Complete service repair manual with Electrical Wiring Diagrams for Komatsu Motor Graders GD655-3E0, GD675-3E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Motor Graders GD655-3E0, GD675-3E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN01775-05 – Motor Grader GD655-3E0, GD675-3E0 Shop Manual.pdf
TEN00149-05 – Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00150-05 – Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf
TEN00448-00 – Motor Grader GD655-3E0 Operation & Maintenance Manual.pdf
TEN00449-01 – Motor Grader GD675-3E0 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,261 pages
File Format: PDF
Language: English
SEN01775-05 – Motor Grader GD655-3E0, GD675-3E0 Shop Manual….2
COVER….2
00 Index and foreword….0
Index….3
Composition of shop manual….4
Table of contents….6
Foreword and general information….17
Safety notice….18
How to read the shop manual….23
Explanation of terms for maintenance standard….25
Handling electric equipment and hydraulic component….27
How to read electric wire code….39
Precautions when carrying out operation….42
Method of disassembling and connecting push-pull type coupler….45
Standard tightening torque table….48
Conversion table….52
01 Specification….0
Specification and technical data….58
Specification and technical data….59
General assembly drawing….59
Specifications….60
Weight table….68
Fuel, coolant, and lubricant selection….69
10 Structure, function and maintenance standard….0
Engine and cooling system….72
Engine and cooling system….73
Cooling line….73
Fan drive….74
Power train….76
Power train….77
Power train diagram….77
Transmission hydraulic piping….78
Transmission control….79
Torque converter….80
Torque converter control valve….85
Transmission….86
Transmission control valve….106
ECMV….108
Main relief valve and torque converter relief valve….114
Final drive….116
Steering system….123
Steering system….124
Steering hydraulic piping drawing….124
Steering valve (Q/Amp manual Orbit-roll type)….125
Priority valve….132
Accumulator pressure governor valve….140
Front axle….142
Brake system….147
Brake system….148
Blake hydraulic piping….148
Brake valve….150
Wheel brake….154
Slack adjuster….155
Accumulator….157
Parking brake….158
Parking brake and bank control valve….159
Undercarriage and frame….161
Undercarriage and frame….162
Tandem drive….162
Main frame….165
Hydraulic system….167
Hydraulic system….168
Work equipment hydraulic piping drawing….168
Hydraulic pump….175
Main control valve….196
CLSS….205
Work equipment….218
Work equipment….220
Work equipment control….220
Hydraulic system….222
Hydraulic tank….225
Swivel joint….226
Pilot check valve….227
Blade accumulator, float valve….231
Blade float device….234
Circle rotation motor….236
Hydraulic cylinder….238
Circle, drawbar….240
Blade….242
Circle rotation gear….244
Scarifier….247
Ripper….249
Cab and its attachments….251
Cab and its attachments….252
Air conditioner (If equipped)….252
Electrical system….255
Electrical system….256
Engine starting circuit….256
Engine stop circuit….258
Preheat circuit….259
Automatic shift control system….260
Transmission controller….261
Monitor….267
Sensors….270
Communication controller….276
KOMTRAX terminal system (if equipped)….277
20 Standard value table….0
Standard service value table….280
Standard service value table….281
Standard value table for engine….281
Standard value table for chassis….282
30 Testing and adjusting….0
Testing and adjusting, Part 1….289
Testing and adjusting, Part 1….291
Tools for testing, adjusting and troubleshooting….291
Measuring exhaust color….294
Measuring exhaust temperature….295
Measuring intake air pressure (boost pressure)….297
Measuring blowby pressure….299
Measuring engine oil pressure….300
Measuring engine speed….301
Testing fan belt tension….301
Testing air conditioner compressor belt tension….302
Measuring torque converter stall speed….303
Checking clutch oil pressure….304
Checking torque converter oil pressure….305
Adjusting speed sensor….306
Flushing torque converter and transmission circuit….308
Testing brake disc….309
Testing and adjusting parking brake….310
Method for emergency release of parking brake….312
Testing and adjusting parking brake pad clearance….313
Testing accumulator charge pressure….314
Testing and adjusting work equipment oil pressure….315
Testing and adjusting LS differential pressure….316
Adjusting PC valve….318
Bleeding air from hydraulic circuit….319
