Komatsu Motor Grader GD755-5R service & repair manual

Description Komatsu Motor Grader GD755-5R service & repair manual

Komatsu Motor Grader GD755-5R pdf workshop service repair manual

Serial number 10001 and up

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

SERVICE MANUAL CONTENT:
Foreword and general information
Safety notice
Explanation of terms for maintenance standard
Handling of hydraulic equipment
Method of disconnecting and connecting push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification and technical data
Specification drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan pump
Cooling fan motor
Cooling fan relief valve
Power train
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
Differential
Differential lock solenoid valve
Tandem drive
Steering system
Steering piping diagram
Priority valve
Accumulator charge valve
Steering valve
Brake system
Brake hydraulic piping diagram
Brake valve
Slack adjuster
Accumulator (for brake)
Wheel brake
Parking brake and bank control valve
Parking brake
Undercarriage and frame
Frame
Tire
Hydraulic system
Hydraulic equipment layout drawing
Work equipment control
Hydraulic tank
Main pump
Double type 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 and its attachments
Cab
Electrical system
Machine monitor
Automatic shift control system
Transmission controller
Engine controller
KOMTRAX system
Starting engine circuit
Preheating circuit
Sensor

Standard value table
Specification and technical data
Standard value table for engine
Standard value table for machine

Testing and adjusting
Precautions before work
Tool for testingadjusting and troubleshooting
Sketches of special tools
Measuring engine speed
Measuring boost pressure
Measuring exhaust gas temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blowby pressure
Measuring engine oil pressure
Handling fuel system device
Releasing remaining pressure in fuel system
Measuring fuel pressure
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no injection cranking operation
Handling voltage circuit of engine controller
Checking muffler body and muffler stack for looseness and damage
Checking muffler function
Check of installed condition of cylinder head and manifolds
Checking engine piping for damage and looseness
Testing fuel return rate and leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Handling high voltage circuit of engine controller
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 circuit
Testing and adjusting toe-in
Adjusting bearing preload
Measuring and adjusting differential lockup oil pressure
Testing and adjusting steering oil pressure
Measuring oil leakage of steering cylinder
Bleeding air from steering circuit
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
Parking brake emergency releasing procedure
Charging brake accumulator with nitrogen gas
Testing and adjusting work equipment oil pressure
Adjusting pump PC valve
Testing and adjusting pump LS differential pressure
Testing lift arm lock cylinder circuit oil pressure
Testing hydraulic fan
Measuring oil leakage of work equipment cylinder
Bleeding air from work equipment circuit
Bleeding air from fan pump
Bleeding air from fan motor
Clearance adjustment of drawbar ball joint
Adjusting clearance of blade circle guide
Adjusting circle rotating gear
Charging blade accumulator gas
Procedure for testing diodes
Special functions of machine monitor (EMMS)
How to start KOMTRAX terminal operations
Lamp display of KOMTRAX terminal
Preparation work for troubleshooting of electrical system
Pm Clinic

Troubleshooting
Failure code table and fuse locations
Precautions before work
Failure codes table
Fuse locations
General Information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
Precautions before work
How to read this manual
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 system assembly
Removal and installation of radiator assembly
Removal and installation of power train oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of cooling fan oil cooler assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of enginetorque converterand transmission assembly
Disconnection and connection of enginetorque converterand transmission assembly
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Power train
Disassembly and assembly of torque converter and transmission assembly
Disassembly and assembly of transmission clutch assembly
Disassembly and assembly of torque converter 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
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 assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Removal and installation of ripper assembly
Removal and installation of circle rotation gear assembly
Disassembly and assembly of circle rotation gear assembly
Removal and installation of circle drawbar assembly
800 Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (adhered glass)
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electric system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX terminal assembly

Air conditioner
Precautions before work
Precautions for refrigerant
Air Conditioner Components
Structure and Function of Refrigeration System
Overview of Refrigeration System
Circuit diagram of refrigerant
Air Conditioner Unit
Compressor
Condenser
Receiver
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
Testing FRESH/RECIRC air changeover
Testing evaporator temperature sensor
Testing relays
Testing blower amp
Troubleshooting Chart
Information in troubleshooting table
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting of compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (Air does not come out or air flow is improper)
Troubleshooting for temperature control
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling compressor oil

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram of differential lock
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Connector list and stereogram

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