056
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING….3056
H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION,CANNOT BE ACTUATED OR CANCELED….3057
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR….3057
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH….3058
H-17 BRAKING FORCE IS INSUFFICIENT….3059
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)….3060
FAILURE TABLE: MODES AND CAUSES….3061
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM….3063
M-1 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP….3067
M-2 TRANSMISSION CONTROLLER CAUTION LAMP LIGHTS UP….3068
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP LIGHTS UP….3068
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP LIGHTS UP (OPT)….3069
M-5 BANK PIN CAUTION LAMP LIGHTS UP….3070
M-6 BRAKE OIL PRESSURE CAUTION LAMP LIGHTS UP….3071
M-7 BATTERY CHANGE CAUTION LAMP LIGHTS UP….3072
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP….3073
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP….3074
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)….3075
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)….3076
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP….3077
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP….3077
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP ….3079
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH….3080
M-16 ARTICULATION GAUGE DOES NOT WORK….3081
M-17 FUEL GAUGE DOES NOT WORK….3083
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK….3085
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)….3086
M-20 MESSAGE CENTER DOES NOT WORK….3087
M-21 SERVICE METER DOES NOT WORK….3088
30 DISASSEMBLY AND ASSEMBLY….3089
METHOD OF USING MANUAL….3091
PRECAUTIONS WHEN CARRYING OUT OPERATION….3093
SPECIAL TOOL LIST….3095
SKETCHES OF SPECIAL TOOLS….3098
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.:50001-51000)….3103
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.:50001-51000)….3104
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.:51001 AND UP)….3104
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.:5101 AND UP)….3105
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)….3106
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)….3107
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:51001 AND UP)….3108
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.:51001 AND UP)….3110
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.:50001-51000)….3111
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.:50001-51000)….3113
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSMBLY (SERIAL NO.:51001 AND UP)….3115
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB ATNK ASSEMBLY (SERIAL NO.:51001 AND UP)….3117
REMOVAL OF ENGINE ASSEMBLY….3118
INSTALLATION OF ENGINE ASSEMBLY….3119
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….3121
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….3122
REMOVAL OF TRANSMISSION ASSEMBLY….3123
INSTALLATION OF TRANSMISSION ASSEMBLY….3125
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY….3128
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY….3130
DISASSEMBLY OF TRANSMISSION ASSEMBLY….3134
ASSEMBLY OF TRANSMISSION ASSEMBLY….3150
REMOVAL OF FINAL DRIVE ASSEMBLY….3171
INSTALLATION OF FINAL DRIVE ASSEMBLY….3174
DISASSEMBLY OF FINAL DRIVE ASSEMBLY….3176
ASSEMBLY OF FINAL DRIVE ASSEMBLY….3177
DISASSEMBLY OF FINAL BRAKE CASE….3180
ASSEMBLY OF FINAL BRAKE CASE….3181
DISASSEMBLY OF SIDE CASE….3183
ASSEMBLY OF SIDE CASE….3184
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….3186
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….3187
DISASSEMBLY OF BEVEL GEAR….3190
ASSEMBLY OF BEVEL GEAR….3191
DISASSEMBLY OF BEVEL PINION ASSEMBLY….3192
ASSEMBLY OF BEVEL PINION ASSEMBLY….3193
REMOVAL OF OPERATOR'S CAB ASSEMBLY….3194