Measuring internal cylinder leakage….320
Testing and adjusting differential lock oil pressure [Differential lock specification]….322
Measuring steering and brake oil pressure….324
Bleeding air from brake piping….325
Charging nitrogen gas for brake, work equipment accumulator….326
Testing and adjusting circle guide clearance….328
Testing and adjusting slip clutch type rotary device….330
Memorizing idle and full position procedure….332
Initial learning method for transmission controller….333
Inspection procedure of diode….335
Testing and adjusting, Part 2….337
Testing and adjusting, Part 2….338
Special functions of machine monitor (EMMS)….338
Self-diagnosis display of gear shift lever….363
Handling of high-voltage circuit of engine controller….364
Preparatory work for troubleshooting for electrical equipment system….365
Moving machine when transmission valve fails….366
Adjusting cab stopper bolt….368
How to start operation of KOMTRAX terminal….370
Lamp display of KOMTRAX terminal….373
Pm-clinic….376
40 Troubleshooting….0
Failure code table and fuse locations….384
Failure code table and fuse locations….385
Failure code table….385
Fuse locations….389
General information on troubleshooting….394
General information on troubleshooting….395
Points to remember when troubleshooting….395
Sequence of events in troubleshooting….396
Testing before troubleshooting….397
Classification and procedures of troubleshooting….398
Connection table for connector pin numbers….399
T- branch box and T- branch adapter table….435
Troubleshooting by failure code, Part 1….440
Troubleshooting by failure code, Part 1….442
Failure code [(DF1000)] Neutral safety….442
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front)….443
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear)….444
Failure code [AB00L6] Signal of alternator disagrees with operating state of engine….445
Failure code [AB00MA] Malfunction of alternator….447
Failure code [B@BAZG] Engine oil pressure too low….449
Failure code [B@BCNS] Engine overheat….450
Failure code [B@CENS] Torque converter oil temperature too high….451
Failure code [B@CKNS] Differential oil overheat….452
Failure code [CA111] Abnormality in controller….453
Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors….454
Failure code [CA122] Charge pressure sensor too high….455
Failure code [CA123] Charge pressure sensor too low….457
Failure code [CA131] Throttle sensor too high….459
Failure code [CA132] Throttle sensor too low….461
Failure code [CA144] Coolant temperature sensor too high….463
Failure code [CA145] Coolant temperature sensor too low….465
Failure code [CA153] Charge temperature sensor too high….467
Failure code [CA154] Charge temperature sensor too low….469
Failure code [CA155] Charge temperature too high and engine speed derated….471
Failure code [CA187] Sensor power source 2 too low….472
Failure code [CA221] Atmospheric pressure sensor too high….474
Failure code [CA222] Atmospheric pressure sensor too low….476
Failure code [CA227] Sensor power source 2 too high….478
Failure code [CA234] Engine over speed….480
Failure code [CA238] Abnormal power source for Ne speed sensor….481
Failure code [CA271] Short circuit in fuel pump actuator….482
Failure code [CA272] Disconnection in fuel pump actuator….484
Failure code [CA281] Abnormal supply pump pressure balance….486
Failure code [CA322] Disconnection or short circuit in injector No.1….487
Failure code [CA323] Disconnection or short circuit in injector No.5….489
Failure code [CA324] Disconnection or short circuit in injector No.3….491
Failure code [CA325] Disconnection or short circuit in injector No.6….493
Failure code [CA331] Disconnection or short circuit in injector No.2….495
Failure code [CA332] Disconnection or short circuit in injector No.4….497
Troubleshooting by failure code, Part 2….500
Troubleshooting by failure code, Part 2….502
Failure code [CA342] Abnormality in engine controller data consistency….502
Failure code [CA351] Abnormality in injector drive circuit….503
Failure code [CA352] Sensor power source 1 too low….505
Failure code [CA386] Sensor power source 1 too high….507
Failure code [CA428] Water detection sensor too high….509
Failure code [CA429] Water detection sensor too low….511
Failure code [CA435] Abnormality in engine oil pressure switch….513
Failure code [CA441] Power supply voltage too low….515
Failure code [CA442] Power supply voltage too high….517
