Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Grader GD555-5, GD655-5, GD675-5, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Grader GD555-5, GD655-5, GD675-5 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.
SEN05215-06 – Motor Grader GD555-5, GD655-5, GD675-5 Shop Manual.pdf
TEN00368-01 – Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00369-01 – Motor Grader GD675-5 Operation & Maintenance Manual.pdf
TEN00445-02 – Motor Grader GD555-5 Operation & Maintenance Manual.pdf
TEN00446-02 – Motor Grader GD655-5 Operation & Maintenance Manual.pdf
TEN00447-02 – Motor Grader GD675-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,174 pages
File Format: PDF
Language: English
MAIN SECTIONS
SEN05215-06 – Motor Grader GD555-5, GD655-5, GD675-5 Shop Manual….2
COVER….2
Notice of revision….4
00 Index and foreword….12
Table of contents….13
Table of contents….13
Foreword and general information….24
Safety notice….24
How to read the shop manual….29
Explanation of terms for maintenance standard….31
Handling of electric equipment and hydraulic components….33
Handling of connectors newly used for engines….42
How to read electric wire code….45
Precautions when carrying out work….48
Method of disassembling and connecting push-pull type coupler….51
Standard tightening torque table….54
List of Abbreviation….58
Conversion table….62
01 Specification….68
Specification drawing….70
Specifications….71
Weight table….77
Table of fuel, coolant and lubricants….78
10 Structure, function and maintenance standard….80
Engine and Cooling….83
Cooling system….83
Cooling fan pump….85
Power train system….93
Power train system drawing….93
Power train piping drawing….95
Transmission control….97
Torque converter….99
Transmission….103
Transmission control valve….125
ECMV….129
Main relief and torque converter relief valve….137
Front axle….139
Final drive (no differential specification)….143
Final drive (differential/ differential lock specification)….145
Differential lock solenoid valve….147
Tandem drive….149
Steering system….151
Steering piping diagram….151
Priority valve….153
Steering valve….159
Brake system….167
Brake hydraulic piping diagram….167
Brake valve….168
Slack adjuster….175
Accumulator (for brake)….177
Charge valve….178
Wheel brake….185
Parking brake and bank control valve….187
Parking brake….189
Undercarriage frame….191
Frame….191
Tire….193
Hydraulic system….195
Hydraulic system….195
Work equipment hydraulic piping diagram….199
Work equipment control….203
Hydraulic tank….205
Main pump….207
Power train pump….219
Control valve….221
CLSS….231
Functions and operation by valve….235
Hydraulic cylinder….245
Swivel joint….247
Pilot check valve….249
Accumulator (for blade)….257
Work equipment….259
Circle and drawbar….259
Blade….261
Lifter….263
Circle rotation motor….265
Circle rotation gear….267
Cab….269
Cab….269
Electrical system….271
Machine monitor….271
Automatic shift control system….275
Transmission controller….283
Engine controller….287
KOMTRAX system….291
Starting engine circuit….295
Stopping engine circuit….297
Preheating circuit….299
Sensor….301
Engine power mode select circuit….313
Cooling fan control function….315
20 Standard value table….320
Standard value table….322
Standard value table for engine….322
Standard value table for machine….324
30 Testing and adjusting….332
Tools for testing, adjusting, and troubleshooting….335
Tools for testing, adjusting, and troubleshooting….335
Engine and cooling system….341
Testing engine speed….341
Testing intake air pressure (boost pressure)….343
Testing exhaust gas temperature….345
Testing exhaust gas color….347
Adjusting valve clearance….349
Testing compression pressure….351
Testing blowby pressure….354
Testing engine oil pressure….356
Handling fuel system device….357
Releasing remaining pressure from fuel system….358
Testing fuel pressure….359
Bleeding air from fuel circuit….360
Testing fuel circuit for leakage….361
Cylinder cut-out test mode….362
No injection cranking….363
Handling voltage circuit of engine controller….364
Checking muffler body and muffler stack for looseness and damage….365
Checking muffler function….366
Checking cylinder head and manifolds for looseness….367
Checking engine piping for damage and looseness….368
Checking fuel delivery, return rate and leakage….369
Replacing fan belt….372
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]….373
Power train….375
Testing power train oil pressure….375
Adjusting transmission speed sensor….387
Emergency escape method in case of transmission valve failure….391
Flushing torque converter and trasmission circuits….395
Testing and adjusting toe-in….397
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]….399
Steering system….401
Testing and adjusting steering oil pressure….401
Testing steering cylinder oil leakage….402
Bleeding air from steering circuit….403
Brake system….405
Testing and adjusting brake oil pressure….405
Releasing remaining pressure from brake circuit….409
Bleeding air from brake circuit….410
Testing wheel brake disc wear….411
Testing and adjusting parking brake….413
Emergency release method of parking brake….415
Filling gas into brake accumulator….417
Hydraulic system….419
Testing and adjusting work equipment oil pressure….419
Testing and adjusting pump LS differential pressure….422
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut]….424
Testing work equipment cylinder oil leakage amount….425
Bleeding air from work equipment circuit….428
Work equipment….429
Clearance adjustment of drawbar ball joint….429
Testing and adjusting circle guide clearance….430
Testing and adjusting slip clutch type circle rotator….432
Filling gas into blade accumulator [machine with blade accumulator]….434
Electrical system….435
Procedure for testing diodes….435
Special functions of machine monitor (EMMS)….436
Handling high voltage circuit of engine controller….485
How to start KOMTRAX terminal operations….487
Indicator lamps of KOMTRAX terminal….496
Preparation work for troubleshooting of electrical system….503
Pm clinic….505
40 Troubleshooting….514
General information on troubleshooting….520
Points to remember when troubleshooting….520
