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SEN05215-05

MOTOR GRADER GD555 -5


GD655 -5
GD675 -5
GD555- 55001
SERIAL NUMBERS GD655- 55001 and up
GD675- 55001
Notice of revision

Notice of revision
4rd. revision 2011/02
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace

() Page to be deleted Discard

List of revised pages


Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 1 (05) 00-26 10-7 10-48
q 2 (05) 00-27 10-8 10-49
q 3 (05) 00-28 10-9 10-50
q 4 (05) 00-29 10-10 10-51
q 5 (05) 00-30 10-11 10-52
q 6 (05) 00-31 10-12 10-53
q 7 (05) 00-32 10-13 10-54
q 8 (05) 00-33 10-14 10-55
00-1 00-34 10-15 10-56
00-2 00-35 10-16 10-57
q 00-3 (05) 00-36 10-17 10-58
q 00-3-1 (05) 00-37 10-18 10-59
q 00-3-2 (05) 00-38 10-19 10-60
q 00-3-3 (05) 00-39 10-20 10-61
q 00-3-4 (05) 00-40 10-21 10-62
q 00-3-5 (05) 00-41 10-22 10-63
q 00-3-6 (05) 00-42 10-23 10-64
q 00-3-7 (05) 00-43 10-24 10-65
q 00-3-8 (05) 00-44 10-25 10-66
q 00-4 (05) 00-45 10-26 10-67
00-5 00-46 10-27 10-68
00-6 00-47 10-28 10-69
00-7 00-48 10-29 10-70
00-8 01-1 10-30 10-71
00-9 01-2 10-31 10-72
00-10 01-3 10-32 10-73
00-11 01-4 10-33 10-74
00-12 01-5 10-34 10-75
00-13 01-6 10-35 10-76
00-14 01-7 10-36 10-77
00-15 01-8 10-37 10-78
00-16 01-9 10-38 10-79
00-17 01-10 10-39 10-80
00-18 01-11 10-40 10-81
00-19 01-12 10-41 10-82
00-20 10-1 10-42 10-83
00-21 q 10-2 (05) 10-43 10-84
00-22 q 10-3 (05) 10-44 10-85
00-23 10-4 10-45 10-86
00-24 10-5 10-46 10-87
00-25 10-6 10-47 10-88

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Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
10-89 10-135 10-187 20-5 (01)
10-90 10-136 10-188 20-6 (01)
10-91 10-137 10-189 20-7 (01)
10-92 10-138 10-190 20-8 (01)
10-93 10-139 10-191 20-9 (04)
10-94 10-140 10-192 20-10 (01)
10-95 10-141 10-193 20-11 (01)
10-96 10-142 10-194 20-12 (01)
10-97 10-143 10-195 30-1 (01)
10-98 10-144 10-196 30-2 (03)
q 10-99 (05) 10-145 10-197 30-3 (01)
Q 10-99-1 (05) 10-146 10-198 30-4 (01)
Q 10-99-2 (05) 10-147 10-199 30-5 (01)
Q 10-99-3 (05) 10-148 10-200 30-6 (01)
Q 10-99-4 (05) 10-149 10-201 30-7 (01)
Q 10-99-5 (05) 10-150 10-202 30-8 (01)
Q 10-99-6 (05) 10-151 10-203 30-9 (01)
10-100 10-152 10-204 30-10 (01)
10-101 10-153 10-205 30-11 (01)
10-102 10-154 10-206 (03) 30-12 (01)
10-103 10-155 10-207 30-13 (01)
10-104 10-156 10-207-1 (03) 30-14 (01)
10-105 10-157 10-207-2 (03) 30-15 (01)
10-106 10-158 10-208 30-16 (01)
10-107 10-159 10-209 30-17 (01)
10-108 10-160 10-210 30-18 (01)
10-109 10-161 10-211 30-19 (01)
10-110 10-162 10-212 30-20 (01)
10-111 10-163 10-213 30-21 (01)
10-112 10-164 10-214 30-22 (01)
10-113 10-165 10-215 30-23 (01)
10-114 10-166 10-216 30-24 (01)
10-115 10-167 10-217 30-25 (01)
10-116 10-168 10-218 30-26 (01)
10-117 10-169 10-219 30-27 (01)
10-118 10-170 10-220 30-28 (01)
10-119 10-171 10-221 30-29 (01)
10-120 10-172 10-222 30-30 (01)
10-121 10-173 10-223 30-31 (01)
10-122 10-174 10-224 30-32 (01)
10-123 10-175 10-225 30-33 (01)
10-124 10-176 10-226 30-34 (01)
10-125 10-177 10-227 30-35 (01)
10-126 10-178 10-228 30-36 (01)
10-127 10-179 10-229 30-37 (01)
10-128 10-180 10-230 30-38 (01)
10-129 10-181 10-231 30-39 (01)
10-130 10-182 10-232 30-40 (01)
10-131 10-183 20-1 (01) 30-41 (03)
10-132 10-184 20-2 (01) 30-42 (01)
10-133 10-185 20-3 (01) 30-43 (01)
10-134 10-186 20-4 (01) 30-44 (01)