INSTALLATION OF OPERATOR'S CAB ASSEMBLY….3196
REMOVAL OF OPERATOR'S CAB FLOOR….3198
INSTALLATION OF OPERATOR'S CAB FLOOR….3200
REMOVAL OF STEERING VALVE (ORBIT-ROLL)….3202
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)….3202
STANDARD INTEGRAL ORBIT-ROLL….3203
DISASSEMBLY OF STEERING VALVE….3205
ASSEMBLY OF STEERING VALVE….3208
REMOVAL OF BLADE ASSEMBLY….3213
INSTALLATION OF BLADE ASSEMBLY….3213
REMOVAL OF CIRCLE DRAWBAR ASSEMBLY….3214
INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY….3215
REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY….3216
INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY….3217
REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)….3218
INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)….3219
DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….3220
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….3222
DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….3224
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….3226
90 OTHERS….3229
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO.:50001-51000)….3230
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO.:51001 AND UP)….3231
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:50001-51000)….3232
HYDRAULIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:51001 AND UP)….3233
HYDRAULIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:51001 AND UP)….3234
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:50001-51000)….3235
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:50001-51000)….3236
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:50001-51000)….3237
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:50001-51000)….3238
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:50001-51000)….3239
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO.:50001-51000)….3240
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:51001 AND UP)….3241
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:51001 AND UP)….3242
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:51001 AND UP)….3243
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:51001 AND UP)….3244
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:51001 AND UP)….3245
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO.:51001 AND UP)….3246
SEBM020911 – Motor Grader GD555-3C, GD655-3C, GD675-3C Shop Manual….3247
COVER….3247
CONTENTS….3248
01 GENERAL….3273
GENERAL ASSEMBLY DRAWING….3274
SPECIFICATIONS….3275
WEIGHT TABLE….3287
FUEL, COOLANT, AND LUBRICANT SELECTION….3289
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….3291
ACCELERATOR CONTROL LINKAGE….3292
ACCELERATOR PEDAL….3293
FAN DRIVE….3294
POWER TRAIN DIAGRAM….3295
TRANSMISSION HYDRAULIC PIPING….3296
TRANSMISSION CONTROL….3300
TORQUE CONVERTER….3301
TORQUE CONVERTER LOCK-UP VALVE (ECMV)….3306
TRANSMISSION….3309
TRANSMISSION VALVE….3338
ECMV (ELECTRONIC CONTROL MODULATION VALVE)….3339
MAIN RELIEF VALVE….3344
TRANSMISSION PUMP….3347
TRANSMISSION AND DIFFERENTIAL LOCK PUMP (WITH DIFFERENTIAL LOCK)….3348
FINAL DRIVE….3350
TANDEM DRIVE….3356
STEERING HYDRAULIC PIPING DRAWING….3360
STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)….3363
PRIORITY ACC GOVERNOR VALVE (SERIAL NO.50001-51000)….3370
PRIORITY VALVE (SERIAL NO.51001 AND UP)….3377
ACCUMULATOR PRESSURE GOVERNOR VALVE (SERIAL NO.51001 AND UP)….3384
FRONT AXLE….3386
BRAKE HYDRAULIC PIPING ….3390
BRAKE VALVE….3394
WHEEL BRAKE….3398
SLACK ADJUSTER….3399
ACCUMULATOR….3402
PARKING BRAKE….3403
PARKING BRAKE AND BANK CONTROL VALVE….3404
WORK EQUIPMENT HYDRAULIC PIPING DRAWING….3406
HYDRAULIC PUMP (SERIAL NO.50001-51000)….3416
HYDRAULIC PUMP (SERIAL NO.51001 AND UP)….3438
MAIN CONTROL VALVE….3461
CLSS….3480
WORK EQUIPMENT CONTROL….3492
HYDRAULIC SYSTEM….3494
HYDRAULIC TANK….3500
SWIVEL JOINT….3501