Sequence of events in troubleshooting….521
Checks before troubleshooting….522
Classification and procedures for troubleshooting….542
Failure codes table….543
Failure and troubleshooting numbers….550
Information in troubleshooting table….552
Troubleshooting method for open circuit in wiring harness of pressure sensor system….554
Connector list and layout….556
Connection table for connector pin numbers….571
T- branch box and T- branch adapter table….607
Locations of fuses….610
Troubleshooting by failurecode….612
Failure code [1500LO] TORQUEFLOW transmission: Double engagement….612
Failure code [15G0MW] Transmission R clutch: Slip….613
Failure code [15H0MW] Transmission FH clutch: Slip….614
Failure code [15J0MW] Transmission FL clutch: Slip….614
Failure code [15K0MW] Transmission 1st clutch: Slip….615
Failure code [15L0MW] Transmission 2nd clutch: Slip….616
Failure code [15M0MW] Transmission 3rd speed clutch: Slip….617
Failure code [15N0MW] Transmission 4th clutch: Slip….618
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF….619
Failure code [15SBMA] ECMV R clutch: Malfunction….621
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF….623
Failure code [15SCMA] ECMV FH clutch: Malfunction….625
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF….627
Failure code [15SDMA] ECMV FL clutch: Malfunction….629
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF….631
Failure code [15SEMA] ECMV 1st clutch: Malfunction….633
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF….635
Failure code [15SFMA] ECMV 2nd clutch: Malfunction….637
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF….639
Failure code [15SGMA] ECMV 3rd clutch: Malfunction….641
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF….643
Failure code [15SHMA] ECMV 4th clutch: Malfunction….645
Failure code [15SJMA] ECMV lockup clutch: Malfunction….647
Failure code [15UONT] Inching clutch: Overheating….647
Failure code [2G42ZG] Front accumulater: Oil pressure drop….648
Failure code [2G43ZG] Rear accumulater: Pressure drop….648
Failure code [AA1ANX] Air cleaner: Clogging….649
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched…..651
Failure code [AB00MA] Alternator: Malfunction….653
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop….655
Failure code: [B@BCNS] Engine coolant overheat….655
Failure code: [B@CENS] Torque converter oil overheat….656
Failure code: [B@CKNS] Differential case: Overheat….657
Failure code: [B@HANS] Hydraulic oil: Overheating….659
Failure code [CA111] Engine controller internal error….661
Failure code [CA115] Engine Ne, Bkup speed sensor error….662
Failure code [CA122] Charge pressure sensor high error….663
Failure code [CA123] Charge pressure sensor low error….665
Failure code [CA131] Throttle sensor high error….667
Failure code [CA132] Throttle sensor low error….669
Failure code [CA144] Coolant sensor high error….671
Failure code [CA145] Coolant sensor low error….673
Failure code [CA153] Charge temperature sensor high error….675
Failure code [CA154] Charge temperature sensor low error….677
Failure code [CA155] Speed derating error by high charge temperature….679
Failure code [CA187] Sensor power supply 2 low error….681
Failure code [CA221] Atmospheric pressure sensor high error….683
Failure code [CA222] Atmospheric pressure sensor low error….685
Failure code [CA227] Sensor power supply 2 high error….687
Failure code [CA234] Engine overspeed….687
Failure code [CA238] Ne speed sensor power supply error….688
Failure code [CA271] IMV/IMA: Short circuit….689
Failure code [CA272] IMV/IMA open circuit….691
Failure code [CA322] Injector #1 (L#1) open/short….693
Failure code [CA323] Injector #5 (L#5) open/short….695
Failure code [CA324] Injector #3 (L#3) open/short….697
Failure code [CA325] Injector #6 (L#6) open/short….699
Failure code [CA331] Injector #2 (L#2) open/short….701
Failure code [CA332] Injector #4 (L#4) open/short….703
Failure code [CA342] Data compatibility error in engine controller….705
Failure code [CA351] Injector drive circuit error….706
Failure code [CA352] Sensor power supply 1 low error….707
Failure code [CA386] Sensor power supply 1 high error….708
Failure code [CA428] Water-in-fuel sensor high error….709
Failure code [CA429] Water-in-fuel sensor low error….711
Failure code [CA431] Idle validation switch error….713
Failure code [CA432] Idle validation action error….717
Failure code [CA435] Engine oil pressure switch error….720
Failure code [CA441] Power supply voltage low error….721
Failure code [CA442] Power supply voltage high error….723
Failure code [CA449] Common rail pressure high error 2….724
Failure code [CA451] Common rail pressure sensor high error….725
Failure code [CA452] Common rail pressure sensor low error….727
Failure code [CA488] Torque derating error by high charge temperature….729
Failure code [CA553] Common rail pressure high error 1….730
Failure code [CA559] Supply pump pressure low error 1….731
Failure code [CA689] Engine Ne speed sensor error….732
Failure code [CA731] Engine Bkup speed sensor phase error….734
Failure code [CA757] All continuous data lost error….735
Failure code [CA778] Engine Bkup speed sensor error….736
Failure code [CA1633] KOMNET (CAN communication) error….739
Failure code [CA2185] Throttle sensor power supply high error….741
Failure code [CA2186] Throttle sensor power supply low error….743
Failure code [CA2249] Supply pump pressure low error 2….745
Failure code [CA2311] Abnormality in IMV (IMA) solenoid….746
Failure code [CA2555] Intake heater relay open circuit….747
Failure code [CA2556] Intake heater relay short circuit….749
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness….751
Failure code [D160KB] Backup lamp relay: Ground fault….753
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault….755
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state….757
Failure code [DAFRKR] CAN communication failure (monitor panel)….759
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)….761
Failure code [DAQOKT] Transmission controller: Non-volatile memory error….763
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)….765
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement….767
