Komatsu Motor Grader GD535-6 service & repair manual

Description Komatsu Motor Grader GD535-6 service & repair manual

Komatsu Motor Grader GD535-6 pdf workshop service repair manual

Serial numbers:
3002 and up

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

SERVICE MANUAL CONTENT:
Index and foreword
Foreword, safety, basic information
How to read the shop manual
Safety notice for operation
Precautions to prevent fire
Actions if fire occurs
Precautions for removal of dangerous materials
Steps necessary to meet exhaust gas regulations
General character and precautions for usage
Precautions when you add DEF
Precautions when you store DEF
Precautions for fire hazard and leakage
The other precautions
Store DEF
Precautions for handling hydraulic equipment
Precautions for disconnection and connection of pipings
Precautions for handling electrical equipment
Precautions for handling fuel system equipment
Precautions for handling intake system equipment
Practical use of KOMTRAX
Disconnect and connect pushpull type coupler
Method for disconnecting and connecting type push-pull type coupler
Precautions for disconnection and connection of connectors
Method for disconnecting and connecting Deutsch connector
Method for disconnecting and connecting slide lock type connector
Method for disconnecting and connecting connector with lock to pull
Method for disconnecting and connecting connector with lock to push
Method for disconnecting and connecting connector with housing to rotate
How to read electrical wire code
Explanation of terms for maintenance standard
Standard tightening torque table
Conversion table
Abbreviation list

Specification
Specification drawing
Weight table
Fuel, coolant, and lubricant
Use of fuel, coolant and lubricants according to ambient temperature

Structure and function
Urea SCR system
Layout drawing of Urea SCR system
Urea SCR system diagram
Function of Urea SCR system
Function of DEF supply system
Inducement strategy
Component parts of Urea SCR system
SCR assembly
DEF tank
DEF pump
DEF injector
DEF hose
DEF tank heating valve
Bootup system
Layout drawing of bootup system
System operating lamp system
System operating lamp system diagram
Function of system operating lamp system
Battery disconnect switch
Function of battery disconnect switch
Operation of battery disconnect switch
Preheating system
Preheating system diagram
Function of automatic preheating system
Operation of automatic preheating system
Function of manual preheating system
Operation of manual preheating system
Engine shutdown secondary switch
Function of engine shutdown secondary switch
Operation of engine shutdown secondary switch
Engine system
Layout drawing of engine system
Function of engine system
Engine control system
Engine control system diagram
Engine automatic warm-up function
Engine automatic warm-up cancel function
Operation of engine control system
Engine power mode selector system
Engine power mode selector system diagram
Function of engine power mode selector system
Operation of engine power mode selector system
Component parts of engine system
Turbocharger
Crankcase ventilation system
Impactor (Filterless)
Exhaust throttle valve
KDPF
Cooling system
Layout drawing of cooling system
Cooling fan control system
Component parts of cooling system
Cooling fan motor
Cooling fan speed sensor
Power train system
Power train system drawing
Power train piping drawing
Transmission control
Component parts of power train system
Torque converter
Transmission
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Front axle
Rear axle
Bevel gear
Final drive
Tandem drive
Steering system
Steering piping drawing
Component parts of steering system
Priority valve
Steering valve
Brake system
Hydraulic piping drawing of brake system
Component parts 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
Structure of bias tire
Function of bias tire
Hydraulic system
Hydraulic piping drawing of work equipment
Work equipment control
Component parts of hydraulic system
Hydraulic tank
Steering and work equipment and brake and cooling fan pump
Power train 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
Electrical system
Automatic gear shift control system
KOMTRAX system
System diagram of KOMTRAX system
Function of KOMTRAX system
Component parts of electrical system
Machine monitor
Transmission controller
Engine controller
Gateway function controller
Communication terminal
Sensors