Failure code [CA449] Common rail pressure too high (2)….519
Failure code [CA451] Common rail pressure sensor too high….523
Failure code [CA452] Common rail pressure sensor too low….525
Failure code [CA488] Charge temperature too high and torque derated….527
Failure code [CA553] Common rail pressure too high (1)….528
Failure code [CA559] Supply pump no pressure (1)….529
Failure code [CA689] Abnormality in engine Ne speed sensor….531
Failure code [CA731] Abnormality in engine Bkup speed sensor phase1….533
Failure code [CA757] Loss of all engine controller data….535
Failure code [CA778] Abnormality in engine Bkup speed sensor….537
Failure code [CA1633] Abnormality in KOMNET….539
Failure code [CA2185] Accelerator pedal sensor power source too high….541
Failure code [CA2186] Accelerator pedal sensor power source too low….543
Failure code [CA2249] Supply pump no pressure (2)….545
Failure code [CA2265] Disconnection in electric lift pump….547
Failure code [CA2266] Short circuit in electric lift pump….549
Failure code [CA2311] Abnormal resistance in IMV solenoid….551
Failure code [CA2555] Disconnection in air intake heater relay….553
Failure code [CA2556] Short circuit in air intake heater relay….555
Troubleshooting by failure code, Part 3….558
Troubleshooting by failure code, Part 3….561
Failure code [D19CKZ] Disconnection or short circuit in differential control relay….561
Failure code [D19KKZ] Differential lock-up relay : Disconnection….563
Failure code [DAQ0KK] Power source voltage of transmission controller too low….567
Failure code [DAQSKR] Communication controller cannot recognize S-NET….568
Failure code [DB2RKR] Communication lost engine controller….569
Failure code [DBF0KK] Power source voltage of communication controller too low….571
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low….573
Failure code [DBFRKR] Communication lost communication controller….575
Failure code [DD1PKB] Power supply line short in RPM set switch….577
Failure code [DD1QKB] Short circuit in RPM set mode switch….579
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch….581
Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch)….582
Failure code [DDTHKA] Disconnection in FH clutch fill switch….583
Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch)….584
Failure code [DDTJKA] Disconnection in FL clutch fill switch….585
Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch)….586
Failure code [DDTKKA] Disconnection in 1st clutch fill switch….587
Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)….589
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch….591
Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch)….593
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch….595
Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch)….597
Failure code [DDTNKA] Disconnection in R clutch fill switch….599
Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch)….600
Failure code [DDTPKA] Disconnection in 4th clutch fill switch….601
Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch)….603
Failure code [DF10KA] Disconnection in transmission shift lever switch….605
Failure code [DF10KB] Short circuit in transmission shift lever switch….609
Failure code [DGF1KX] Transmission oil temperature out of range….613
Failure code [DGT1KX] Torque converter oil temperature out of range….615
Failure code [DJF1KA] Disconnection in fuel level sensor….617
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range….619
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range….621
Failure code [DKD0KA] Disconnection in articulate sensor….623
Failure code [DLE2KA] Disconnection in engine speed sensor….625
Failure code [DLF1KA] Disconnection in transmission input speed sensor….626
Failure code [DLT3KA] Disconnection in transmission output speed sensor….627
Failure code [DV00KB] Short circuit in caution buzzer….628
Failure code [DW4BKA] Disconnection in parking brake relay….629
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid….631
Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid….632
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid….633
Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid….635
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid….637
Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid….639
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid….641
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid….642