Failure code [DAQRKR] Transmission controller CAN communication: Communication error….769
Failure code [DAQRMA] Transmission controller option setting: Malfunction….773
Failure code [DB2RKR] Engine controller CAN communication: Communication error….774
Failure code [DD1NLD] Fan reverse switch signal: Short circuit….781
Failure code [DD1PKB] RPM set switch power supply short circuit….783
Failure code [DD1QKB] RPM set mode switch short circuit….785
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error….787
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit….789
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit….789
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit….790
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit….790
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit….791
Failure code [DDTNKA] Fill switch for R clutch: Open circuit….792
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit….793
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input….794
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error….798
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range….801
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault….803
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range….805
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault….807
Failure code [DJF1KA] Fuel level sensor: Open circuit….809
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range….811
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range….813
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit….815
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match….816
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit….817
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match….818
Failure code [DLM3KA] Fan speed sensor: Open circuit….819
Failure code [DLM3LC] Fan speed sensor: Short circuit….820
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit….821
Failure code [DV00KB] Buzzer: Short circuit….823
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit….825
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit….827
Failure code [DW7BKA] Fan reverse solenoid: Open circuit….828
Failure code [DW7BKB] Fan reverse solenoid: Short circuit….829
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line….831
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit….833
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit….834
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line….835
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit….837
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit….838
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line….839
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit….841
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit….842
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line….843
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit….845
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit….847
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line….849
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit….851
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit….853
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line….855
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit….857
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit….859
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line….861
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit….863
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit….865
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line….867
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit….869
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit….870
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line….871
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit….873
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit….875
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line….877
Troubleshooting of electrical system (E-mode)….879
E-1 Engine does not start (starting motor does not turn)….879
E-2 Preheating does not work….885
E-3 When starting switch is turned to ON position, machine monitor displays nothing….890
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen….893
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine monitor does not display correct screen….893
E-6 Emergency stop monitor lights up while engine is running….894
E-7 Speedometer or engine tachometer does not indicate correctly….898
E-8 Engine coolant temperature gauge does not indicate correctly….899
E-9 Articulation angle indicator does not indicate correctly….901
E-10 Torque converter oil temperature gauge does not indicate correctly….903
E-11 Fuel level gauge does not indicate correctly….905
E-12 Character display does not display correctly….907
E-13 Centralized warning lamp does not light up or does not go off….909
E-14 Alarm buzzer does not sound or does not stop sounding….911
E-15 Machine monitor mode selector switch does not work….913
E-16 Transmission mode does not switch….917
E-17 Engine mode does not switch….919
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]….921
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]….925
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]….927
E-21 Horn does not sound or does not stop sounding….931
E-22 Backup alarm does not sound or does not stop sounding….933
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off….936
E-24 Working lamp does not light up or does not go off….943
E-25 Turn signal lamp and hazard lamp do not flash…..949
E-26 Stop lamp does not light up or does not go off….955
E-27 Backup lamp does not light up or does not go off….957
E-28 Windshield wiper does not operate….959
E-29 Window washer does not operate….967
E-30 KOMTRAX system does not operate correctly….971
Troubleshooting of hydraulic and mechanical system (H-mode)….975
How to read troubleshooting matrix….975
H-1 Engine speed lowers significantly or engine stalls…..981
H-2 Machine does not start….982
H-3Gear is not shifted…..983
H-4 Travel lacks speed or power…..984
H-5 Torque converter lockup does not work or is not released…..989