PILOT CHECK VALVE….3504
BLADE ACCUMULATOR, FLOAT VALVE….3509
SHUT-OFF VALVE….3513
BLADE FLOAT DEVICE….3514
CIRCLE ROTATION MOTOR….3516
HYDRAULIC CYLINDER….3518
CIRCLE, DRAWBAR….3524
LIFTER BRACKET LOCK PIN….3526
BLADE….3528
CIRCLE ROTATION GEAR….3530
SCARIFIER….3534
RIPPER….3536
MAIN FRAME….3539
AIR CONDITIONER (IF EQUIPPED)….3540
ENGINE STARTING CIRCUIT….3544
ENGINE STOP CIRCUIT….3548
PREHEAT CIRCUIT….3550
AUTOMATIC SHIFT CONTROL SYSTEM….3552
TRANSMISSION CONTROLLER….3553
MONITOR….3557
SENSORS….3560
20 TESTING AND ADJUSTING….3567
STANDARD VALUE TABLE….3568
STANDARD VALUE TABLE FOR ENGINE….3568
STANDARD VALUE TABLE FOR CHASSIS….3572
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM….3579
TESTING AND ADJUSTING….3589
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….3590
MEASURING EXHAUST COLOR….3591
MEASURING BLOWBY PRESSURE….3592
MEASURING ENGINE OIL PRESSURE….3593
MEASURING ENGINE SPEED….3593
TESTING FAN BELT TENSION….3594
TESTING AIR CONDITIONER COMPRESSOR BELT TENSION….3595
MEASURING TORQUE CONVERTER STALL SPEED….3595
CHECKING CLUTCH OIL PRESSURE….3596
CHECKING TORQUE CONVERTER OIL PRESSURE….3597
ADJUSTING SPEED SENSOR….3598
FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT….3600
ADJUSTING ACCELERATOR CONTROL LINKAGE….3601
TESTING BRAKE DISC….3602
TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE….3603
TESTING ACCUMULATOR CHARGE PRESSURE….3604
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE….3604
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE….3605
ADJUSTING PC VALVE….3607
BLEEDING AIR FROM HYDRAULIC CIRCUIT….3607
MEASURING INTERNAL CYLINDER LEAKAGE….3608
MEASURING STEERING, BRAKE OIL PRESSURE….3610
BLEEDING AIR FROM BRAKE PIPING….3611
CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR….3612
TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE….3613
TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE….3615
MEMORIZING IDLE AND FULL POSITION PROCEDURE….3617
INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER….3618
DIODE CHECKING PROCEDURE….3620
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS….3621
ADJUSTING CAB STOPPER BOLT….3623
TROUBLESHOOTING….3625
TROUBLESHOOTING POINTS TO REMEMBER….3626
TROUBLESHOOTING SEQUENCE….3627
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE….3628
CHECKS BEFORE TROUBLESHOOTING….3636
CONNECTOR TYPES AND MOUNTING LOCATIONS….3637
CONNECTOR ARRANGEMENT DIAGRAM….3646
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….3654
MESSAGE CENTER DISPLAY AND TABLE ERROR CODES….3675
USING THE TROUBLESHOOTING CHARTS….3679
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….3681
ELECTRICAL CIRCUIT DIAGRAM….3682
E-1 ENGINE DOES NOT START….3686
E-2 ENGINE DOES NOT STOP….3696
E-3 ENGINE PREHEATING PILOT LAMP DOES NOT GLOW….3698
E-4 ELECTRICAL COMPONENTS DO NOT WORK….3700
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)….3703
TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE….3706
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE….3710
ELECTRICAL CIRCUIT DIAGRAM….3730
T-1 FAILURE CODE [A1]….3734
T-2 FAILURE CODE [A2]….3735
T-3 FAILURE CODE [A3]….3736
T-4 FAILURE CODE [A4]….3737
T-5 FAILURE CODE [A5]….3738
T-6 FAILURE CODE [A8]….3739
T-7 FAILURE CODE [b1]….3740
T-8 FAILURE CODE [b2]….3741
T-9 FAILURE CODE [b3]….3742
T-10 FAILURE CODE [b4]….3743
T-11 FAILURE CODE [b5]….3744
T-12 FAILURE CODE [b6]….3745
T-13 FAILURE CODE [b7]….3746
T-14 FAILURE CODE [b8]….3747
T-15 FAILURE CODE [C0]….3748
T-16 FAILURE CODE [C1]….3749
T-17 FAILURE CODE [C3]….3750
T-18 FAILURE CODE [C4]….3752
T-19 FAILURE CODE [C5]….3754
T-20 FAILURE CODE [C6]….3755
T-21 FAILURE CODE [C7]….3756
T-22 FAILURE CODE [C8]….3757
T-23 FAILURE CODE [C9]….3758
T-24 FAILURE CODE [d1]….3759
T-25 FAILURE CODE [d2]….3760
T-26 FAILURE CODE [d4]….3761
T-27 FAILURE CODE [d5]….3762
T-28 FAILURE CODE [d6]….3763