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid….643
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid….644
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid….645
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid….646
Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid….647
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid….649
Troubleshooting of electrical system (E-mode)….652
Troubleshooting of electrical system (E-mode)….654
Contents of troubleshooting table….654
E-1 Engine does not start at all or does not start easily….655
E-2 Transmission mode does not change….662
E-3 Differential lock function does not work or is not reset [Differential lock specification]….664
E-4 Wheel brake does not work normally….667
E-5 Parking brake does not work or is not reset….669
E-6 Lift arm lock pin is not locked or reset [Lift arm specification]….671
E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification]….674
E-8 Blade float function does not work or is not reset [Blade accumulator and float specification]….677
E-9 When starting switch is turned ON, machine monitor does not operate normally….684
E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display….686
E-11 When starting switch is turned ON, caution item lights up….687
E-12 While engine is running, emergency stop item lights up….688
E-13 Indication of speedometer and engine tachometer is abnormal….697
E-14 Indication of engine coolant temperature gauge is abnormal….698
E-15 Indication of articulate gauge is abnormal….700
E-16 Indication of torque converter oil temperature gauge is abnormal….701
E-17 Indication of fuel level gauge is abnormal….702
E-18 Display of character display is abnormal….704
E-19 Centralized warning lamp does not light up or go off….705
E-20 Alarm buzzer does not sound or stop….706
E-21 Machine monitor mode selector switch does not function….708
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off….711
E-23 Working lamp does not light up or go off….716
E-24 Turn signal lamp and hazard lamp do not blink or go off….720
E-25 Brake lamp does not light up or go off….725
E-26 Backup lamp does not light up or go off….727
E-27 Backup buzzer does not sound or stop….728
E-28 Air conditioner does not work or stop….729
E-29 KOMTRAX system does not operate normally….732
Troubleshooting of hydraulic and mechanical system (H-mode)….735
Troubleshooting of hydraulic and mechanical system (H-mode)….737
Contents of troubleshooting table….737
H-1 Excessive drop in engine speed, or engine stalls….738
H-2 Machine does not move in either forward or reverse direction….739
H-3 Transmission does not shift up or shift down….740
H-4 Machine is slow or lacks power when traveling….741
H-5 Torque converter lockup function cannot be actuated or canceled….743
H-6 Excessive time lag when starting or shifting gear….744
H-7 Torque converter oil temperature is high….745
H-8 Differential lock function is not operated or reset [Differential lock specification]….747
H-9 Machine is slow or lacks power when steering….748
H-10 Wheel brake does not work normally….749
H-11 Parking brake is not applied or released….750
H-12 All work equipment is slow or lacks power….751
H-13 No work equipment moves….752
H-14 Abnormal noise generated around pump….753
H-15 Blade is slow or lacks power in lifting….754
H-16 Excessive blade drift….755
H-17 Drawbar side shift operation is slow or lacks power….756
H-18 Blade side shift operation is slow or lacks power….757
H-19 Power tilt operation is slow or lacks power….758
H-20 Articulate operation is slow or lacks power….759
H-21 Leaning operation is slow or lacks power….760
H-22 Excessive drift of leaning….761
H-23 Blade does not rotate….762
H-24 Lift arm lock pin is not locked or reset [Lift arm specification]….763
H-25 Blade accumulator function is not operated or reset [Blade accumulator and float specification]….764
H-26 Blade float function is not operated or reset [Blade accumulator and float specification]….765
Troubleshooting of engine (S-mode)….767
Troubleshooting of engine (S-mode)….769
Method of using troubleshooting charts….769
S-1 Starting performance is poor….772
S-2 Engine does not start….773
S-3 Engine does not pick up smoothly….776
S-4 Engine stops during operations….777
S-5 Engine does not rotate smoothly….778
S-6 Engine lacks output (or lacks power)….779
S-7 Exhaust smoke is black (incomplete combustion)….780