H-6 A large time lag results at start or in gear shift….990
H-7 Oil temperature of torque converter is high…..995
H-8 Differential lock-up function does not work or is not released….1000
H-9 Steering lacks speed or power…..1001
H-10 Steering wheel does not move….1002
H-11 Wheel brake does not work at all or sufficiently….1003
H-12 Wheel brake cannot be released or drags….1004
H-13 Parking brake does not work at all or insufficiently….1005
H-14 Parking brake (including emergency release system) cannot be released or drags…..1006
H-15 All work equipment operation lacks speed or power…..1007
H-16 Work equipment does not work at all….1008
H-17 Unusual noise comes out from around hydraulic pump….1009
H-18 Blade lift operation lacks speed or power….1010
H-19 Hydraulic drift of blade lift cylinders is large…..1011
H-20 Drawbar side shift operation lacks speed or power….1012
H-21 Blade side shift operation lacks speed or power….1013
H-22 Power tilt operation lacks speed or power….1014
H-23 Articulate operation lacks speed or power….1015
H-24 Leaning operation lacks speed or power….1016
H-25 Hydraulic drift of leaning cylinders (leaning) is large….1017
H-26 Blade does not rotate….1018
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)….1019
H-28 Blade accumulator function does not work or cannot be released(for machine with blade accumulator float specification)….1020
H-29 Blade float function does not work or cannot be released….1021
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)….1022
Troubleshooting of engine (S-mode)….1023
Method of using troubleshooting chart….1023
S-1 Startability is poor….1027
S-2 Engine does not start….1028
S-3 Engine does not pick up smoothly….1031
S-4 Engine stops during operation….1032
S-5 Engine runs rough or is unstable….1033
S-6 Engine lacks power….1034
S-7 Exhaust smoke is black (incomplete combustion)….1035
S-8 Oil consumption is excessive (or exhaust smoke is blue)….1036
S-9 Oil becomes contaminated early….1037
S-10 Fuel consumption is excessive….1038
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)….1039
S-12 Oil pressure drops….1040
S-13 Oil level rises (coolant or fuel in oil)….1041
S-14 Coolant temperature rises too high (overheating)….1042
S-15 Unusual noise is made….1043
S-16 Vibration is excessive….1044
50 Disassembly and assembly….1046
General information on disassembly and assembly….1049
How to read this manual….1049
Coating materials list….1051
Special tools list….1054
Sketches of special tools….1058
Engine and cooling system….1062
Removal and installation of fuel supply pump assembly….1062
Removal and installation of fuel injector assembly….1067
Removal and installation of cylinder head assembly….1077
Removal and installation of engine front oil seal….1095
Removal and installation of engine rear oil seal….1098
Removal and installation of cooling fan pump assembly….1102
Removal and installation of cooling fan and fan motor assembly….1104
Removal and installation of radiator assembly….1108
Removal and installation of aftercooler assembly….1112
Removal and installation of power train oil cooler assembly….1115
Removal and installation of fuel tank assembly….1118
Removal and installation of engine hood assembly….1122
Power train….1124
Removal and installation of engine and transmission/torque converter assembly….1124
Disassembly and assembly of engine and transmission/torque converter assembly….1132
Disassembly and assembly of torque converter assembly….1134
Disassembly and assembly of transmission assembly….1142
Removal and installation of tandem drive and final drive assembly….1180
Disassembly and assembly of tandem drive assembly….1184
Disassembly and assembly of final drive assembly….1189
Steering system….1208
Removal and installation of steering valve (orbit-roll) assembly….1208
Disassembly and assembly of steering valve (orbit-roll) assembly….1214
Brake system….1225
Disassembly and assembly of wheel brake assembly….1225
Undercarriage and frame….1230
Removal and installation of center hinge pin….1230
Hydraulic system….1243
Removal and installation of hydraulic tank, battery and frame assembly….1243
Removal and installation of hydraulic tank assembly….1250
Removal and installation of control valve assembly….1257
Disassembly and assembly of control valve assembly….1263
Disassembly and assembly of hydraulic cylinder assembly….1266
Work equipment….1271
Removal and installation of blade assembly….1271
Removal and installation of circle drawbar assembly….1273
Removal and installation of circle rotation gear assembly….1276
Disassembly and assembly of circle rotation gear assembly….1278
Removal and installation of ripper assembly….1283
Cab and its attachments….1286
Removal and installation of operator cab assembly….1286
Removal and installation of floor frame assembly….1298
Removal and installation of operator cab glass (adhered glass)….1302
Removal and installation of air conditioner unit assembly….1312
Electrical system….1318
Removal and installation of engine controller assembly….1318
Removal and installation of machine monitor assembly….1320
Removal and installation of transmission controller assembly….1322
Removal and installation of KOMTRAX terminal assembly….1324
60 Maintenance standard….1326
Engine and Cooling….1329
Engine mount and transmission mount….1329
Cooling system….1331
Cooling fan motor….1333
Power train system….1337
Transmission control….1337
Torque converter….1339
Transmission….1341
Main relief valve and torque converter relief valve….1349
Front axle….1351
Final drive (no differential specification)….1355
Final drive (differential/ differential lock specification)….1357
Differential lock solenoid valve….1359
Tandem drive….1361
Brake system….1363
Slack adjuster….1363
Wheel brake….1365
Parking brake….1367
Hydraulic system….1369
Power train pump….1369
Control valve….1371
Hydraulic cylinder….1379
Work equipment….1381
Circle and drawbar….1381
Blade….1383
Lifter….1385
Circle rotation gear….1387
80 Appendix….1390
Air conditioner….1392
Precautions for refrigerant….1392
Air Conditioner Components….1393
Structure and Function of Refrigeration System….1395