T-29 FAILURE CODE [d7]….3764
T-30 FAILURE CODE [E1]….3765
T-31 FAILURE CODE [E2]….3766
T-32 FAILURE CODE [E3]….3767
T-33 FAILURE CODE [E4]….3769
T-34 FAILURE CODE [E5]….3769
T-35 FAILURE CODE [E6]….3770
T-36 FAILURE CODE [E7]….3771
T-37 FAILURE CODE [E8]….3771
T-38 FAILURE CODE [F1]….3773
T-39 FAILURE CODE [F2]….3773
T-40 FAILURE CODE [F3]….3774
T-41 FAILURE CODE [F4]….3775
T-42 FAILURE CODE [F5]….3775
T-43 FAILURE CODE [F6]….3776
T-44 FAILURE CODE [F7]….3776
T-45 FAILURE CODE [F8]….3777
T-46 FAILURE CODE [91]….3778
T-47 FAILURE CODE [92]….3778
T-48 FAILURE CODE [93]….3779
T-49 FAILURE CODE [94]….3780
T-50 FAILURE CODE [95]….3780
T-51 FAILURE CODE [96]….3781
T-52 FAILURE CODE [97]….3781
T-53 FAILURE CODE [98]….3783
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….3785
FAILURE TABLE: MODES AND CAUSES….3786
H-1 ALL WORK EQUIPMENT IS SLOW OR LACKS POWER….3788
H-2 NO WORK EQUIPMENT MOVES….3789
H-3 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS….3789
H-4 ABNORMAL NOISE GENERATED AROUND THE PUMP….3790
H-5 EXCESSIVE BLADE DRIFT….3790
H-6 IMPOSSIBLE TO RAISE FRONT OF MACHINE USING THE BLADE….3791
H-7 LACK OF ACTUATING POWER IN THE ARTICULATING, DRAWBAR SHIFT, SCARIFIER, LEANING, AND BLADE SHIFT CYLINDERS (LEFT, RIGHT)….3791
H-8 EXCESSIVE LEANING CYLINDER DRIFT (TIRES LEAN)….3792
H-9 IMPOSSIBLE TO ROTATE THE CIRCLE….3792
H-10 EXCESSIVE SCARIFIER DRIFT….3793
H-11 MACHINE DOES NOT MOVE IN EITHER FORWARD OR REVERSE….3793
H-12 TRANSMISSION DOES NOT SHIFT-UP OR SHIFT-DOWN….3794
H-13 MACHINE IS SLOW OR LACKS POWER WHEN TRAVELING….3794
H-14 TORQUE CONVERTER LOCK-UP MALFUNCTION,CANNOT BE ACTUATED OR CANCELED….3795
H-15 EXCESSIVE TIME LAG WHEN STARTING OR SHIFTING GEAR….3795
H-16 TORQUE CONVERTER OIL TEMPERATURE IS HIGH….3796
H-17 BRAKING FORCE IS INSUFFICIENT….3797
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)….3799
FAILURE TABLE: MODES AND CAUSES….3800
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM….3802
M-1 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP….3806
M-2 TRANSMISSION CONTROLLER CAUTION LAMP LIGHTS UP….3807
M-3 TRANSMISSION OIL TEMPERATURE CAUTION LAMP LIGHTS UP….3807
M-4 DIFFERENTIAL OIL TEMPERATURE CAUTION LAMP LIGHTS UP (OPT)….3808
M-5 BANK PIN CAUTION LAMP LIGHTS UP….3809
M-6 BRAKE OIL PRESSURE CAUTION LAMP LIGHTS UP….3810
M-7 BATTERY CHANGE CAUTION LAMP LIGHTS UP….3811
M-8 PREHEATING DISPLAY DOES NOT LIGHT UP….3812
M-9 HIGH BEAM DISPLAY DOES NOT LIGHT UP….3813
M-10 WORKING LAMP DISPLAY DOES NOT LIGHT UP (OPT)….3814
M-11 DIFFERENTIAL LOCK ACTUATION DISPLAY DOES NOT LIGHT UP (OPT)….3815
M-12 ACCUMULATOR ACTUATION DISPLAY DOES NOT LIGHT UP….3816
M-13 FLOAT ACTUATION DISPLAY DOES NOT LIGHT UP….3816
M-14 PARKING BRAKE DISPLAY DOES NOT LIGHT UP ….3818
M-15 TURN SIGNAL LAMP DISPLAY DOES NOT FLASH….3819
M-16 ARTICULATION GAUGE DOES NOT WORK….3820
M-17 FUEL GAUGE DOES NOT WORK….3822
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK….3824
M-19 TORQUE CONVERTER TEMPERATURE GAUGE DOES NOT WORK (OPT)….3825
M-20 MESSAGE CENTER DOES NOT WORK….3826
M-21 SERVICE METER DOES NOT WORK….3827
30 DISASSEMBLY AND ASSEMBLY….3829
METHOD OF USING MANUAL….3831
PRECAUTIONS WHEN CARRYING OUT OPERATION….3833
SPECIAL TOOL LIST….3836
SKETCHES OF SPECIAL TOOLS….3839
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.:50001-51000)….3844
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.:50001-51000)….3845
REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.:51001 AND UP)….3845
INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.:5101 AND UP)….3846
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)….3847
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.:50001-51000)….3848
REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.:51001 AND UP)….3849
INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.:51001 AND UP)….3851