S-8 Oil consumption is excessive (or exhaust smoke is blue)….781
S-9 Oil becomes contaminated quickly….782
S-10 Fuel consumption is excessive….783
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)….784
S-12 Oil pressure drops….785
S-13 Oil level rises (water, fuel in oil)….786
S-14 Coolant temperature becomes too high (overheating)….787
S-15 Abnormal noise is made….788
S-16 Vibration is excessive….789
50 Disassembly and assembly….0
General information on disassembly and assembly….791
How to read this manual….792
How to read this manual….792
Coating materials list….794
Special tool list….797
Sketches of special tools….802
Engine and cooling system….809
Engine and cooling system….810
Removal and installation of fuel supply pump assembly….810
Removal and installation of fuel injector assembly….813
Removal and installation of cylinder head assembly….818
Removal and installation of engine front seal….831
Removal and installation of engine rear seal….835
Removal and installation of engine assembly….841
Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly….845
Removal and installation of air conditioner condenser….849
Removal and installation of oil cooler assembly….852
Removal and installation of aftercooler assembly….854
Removal and installation of radiator assembly….857
Removal and installation of engine hood….860
Power train, Part 1….865
Power train, Part 1….866
Removal and installation of engine and transmission assembly….866
Removal and installation of transmission assembly….872
Disassembly and assembly of torque converter assembly….878
Disassembly and assembly of transmission assembly….885
Power train, Part 2….923
Power train, Part 2….924
Removal and installation of final drive assembly….924
Disassembly and assembly of final drive assembly….929
Disassembly and assembly of final brake case assembly….934
Disassembly and assembly of side case assembly (For standard final drive)….938
Disassembly and assembly of bevel gear assembly….941
Disassembly and assembly of bevel gear shaft….945
Disassembly and assembly of bevel pinion assembly….947
Steering system….950
Steering system….951
Removal and installation of steering valve (Orbit-roll)….951
Disassembly and assembly of steering valve….952
Hydraulic system….963
Hydraulic system….964
Disassembly and assembly of work equipment control valve assembly….964
Disassembly and assembly of hydraulic cylinder assembly….967
Work equipment….972
Work equipment….973
Removal and installation of blade assembly….973
Removal and installation of circle drawbar assembly….974
Removal and installation of blade circle gear assembly….976
Removal and installation of blade circle rotation gear assembly (with shear pin)….978
Disassembly and assembly of blade circle rotation gear assembly (with shear pin)….980
Disassembly and assembly of circle rotation gear assembly (with slip clutch)….984
Cab and its attachments….990
Cab and its attachments….991
Removal and installation of operator's cab assembly….991
Removal and installation of floor frame assembly….993
Disassembly and assembly of operator’s seat assembly….996
Removal and installation of operator's cab glass (stuck glass)….1005
Removal and installation of air conditioner unit assembly….1011
Electrical system….1014
Electrical system….1015
Removal and installation of machine monitor assembly….1015
Removal and installation of engine controller assembly….1016
Removal and installation of transmission controller assembly….1017
Removal and installation of KOMTRAX controller assembly….1018
Removal and installation of COMMUNICATION controller assembly….1019
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….1021
Hydraulic diagrams and drawings….1022
Power train hydraulic circuit diagram….1022
Brake hydraulic circuit….1024
Hydraulic circuit diagram (1/2)….1025
Hydraulic circuit diagram (2/2)….1026
Electrical diagrams and drawings….1028
Electrical diagrams and drawings….1029
Electrical circuit diagram (1/6)….1029
Electrical circuit diagram (2/6)….1030
Electrical circuit diagram (3/6)….1031
Electrical circuit diagram (4/6)….1032
Electrical circuit diagram (5/6)….1033
Electrical circuit diagram (6/6)….1034
Connector arrangement diagram….1035
TEN00149-05 – Motor Grader GD655-3E0 Operation & Maintenance Manual….1037
COVER….1037
FOREWORD….1038
BEFORE READING THIS MANUAL….1039
SAFETY INFORMATION….1040
INTENDED USE….1041
USE OF MACHINE….1041