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
Method for testing engine speed
Testing boost pressure
Method for testing boost pressure
Testing exhaust gas color
Exhaust gas color testing method with handy smoke checker
Exhaust gas color testing method with smoke meter
Testing and adjusting valve clearance
Method for testing valve clearance
Method for adjusting valve clearance
Testing compression pressure
Method for testing compression pressure
Testing blowby pressure
Method for testing blowby pressure
Testing engine oil pressure
Method for testing engine oil pressure
Handling fuel system devices
Releasing remaining pressure from fuel system
Testing fuel pressure
Method for testing fuel pressure
Bleeding air from fuel system
Method for bleeding air from fuel system
Testing fuel circuit for leakage
Method for testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling noinjection cranking operation
Handling voltage circuit of engine controller
Testing KDPF, SCR and muffler stack for looseness and damage
Method for testing KDPF, SCR and muffler stack for looseness and damage
Testing installed condition of cylinder heads and manifolds
Method for testing installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Method for testing engine piping for damage and looseness
Testing fuel discharge, return and leakage
Method for testing fuel discharge, return and leakage
Testing alternator belt
Method for testing alternator belt
Testing automatic tensioner
Method for testing automatic tensioner
Writing ash in soot accumulation correction to engine controller
Method for writing ash in soot accumulation correction to engine controller
Testing SCR related functions
Testing DEF pump raised pressure
Testing injection amount from DEF injector
Testing DEF line heater relay
Testing DEF pump heater relay
Testing DEF tank heater valve
Testing SCR NOx removal efficiency
Cleaning DEF tank
Method for cleaning DEF tank
Cleaning DEF pump
Method for cleaning DEF pump
Power train
Testing power train oil pressure
Method for testing power train oil pressure
Adjusting transmission speed sensor
Method for adjusting transmission speed sensor
Retrieval of disabled machine due to transmission valve failure
Retrieving method for disabled machine due to transmission valve failure
Flushing for torque converter and transmission circuits
Method for flushing torque converter and transmison circuits
Testing and adjusting toe-in
Method for testing toe-in
Method for adjusting toe-in
Adjusting bearing preload
Method for adjusting bearing preload
Steering system
Testing and adjusting steering oil pressure
Method for testing steering oil pressure
Method for adjusting steering oil pressure
Testing oil leakage of steering cylinder
Method for testing oil leakage of steering cylinder
Bleeding air from steering circuit
Method for bleeding air from steering circuit
Brake system
Releasing remaining pressure from brake circuit
Method for releasing remaining pressure from brake circuit
Testing and adjusting brake oil pressure
Method for testing brake oil pressure
Method for adjusting brake oil pressure
Bleeding air from brake circuit
Method for bleeding air from brake circuit
Testing wear of wheel brake disc
Method for testing wear of wheel brake disc
Testing and adjusting parking brake pad
Method for testing wear of parking brake pad
Method for adjusting parking brake pad clearance
Releasing parking brake manually
Method for parking brake manual releasing procedure
Charging brake accumulator with gas
Method for charging brake accumulator with gas
Hydraulic system
Testing work equipment oil pressure
Method for testing work equipment oil pressure
Testing lifter lock pin circuit pressure
Method for testing lifter lock pin circuit pressure
Testing cooling fan speed
Method for testing cooling fan speed
Testing cooling fan circuit oil pressure
Method for testing cooling fan circuit oil pressure
Testing oil leakage of work equipment cylinder
Method for testing oil leakage of work equipment cylinder
Bleeding air from work equipment circuit
Method for bleeding air from work equipment circuit
Work equipment
Adjusting drawbar ball joint clearance
Method for adjusting drawbar ball joint clearance
Testing and adjusting circle guide clearance
Method for testing circle guide clearance
Method for adjusting circle guide clearance
Testing and adjusting slip clutch type circle drive
Method for testing slip clutch type circle drive
Method for adjusting slip clutch type circle drive
Electrical system
Setting and adjusting various equipment
Special functions of machine monitor
Operator mode
Checking function of LCD display
Confirmation function of service meter and odometer
Function of usage limitation setting / changing password
Service mode
Monitoring/defined
Monitoring/Custom
Abnormality Record (Mechanical System)
Abnormality Record (Electrical System)
Maintenance Time Reset
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default Setting Menu
Diagnostic Tests Menu
Adjustment Menu
No Injection
KOMTRAX Settings
Service Message
Handling highvoltage circuit of engine controller
KOMTRAX terminal startup procedure
Handling battery disconnect switch
Testing diodes
Method for testing diode using digital tester
Method for testing diode using analog tester
Preparatory work for troubleshooting of electrical system failure
Pm Clinic