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Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
30-45 (01) 30-97 (01) 30-149 (01) 40-19 (01)
30-46 (01) 30-98 (01) 30-150 (01) 40-20 (01)
30-47 (01) 30-99 (01) 30-151 (01) 40-21 (01)
30-48 (01) 30-100 (01) 30-152 (01) 40-22 (01)
30-49 (01) 30-101 (01) 30-153 (01) 40-23 (01)
30-50 (01) 30-102 (01) 30-154 (01) 40-24 (01)
30-51 (01) 30-103 (01) 30-155 (01) 40-25 (01)
30-52 (01) 30-104 (01) 30-156 (01) 40-26 (01)
30-53 (01) 30-105 (01) 30-157 (03) 40-27 (01)
30-54 (01) 30-106 (01) 30-158 (01) 40-28 (01)
30-55 (01) 30-107 (01) 30-159 (01) 40-29 (01)
30-56 (01) 30-108 (01) 30-160 (01) 40-30 (01)
30-57 (01) 30-109 (01) 30-160-1 (03) 40-31 (01)
30-58 (01) 30-110 (01) 30-160-2 (03) 40-32 (01)
30-59 (01) 30-111 (01) 30-160-3 (03) 40-33 (01)
30-60 (01) 30-112 (01) 30-160-4 (03) 40-34 (01)
30-61 (01) 30-113 (01) 30-161 (03) 40-35 (01)
30-62 (01) 30-114 (01) 30-162 (01) 40-36 (01)
30-63 (01) 30-115 (01) 30-163 (01) 40-37 (01)
30-64 (01) 30-116 (01) 30-163-1 (03) 40-38 (01)
30-65 (01) 30-117 (01) 30-163-2 (03) 40-39 (01)
30-66 (01) 30-118 (01) 30-163-3 (03) 40-40 (01)
30-67 (01) 30-119 (01) 30-163-4 (03) 40-41 (01)
30-68 (01) 30-120 (01) 30-164 (01) 40-42 (01)
30-69 (01) 30-121 (01) 30-165 (01) 40-43 (01)
30-70 (01) 30-122 (01) 30-166 (01) 40-44 (01)
30-71 (01) 30-123 (01) 30-167 (01) 40-45 (01)
30-72 (01) 30-124 (01) 30-168 (01) 40-46 (01)
30-73 (01) 30-125 (01) 30-169 (01) 40-47 (01)
30-74 (01) 30-126 (01) 30-170 (01) 40-48 (01)
30-75 (01) 30-127 (01) 30-171 (01) 40-49 (01)
30-76 (01) 30-128 (01) 30-172 (01) 40-50 (01)
30-77 (04) 30-129 (01) 30-173 (01) 40-51 (01)
30-78 (01) 30-130 (01) 30-174 (01) 40-52 (01)
30-79 (01) 30-131 (01) 40-1 (01) 40-53 (01)
30-80 (01) 30-132 (01) 40-2 (01) 40-54 (01)
30-81 (01) 30-133 (01) 40-3 (01) 40-55 (01)
30-82 (01) 30-134 (01) 40-4 (01) 40-56 (01)
30-83 (01) 30-135 (01) 40-5 (01) 40-57 (01)
30-84 (01) 30-136 (01) 40-6 (01) 40-58 (01)
30-85 (01) 30-137 (01) 40-7 (01) 40-59 (01)
30-86 (01) 30-138 (01) 40-8 (01) 40-60 (01)
30-87 (01) 30-139 (01) 40-9 (01) 40-61 (01)
30-88 (01) 30-140 (01) 40-10 (01) 40-62 (01)
30-89 (04) 30-141 (01) 40-11 (01) 40-63 (01)
30-90 (01) 30-142 (01) 40-12 (01) 40-64 (01)
30-91 (01) 30-143 (01) 40-13 (01) 40-65 (01)
30-92 (01) 30-144 (01) 40-14 (01) 40-66 (01)
30-93 (01) 30-145 (01) 40-15 (01) 40-67 (01)
30-94 (01) 30-146 (01) 40-16 (01) 40-68 (01)
30-95 (01) 30-147 (01) 40-17 (01) 40-69 (01)
30-96 (01) 30-148 (01) 40-18 (01) 40-70 (01)