Overview of Refrigeration System….1396
Air Conditioner Unit….1397
Compressor….1400
Condenser….1401
Receiver drier….1402
Air conditioner control panel….1403
Procedure for check and troubleshooting….1405
Circuit diagram and layout of connector pins….1407
System diagram….1409
Detail of air conditioner unit….1411
Parts and connectors layout….1413
Testing air leakage (ducts)….1415
Check with self-diagnosis (control panel display)….1416
Testing temperature control….1417
Testing Fresh/Recirc air changeover….1418
Testing evaporator temperature sensor….1419
Testing relays….1420
Testing blower amp….1421
Troubleshooting Chart 1….1422
Troubleshooting Chart 2….1424
Information in troubleshooting table….1426
Troubleshooting for power supply system (Air conditioner does not operate)….1427
Troubleshooting of compressor and refrigerant system (Air is not cooled)….1429
Troubleshooting for blower motor system (Air does not come out or air flow is improper)….1433
Troubleshooting for temperature control….1435
Troubleshooting for FRESH/RECIRC air changeover….1437
Troubleshooting with gauge pressure….1439
Connection of service tool….1441
Precautions for disconnecting and connecting air conditioner piping….1443
Handling compressor oil….1445
90 Diagrams and drawings….1448
Hydraulic diagrams and drawings….1450
Symbols used in hydraulic circuit diagrams….1450
Hydraulic circuit diagram….1452
Power train hydraulic circuit diagram….1454
Differential hydraulic circuit diagram….1455
Electrical diagrams and drawings….1456
Symbols used in electric circuit diagrams….1456
Electrical circuit diagram….1460
Index….1470
TEN00368-01 – Motor Grader GD655-5 Operation & Maintenance Manual….1478
COVER….1478
FOREWORD….1479
BEFORE READING THIS MANUAL….1480
SAFETY INFORMATION….1481
INTENDED USE….1482
USE OF MACHINE….1482
DIRECTIONS OF MACHINE….1482
VISIBILITY FROM OPERATOR'S SEAT….1483
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1484
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1484
EPA REGULATIONS, ENGINE NUMBER PLATE….1484
SERVICE METER POSITION….1485
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1485
CONTENTS….1486
SAFETY….1489
SAFETY INFORMATION….1490
SAFETY LABELS….1493
POSITION FOR ATTACHING SAFETY LABELS….1494
SAFETY LABELS….1495
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1501
PRECAUTIONS BEFORE STARTING OPERATION….1501
PREPARATIONS FOR SAFE OPERATION….1501
FIRE PREVENTION….1503
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1504
DO NOT GET CAUGHT IN WORK EQUIPMENT….1506
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1506
UNAUTHORIZED MODIFICATION….1507
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1507
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1507
PRECAUTIONS FOR OPERATION….1508
PRECAUTIONS FOR JOBSITE….1508
STARTING ENGINE….1510
OPERATION….1513
TRANSPORTATION….1517
TOWING….1518
PRECAUTIONS FOR MAINTENANCE….1519
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1519
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1523
TIRES….1528
OPERATION….1531
GENERAL VIEW….1532
GENERAL VIEW OF MACHINE….1532
GENERAL VIEW OF CONTROLS AND GAUGES….1533
EXPLANATION OF COMPONENTS….1536
MONITOR PANEL….1536
OTHER FUNCTIONS OF MACHINE MONITOR….1556
SWITCHES….1564
CONTROL LEVERS, PEDALS….1581
DUST INDICATOR….1593
ARTICULATE LOCK PIN….1593
FUSE BOX….1594
SLOW BLOW FUSE….1595
ELECTRIC POWER TAKEOFF….1596
HANDLING BATTERY DISCONNECTOR SWITCH….1597
OPENING, CLOSING CAB DOORS….1598
BACKUP ALARM….1599
AM/FM RADIO….1600
AIR CONDITIONER….1606
OPERATION MANUAL STORAGE….1610
TOOL BOX….1610
GREASE PUMP HOLDER….1611
CUP HOLDER….1611
ASHTRAY….1611
FIRE EXTINGUISHER….1611
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1612
OPERATION….1613
CHECK BEFORE STARTING ENGINE….1613
STARTING ENGINE….1631
OPERATIONS, CHECKS AFTER STARTING ENGINE….1634
STOPPING ENGINE….1636
CHECK AFTER STOPPING ENGINE….1636
TRAVELING POSTURE FOR MACHINE….1637
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1638
TURNING MACHINE….1649
OPERATING WORK EQUIPMENT….1652
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1659
PRECAUTIONS WHEN OPERATION….1680
ADJUSTING WORK EQUIPMENT POSTURE….1685
PARKING MACHINE….1694
CHECKS AFTER COMPLETION OF OPERATION….1696
LOCKING….1697
HANDLING THE TIRES….1698
COMBINATION OF SNOW RADIAL TIRE AND CHAIN….1699
TRANSPORTATION….1700
STEPS FOR TRANSPORTATION….1700
LOADING, UNLOADING WORK….1700
PRECAUTIONS FOR LOADING….1701
LIFTING MACHINE….1702
COLD WEATHER OPERATION….1704
PRECAUTIONS FOR LOW TEMPERATURE….1704
CAUTIONS AFTER COMPLETION OF WORK….1705
AFTER COLD WEATHER….1705
LONG-TERM STORAGE….1706
BEFORE STORAGE….1706
DURING STORAGE….1706
AFTER STORAGE….1706
TROUBLESHOOTING….1707
AFTER RUNNING OUT OF FUEL….1707
WHEN LEANING PIPING IS DAMAGED….1707
TOWING THE MACHINE….1708
IF BATTERY IS DISCHARGED….1710
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE….1713
METHODS OF LOWERING WORK EQUIPMENTS AFTER THE ENGINE STOPS (RELEASE OF THE HYDRAULIC CIRCUIT PRESSURE FOR WORK EQUIPMENTS)….1714
OTHER TROUBLE….1716
MAINTENANCE….1725
GUIDES TO MAINTENANCE….1726
OUTLINES OF SERVICE….1728
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1728
RELATING TO ELECTRIC SYSTEM….1731
WEAR PARTS….1732
WEAR PARTS LIST….1732
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1734
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1735
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1736
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1737
TORQUE LIST….1737
PERIODIC REPLACEMENT OF CRITICAL PARTS….1738
CRITICAL PARTS….1738
MAINTENANCE SCHEDULE CHART….1739
MAINTENANCE SCHEDULE CHART….1739
SERVICE PROCEDURE….1741
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1741
WHEN REQUIRED….1742
CHECK BEFORE STARTING….1763
EVERY 50 HOURS SERVICE….1764
EVERY 250 HOURS SERVICE….1767
EVERY 500 HOURS SERVICE….1779
EVERY 1000 HOURS SERVICE….1785
EVERY 2000 HOURS SERVICE….1793
EVERY 4000 HOURS SERVICE….1799
EVERY 8000 HOURS SERVICE….1801
SPECIFICATIONS….1803
SPECIFICATIONS….1804
ATTACHMENTS, OPTIONS….1807
HANDLING BLADE ACCUMULATOR….1808
FEATURES OF BLADE ACCUMULATOR….1808
METHOD OF OPERATING BLADE ACCUMULATOR….1809
INDEX….1811
TEN00369-01 – Motor Grader GD675-5 Operation & Maintenance Manual….1815
