Komatsu Motor Grader GD955-7E0 service & repair manual

Description Komatsu Motor Grader GD955-7E0 service & repair manual

Komatsu Motor Grader GD955-7E0 pdf workshop service repair manual

Serial number 70001 and up

Technical documentation, specifications, troubleshooting, maintenance, lubrication, 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
Procedures If Fire Occurs
Precautions for Disposing of 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
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
Standard Tightening Torque Table
Conversion Table
Abbreviation List

Specifications
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Bootup System
Layout Drawing of Bootup System
System Operating Lamp System
Battery Disconnect Switch
Starting Motor Disconnect Switch
Preheating System
Engine Shutdown Secondary Switch
Emergency Engine Stop Switch
External Power Supply Engine Preheater
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System
Automatic Idle Stop System
RPM Set
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 Plus System
Machine Lockout System
Seating Switch System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Transmission Control System
Transmission Protection Function
Component Parts of Power Train System
Steering System
Layout Drawing of Steering System
Secondary Steering System
Steering Column
Steering Lever System
Component Parts of Steering System
Work Equipment System
Layout Drawing of Work Equipment System
Work Equipment Control System
Work Equipment Lock System
Component Parts of Work Equipment System
Brake System
Layout Drawing of Brake System
Parking Brake Control System
Component Parts of Brake System
Auto-Greasing System
Layout Drawing of AutoGreasing System
Auto-Greasing System Diagram
Auto-Greasing System
Service Center
Service Center
Function of Service Center
KOWA Oil Sampling System
Layout Drawing of KOWA Oil Sampling System
Function of KOWA Oil Sampling System
Undercarriage and Frame
Frame and Center Hinge Pin
Tires
Work Equipment
Bearing Type Circle and Drawbar
Blade
Lifter
Ripper
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Engine: GD955-7E0
Standard Value Table for Machine
Standard Value Table for Machine: GD955-7E0

Testing and Adjusting
Precautions Before Work
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 Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Test Fuel Low Pressure Circuit Devices
Handle Cylinder Cutout Mode Operation
Handle NoInjection Cranking Operation
Examine KDPF, SCR and Muffler Stack for Looseness and Damage
Examine Installation of Cylinder Head Cover and Manifolds
Examine Engine Piping for Damage and Looseness
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine Alternator Belt
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Pump
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Input Shaft Speed Sensor
How to Adjust Transmission Intermediate Shaft Speed Sensor (Upper)
Adjust Transmission Intermediate Shaft Speed Sensor (Lower)
Adjust Transmission Output Shaft Speed Sensor
Examine After You Adjust Transmission Speed Sensor
Adjust Travel 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
Bleed Air from Steering Circuit
Calibrate Steering Control Lever
Examine and Adjust Toein
Brake System
Release Remained Pressure from Brake Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Accumulator Charge Pressure
Examine and Charge Accumulator Nitrogen Gas Pressure for Brake
Bleed Air from Brake Circuit
Examine Brake Performance
Examine Brake Pedal
Examine Pressure Decrease of Brake
Examine Wear of Wheel Brake Disc
Examine Releasing Pressure of Parking Brake
Release Parking Brake Manually
Hydraulic System
Release Remained Pressure from Work Equipment Circuit
Examine and Adjust Work Equipment Oil Pressure
Examine and Adjust Work Equipment EPC Oil Pressure
Examine and adjust oil pressure in pump PC control circuit
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Bleed Air from Work Equipment Circuit
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Examine Oil Leakage from Hydraulic Cylinder
Work Equipment
Adjust Clearance of Ball Joint
Adjust Circle Rotation Device
Charge Blade Accumulator Nitrogen Gas Pressure
CAB Related Parts
Adjust Play of Operator's Seat
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem
Adjust Rearview Camera Angle
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Related Information for Troubleshooting
Precautions for Troubleshooting
Sequence of Events in Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
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
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
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
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 Fuel Doser Assembly
Remove and Install Damper
Disassemble and Assemble Damper
Remove and Install Engine Hood 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 DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Drain and Add Fuel
Drain and Add Coolant
Collect and Refill Refrigerant
Power Train
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Tandem Drive Assembly
Disassemble and Assemble Final Drive Assembly
Drain and Add Transmission Oil
Steering System
Remove and Install Steering Valve Assembly
Brake System
Disassemble and Assemble Wheel Brake Assembly
Remove and Install Brake Accumulator
Hydraulic System
Remove and Install Hydraulic Tank, Battery, and Brake Accumulator Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Pump Assembly (Brake and Cooling Fan)
Remove and Install Steering Pump
Remove and Install Work Equipment Pump
Remove and Install Pump Assembly (Power Train, Transmission Lubrication, Differential Lock)
Remove and Install Control Valve Assembly
Drain and Add Hydraulic Oil
Work Equipment
Remove and Install Ripper Assembly
Remove and Install Blade Assembly
Remove and Install Circle and Drawbar Assembly
Remove and Install Circle Rotation Device Assembly
Disassemble and Assemble Circle Rotation Device Assembly
Remove and Install Blade Lift Cylinder
Remove and Install Drawbar SideShift Cylinder
Remove and Install Articulate Cylinder
Remove and Install Blade Power Tilt Cylinder
Remove and Install Blade SideShift Cylinder
Remove and Install Leaning Cylinder
Remove and Install Steering Cylinder
Remove and Install Ripper Cylinder
Disassemble and Assemble Hydraulic Cylinder Assembly
Disassemble and Assemble Ripper Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Door
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Remove and Install Work Equipment Control Lever Assembly
Electrical System
Remove and Install Engine Controller
Remove and Install Transmission Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Fan Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Monitor Controller 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 KomVision Camera Assembly
Remove and Install KomVision Radar Assembly
Remove and Install KomVision Controller
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Rearview Camera
Remove and Install Wireless LAN Unit Assembly