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Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
40-71 (01) 40-123 (01) 40-175 (01) 40-227 (01)
40-72 (01) 40-124 (01) 40-176 (01) 40-228 (01)
40-73 (01) 40-125 (01) 40-177 (01) 40-229 (01)
40-74 (01) 40-126 (01) 40-178 (01) 40-230 (01)
40-75 (01) 40-127 (01) 40-179 (01) 40-231 (01)
40-76 (01) 40-128 (01) 40-180 (01) 40-232 (01)
40-77 (01) 40-129 (01) 40-181 (01) 40-233 (01)
40-78 (01) 40-130 (01) 40-182 (01) 40-234 (01)
40-79 (01) 40-131 (01) 40-183 (01) 40-235 (01)
40-80 (01) 40-132 (01) 40-184 (01) 40-236 (01)
40-81 (01) 40-133 (01) 40-185 (01) 40-237 (01)
40-82 (01) 40-134 (01) 40-186 (01) 40-238 (01)
40-83 (01) 40-135 (01) 40-187 (01) 40-239 (01)
40-84 (01) 40-136 (01) 40-188 (01) 40-240 (01)
40-85 (01) 40-137 (01) 40-189 (01) 40-241 (01)
40-86 (01) 40-138 (01) 40-190 (01) 40-242 (01)
40-87 (01) 40-139 (01) 40-191 (01) 40-243 (01)
40-88 (01) 40-140 (01) 40-192 (01) 40-244 (01)
40-89 (01) 40-141 (01) 40-193 (01) 40-245 (01)
40-90 (01) 40-142 (01) 40-194 (01) 40-246 (01)
40-91 (01) 40-143 (01) 40-195 (01) 40-247 (01)
40-92 (01) 40-144 (01) 40-196 (01) 40-248 (01)
40-93 (01) 40-145 (01) 40-197 (01) 40-249 (01)
40-94 (01) 40-146 (01) 40-198 (01) 40-250 (01)
40-95 (01) 40-147 (01) 40-199 (01) 40-251 (01)
40-96 (01) 40-148 (01) 40-200 (01) 40-252 (01)
40-97 (01) 40-149 (01) 40-201 (01) 40-253 (01)
40-98 (01) 40-150 (01) 40-202 (01) 40-254 (01)
40-99 (01) 40-151 (01) 40-203 (01) 40-255 (01)
40-100 (01) 40-152 (01) 40-204 (01) 40-256 (01)
40-101 (01) 40-153 (01) 40-205 (01) 40-257 (01)
40-102 (01) 40-154 (01) 40-206 (01) 40-258 (01)
40-103 (01) 40-155 (01) 40-207 (01) 40-259 (01)
40-104 (01) 40-156 (01) 40-208 (01) 40-260 (01)
40-105 (01) 40-157 (01) 40-209 (01) 40-261 (01)
40-106 (01) 40-158 (01) 40-210 (01) 40-262 (01)
40-107 (01) 40-159 (01) 40-211 (01) 40-263 (01)
40-108 (01) 40-160 (01) 40-212 (01) 40-264 (01)
40-109 (01) 40-161 (01) 40-213 (01) 40-265 (01)
40-110 (01) 40-162 (01) 40-214 (01) 40-266 (01)
40-111 (01) 40-163 (01) 40-215 (01) 40-267 (01)
40-112 (01) 40-164 (01) 40-216 (01) 40-268 (01)
40-113 (01) 40-165 (01) 40-217 (01) 40-269 (01)
40-114 (01) 40-166 (01) 40-218 (01) 40-270 (01)
40-115 (01) 40-167 (01) 40-219 (01) 40-271 (01)
40-116 (01) 40-168 (01) 40-220 (01) 40-272 (01)
40-117 (01) 40-169 (01) 40-221 (01) 40-273 (01)
40-118 (01) 40-170 (01) 40-222 (01) 40-274 (01)
40-119 (01) 40-171 (01) 40-223 (01) 40-275 (01)
40-120 (01) 40-172 (01) 40-224 (01) 40-276 (01)
40-121 (01) 40-173 (01) 40-225 (01) 40-277 (01)
40-122 (01) 40-174 (01) 40-226 (01) 40-278 (01)

