Komatsu Motor Grader GD535-5 service & repair manual

Description Komatsu Motor Grader GD535-5 service & repair manual

Komatsu Motor Grader GD535-5 pdf workshop service repair manual

Serial numbers:
1001 and up
B10001 and up

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

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic components
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out work
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification drawing (Canopy specification)
Specification drawing (Cab specification)
Specifications (Canopy specification)
Specifications (Cab specification)
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Cooling system
Fan drive
Power train system
Power train system drawing
Power train piping drawing
Transmission control
Torque converter
Transmission
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Front axle
Rear axle
Differential
Differential lock solenoid valve
Final drive
Tandem drive
Steering system
Steering piping drawing
Priority valve
Steering valve
Brake system
Hydraulic piping drawing of brake system
Brake valve
Brake circuit accumulator
Brake circuit accumulator charge valve
Wheel brake
Parking brake solenoid valve and lifter lock pin solenoid valve
Parking brake
Undercarriage and frame
Frame
Tire
Hydraulic system
Hydraulic system
Hydraulic piping drawing of work equipment
Work equipment control
Hydraulic tank
Work equipment pump and steering pump
Power train pump
Power train pump and differential lock pump
Brake pump
Control valve
Functions and valve operations
Hydraulic cylinder
Swivel joint
Pilot check valve
Work equipment system
Circle and drawbar
Blade
Lifter
Circle rotation motor
Circle rotation gear
Cab and its attachments
ROPS canopy
ROPS cab
Electrical system
Machine monitor
Automatic gear shift control system
Transmission controller
Engine controller
KOMTRAX system
KOMTRAX terminal
Engine starting circuit
Engine stop circuit
Preheating circuit
Sensors
Engine power mode selector circuit

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 boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system devices
Releasing remaining pressure from fuel system
Testing fuel pressure
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling noinjection cranking operation
Handling voltage circuit of engine controller
Testing muffler (main body) and stacked muffler for looseness and damage
Testing muffler function
Testing installed condition of cylinder heads and manifolds
Testing of engine piping for damage and looseness
Testing fuel discharge, return rate, and leakage
Checking and replacing alternator belt
Checking and replacing auto-tensioner
Power train
Testing power train oil pressure
Adjusting transmission speed sensor
Retrieval of disabled machine due to transmission valve failure
Flushing procedure for torque converter and transmission circuits
Testing and adjusting toein
Adjusting bearing preload
Testing and adjusting differential lock oil pressure (differential lock specification)
Steering system
Testing and adjusting steering oil pressure
Testing oil leakage of steering cylinder
Bleeding air from steering circuit
Brake system
Releasing remaining pressure from brake circuit
Testing and adjusting brake oil pressure
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing and adjusting parking brake pad
Releasing parking brake manually
Charging brake accumulator with gas
Hydraulic system
Testing work equipment oil pressure
Testing lifter lock pin circuit pressure
Testing oil leakage of work equipment cylinder
Bleeding air from work equipment circuit
Work equipment
Adjusting drawbar ball joint clearance
Testing and adjusting circle guide clearance
Testing and adjusting slip clutch type circle drive
Electrical system
Procedure for testing diodes
Special functions of machine monitor
Handling highvoltage circuit of engine controller
KOMTRAX terminal startup procedure
Preparatory work for troubleshooting of electrical system failure
Pm Clinic
Pm Clinic

Troubleshooting
Information related to troubleshooting
Points to remember when troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Troubleshooting procedure
Failure code list
Symptoms and troubleshooting numbers
Information described in troubleshooting table
Diagnosis of open harness in pressure sensor system
Connector list and layout
Connector pin layout
T-box and T-adapter list
Locations of fuses
Troubleshooting by failure code (display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of air conditioner compressor belt
Removal and installation of alternator belt
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of radiator assembly (Canopy specification)
Removal and installation of radiator assembly (Cab specification)
Removal and installation of aftercooler assembly (Canopy specification)
Removal and installation of aftercooler assembly (Cab specification)
Removal and installation of power train oil cooler assembly (Canopy specification)
Removal and installation of power train oil cooler assembly (Cab specification)
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of air conditioner compressor assembly
Power train
Removal and installation of engine, transmission, and torque converter assembly
Disconnection and connection of engine, transmission, and 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 differential assembly
Disassembly and assembly of final drive assembly
Steering system
Removal and installation of Orbitrol valve assembly (Canopy specification)
Removal and installation of Orbitrol valve assembly (Cab specification)
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 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
Canopy, cab and attachments
Removal and installation of canopy assembly (Canopy specification)
Removal and installation of operator's cab assembly (Cab specification)
Removal and installation of operator cab glass (adhered glass) (Cab specification)
Removal and installation of floor frame assembly (Canopy specification)
Removal and installation of floor frame assembly (Cab specification)
Removal and installation of canopy and floor frame assembly (Canopy specification)
Removal and installation of operator's cab and floor frame assembly (Canopy specification)
Removal and installation of air conditioner unit assembly
Removal and installation operator's seat
Removal and installation seat belt
Electrical system
Removal and installation of engine controller assembly
Removal and installation of machine monitor assembly
Removal and installation of transmission controller assembly (Canopy specification)
Removal and installation of transmission controller assembly (Cab specification)
Removal and installation of KOMTRAX terminal assembly (Canopy specification)
Removal and installation of KOMTRAX terminal assembly (Cab specification)

Maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Power train system
Torque converter
Transmission
Main relief valve and torque converter relief valve
Front axle
Rear axle
Differential
Final drive
Differential lock solenoid valve
Tandem drive
Steering system
Steering cylinder
Brake system
Wheel brake
Parking brake
Undercarriage and frame
Frame and center hinge pin
Hydraulic system
Hydraulic tank
Work equipment pump and steering pump
Power train pump
Power train pump and differential lock pump
Parking brake solenoid valve and lifter lock pin solenoid valve
Leaning cylinder
Articulate cylinder
Blade lift cylinder
Drawbar shift cylinder
Blade side shift cylinder
Power tilt cylinder
Scarifier cylinder
Work equipment
Circle and drawbar
Blade
Lifter
Circle rotation gear

Appendix
Air conditioner system
Precautions for refrigerant
Air conditioner component
Specifications of air conditioner
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Component parts of air conditioner system
Air conditioner unit
Component parts of air conditioner unit
Compressor
Condenser
Receiver drier
Explanation of procedure for testing and troubleshooting of air conditioner
Circuit diagram and arrangement of connector pins for air conditioner
Air conditioner system diagram
Input and output signals of air conditioner control panel
Installation locations of air conditioner parts and arrangement of connectors
Testing air leakage (duct)
Method for testing air leakage (duct)
Testing air conditioner using self-diagnosis function
Check temperature control function
Method for checking temperature control function
Testing fresh/recirc air changeover
Method for testing fresh/recirc air changeover
Test evaporator temperature sensor
Method for checking evaporator temperature sensor
Test relays
Method for testing relays
Check blower AMP
Method for checking blower AMP
Air conditioner troubleshooting chart
Information described in troubleshooting table
A-1 Troubleshooting for power supply system (air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled)
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal)
A-4 Troubleshooting for temperature control function
A-5 Troubleshooting for fresh/recirc air changeover
A-6 Troubleshooting for hot water cut valve
Troubleshooting using gauge pressure
Connection of service tool
Method for connecting service tool
Precautions for disconnecting and connecting hoses and tubes in air conditioner pipings
Handle compressor oil

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Power train hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Chassis electric circuit diagram
Floor electric circuit diagram (Canopy specification)
Floor electric circuit diagram (Cab specification)

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