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.:50001-51000)….3852
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.:50001-51000)….3854
REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSMBLY (SERIAL NO.:51001 AND UP)….3856
INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB ATNK ASSEMBLY (SERIAL NO.:51001 AND UP)….3858
REMOVAL OF ENGINE ASSEMBLY….3859
INSTALLATION OF ENGINE ASSEMBLY….3860
REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….3862
INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT….3863
REMOVAL OF TRANSMISSION ASSEMBLY….3864
INSTALLATION OF TRANSMISSION ASSEMBLY….3866
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY….3869
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY….3871
DISASSEMBLY OF TRANSMISSION ASSEMBLY….3875
ASSEMBLY OF TRANSMISSION ASSEMBLY….3891
REMOVAL OF FINAL DRIVE ASSEMBLY….3912
INSTALLATION OF FINAL DRIVE ASSEMBLY….3915
DISASSEMBLY OF FINAL DRIVE ASSEMBLY….3917
ASSEMBLY OF FINAL DRIVE ASSEMBLY….3918
DISASSEMBLY OF FINAL BRAKE CASE….3921
ASSEMBLY OF FINAL BRAKE CASE….3922
DISASSEMBLY OF SIDE CASE….3924
ASSEMBLY OF SIDE CASE….3925
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….3927
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY….3928
DISASSEMBLY OF BEVEL GEAR….3931
ASSEMBLY OF BEVEL GEAR….3932
DISASSEMBLY OF BEVEL PINION ASSEMBLY….3933
ASSEMBLY OF BEVEL PINION ASSEMBLY….3934
REMOVAL OF OPERATOR'S CAB ASSEMBLY….3935
INSTALLATION OF OPERATOR'S CAB ASSEMBLY….3937
REMOVAL OF OPERATOR'S CAB FLOOR….3939
INSTALLATION OF OPERATOR'S CAB FLOOR….3941
REMOVAL OF STEERING VALVE (ORBIT-ROLL)….3943
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)….3943
STANDARD INTEGRAL ORBIT-ROLL….3944
DISASSEMBLY OF STEERING VALVE….3946
ASSEMBLY OF STEERING VALVE….3949
REMOVAL OF BLADE ASSEMBLY….3954
INSTALLATION OF BLADE ASSEMBLY….3954
REMOVAL OF CIRCLE DRAWBAR ASSEMBLY….3955
INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY….3956
REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY….3957
INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY….3958
REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)….3959
INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WTH SHEAR PIN)….3960
DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….3961
ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)….3963
DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….3965
ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)….3967
90 OTHERS….3971
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO.:50001-51000)….3973
TRANSMISSION HYDRAULIC CIRCUIT (SERIAL NO.:51001 AND UP)….3974
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.:50001-51000)….3975
HYDRAULIC CIRCUIT DIAGRAM (1/2) (SERIAL NO.:51001 AND UP)….3976
HYDRAULIC CIRCUIT DIAGRAM (2/2) (SERIAL NO.:51001 AND UP)….3977
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:50001-51000)….3978
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:50001-51000)….3979
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:50001-51000)….3980
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:50001-51000)….3981
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:50001-51000)….3982
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO.:50001-51000)….3983
ELECTRICAL CIRCUIT DIAGRAM (1/6) (SERIAL NO.:51001 AND UP)….3984
ELECTRICAL CIRCUIT DIAGRAM (2/6) (SERIAL NO.:51001 AND UP)….3985
ELECTRICAL CIRCUIT DIAGRAM (3/6) (SERIAL NO.:51001 AND UP)….3986
ELECTRICAL CIRCUIT DIAGRAM (4/6) (SERIAL NO.:51001 AND UP)….3987
ELECTRICAL CIRCUIT DIAGRAM (5/6) (SERIAL NO.:51001 AND UP)….3988
ELECTRICAL CIRCUIT DIAGRAM (6/6) (SERIAL NO.:51001 AND UP)….3989
TEN00095-01 – Motor Grader GALEO GD655-3C Operation & Maintenance Manual….3990
COVER….3990
FOREWORD….3991
FOREWORD….3992
SAFETY INFORMATION….3995
INTENDED USE….3997