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Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
40-279 (01) 40-331 (01) 40-383 (01) 40-435 (01)
40-280 (01) 40-332 (01) 40-384 (01) 40-436 (01)
40-281 (01) 40-333 (01) 40-385 (01) 40-437 (01)
40-282 (01) 40-334 (01) 40-386 (01) 40-438 (01)
40-283 (01) 40-335 (01) 40-387 (01) 40-439 (01)
40-284 (01) 40-336 (01) 40-388 (01) 40-440 (01)
40-285 (01) 40-337 (01) 40-389 (01) 40-441 (01)
40-286 (01) 40-338 (01) 40-390 (01) 40-442 (01)
40-287 (01) 40-339 (01) 40-391 (01) 40-443 (01)
40-288 (01) 40-340 (01) 40-392 (01) 40-444 (01)
40-289 (01) 40-341 (01) 40-393 (01) 40-445 (01)
40-290 (01) 40-342 (01) 40-394 (01) 40-446 (01)
40-291 (01) 40-343 (01) 40-395 (01) 40-447 (01)
40-292 (01) 40-344 (01) 40-396 (01) 40-448 (01)
40-293 (01) 40-345 (01) 40-397 (01) 40-449 (01)
40-294 (01) 40-346 (01) 40-398 (01) 40-450 (01)
40-295 (01) 40-347 (01) 40-399 (01) 40-451 (01)
40-296 (01) 40-348 (01) 40-400 (01) 40-452 (01)
40-297 (01) 40-349 (01) 40-401 (01) 40-453 (01)
40-298 (01) 40-350 (01) 40-402 (01) 40-454 (01)
40-299 (01) 40-351 (01) 40-403 (01) 40-455 (01)
40-300 (01) 40-352 (01) 40-404 (01) 40-456 (01)
40-301 (01) 40-353 (01) 40-405 (01) 40-457 (01)
40-302 (01) 40-354 (01) 40-406 (01) 40-458 (03)
40-303 (01) 40-355 (01) 40-407 (01) 40-459 (03)
40-304 (01) 40-356 (01) 40-408 (01) 40-459-1 (03)
40-305 (01) 40-357 (01) 40-409 (01) 40-459-2 (03)
40-306 (01) 40-358 (01) 40-410 (01) 40-460 (01)
40-307 (01) 40-359 (01) 40-411 (01) 40-461 (01)
40-308 (01) 40-360 (01) 40-412 (01) 40-462 (01)
40-309 (01) 40-361 (01) 40-413 (01) 40-463 (01)
40-310 (01) 40-362 (01) 40-414 (01) 40-464 (01)
40-311 (01) 40-363 (01) 40-415 (01) 40-465 (01)
40-312 (01) 40-364 (01) 40-416 (01) 40-466 (01)
40-313 (01) 40-365 (01) 40-417 (01) 40-467 (01)
40-314 (01) 40-366 (01) 40-418 (01) 40-468 (01)
40-315 (01) 40-367 (01) 40-419 (01) 40-469 (01)
40-316 (01) 40-368 (01) 40-420 (01) 40-470 (01)
40-317 (01) 40-369 (01) 40-421 (01) 40-471 (01)
40-318 (01) 40-370 (01) 40-422 (01) 40-472 (01)
40-319 (01) 40-371 (01) 40-423 (01) 40-473 (01)
40-320 (01) 40-372 (01) 40-424 (01) 40-474 (01)
40-321 (01) 40-373 (01) 40-425 (01) 40-475 (01)
40-322 (01) 40-374 (01) 40-426 (01) 40-476 (01)
40-323 (01) 40-375 (01) 40-427 (01) 40-477 (01)
40-324 (01) 40-376 (01) 40-428 (01) 40-478 (01)
40-325 (01) 40-377 (01) 40-429 (01) 40-479 (01)
40-326 (01) 40-378 (01) 40-430 (01) 40-480 (01)
40-327 (01) 40-379 (01) 40-431 (01) 40-481 (01)
40-328 (01) 40-380 (01) 40-432 (01) 40-482 (01)
40-329 (01) 40-381 (01) 40-433 (01) 40-483 (01)
40-330 (01) 40-382 (01) 40-434 (01) 40-484 (01)