Troubleshooting
Information related to troubleshooting
Points to remember when troubleshooting
Troubleshooting points for Urea SCR system
How to proceed in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Troubleshooting procedure
Symptom and troubleshooting numbers
Information described in troubleshooting table
Diagnosis of open harness in pressure sensor system
Connector list and layout
Connector pin layout
Tbox and Tadapter list
Locations of fuses
Precautions for cleaning and replacing KDPF (KCSF and KDOC)
Precaution of short circuit electrical connector (for failure code [CA1883] and [CA3135])
Failure code list
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 tools list
Sketches of special tools
Preparation
Drain and add coolant
Drain coolant
Add coolant
Drain and add hydraulic oil
Drain hydraulic oil
Add hydraulic oil
Drain and add fuel
Drain fuel
Add fuel
Engine and cooling system
Remove and install supply pump assembly
Remove supply pump assembly
Install supply pump assembly
Remove and install injector assembly
Remove injector assembly
Install injector assembly
Remove and install cylinder head assembly
Remove cylinder head assembly
Install cylinder head assembly
Remove and install starting motor assembly
Remove starting motor assembly
Install starting motor assembly
Remove and install alternator belt
Remove alternator belt
Install alternator belt
Remove and install alternator assembly
Remove alternator assembly
Install alternator assembly
Remove and install autotensioner
Remove autotensioner
Install autotensioner
Remove and install engine front oil seal
Remove engine front oil seal
Install engine front oil seal
Remove and install engine rear oil seal
Remove engine rear oil seal
Install engine rear oil seal
Remove and install steering and work equipment, brake and cooling fan pump assembly
Remove steering and work equipment, brake and cooling fan pump assembly
Install steering and work equipment, brake and cooling fan pump assembly
Remove and install cooling fan and fan motor assembly
Remove cooling fan and fan motor assembly
Install cooling fan and fan motor assembly
Remove and install radiator assembly
Remove radiator assembly
Install radiator assembly
Remove and install aftercooler assembly
Remove aftercooler assembly
Install aftercooler assembly
Remove and install power train oil cooler assembly
Remove power train oil cooler assembly
Install power train oil cooler assembly
Remove and install fuel tank assembly
Remove fuel tank assembly
Install fuel tank assembly
Remove and install engine hood assembly
Remove engine hood assembly
Install engine hood assembly
Remove and install grille assembly
Remove grille assembly
Install grille assembly
Remove and install bellows pipe assembly
Remove bellows pipe assembly
Install bellows pipe assembly
Remove and install DEF tank assembly
Remove DEF tank assembly
Install DEF tank assembly
Remove and install DEF tank sensor flange assembly
Remove DEF tank sensor flange assembly
Install DEF tank sensor flange assembly
Remove and install DEF tank sensor
Remove DEF tank sensor
Install DEF tank sensor
Remove and install DEF tank strainer
Remove DEF tank strainer
Install DEF tank strainer
Remove and install KDPF assembly
Remove KDPF assembly
Install KDPF assembly
Disassemble and assemble KDPF assembly
Disassemble KDPF assembly
Assemble KDPF assembly
Remove and install SCR assembly
Remove SCR assembly
Install SCR assembly
Remove and install KDPF and SCR assembly
Remove KDPF and SCR assembly
Install KDPF and SCR assembly
Remove and install exhaust throttle valve
Remove exhaust throttle valve
Install exhaust throttle valve
Remove and install DEF injector
Remove DEF injector
Install DEF injector
Remove and install DEF pump
Remove DEF pump
Install DEF pump
Remove and install DEF hose
Remove DEF hose
Install DEF hose
Remove and install air cleaner assembly
Remove air cleaner assembly
Install air cleaner assembly
Remove and install exhaust pipe cover
Remove exhaust pipe cover
Install exhaust pipe cover
Power train
Remove and install engine, torque converter, and transmission assembly
Remove engine, torque converter, and transmission assembly
Install engine, torque converter, and transmission assembly
Disconnect and connect engine, torque converter, and transmission assembly
Disconnect engine, torque converter, and transmission assembly