DIRECTIONS OF MACHINE….1041
VISIBILITY FROM OPERATOR'S SEAT….1042
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1043
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1043
EPA REGULATIONS, ENGINE NUMBER PLATE….1043
SERVICE METER POSITION….1044
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1044
CONTENTS….1045
SAFETY….1048
SAFETY INFORMATION….1049
SAFETY LABELS….1052
POSITION FOR ATTACHING SAFETY LABELS….1053
SAFETY LABELS….1054
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1059
PRECAUTIONS BEFORE STARTING OPERATION….1059
PREPARATIONS FOR SAFE OPERATION….1059
FIRE PREVENTION….1061
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1062
DO NOT GET CAUGHT IN WORK EQUIPMENT….1064
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1064
UNAUTHORIZED MODIFICATION….1065
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1065
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1065
PRECAUTIONS FOR OPERATION….1066
PRECAUTIONS FOR JOBSITE….1066
STARTING ENGINE….1068
OPERATION….1071
TRANSPORTATION….1075
TOWING….1076
PRECAUTIONS FOR MAINTENANCE….1077
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1077
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1082
TIRES….1087
OPERATION….1090
GENERAL VIEW….1091
GENERAL VIEW OF MACHINE….1091
GENERAL VIEW OF CONTROLS AND GAUGES….1092
EXPLANATION OF COMPONENTS….1095
MONITOR PANEL….1095
OTHER FUNCTIONS OF MACHINE MONITOR….1113
SWITCHES….1118
CONTROL LEVERS, PEDALS….1132
DUST INDICATOR….1142
ARTICULATE LOCK PIN….1142
FUSE BOX….1143
SLOW BLOW FUSE….1144
CIRCUIT BREAKER….1144
HANDLING BATTERY DISCONNECTOR SWITCH….1145
OPERATION….1146
CHECK BEFORE STARTING ENGINE….1146
STARTING ENGINE….1160
OPERATIONS, CHECKS AFTER STARTING ENGINE….1163
STOPPING ENGINE….1164
CHECK AFTER STOPPING ENGINE….1164
TRAVELING POSTURE FOR MACHINE….1165
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1166
TURNING MACHINE….1175
OPERATING WORK EQUIPMENT….1178
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1184
PRECAUTIONS WHEN OPERATION….1205
ADJUSTING WORK EQUIPMENT POSTURE….1209
PARKING MACHINE….1218
CHECKS AFTER COMPLETION OF OPERATION….1220
LOCKING….1221
HANDLING THE TIRES….1221
TRANSPORTATION….1222
STEPS FOR TRANSPORTATION….1222
LOADING, UNLOADING WORK….1222
PRECAUTIONS FOR LOADING….1223
COLD WEATHER OPERATION….1224
PRECAUTIONS FOR LOW TEMPERATURE….1224
CAUTIONS AFTER COMPLETION OF WORK….1225
AFTER COLD WEATHER….1225
LONG-TERM STORAGE….1226
BEFORE STORAGE….1226
DURING STORAGE….1226
AFTER STORAGE….1226
TROUBLESHOOTING….1227
AFTER RUNNING OUT OF FUEL….1227
WHEN LEANING PIPING IS DAMAGED….1228
TOWING THE MACHINE….1229
IF BATTERY IS DISCHARGED….1231
OTHER TROUBLE….1235
MAINTENANCE….1242
GUIDES TO MAINTENANCE….1243
OUTLINES OF SERVICE….1245
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1245
RELATING TO ELECTRIC SYSTEM….1249
WEAR PARTS….1250
WEAR PARTS LIST….1250
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1251
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1252
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1253
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1254
TORQUE LIST….1254
PERIODIC REPLACEMENT OF CRITICAL PARTS….1255
CRITICAL PARTS….1255
MAINTENANCE SCHEDULE CHART….1256
MAINTENANCE SCHEDULE CHART….1256
SERVICE PROCEDURE….1258
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1258
WHEN REQUIRED….1259
CHECK BEFORE STARTING….1274
EVERY 50 HOURS SERVICE….1275
EVERY 250 HOURS SERVICE….1276
EVERY 500 HOURS SERVICE….1290
EVERY 1000 HOURS SERVICE….1298
EVERY 2000 HOURS SERVICE….1307
EVERY 4000 HOURS SERVICE….1312
EVERY 8000 HOURS SERVICE….1314
SPECIFICATIONS….1316
SPECIFICATIONS….1317
ATTACHMENTS, OPTIONS….1320
HANDLING BLADE ACCUMULATOR….1321
FEATURES OF BLADE ACCUMULATOR….1321
METHOD OF OPERATING BLADE ACCUMULATOR….1322
AM/FM RADIO-CASSETTE STEREO….1323
EXPLANATION OF COMPONENTS….1323
METHOD OF OPERATION….1328
PRECAUTIONS WHEN USING….1331
AIR CONDITIONER….1332
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1332
METHOD OF OPERATION….1335
PRECAUTIONS WHEN USING….1336
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1336
HANDLING AIR-SUSPENSION SEAT….1337
ADJUST OPERATOR'S SEAT….1337
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1339
BASIC PRECAUTIONS….1339
INDEX….1340
TEN00150-05 – Motor Grader GD675-3E0 Operation & Maintenance Manual….1344
COVER….1344
FOREWORD….1345
BEFORE READING THIS MANUAL….1346
SAFETY INFORMATION….1347
INTENDED USE….1348