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Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
40-485 (01) 50-7 (02) 50-59 (02) 50-111 (02)
40-486 (01) 50-8 (02) 50-60 (02) 50-112 (02)
40-487 (01) 50-9 (02) 50-61 (02) 50-113 (02)
40-488 (01) 50-10 (02) 50-62 (02) 50-114 (02)
40-489 (01) 50-11 (02) 50-63 (02) 50-115 (02)
40-490 (01) 50-12 (02) 50-64 (02) 50-116 (02)
40-491 (01) 50-13 (02) 50-65 (02) 50-117 (02)
40-492 (01) 50-14 (02) 50-66 (02) 50-118 (02)
40-493 (01) 50-15 (02) 50-67 (02) 50-119 (02)
40-494 (01) 50-16 (02) 50-68 (02) 50-120 (02)
40-495 (01) 50-17 (02) 50-69 (02) 50-121 (02)
40-496 (01) 50-18 (02) 50-70 (02) 50-122 (02)
40-497 (01) 50-19 (02) 50-71 (02) 50-123 (02)
40-498 (01) 50-20 (02) 50-72 (02) 50-124 (02)
40-499 (01) 50-21 (02) 50-73 (02) 50-125 (02)
40-500 (01) 50-22 (02) 50-74 (02) 50-126 (02)
40-501 (01) 50-23 (02) 50-75 (02) 50-127 (02)
40-502 (01) 50-24 (02) 50-76 (02) 50-128 (02)
40-503 (01) 50-25 (02) 50-77 (02) 50-129 (02)
40-504 (01) 50-26 (02) 50-78 (02) 50-130 (02)
40-505 (01) 50-27 (02) 50-79 (02) 50-131 (02)
40-506 (01) 50-28 (02) 50-80 (02) 50-132 (02)
40-507 (01) 50-29 (02) 50-81 (02) 50-133 (02)
40-508 (01) 50-30 (02) 50-82 (02) 50-134 (02)
40-509 (01) 50-31 (02) 50-83 (02) 50-135 (02)
40-510 (01) 50-32 (02) 50-84 (02) 50-136 (02)
40-511 (01) 50-33 (02) 50-85 (02) 50-137 (02)
40-512 (01) 50-34 (02) 50-86 (02) 50-138 (02)
40-513 (01) 50-35 (02) 50-87 (02) 50-139 (02)
40-514 (01) 50-36 (02) 50-88 (02) 50-140 (02)
40-515 (01) 50-37 (02) 50-89 (02) 50-141 (02)
40-516 (01) 50-38 (02) 50-90 (02) 50-142 (02)
40-517 (01) 50-39 (02) 50-91 (02) 50-143 (02)
40-518 (01) 50-40 (02) 50-92 (02) 50-144 (02)
40-519 (01) 50-41 (02) 50-93 (02) 50-145 (02)
40-520 (01) 50-42 (02) 50-94 (02) 50-146 (02)
40-521 (01) 50-43 (02) 50-95 (02) 50-147 (02)
40-522 (01) 50-44 (02) 50-96 (02) 50-148 (02)
40-523 (01) 50-45 (02) 50-97 (02) 50-149 (02)
40-524 (01) 50-46 (02) 50-98 (02) 50-150 (02)
40-525 (01) 50-47 (02) 50-99 (02) 50-151 (02)
40-526 (01) 50-48 (02) 50-100 (02) 50-152 (02)
40-527 (01) 50-49 (02) 50-101 (02) 50-153 (02)
40-528 (01) 50-50 (02) 50-102 (02) 50-154 (02)
40-529 (01) 50-51 (02) 50-103 (02) 50-155 (02)
40-530 (01) 50-52 (02) 50-104 (02) 50-156 (02)
50-1 (02) 50-53 (02) 50-105 (02) 50-157 (02)
50-2 (02) 50-54 (02) 50-106 (02) 50-158 (02)
50-3 (02) 50-55 (02) 50-107 (02) 50-159 (02)
50-4 (02) 50-56 (02) 50-108 (02) 50-160 (02)
50-5 (02) 50-57 (02) 50-109 (02) 50-161 (02)
50-6 (02) 50-58 (02) 50-110 (02) 50-162 (02)

