Komatsu Motor Grader GD655-6 GD675-6 service & repair manual

Description Komatsu Motor Grader GD655-6 GD675-6 service & repair manual

Komatsu Motor Grader GD655-6, GD675-6 pdf workshop service repair manual

Serial number 60001 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
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect PushPull Type Coupler
Precautions for Disconnection and Connection of Connectors
Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
Disconnect and Connect Connector with Lock to Pull
Disconnect and Connect Connector with Lock to Push
Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specification
Abbreviation List
Specification Drawing
Weight Table
Table of Fuel, Coolant, and Lubricants

Structure and Function
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Preheating System
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Cooling Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
Rearview Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Hydraulic System Diagram
CLSS
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Automatic Shift Control System
Transmission Control System
Transmission Gear Shift Control System
Transmission Protection Function
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Function of Work Equipment System
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Function of Steering System
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Component Parts of Brake System
Undercarriage and Frame
Frame and Center Hinge Pin
Tires
Work Equipment
Structure of Circle and Drawbar
Function of Circle and Drawbar
Structure of Blade
Function of Blade
Structure of Lifter
Function of Lifter
CAB Related Parts
ROPS CAB

Standard Value Table
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Engine: GD655-6
Standard Value Table for Engine: GD675-6
Standard Value Table for Machine
Standard Value Table for Machine: GD655-6
Standard Value Table for Machine: GD675-6
Machine Posture and Procedures to Measure Performance
Standard Value Table for Electricity

Testing and Adjusting
Precautions Before Work
Abbreviation List
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Discharge, Return and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cutout Mode Operation
Handle NoInjection Cranking Operation
Examine KDPF, SCR and Muffler Stack for Looseness and Damage
Examine Installed Condition of Cylinder Heads and Manifolds
Examine Engine Piping for Damage and Looseness
Examine and Adjust Air Conditioner Compressor Belt Tension
Examine Alternator Belt
Examine Automatic Tensioner
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Pump
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Input Shaft Speed Sensor
Adjust Transmission Intermediate Shaft Speed Sensor
Adjust Transmission Output Shaft Speed Sensor
Examine After You Adjust Transmission Speed Sensor
Flush Torque Converter and Transmission Hydraulic Circuit
Move Disabled Machine Due to Transmission Valve Failure
Examine Drive Shaft for Looseness, Backlash, and Damage
Examine and Adjust Differential Lock Hydraulic Oil Pressure
Steering System
Examine and Adjust Steering Circuit Oil Pressure
Examine Internal Oil Leakage of Steering Cylinder
Bleed Air from Steering Circuit
Examine and Adjust Toein
Adjust Bearing Preload
Brake System
Release Remained Pressure from Brake Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Accumulator Charge Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
Bleed Air from Brake Circuit
Examine Pressure Decrease of Wheel Brake
Examine Wear of Wheel Brake Disc
Examine Parking Brake Oil Pressure
Release Parking Brake Manually
Examine and Adjust Parking Brake Pad
Hydraulic System
Examine and Adjust Work Equipment Oil Pressure
Examine and adjust oil pressure in pump PC control circuit
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Examine Oil Pressure of Lifter Lock Pin Circuit
Bleed Air from Work Equipment Circuit
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Examine Oil Leakage from Work Equipment Cylinder
Work Equipment
Adjust Clearance in Drawbar Joint
Examine and Adjust Clearance in Circle Guide
Examine and Adjust Circle Rotation Gear
Charge Blade Accumulator Nitrogen Gas Pressure
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)
Start Up KOMTRAX System (Machine with Gateway Function Controller)
Stop Use of KOMTRAX System (Machine with Gateway Function Controller)
Adjust Rearview Camera Angle
Set Region of Bluetooth Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)
Examine Diodes
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector List and Layout (Machine with KOMTRAX Terminal)
Connector List and Layout (Machine with Gateway Function Controller)
Connector Contact Connection Table
TBranch Box and TBranch Adapter Table
Fuse Location Table (Machine with KOMTRAX Terminal)
Fuse Location Table (Machine with Gateway Function Controller)
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Abbreviation List
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
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Automatic Tensioner
Remove and Install Radiator Assembly
Remove and Install Aftercooler Assembly
Remove and Install Power Train Oil Cooler Assembly
Remove and Install Cooling Fan Motor Assembly
Remove and Install Engine, Torque Converter, and Transmission Assembly
Disconnect and Connect Engine, Torque Converter, and Transmission Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install KCCV Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Remove and Install Tandem Drive and Final Drive Assembly
Disassemble and Assemble Tandem Drive Assembly
Disassemble and Assemble Differential Assembly
Disassemble and Assemble Final Drive Assembly
Steering System
Remove and Install Steering Valve Assembly
Brake System
Disassemble and Assemble Wheel Brake Assembly
Undercarriage and Frame
Remove and Install Center Hinge Pin
Hydraulic System
Remove and Install Hydraulic Tank, Battery and Frame Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Cooling Fan Pump Assembly
Remove and Install Control Valve Assembly
Work Equipment
Remove and Install Ripper Assembly
Remove and Install Blade Assembly
Remove and Install Circle and Drawbar Assembly
Remove and Install Circle Rotation Gear Assembly
Disassemble and Assemble Circle Rotation Gear Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Door
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Floor Frame Assembly
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install KDPF Temperature Sensor
Remove and Install KDPF Differential Pressure Sensor
Remove and Install SCR Temperature Sensor
Remove and Install Ammonia Sensor
Remove and Install SCR Outlet NOx Sensor
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal

Maintenance Standard
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Torque Converter
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for F, R, 1st, 2nd, 3rd, 4th Clutch ECMV
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Differential
Maintenance Standard for Final Drive
Maintenance Standard for Tandem Drive
Steering System
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Slack Adjuster
Maintenance Standard for Brake
Undercarriage and Frame
Maintenance Standard for Frame and Center Hinge Pin
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Steering and Work Equipment Pump
Maintenance Standard for Power Train Pump and Differential Lock Pump
Maintenance Standard for Control Valve
Maintenance Standard for Differential Lock Solenoid Valve
Maintenance Standard for Parking Brake Solenoid Valve and Lifter Lock Pin Control Valve
Work Equipment
Maintenance Standard for Circle and Drawbar
Maintenance Standard for Blade
Maintenance Standard for Lifter
Maintenance Standard for Circle Rotation Gear
Maintenance Standard for Blade Lift Cylinder
Maintenance Standard for Blade Side Shift Cylinder
Maintenance Standard for Leaning Cylinder
Maintenance Standard for Articulate Cylinder
Maintenance Standard for Drawbar Side Shift Cylinder
Maintenance Standard for Blade Power Tilt Cylinder

Appendix
Precautions Before Work
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure 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 Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Control Panel
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with SelfDiagnosis Function
Examine Temperature Control Function
How to Examine Temperature Control Function
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Evaporator Temperature Sensor
How to Examine Evaporator Temperature Sensor
Examine Relay
How to Examine Relay
Examine Blower Amplifier
How to Examine Blower Amplifier
Air Conditioner Troubleshooting Chart
Information Shown 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 by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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