USE OF MACHINE….1348
DIRECTIONS OF MACHINE….1348
VISIBILITY FROM OPERATOR'S SEAT….1349
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1350
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1350
EPA REGULATIONS, ENGINE NUMBER PLATE….1350
SERVICE METER POSITION….1351
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1351
CONTENTS….1352
SAFETY….1355
SAFETY INFORMATION….1356
SAFETY LABELS….1359
POSITION FOR ATTACHING SAFETY LABELS….1360
SAFETY LABELS….1361
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1366
PRECAUTIONS BEFORE STARTING OPERATION….1366
PREPARATIONS FOR SAFE OPERATION….1366
FIRE PREVENTION….1368
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1369
DO NOT GET CAUGHT IN WORK EQUIPMENT….1371
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1371
UNAUTHORIZED MODIFICATION….1372
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1372
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1372
PRECAUTIONS FOR OPERATION….1373
PRECAUTIONS FOR JOBSITE….1373
STARTING ENGINE….1375
OPERATION….1378
TRANSPORTATION….1382
TOWING….1383
PRECAUTIONS FOR MAINTENANCE….1384
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1384
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1389
TIRES….1394
OPERATION….1397
GENERAL VIEW….1398
GENERAL VIEW OF MACHINE….1398
GENERAL VIEW OF CONTROLS AND GAUGES….1399
EXPLANATION OF COMPONENTS….1402
MONITOR PANEL….1402
OTHER FUNCTIONS OF MACHINE MONITOR….1420
SWITCHES….1425
CONTROL LEVERS, PEDALS….1439
DUST INDICATOR….1449
ARTICULATE LOCK PIN….1449
FUSE BOX….1450
SLOW BLOW FUSE….1451
CIRCUIT BREAKER….1451
HANDLING BATTERY DISCONNECTOR SWITCH….1452
OPERATION….1453
CHECK BEFORE STARTING ENGINE….1453
STARTING ENGINE….1467
OPERATIONS, CHECKS AFTER STARTING ENGINE….1470
STOPPING ENGINE….1471
CHECK AFTER STOPPING ENGINE….1471
TRAVELING POSTURE FOR MACHINE….1472
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1473
TURNING MACHINE….1482
OPERATING WORK EQUIPMENT….1485
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1491
PRECAUTIONS WHEN OPERATION….1512
ADJUSTING WORK EQUIPMENT POSTURE….1516
PARKING MACHINE….1525
CHECKS AFTER COMPLETION OF OPERATION….1527
LOCKING….1528
HANDLING THE TIRES….1528
TRANSPORTATION….1529
STEPS FOR TRANSPORTATION….1529
LOADING, UNLOADING WORK….1529
PRECAUTIONS FOR LOADING….1530
COLD WEATHER OPERATION….1531
PRECAUTIONS FOR LOW TEMPERATURE….1531
CAUTIONS AFTER COMPLETION OF WORK….1532
AFTER COLD WEATHER….1532
LONG-TERM STORAGE….1533
BEFORE STORAGE….1533
DURING STORAGE….1533
AFTER STORAGE….1533
TROUBLESHOOTING….1534
AFTER RUNNING OUT OF FUEL….1534
WHEN LEANING PIPING IS DAMAGED….1535
TOWING THE MACHINE….1536
IF BATTERY IS DISCHARGED….1538
OTHER TROUBLE….1542
MAINTENANCE….1549
GUIDES TO MAINTENANCE….1550
OUTLINES OF SERVICE….1552
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1552
RELATING TO ELECTRIC SYSTEM….1556
WEAR PARTS….1557
WEAR PARTS LIST….1557
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1558
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1559
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1560
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1561
TORQUE LIST….1561
PERIODIC REPLACEMENT OF CRITICAL PARTS….1562
CRITICAL PARTS….1562
MAINTENANCE SCHEDULE CHART….1563
MAINTENANCE SCHEDULE CHART….1563
SERVICE PROCEDURE….1565
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1565
WHEN REQUIRED….1566
CHECK BEFORE STARTING….1581
EVERY 50 HOURS SERVICE….1582
EVERY 250 HOURS SERVICE….1583
EVERY 500 HOURS SERVICE….1597
EVERY 1000 HOURS SERVICE….1605
EVERY 2000 HOURS SERVICE….1614
EVERY 4000 HOURS SERVICE….1619
EVERY 8000 HOURS SERVICE….1621
SPECIFICATIONS….1623
SPECIFICATIONS….1624
ATTACHMENTS, OPTIONS….1627
HANDLING BLADE ACCUMULATOR….1628
FEATURES OF BLADE ACCUMULATOR….1628
METHOD OF OPERATING BLADE ACCUMULATOR….1629
AM/FM RADIO-CASSETTE STEREO….1630
EXPLANATION OF COMPONENTS….1630
METHOD OF OPERATION….1635
PRECAUTIONS WHEN USING….1638
AIR CONDITIONER….1639
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1639
METHOD OF OPERATION….1642
PRECAUTIONS WHEN USING….1643
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1643
HANDLING AIR-SUSPENSION SEAT….1644
ADJUST OPERATOR'S SEAT….1644
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1646
BASIC PRECAUTIONS….1646
INDEX….1647
TEN00448-00 – Motor Grader GD655-3E0 Operation & Maintenance Manual….1651
COVER….1651
FOREWORD….1652
BEFORE READING THIS MANUAL….1653
SAFETY INFORMATION….1654