Maintenance Standard
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard of Fuel Tank
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard of Pump Assembly (Brake and Cooling Fan)
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 F, R Clutch
Maintenance Standard of 1st, 2nd Clutch
Maintenance Standard for 3rd, 4th Clutch
Maintenance Standard of H, L Clutch
Maintenance Standard for Transmission Control Valve
Maintenance Standard for F, R, 1st, 2nd, 3rd, 4th Clutch ECMV
Maintenance Standard of H, L Clutch ECMV
Maintenance Standard for Valve Assembly (Main Relief, Torque Converter Relief)
Maintenance Standard for Transmission Lubrication 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 Column
Maintenance Standard for Steering Cylinder
Maintenance Standard of Steering Angle Sensor
Maintenance Standard of Articulate Angle Sensor
Brake System
Maintenance Standard for Accumulator Charge Valve
Maintenance Standard of Brake and Parking Brake
Undercarriage and Frame
Maintenance Standard for Frame and Center Hinge Pin
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment Pump
Maintenance Standard of Pump Assembly (Power Train Control, Power Train Lubrication, Differential Lock)
Maintenance Standard for Control Valve
Maintenance Standard for Differential Lock Solenoid Valve
Maintenance Standard for Parking Brake Solenoid Valve
Work Equipment
Maintenance Standard of Bearing Type Circle
Maintenance Standard for Work Equipment Lock Solenoid Valve
Maintenance Standard for Blade
Maintenance Standard for Lifter
Maintenance Standard for Circle Rotation Device
Maintenance Standard for Blade Lift Cylinder
Maintenance Standard for Blade SideShift Cylinder
Maintenance Standard for Leaning Cylinder
Maintenance Standard for Articulate Cylinder
Maintenance Standard for Drawbar SideShift Cylinder
Maintenance Standard for Blade Power Tilt Cylinder
Maintenance Standard of Ripper Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Others
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Layout Drawing of Air Conditioner System
Specifications of Air Conditioner
Structure of Refrigeration Cycle
Function of Refrigeration Cycle
Component Parts of Air Conditioner System
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
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Conditioner with SelfDiagnosis Function
Examine Air Leakage (Duct)
Examine Temperature Control Function
Examine Fresh/Recirc Air Changeover
Examine Evaporator Temperature Sensor
Examine Relay
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
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
KomVision System
Structure and Operation of KomVision System
Examine and Adjust KomVision System
Camera Calibration
How to Adjust Radar
Troubleshooting for KomVision System

Circuit Diagrams
How to Read the Codes for Electric Cable
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (When Blade Left Side Raise + Left Turn + Brake Push (Cut Out) + Parking Brake Released + Differential Lock Released)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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