Connect engine, torque converter, and transmission assembly
Disassemble and assemble torque converter assembly
Disassemble torque converter assembly
Assemble torque converter assembly
Disassemble and assemble transmission assembly
Disassemble transmission assembly
Assemble transmission assembly
Remove and install tandem drive and final drive assembly
Remove tandem drive and final drive assembly
Install tandem drive and final drive assembly
Disassemble and assemble tandem drive assembly
Disassemble tandem drive assembly
Assemble tandem drive assembly
Disassemble and assemble bevel gear assembly
Disassemble bevel gear assembly
Assemble bevel gear assembly
Disassemble and assemble final drive assembly
Disassemble final drive assembly
Assemble final drive assembly
Steering system
Remove and install orbitrol valve assembly
Remove orbitrol valve assembly
Install orbitrol valve assembly
Brake system
Disassemble and assemble wheel brake assembly
Disassemble wheel brake assembly
Assemble wheel brake assembly
Undercarriage and frame
Remove and install center hinge pin
Remove center hinge pin
Install center hinge pin
Hydraulic system
Remove and install hydraulic tank, battery, and frame assembly
Remove hydraulic tank, battery, and frame assembly
Install hydraulic tank, battery, and frame assembly
Remove and install hydraulic tank assembly
Remove hydraulic tank assembly
Install hydraulic tank assembly
Remove and install control valve assembly
Remove control valve assembly
Install control valve assembly
Disassemble and assemble hydraulic cylinder assembly
Disassemble hydraulic cylinder assembly
Assemble hydraulic cylinder assembly
Work equipment
Remove and install blade assembly
Remove blade assembly
Install blade assembly
Remove and install circle and drawbar assembly
Remove circle and drawbar assembly
Install circle and drawbar assembly
Remove and install circle rotation gear assembly
Remove circle rotation gear assembly
Install circle rotation gear assembly
Disassemble and assemble circle rotation gear assembly
Disassemble circle rotation gear assembly
Assemble circle rotation gear assembly
Cab related parts
Remove and install canopy assembly
Remove canopy assembly
Install canopy assembly
Remove and install floor frame assembly
Remove floor frame assembly
Install floor frame assembly
Remove and install canopy and floor frame assembly
Remove canopy and floor frame assembly
Install canopy and floor frame assembly
Remove and install operator seat assembly
Remove operator seat assembly
Install operator seat assembly
Remove and install seatbelt
Remove seatbelt
Install seatbelt
Electrical system
Remove and install engine controller assembly
Remove engine controller assembly
Install engine controller assembly
Remove and install machine monitor assembly
Remove machine monitor assembly
Install machine monitor assembly
Remove and install transmission controller assembly
Remove transmission controller assembly
Install transmission controller assembly
Remove and install intake manifold pressure and temperature sensor
Remove intake manifold pressure and temperature sensor
Install intake manifold pressure and temperature sensor
Remove and install KDPF temperature sensor
Remove KDPF temperature sensor
Install KDPF temperature sensor
Remove and install KDPF differential pressure sensor
Remove KDPF differential pressure sensor
Install KDPF differential pressure sensor
Remove and install SCR temperature sensor
Remove SCR temperature sensor
Install SCR temperature sensor
Remove and install SCR outlet NOx sensor
Remove SCR outlet NOx sensor
Install SCR outlet NOx sensor
Remove and install gateway function controller
Remove gateway function controller
Install gateway function controller

Maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan motor
Power train system
Torque converter
Transmission
Main relief valve and torque converter relief valve
Front axle
Rear axle
Bevel gear
Final drive
Tandem drive
Steering system
Steering cylinder
Brake system
Wheel brake
Parking brake
Undercarriage and frame
Frame and center hinge pin
Hydraulic system
Hydraulic tank
Steering and work equipment and brake and cooling fan pump
Power train 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

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

Engine SAA4D107E-5 workshop service repair manual