INTENDED USE….1655
USE OF MACHINE….1655
DIRECTIONS OF MACHINE….1655
VISIBILITY FROM OPERATOR'S SEAT….1656
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1657
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1657
EPA REGULATIONS, ENGINE NUMBER PLATE….1657
SERVICE METER POSITION….1658
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1658
CONTENTS….1659
SAFETY….1662
SAFETY INFORMATION….1663
SAFETY LABELS….1666
POSITION FOR ATTACHING SAFETY LABELS….1667
SAFETY LABELS….1668
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….1674
PRECAUTIONS BEFORE STARTING OPERATION….1674
PREPARATIONS FOR SAFE OPERATION….1674
FIRE PREVENTION….1676
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….1677
DO NOT GET CAUGHT IN WORK EQUIPMENT….1679
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….1679
UNAUTHORIZED MODIFICATION….1680
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….1680
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….1680
PRECAUTIONS FOR OPERATION….1681
PRECAUTIONS FOR JOBSITE….1681
STARTING ENGINE….1683
OPERATION….1686
TRANSPORTATION….1690
TOWING….1691
PRECAUTIONS FOR MAINTENANCE….1692
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….1692
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1697
TIRES….1702
OPERATION….1704
GENERAL VIEW….1705
GENERAL VIEW OF MACHINE….1705
GENERAL VIEW OF CONTROLS AND GAUGES….1706
EXPLANATION OF COMPONENTS….1709
MONITOR PANEL….1709
OTHER FUNCTIONS OF MACHINE MONITOR….1727
SWITCHES….1732
CONTROL LEVERS, PEDALS….1746
DUST INDICATOR….1756
ARTICULATE LOCK PIN….1756
FUSE BOX….1757
SLOW BLOW FUSE….1758
CIRCUIT BREAKER….1758
HANDLING BATTERY DISCONNECTOR SWITCH….1759
OPERATION….1760
CHECK BEFORE STARTING ENGINE….1760
STARTING ENGINE….1774
OPERATIONS, CHECKS AFTER STARTING ENGINE….1777
CHECK AFTER STOPPING ENGINE….1778
TRAVELING POSTURE FOR MACHINE….1779
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING….1780
TURNING MACHINE….1789
OPERATING WORK EQUIPMENT….1792
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER….1798
PRECAUTIONS WHEN OPERATION….1819
ADJUSTING WORK EQUIPMENT POSTURE….1823
PARKING MACHINE….1832
CHECKS AFTER COMPLETION OF OPERATION….1834
LOCKING….1835
HANDLING THE TIRES….1835
TRANSPORTATION….1836
STEPS FOR TRANSPORTATION….1836
LOADING, UNLOADING WORK….1836
PRECAUTIONS FOR LOADING….1837
COLD WEATHER OPERATION….1838
PRECAUTIONS FOR LOW TEMPERATURE….1838
CAUTIONS AFTER COMPLETION OF WORK….1839
AFTER COLD WEATHER….1839
LONG-TERM STORAGE….1840
BEFORE STORAGE….1840
DURING STORAGE….1840
AFTER STORAGE….1840
TROUBLESHOOTING….1841
AFTER RUNNING OUT OF FUEL….1841
WHEN LEANING PIPING IS DAMAGED….1842
TOWING THE MACHINE….1843
IF BATTERY IS DISCHARGED….1845
OTHER TROUBLE….1849
MAINTENANCE….1856
GUIDES TO MAINTENANCE….1857
OUTLINES OF SERVICE….1859
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1859
RELATING TO ELECTRIC SYSTEM….1863
WEAR PARTS….1864
WEAR PARTS LIST….1864
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1865
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1866
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1867
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1868
TORQUE LIST….1868
PERIODIC REPLACEMENT OF CRITICAL PARTS….1869
CRITICAL PARTS….1869
MAINTENANCE SCHEDULE CHART….1870
MAINTENANCE SCHEDULE CHART….1870
SERVICE PROCEDURE….1872
INITIAL 250 HOURS SERVICE (only after the first 250 hours)….1872
WHEN REQUIRED….1873
CHECK BEFORE STARTING….1888
EVERY 50 HOURS SERVICE….1889
EVERY 250 HOURS SERVICE….1890
EVERY 500 HOURS SERVICE….1904
EVERY 1000 HOURS SERVICE….1912
EVERY 2000 HOURS SERVICE….1921
EVERY 4000 HOURS SERVICE….1926
EVERY 8000 HOURS SERVICE….1928
SPECIFICATIONS….1930
SPECIFICATIONS….1931
ATTACHMENTS, OPTIONS….1934
HANDLING BLADE ACCUMULATOR….1935
FEATURES OF BLADE ACCUMULATOR….1935
METHOD OF OPERATING BLADE ACCUMULATOR….1936
AM/FM RADIO-CASSETTE STEREO….1937
EXPLANATION OF COMPONENTS….1937
METHOD OF OPERATION….1942
PRECAUTIONS WHEN USING….1945
AIR CONDITIONER….1946
LOCATIONS AND FUNCTIONS OF CONTROL PANEL….1946
METHOD OF OPERATION….1949
PRECAUTIONS WHEN USING….1950
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….1950
HANDLING AIR-SUSPENSION SEAT….1951
ADJUST OPERATOR'S SEAT….1951
HANDLING MACHINES EQUIPPED WITH KOMTRAX….1953
BASIC PRECAUTIONS….1953
INDEX….1954
TEN00449-01 – Motor Grader GD675-3E0 Operation & Maintenance Manual….1958
Komatsu Motor Graders GD655-3E0, GD675-3E0 Repair Service Manuals