DIRECTIONS OF MACHINE….3997
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….3998
MACHINE SERIAL NO. PLATE POSITION….3998
ENGINE SERIAL NO. PLATE POSITION….3998
SERVICE METER POSITION….3999
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….3999
CONTENTS….4000
SAFETY….4003
SAFETY INFORMATION….4004
SAFETY LABELS….4006
POSITION FOR ATTACHING SAFETY LABELS….4007
SAFETY LABELS….4008
GENERAL PRECAUTIONS….4013
SAFETY RULES….4013
IF PROBLEMS ARE FOUND….4013
CLOTHING AND PERSONAL PROTECTIVE ITEMS….4013
FIRE EXTINGUISHER AND FIRST AID KIT….4013
SAFETY FEATURES….4013
KEEP MACHINE CLEAN….4014
INSIDE OPERATOR'S COMPARTMENT….4014
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….4014
HANDRAILS AND STEPS….4015
MOUNTING AND DISMOUNTING….4015
DO NOT GET CAUGHT IN ARTICULATED PORTION….4015
PREVENTION OF BURNS….4016
FIRE PREVENTION….4017
ACTION IF FIRE OCCURS….4017
WINDOW WASHER LIQUID….4018
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….4018
PRECAUTIONS FOR ATTACHMENTS….4018
UNAUTHORIZED MODIFICATION….4018
SAFETY AT WORKSITE….4019
WORKING ON LOOSE GROUND….4019
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….4020
ENSURE GOOD VISIBILITY….4020
VENTILATION FOR ENCLOSED AREAS….4020
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….4021
EMERGENCY ESCAPE FROM OPERATOR'S CAB….4021
ASBESTOS DUST HAZARD PREVENTION….4021
PRECAUTIONS DURING OPERATION….4022
STARTING ENGINE….4022
CHECKS BEFORE STARTING ENGINE, ADJUST….4022
PRECAUTIONS WHEN STARTING….4022
PRECAUTIONS IN COLD AREAS….4023
OPERATION….4024
CHECKS BEFORE STARTING OPERATION….4024
PRECAUTIONS BEFORE MOVING OFF….4024
PRECAUTIONS WHEN TRAVELING….4025
PRECAUTIONS WHEN TRAVELING ON SLOPES….4026
PRECAUTIONS WHEN OPERATIONS ON SLOPES….4026
PROHIBITED OPERATIONS….4026
PRECAUTIONS WHEN OPERATING….4026
OPERATE CAREFULLY ON SNOW….4027
PARKING MACHINE….4027
TRANSPORTATION….4028
LOADING AND UNLOADING….4028
SHIPPING….4028
BATTERY….4029
BATTERY HAZARD PREVENTION….4029
STARTING WITH BOOSTER CABLES….4030
TOWING….4031
WHEN TOWING….4031
PRECAUTIONS FOR MAINTENANCE….4032
WARNING TAG….4032
KEEP WORK PLACE CLEAN AND TIDY….4032
APPOINT LEADER WHEN WORKING WITH OTHERS….4032
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….4033
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….4034
PROPER TOOLS….4034
ACCUMULATOR….4035
PERSONNEL….4035
ATTACHMENTS….4035
WORK UNDER THE MACHINE….4035
NOISE….4035
PRECAUTIONS WHEN USING HAMMER….4036
REPAIR WELDING….4036
REMOVING BATTERY TERMINAL….4036
PRECAUTIONS WITH HIGH-PRESSURE OIL….4036
PRECAUTIONS WITH HIGH-PRESSURE FUEL….4036
HANDLING HIGH-PRESSURE HOSES….4037
WASTE MATERIALS….4037
MAINTENANCE OF AIR CONDITIONER….4037
COMPRESSED AIR….4037
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS….4037
PRECAUTIONS WITH TIRES….4038
HANDLING TIRES….4038
PRECAUTIONS WHEN STORING TIRE….4038
OPERATION….4039
GENERAL VIEW….4040
GENERAL VIEW OF MACHINE….4040
GENERAL VIEW OF CONTROLS AND GAUGES….4041
EXPLANATION OF COMPONENTS….4044
METERS AND LAMPS….4044
SWITCHES….4051
CONTROL LEVERS, PEDALS….4062
DUST INDICATOR….4071
ARTICULATE LOCK PIN….4071
FUSE BOX….4071
OPERATION….4073
CHECK BEFORE STARTING ENGINE….4073
STARTING ENGINE….4085
OPERATIONS, CHECKS AFTER STARTING ENGINE….4089
STOPPING ENGINE….4091
CHECK AFTER STOPPING ENGINE….4091
TRAVELING POSTURE FOR MACHINE….4092
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….4093
TURNING MACHINE….4097
OPERATING WORK EQUIPMENT….4100
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….4106
PRECAUTIONS WHEN OPERATION….4127
ADJUSTING WORK EQUIPMENT POSTURE….4131
PARKING MACHINE….4141
CHECKS AFTER COMPLETION OF OPERATION….4142
LOCKING….4143
HANDLING THE TIRES….4143
TRANSPORTATION….4144
LOADING, UNLOADING WORK….4144
PRECAUTIONS FOR LOADING….4145
COLD WEATHER OPERATION….4146
PRECAUTIONS FOR LOW TEMPERATURE….4146