COVER….1815
FOREWORD….1816
BEFORE READING THIS MANUAL….1817
SAFETY INFORMATION….1818
INTENDED USE….1819
USE OF MACHINE….1819
DIRECTIONS OF MACHINE….1819
VISIBILITY FROM OPERATOR'S SEAT….1820
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1821
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1821
EPA REGULATIONS, ENGINE NUMBER PLATE….1821
SERVICE METER POSITION….1822
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1822
CONTENTS….1823
SAFETY….1826
SAFETY INFORMATION….1827
SAFETY LABELS….1830
POSITION FOR ATTACHING SAFETY LABELS….1831
SAFETY LABELS….1832
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1838
PRECAUTIONS BEFORE STARTING OPERATION….1838
PREPARATIONS FOR SAFE OPERATION….1838
FIRE PREVENTION….1840
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1841
DO NOT GET CAUGHT IN WORK EQUIPMENT….1843
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1843
UNAUTHORIZED MODIFICATION….1844
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1844
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1844
PRECAUTIONS FOR OPERATION….1845
PRECAUTIONS FOR JOBSITE….1845
STARTING ENGINE….1847
OPERATION….1850
TRANSPORTATION….1854
TOWING….1855
PRECAUTIONS FOR MAINTENANCE….1856
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1856
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1860
TIRES….1865
OPERATION….1868
GENERAL VIEW….1869
GENERAL VIEW OF MACHINE….1869
GENERAL VIEW OF CONTROLS AND GAUGES….1870
EXPLANATION OF COMPONENTS….1873
MONITOR PANEL….1873
OTHER FUNCTIONS OF MACHINE MONITOR….1893
SWITCHES….1901
CONTROL LEVERS, PEDALS….1918
DUST INDICATOR….1930
ARTICULATE LOCK PIN….1930
FUSE BOX….1931
SLOW BLOW FUSE….1932
ELECTRIC POWER TAKEOFF….1933
HANDLING BATTERY DISCONNECTOR SWITCH….1934
OPENING, CLOSING CAB DOORS….1935
BACKUP ALARM….1936
AM/FM RADIO….1937
AIR CONDITIONER….1943
OPERATION MANUAL STORAGE….1947
TOOL BOX….1947
GREASE PUMP HOLDER….1948
CUP HOLDER….1948
ASHTRAY….1948
FIRE EXTINGUISHER….1948
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1949
OPERATION….1950
CHECK BEFORE STARTING ENGINE….1950
STARTING ENGINE….1968
OPERATIONS, CHECKS AFTER STARTING ENGINE….1971
STOPPING ENGINE….1973
CHECK AFTER STOPPING ENGINE….1973
TRAVELING POSTURE FOR MACHINE….1974
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1975
TURNING MACHINE….1986
OPERATING WORK EQUIPMENT….1989
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1996
PRECAUTIONS WHEN OPERATION….2017
ADJUSTING WORK EQUIPMENT POSTURE….2022
PARKING MACHINE….2031
CHECKS AFTER COMPLETION OF OPERATION….2033
LOCKING….2034
HANDLING THE TIRES….2035
COMBINATION OF SNOW RADIAL TIRE AND CHAIN….2036
TRANSPORTATION….2037
STEPS FOR TRANSPORTATION….2037
LOADING, UNLOADING WORK….2037
PRECAUTIONS FOR LOADING….2038
LIFTING MACHINE….2039
COLD WEATHER OPERATION….2041
PRECAUTIONS FOR LOW TEMPERATURE….2041
CAUTIONS AFTER COMPLETION OF WORK….2042
AFTER COLD WEATHER….2042
LONG-TERM STORAGE….2043
BEFORE STORAGE….2043
DURING STORAGE….2043
AFTER STORAGE….2043
TROUBLESHOOTING….2044
AFTER RUNNING OUT OF FUEL….2044
WHEN LEANING PIPING IS DAMAGED….2044
TOWING THE MACHINE….2045
IF BATTERY IS DISCHARGED….2047
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE….2050
METHODS OF LOWERING WORK EQUIPMENTS AFTER THE ENGINE STOPS (RELEASE OF THE HYDRAULIC CIRCUIT PRESSURE FOR WORK EQUIPMENTS)….2051
OTHER TROUBLE….2053
MAINTENANCE….2062
GUIDES TO MAINTENANCE….2063
OUTLINES OF SERVICE….2065
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2065
RELATING TO ELECTRIC SYSTEM….2068
WEAR PARTS….2069
WEAR PARTS LIST….2069
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….2071
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2072
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….2073
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2074
TORQUE LIST….2074
PERIODIC REPLACEMENT OF CRITICAL PARTS….2075
CRITICAL PARTS….2075
MAINTENANCE SCHEDULE CHART….2076
MAINTENANCE SCHEDULE CHART….2076
SERVICE PROCEDURE….2078
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….2078
WHEN REQUIRED….2079
CHECK BEFORE STARTING….2100
EVERY 50 HOURS SERVICE….2101
EVERY 250 HOURS SERVICE….2104
EVERY 500 HOURS SERVICE….2116
EVERY 1000 HOURS SERVICE….2122
EVERY 2000 HOURS SERVICE….2130
EVERY 4000 HOURS SERVICE….2136
EVERY 8000 HOURS SERVICE….2138
SPECIFICATIONS….2140
SPECIFICATIONS….2141
ATTACHMENTS, OPTIONS….2144
HANDLING BLADE ACCUMULATOR….2145
FEATURES OF BLADE ACCUMULATOR….2145
METHOD OF OPERATING BLADE ACCUMULATOR….2146
INDEX….2148
TEN00445-02 – Motor Grader GD555-5 Operation & Maintenance Manual….2152
COVER….2152
FOREWORD….2153
BEFORE READING THIS MANUAL….2154
SAFETY INFORMATION….2155
INTENDED USE….2156
USE OF MACHINE….2156
DIRECTIONS OF MACHINE….2156
VISIBILITY FROM OPERATOR'S SEAT….2157
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2158
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2158
EPA REGULATIONS, ENGINE NUMBER PLATE….2158
SERVICE METER POSITION….2159
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2159
CONTENTS….2160
SAFETY….2163
SAFETY INFORMATION….2164
SAFETY LABELS….2167
POSITION FOR ATTACHING SAFETY LABELS….2168
SAFETY LABELS….2169
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….2176
PRECAUTIONS BEFORE STARTING OPERATION….2176
PREPARATIONS FOR SAFE OPERATION….2176
FIRE PREVENTION….2178
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….2179
DO NOT GET CAUGHT IN WORK EQUIPMENT….2181
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….2181
UNAUTHORIZED MODIFICATION….2182
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….2182
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….2182
PRECAUTIONS FOR OPERATION….2183
PRECAUTIONS FOR JOBSITE….2183
STARTING ENGINE….2185
OPERATION….2188
TRANSPORTATION….2192
TOWING….2193
PRECAUTIONS FOR MAINTENANCE….2194
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….2194
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….2198
TIRES….2203
OPERATION….2205
GENERAL VIEW….2206
GENERAL VIEW OF MACHINE….2206
GENERAL VIEW OF CONTROLS AND GAUGES….2207
EXPLANATION OF COMPONENTS….2210
MONITOR PANEL….2210
OTHER FUNCTIONS OF MACHINE MONITOR….2230
SWITCHES….2238
CONTROL LEVERS, PEDALS….2255
