Komatsu Motor Grader GD555-5 GD655-5 GD675-5 service & repair manual

Description Komatsu Motor Grader GD555-5 GD655-5 GD675-5 service & repair manual

Komatsu Motor Grader GD555-5, GD655-5, GD675-5 pdf workshop service repair manual + operation & maintenance manual

Serial number 55001 and up

Technical documentation, specifications, troubleshooting, maintenance, lubrication, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Specifications
Specification drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and Cooling
Cooling system
Cooling fan pump
Power train system
Power train system drawing
Power train piping drawing
Transmission control
Torque converter
Transmission
Transmission control valve
ECMV
Main relief and torque converter relief valve
Front axle
Final drive (no differential specification)
Final drive (differential/ differential lock specification)
Differential lock solenoid valve
Tandem drive
Steering system
Steering piping diagram
Priority valve
Steering valve
Brake system
Brake hydraulic piping diagram
Brake valve
Slack adjuster
Accumulator (for brake)
Wheel brake
Charge valve
Parking brake and bank control valve
Parking brake
Undercarriage frame
Frame
Tire
Hydraulic system
Work equipment hydraulic piping diagram
Work equipment control
Hydraulic tank
Main pump
Power train pump
Control valve
CLSS
Functions and operation by valve
Hydraulic cylinder
Swivel joint
Pilot check valve
Accumulator (for blade)
Work equipment
Circle and drawbar
Blade
Lifter
Circle rotation motor
Circle rotation gear
Cab
Electrical ststem
Machine monitor
Automatic shift control system
Transmission controller
Engine controller
KOMTRAX system
Starting engine circuit
Stopping engine circuit
Preheating circuit
Sensor
Engine power mode select circuit
Cooling fan control function

Standard value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas temperature
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system device
Releasing remaining pressure from fuel system
Testing fuel pressure
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Cylinder cut-out test mode
No injection cranking
Handling voltage circuit of engine controller
Checking muffler body and muffler stack for looseness and damage
Checking muffler function
Checking cylinder head and manifolds for looseness
Checking engine piping for damage and looseness
Checking fuel delivery, return rate and leakage
Replacing alternator belt
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]
Power train
Testing power train oil pressure
Adjusting transmission speed sensor
Emergency escape method in case of transmission valve failure
Flushing torque converter and trasmission circuits
Testing and adjusting toe-in
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]
Steering system
Testing and adjusting steering oil pressure
Testing steering cylinder oil leakage
Bleeding air from steering circuit
Brake system
Testing and adjusting brake oil pressure
Releasing remaining pressure from brake circuit
Bleeding air from brake circuit
Testing wheel brake disc wear
Testing and adjusting parking brake
Emergency release method of parking brake
Filling gas into brake accumulator
Hydraulic system
Testing and adjusting work equipment oil pressure
Testing and adjusting pump LS differential pressure
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut]
Testing work equipment cylinder oil leakage amount
Bleeding air from work equipment circuit
Work equipment
Clearance adjustment of drawbar ball joint
Testing and adjusting circle guide clearance
Testing and adjusting slip clutch type circle rotator
Filling gas into blade accumulator [machine with blade accumulator]
Electrical system
Procedure for testing diodes
Special functions of machine monitor (EMMS)
Handling high voltage circuit of engine controller
How to start KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Preparation work for troubleshooting of electrical system

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Failure and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Locations of fuses
Troubleshooting by failurecode

Disassembly and assembly
General information on disassembly and assembly
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of cooling fan pump assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of power train oil cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Power train
Removal and installation of engine and transmission/torque converter assembly
Disassembly and assembly of engine and transmission/torque converter assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Removal and installation of tandem drive and final drive assembly
Disassembly and assembly of tandem drive assembly
Disassembly and assembly of final drive assembly
Steering system
Removal and installation of steering valve (orbit-roll) assembly
Disassembly and assembly of steering valve (orbit-roll) assembly
Brake system
Disassembly and assembly of wheel brake assembly
Undercarriage and frame
Removal and installation of center hinge pin
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Removal and installation of circle drawbar assembly
Removal and installation of circle rotation gear assembly
Disassembly and assembly of circle rotation gear assembly
Removal and installation of ripper assembly
Cab and its attachments
Removal and installation of operator cab assembly
Removal and installation of floor frame assembly
Removal and installation of operator cab glass (adhered glass)
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of machine monitor assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX terminal assembly

Maintenance standard
Engine and Cooling
Engine mount and transmission mount
Cooling system
Cooling fan motor
Power train system
Transmission control
Torque converter
Transmission
Main relief valve and torque converter relief valve
Front axle
Final drive (no differential specification)
Final drive (differential/ differential lock specification)
Differential lock solenoid valve
Tandem drive
Brake system
Slack adjuster
Wheel brake
Parking brake
Hydraulic system
Power train pump
Control valve
Hydraulic cylinder
Work equipment
Circle and drawbar
Blade
Lifter
Circle rotation gear

Air conditioner
Precautions for refrigerant
Air Conditioner Components
Structure and Function of Refrigeration System
Overview of Refrigeration System
Air Conditioner Unit
Compressor
Condenser
Receiver drier
Air conditioner control panel
Procedure for check and troubleshooting
Circuit diagram and layout of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (ducts)
Check with self-diagnosis (control panel display)
Testing temperature control

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Power train hydraulic circuit diagram
Differential hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams

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