CAUTIONS AFTER COMPLETION OF WORK….4147
AFTER COLD WEATHER….4147
LONG-TERM STORAGE….4148
BEFORE STORAGE….4148
DURING STORAGE….4148
AFTER STORAGE….4148
TROUBLESHOOTING….4149
AFTER RUNNING OUT OF FUEL….4149
WHEN LEANING PIPING IS DAMAGED….4150
TOWING THE MACHINE….4151
IF BATTERY IS DISCHARGED….4153
OTHER TROUBLE….4156
MAINTENANCE….4163
GUIDES TO MAINTENANCE….4164
OUTLINES OF SERVICE….4166
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4166
RELATING TO ELECTRIC SYSTEM….4169
WEAR PARTS….4170
WEAR PARTS LIST….4170
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4171
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….4175
TORQUE LIST….4175
PERIODIC REPLACEMENT OF CRITICAL PARTS….4177
CRITICAL PARTS….4177
MAINTENANCE SCHEDULE CHART….4178
MAINTENANCE SCHEDULE CHART….4178
SERVICE PROCEDURE….4180
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….4180
WHEN REQUIRED….4181
CLEAN INSIDE OF COOLING SYSTEM….4181
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….4184
CLEAN, CHECK WATER SEPARATOR….4188
CHECK ELECTRICAL INTAKE AIR HEATER….4189
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT….4189
CHECK INCHING PEDAL….4189
CLEAN AIR CONDITIONER AIR FILTER….4190
CHECK REFRIGERANT (GAS) LEVEL….4191
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT….4191
SELECTION AND INSPECTION OF TIRES….4192
CHECK BEFORE STARTING….4194
EVERY 50 HOURS SERVICE….4195
LUBRICATING….4195
EVERY 250 HOURS SERVICE….4196
LUBRICATING….4196
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….4202
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL….4203
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….4204
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL….4205
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL….4205
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….4206
CHECK LEVEL OF BATTERY ELECTROLYTE….4207
CHECK BALL JOINT CLEARANCE, ADJUST….4209
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT….4209
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR….4209
CHECK FAN BELT TENSION, ADJUST….4210
EVERY 500 HOURS SERVICE….4211
REPLACE FUEL FILTER CARTRIDGE….4211
CLEAN, CHECK RADIATOR FINS….4213
CHECK CIRCLE GUIDE CLEARANCE, ADJUST….4214
EVERY 1000 HOURS SERVICE….4217
LUBRICATING….4217
REPLACE TRANSMISSION OIL FILTER CARTRIDGE….4218
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER….4219
CHANGE OIL IN FINAL DRIVE CASE….4220
REPLACE HYDRAULIC TANK FILTER ELEMENT….4220
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR….4221
CHECK TOE-IN, ADJUST….4222
CHECK FRONT WHEEL BEARING PLAY, ADJUST….4223
REPLACE CORROSION RESISTOR CARTRIDGE….4224
EVERY 2000 HOURS SERVICE….4225
CHANGE OIL IN HYDRAULIC TANK….4225
CHANGE OIL IN CIRCLE REVERSE GEAR CASE….4226
CHANGE OIL IN TANDEM DRIVE CASE….4227
CHECK DISC BRAKE….4228
CHECK ALTERNATOR, STARTING MOTOR….4230
CHECK ENGINE VALVE CLEARANCE, ADJUST….4230
CHECK VIBRATION DAMPER….4230
CLEAN, CHECK TURBOCHARGER….4230
CHECK ACCUMULATOR GAS PRESSURE….4230
CHANGE GREASE IN FRONT WHEEL BEARING….4230
EVERY 4000 HOURS SERVICE….4231
CHECK WATER PUMP….4231
CHECK AND ADJUST AIR COMPRESSOR….4231
CHECK FAN PULLEY….4231
CHECK INJECTOR….4231
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….4231
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….4232
EVERY 8000 HOURS SERVICE….4233
REPLACE INJECTOR NOZZLE TIP….4233
REPLACE HIGH-PRESSURE PIPING CLAMP….4233
REPLACE FUEL SPRAY PREVENTION CAP….4233
SPECIFICATIONS….4234
SPECIFICATIONS….4235
ATTACHMENTS, OPTIONS….4237
HANDLING BLADE ACCUMULATOR….4238
FEATURES OF BLADE ACCUMULATOR….4238
METHOD OF OPERATING BLADE ACCUMULATOR….4239
AM/FM RADIO-CASSETTE STEREO….4240
EXPLANATION OF COMPONENTS….4240
METHOD OF OPERATION….4245
PRECAUTIONS WHEN USING….4248
AIR CONDITIONER….4249
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….4249
METHOD OF OPERATION….4251