ARTICULATE LOCK PIN….2267
FUSE BOX….2268
SLOW BLOW FUSE….2269
ELECTRIC POWER TAKEOFF….2270
HANDLING BATTERY DISCONNECT SWITCH….2271
OPENING, CLOSING CAB DOORS….2272
BACKUP ALARM….2273
AM/FM RADIO….2274
AIR CONDITIONER….2280
OPERATION MANUAL STORAGE….2284
TOOL BOX….2284
GREASE PUMP HOLDER….2285
CUP HOLDER….2285
ASHTRAY….2285
FIRE EXTINGUISHER….2285
HANDLING MACHINES EQUIPPED WITH KOMTRAX….2286
OPERATION….2287
CHECK BEFORE STARTING ENGINE….2287
STARTING ENGINE….2305
OPERATIONS, CHECKS AFTER STARTING ENGINE….2308
STOPPING ENGINE….2310
CHECK AFTER STOPPING ENGINE….2310
TRAVELING POSTURE FOR MACHINE….2311
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….2312
TURNING MACHINE….2323
OPERATING WORK EQUIPMENT….2326
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….2333
PRECAUTIONS WHEN OPERATION….2354
ADJUSTING WORK EQUIPMENT POSTURE….2359
PARKING MACHINE….2368
CHECKS AFTER COMPLETION OF OPERATION….2370
LOCKING….2371
HANDLING THE TIRES….2372
COMBINATION OF SNOW RADIAL TIRE AND CHAIN….2373
TRANSPORTATION….2374
STEPS FOR TRANSPORTATION….2374
PRECAUTIONS FOR LOADING….2375
LIFTING MACHINE….2376
COLD WEATHER OPERATION….2378
PRECAUTIONS FOR LOW TEMPERATURE….2378
CAUTIONS AFTER COMPLETION OF WORK….2379
AFTER COLD WEATHER….2379
LONG-TERM STORAGE….2380
BEFORE STORAGE….2380
DURING STORAGE….2380
AFTER STORAGE….2380
TROUBLESHOOTING….2381
AFTER RUNNING OUT OF FUEL….2381
WHEN LEANING PIPING IS DAMAGED….2381
TOWING THE MACHINE….2382
IF BATTERY IS DISCHARGED….2384
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE….2387
LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK EQUIPMENT OIL PRESSURE)….2388
OTHER TROUBLE….2390
MAINTENANCE….2399
GUIDES TO MAINTENANCE….2400
OUTLINES OF SERVICE….2402
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2402
RELATING TO ELECTRIC SYSTEM….2405
WEAR PARTS….2406
WEAR PARTS LIST….2406
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….2408
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2409
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….2410
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2411
TORQUE LIST….2411
PERIODIC REPLACEMENT OF CRITICAL PARTS….2412
CRITICAL PARTS….2413
MAINTENANCE SCHEDULE CHART….2414
MAINTENANCE SCHEDULE CHART….2414
SERVICE PROCEDURE….2416
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….2416
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)….2416
WHEN REQUIRED….2417
CHECK BEFORE STARTING….2439
EVERY 50 HOURS SERVICE….2440
EVERY 250 HOURS SERVICE….2443
EVERY 500 HOURS SERVICE….2455
EVERY 1000 HOURS SERVICE….2461
EVERY 2000 HOURS SERVICE….2469
EVERY 4000 HOURS SERVICE….2475
EVERY 8000 HOURS SERVICE….2477
SPECIFICATIONS….2479
SPECIFICATIONS….2480
ATTACHMENTS, OPTIONS….2483
HANDLING BLADE ACCUMULATOR….2484
FEATURES OF BLADE ACCUMULATOR….2484
METHOD OF OPERATING BLADE ACCUMULATOR….2485
MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….2486
PRECAUTION FOR THE MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….2486
INDEX….2489
TEN00446-02 – Motor Grader GD655-5 Operation & Maintenance Manual….2493
COVER….2493
FOREWORD….2494
BEFORE READING THIS MANUAL….2495
SAFETY INFORMATION….2496
INTENDED USE….2497
USE OF MACHINE….2497
DIRECTIONS OF MACHINE….2497
VISIBILITY FROM OPERATOR'S SEAT….2498
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2499
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2499
EPA REGULATIONS, ENGINE NUMBER PLATE….2499
SERVICE METER POSITION….2500
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2500
CONTENTS….2501
SAFETY….2504
SAFETY INFORMATION….2505
SAFETY LABELS….2508
POSITION FOR ATTACHING SAFETY LABELS….2509
SAFETY LABELS….2510
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….2517
PRECAUTIONS BEFORE STARTING OPERATION….2517
PREPARATIONS FOR SAFE OPERATION….2517
FIRE PREVENTION….2519
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….2520
DO NOT GET CAUGHT IN WORK EQUIPMENT….2522
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….2522
UNAUTHORIZED MODIFICATION….2523
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….2523
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….2523
PRECAUTIONS FOR OPERATION….2524
PRECAUTIONS FOR JOBSITE….2524
STARTING ENGINE….2526
OPERATION….2529
TRANSPORTATION….2533
TOWING….2534
PRECAUTIONS FOR MAINTENANCE….2535
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….2535
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….2539
TIRES….2544
OPERATION….2546
GENERAL VIEW….2547
GENERAL VIEW OF MACHINE….2547
GENERAL VIEW OF CONTROLS AND GAUGES….2548
EXPLANATION OF COMPONENTS….2551
MONITOR PANEL….2551
OTHER FUNCTIONS OF MACHINE MONITOR….2571
SWITCHES….2579
CONTROL LEVERS, PEDALS….2596
ARTICULATE LOCK PIN….2608
FUSE BOX….2609
SLOW BLOW FUSE….2610
ELECTRIC POWER TAKEOFF….2611
HANDLING BATTERY DISCONNECT SWITCH….2612
OPENING, CLOSING CAB DOORS….2613
BACKUP ALARM….2614
AM/FM RADIO….2615
AIR CONDITIONER….2621
OPERATION MANUAL STORAGE….2625
TOOL BOX….2625
GREASE PUMP HOLDER….2626
CUP HOLDER….2626
ASHTRAY….2626
FIRE EXTINGUISHER….2626
HANDLING MACHINES EQUIPPED WITH KOMTRAX….2627
OPERATION….2628
CHECK BEFORE STARTING ENGINE….2628
STARTING ENGINE….2646
OPERATIONS, CHECKS AFTER STARTING ENGINE….2649
STOPPING ENGINE….2651
CHECK AFTER STOPPING ENGINE….2651
TRAVELING POSTURE FOR MACHINE….2652
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….2653
TURNING MACHINE….2664
OPERATING WORK EQUIPMENT….2667
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….2674
PRECAUTIONS WHEN OPERATION….2695
ADJUSTING WORK EQUIPMENT POSTURE….2700
PARKING MACHINE….2709
CHECKS AFTER COMPLETION OF OPERATION….2711
LOCKING….2712
HANDLING THE TIRES….2713
COMBINATION OF SNOW RADIAL TIRE AND CHAIN….2714
TRANSPORTATION….2715
STEPS FOR TRANSPORTATION….2715
PRECAUTIONS FOR LOADING….2716
LIFTING MACHINE….2717
COLD WEATHER OPERATION….2719
PRECAUTIONS FOR LOW TEMPERATURE….2719
CAUTIONS AFTER COMPLETION OF WORK….2720
AFTER COLD WEATHER….2720
LONG-TERM STORAGE….2721
BEFORE STORAGE….2721
DURING STORAGE….2721
AFTER STORAGE….2721
TROUBLESHOOTING….2722
AFTER RUNNING OUT OF FUEL….2722
WHEN LEANING PIPING IS DAMAGED….2722
TOWING THE MACHINE….2723
IF BATTERY IS DISCHARGED….2725
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE….2728
LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK EQUIPMENT OIL PRESSURE)….2729
OTHER TROUBLE….2731
MAINTENANCE….2740
GUIDES TO MAINTENANCE….2741
OUTLINES OF SERVICE….2743
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2743
RELATING TO ELECTRIC SYSTEM….2746
WEAR PARTS….2747
WEAR PARTS LIST….2747
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….2749
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2750
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….2751
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….2752
TORQUE LIST….2752
PERIODIC REPLACEMENT OF CRITICAL PARTS….2753
CRITICAL PARTS….2754
MAINTENANCE SCHEDULE CHART….2755
MAINTENANCE SCHEDULE CHART….2755
SERVICE PROCEDURE….2757
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….2757
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)….2757
WHEN REQUIRED….2758
CHECK BEFORE STARTING….2780
EVERY 50 HOURS SERVICE….2781
EVERY 250 HOURS SERVICE….2784
EVERY 500 HOURS SERVICE….2796
EVERY 1000 HOURS SERVICE….2802
EVERY 2000 HOURS SERVICE….2810
EVERY 4000 HOURS SERVICE….2816
EVERY 8000 HOURS SERVICE….2818
SPECIFICATIONS….2820
SPECIFICATIONS….2821
ATTACHMENTS, OPTIONS….2824
HANDLING BLADE ACCUMULATOR….2825
FEATURES OF BLADE ACCUMULATOR….2825
METHOD OF OPERATING BLADE ACCUMULATOR….2826
MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….2827
PRECAUTION FOR THE MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….2827
INDEX….2830
TEN00447-02 – Motor Grader GD675-5 Operation & Maintenance Manual….2834
COVER….2834
FOREWORD….2835
BEFORE READING THIS MANUAL….2836
SAFETY INFORMATION….2837
INTENDED USE….2838
USE OF MACHINE….2838
DIRECTIONS OF MACHINE….2838
VISIBILITY FROM OPERATOR'S SEAT….2839
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2840
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2840
EPA REGULATIONS, ENGINE NUMBER PLATE….2840
SERVICE METER POSITION….2841
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….2841
CONTENTS….2842
SAFETY….2845
SAFETY INFORMATION….2846
SAFETY LABELS….2849
POSITION FOR ATTACHING SAFETY LABELS….2850
SAFETY LABELS….2851
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….2858
PRECAUTIONS BEFORE STARTING OPERATION….2858
PREPARATIONS FOR SAFE OPERATION….2858
FIRE PREVENTION….2860
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….2861
DO NOT GET CAUGHT IN WORK EQUIPMENT….2863
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….2863
UNAUTHORIZED MODIFICATION….2864
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….2864
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….2864
PRECAUTIONS FOR OPERATION….2865
PRECAUTIONS FOR JOBSITE….2865
STARTING ENGINE….2867
OPERATION….2870
TRANSPORTATION….2874
TOWING….2875
PRECAUTIONS FOR MAINTENANCE….2876
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….2876
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….2880
TIRES….2885
OPERATION….2887
GENERAL VIEW….2888
GENERAL VIEW OF MACHINE….2888
GENERAL VIEW OF CONTROLS AND GAUGES….2889
EXPLANATION OF COMPONENTS….2892
MONITOR PANEL….2892
OTHER FUNCTIONS OF MACHINE MONITOR….2912
SWITCHES….2920
CONTROL LEVERS, PEDALS….2937
ARTICULATE LOCK PIN….2949
FUSE BOX….2950
SLOW BLOW FUSE….2951
ELECTRIC POWER TAKEOFF….2952
HANDLING BATTERY DISCONNECT SWITCH….2953
OPENING, CLOSING CAB DOORS….2954
BACKUP ALARM….2955
AM/FM RADIO….2956
AIR CONDITIONER….2962
OPERATION MANUAL STORAGE….2966
TOOL BOX….2966
GREASE PUMP HOLDER….2967
CUP HOLDER….2967
ASHTRAY….2967
FIRE EXTINGUISHER….2967
HANDLING MACHINES EQUIPPED WITH KOMTRAX….2968
OPERATION….2969
CHECK BEFORE STARTING ENGINE….2969
STARTING ENGINE….2987
OPERATIONS, CHECKS AFTER STARTING ENGINE….2990
STOPPING ENGINE….2992
CHECK AFTER STOPPING ENGINE….2992
TRAVELING POSTURE FOR MACHINE….2993
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….2994
TURNING MACHINE….3005
OPERATING WORK EQUIPMENT….3008
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….3015
PRECAUTIONS WHEN OPERATION….3036
ADJUSTING WORK EQUIPMENT POSTURE….3041
PARKING MACHINE….3050
CHECKS AFTER COMPLETION OF OPERATION….3052
LOCKING….3053
HANDLING THE TIRES….3054
COMBINATION OF SNOW RADIAL TIRE AND CHAIN….3055
TRANSPORTATION….3056
STEPS FOR TRANSPORTATION….3056
PRECAUTIONS FOR LOADING….3057
LIFTING MACHINE….3058
COLD WEATHER OPERATION….3060
PRECAUTIONS FOR LOW TEMPERATURE….3060
CAUTIONS AFTER COMPLETION OF WORK….3061
AFTER COLD WEATHER….3061
LONG-TERM STORAGE….3062
BEFORE STORAGE….3062
DURING STORAGE….3062
AFTER STORAGE….3062
TROUBLESHOOTING….3063
AFTER RUNNING OUT OF FUEL….3063
WHEN LEANING PIPING IS DAMAGED….3063
TOWING THE MACHINE….3064
IF BATTERY IS DISCHARGED….3066
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE….3069
LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK EQUIPMENT OIL PRESSURE)….3070
OTHER TROUBLE….3072
MAINTENANCE….3081
GUIDES TO MAINTENANCE….3082
OUTLINES OF SERVICE….3084
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3084
RELATING TO ELECTRIC SYSTEM….3087
WEAR PARTS….3088
WEAR PARTS LIST….3088
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….3090
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3091
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….3092
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….3093
TORQUE LIST….3093
PERIODIC REPLACEMENT OF CRITICAL PARTS….3094
CRITICAL PARTS….3095
MAINTENANCE SCHEDULE CHART….3096
MAINTENANCE SCHEDULE CHART….3096
SERVICE PROCEDURE….3098
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….3098
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS)….3098
WHEN REQUIRED….3099
CHECK BEFORE STARTING….3121
EVERY 50 HOURS SERVICE….3122
EVERY 250 HOURS SERVICE….3125
EVERY 500 HOURS SERVICE….3137
EVERY 1000 HOURS SERVICE….3143
EVERY 2000 HOURS SERVICE….3151
EVERY 4000 HOURS SERVICE….3157
EVERY 8000 HOURS SERVICE….3159
SPECIFICATIONS….3161
SPECIFICATIONS….3162
ATTACHMENTS, OPTIONS….3165
HANDLING BLADE ACCUMULATOR….3166
FEATURES OF BLADE ACCUMULATOR….3166
METHOD OF OPERATING BLADE ACCUMULATOR….3167
MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….3168
PRECAUTION FOR THE MACHINE EQUIPPED WITH ‘INTELLIGENT MACHINE CONTROL’ DEVICE….3168
INDEX….3171
Komatsu Motor Grader GD555, GD655, GD675 Repair Service Manuals