PRECAUTIONS WHEN USING….4251
TESTING AND MAINTENANCE….4251
HANDLING AIR-SUSPENSION SEAT….4252
ADJUST OPERATOR'S SEAT….4252
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4254
BASIC PRECAUTIONS….4254
INDEX….4255
TEN00178-02 – Motor Grader GD555-3C Operation & Maintenance Manual….4258
COVER….4258
FOREWORD….4259
FOREWORD….4260
SAFETY INFORMATION….4261
INTENDED USE….4263
DIRECTIONS OF MACHINE….4263
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….4264
MACHINE SERIAL NO. PLATE POSITION….4264
ENGINE SERIAL NO. PLATE POSITION….4264
SERVICE METER POSITION….4265
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….4265
CONTENTS….4266
SAFETY….4269
SAFETY INFORMATION….4270
SAFETY LABELS….4272
POSITION FOR ATTACHING SAFETY LABELS….4273
SAFETY LABELS….4274
GENERAL PRECAUTIONS….4279
PRECAUTIONS DURING OPERATION….4288
STARTING ENGINE….4288
OPERATION….4290
TRANSPORTATION….4295
BATTERY….4296
TOWING….4298
PRECAUTIONS FOR MAINTENANCE….4299
PRECAUTIONS WITH TIRES….4305
OPERATION….4307
GENERAL VIEW….4308
GENERAL VIEW OF MACHINE….4308
GENERAL VIEW OF CONTROLS AND GAUGES….4309
EXPLANATION OF COMPONENTS….4312
METERS AND LAMPS….4312
SWITCHES….4319
CONTROL LEVERS, PEDALS….4330
DUST INDICATOR….4339
ARTICULATE LOCK PIN….4339
FUSE BOX….4339
OPERATION….4341
CHECK BEFORE STARTING ENGINE….4341
STARTING ENGINE….4353
OPERATIONS, CHECKS AFTER STARTING ENGINE….4357
STOPPING ENGINE….4359
CHECK AFTER STOPPING ENGINE….4359
TRAVELING POSTURE FOR MACHINE….4360
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….4361
TURNING MACHINE….4365
OPERATING WORK EQUIPMENT….4368
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….4374
PRECAUTIONS WHEN OPERATION….4395
ADJUSTING WORK EQUIPMENT POSTURE….4400
PARKING MACHINE….4411
CHECKS AFTER COMPLETION OF OPERATION….4412
LOCKING….4413
HANDLING THE TIRES….4413
TRANSPORTATION….4414
LOADING, UNLOADING WORK….4414
PRECAUTIONS FOR LOADING….4415
COLD WEATHER OPERATION….4416
PRECAUTIONS FOR LOW TEMPERATURE….4416
CAUTIONS AFTER COMPLETION OF WORK….4417
AFTER COLD WEATHER….4417
LONG-TERM STORAGE….4418
BEFORE STORAGE….4418
DURING STORAGE….4418
AFTER STORAGE….4418
TROUBLESHOOTING….4419
AFTER RUNNING OUT OF FUEL….4419
WHEN LEANING PIPING IS DAMAGED….4420
TOWING THE MACHINE….4421
IF BATTERY IS DISCHARGED….4423
OTHER TROUBLE….4426
MAINTENANCE….4433
GUIDES TO MAINTENANCE….4434
OUTLINES OF SERVICE….4436
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4436
RELATING TO ELECTRIC SYSTEM….4439
WEAR PARTS….4440
WEAR PARTS LIST….4440
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4441
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….4445
TORQUE LIST….4445
PERIODIC REPLACEMENT OF CRITICAL PARTS….4447
CRITICAL PARTS….4447
MAINTENANCE SCHEDULE CHART….4448
MAINTENANCE SCHEDULE CHART….4448
SERVICE PROCEDURE….4450
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….4450
WHEN REQUIRED….4451
CHECK BEFORE STARTING….4464
EVERY 50 HOURS SERVICE….4465
EVERY 250 HOURS SERVICE….4466
EVERY 500 HOURS SERVICE….4481
EVERY 1000 HOURS SERVICE….4487
EVERY 2000 HOURS SERVICE….4494
EVERY 4000 HOURS SERVICE….4500
SPECIFICATIONS….4501
SPECIFICATIONS….4502
ATTACHMENTS, OPTIONS….4505
HANDLING BLADE ACCUMULATOR….4506
FEATURES OF BLADE ACCUMULATOR….4506
METHOD OF OPERATING BLADE ACCUMULATOR….4507
AM/FM RADIO-CASSETTE STEREO….4508
EXPLANATION OF COMPONENTS….4508
METHOD OF OPERATION….4513
PRECAUTIONS WHEN USING….4516
AIR CONDITIONER….4517
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….4517
METHOD OF OPERATION….4519
PRECAUTIONS WHEN USING….4519
TESTING AND MAINTENANCE….4519
HANDLING AIR-SUSPENSION SEAT….4520
ADJUST OPERATOR'S SEAT….4520
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4522
BASIC PRECAUTIONS….4522
INDEX….4523
Komatsu Motor Graders GD555C, GD655C, GD675C Repair Service Manuals
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