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(05)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
50-163 (02) 50-215 (02) 50-267 (02) 60-39
50-164 (02) 50-216 (02) 50-268 (02) 60-40
50-165 (02) 50-217 (02) 50-269 (02) 60-41
50-166 (02) 50-218 (02) 50-270 (02) 60-42
50-167 (02) 50-219 (02) 50-271 (02) 60-43
50-168 (02) 50-220 (02) 50-272 (02) 60-44
50-169 (02) 50-221 (02) 50-273 (02) 60-45
50-170 (02) 50-222 (02) 50-274 (02) 60-46
50-171 (02) 50-223 (02) 50-275 (02) 60-47
50-172 (02) 50-224 (02) 50-276 (02) 60-48
50-173 (02) 50-225 (02) 50-277 (02) 60-49
50-174 (02) 50-226 (02) 50-278 (02) 60-50
50-175 (02) 50-227 (02) 50-279 (02) 60-51
50-176 (02) 50-228 (02) 50-280 (02) 60-52
50-177 (02) 50-229 (02) 60-1 60-53
50-178 (02) 50-230 (02) 60-2 60-54
50-179 (02) 50-231 (02) 60-3 60-55
50-180 (02) 50-232 (02) 60-4 60-56
50-181 (02) 50-233 (02) 60-5 60-57
50-182 (02) 50-234 (02) 60-6 60-58
50-183 (02) 50-235 (02) 60-7 60-59
50-184 (02) 50-236 (02) 60-8 60-60
50-185 (02) 50-237 (02) 60-9 60-61
50-186 (02) 50-238 (02) 60-10 60-62
50-187 (02) 50-239 (02) 60-11 60-63
50-188 (02) 50-240 (02) 60-12 60-64
50-189 (02) 50-241 (02) 60-13 80-1 (01)
50-190 (02) 50-242 (02) 60-14 80-2 (01)
50-191 (02) 50-243 (02) 60-15 80-3 (01)
50-192 (02) 50-244 (02) 60-16 80-4 (01)
50-193 (02) 50-245 (02) 60-17 80-5 (01)
50-194 (02) 50-246 (02) 60-18 80-6 (01)
50-195 (02) 50-247 (02) 60-19 80-7 (01)
50-196 (02) 50-248 (02) 60-20 80-8 (01)
50-197 (02) 50-249 (02) 60-21 80-9 (01)
50-198 (02) 50-250 (02) 60-22 80-10 (01)
50-199 (02) 50-251 (02) 60-23 80-11 (01)
50-200 (02) 50-252 (02) 60-24 80-12 (01)
50-201 (02) 50-253 (02) 60-25 80-13 (01)
50-202 (02) 50-254 (02) 60-26 80-14 (01)
50-203 (02) 50-255 (02) 60-27 80-15 (01)
50-204 (02) 50-256 (02) 60-28 80-16 (01)
50-205 (02) 50-257 (02) 60-29 80-17 (01)
50-206 (02) 50-258 (02) 60-30 80-18 (01)
50-207 (02) 50-259 (02) 60-31 80-19 (01)
50-208 (02) 50-260 (02) 60-32 80-20 (01)
50-209 (02) 50-261 (02) 60-33 80-21 (01)
50-210 (02) 50-262 (02) 60-34 80-22 (01)
50-211 (02) 50-263 (02) 60-35 80-23 (01)
50-212 (02) 50-264 (02) 60-36 80-24 (01)
50-213 (02) 50-265 (02) 60-37 80-25 (01)
50-214 (02) 50-266 (02) 60-38 80-26 (01)

GD555-5, GD655-5, GD675-5 7


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Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
80-27 (01) 90-21 (01)
80-28 (01) 90-23 (01)
80-29 (01) 90-25 (01)
80-30 (01) 90-27 (01)
80-31 (01) 90-29 (01)
80-32 (01) 90-31 (01)
80-33 (01) 90-33 (01)
80-34 (01) 90-35 (03)
80-35 (01) q 1 (05)
80-36 (01) 2 (02)
80-37 (01) 3 (02)
80-38 (01) 4 (02)
80-39 (01) 5 (02)
80-40 (01) 6 (03)
80-41 (01) Colo-
q (05)
80-42 (01) phon
80-43 (01)
80-44 (01)
80-45 (01)
80-46 (01)
80-47 (01)
80-48 (01)
80-49 (01)
80-50 (01)
80-51 (01)
80-52 (01)
80-53 (01)
80-54 (01)
80-55 (01)
80-56 (01)
80-57 (01)
80-58 (01)
90-1
90-2 (01)
90-3
90-4
90-5
(90-6)
90-7 (01)
(90-8)
90-9 (01)
(90-10)
90-11 (01)
(90-12)
90-13 (01)
90-14 (01)
90-15 (01)
90-16 (01)
90-17 (01)
(90-18)
90-19 (01)
(90-20)

8 GD555-5, GD655-5, GD675-5


(05)
DRAFT

GD555-5,GD655-5,GD675-5
SEN0521502-00

MOTOR GRADER
Shop Manual

GD555-5
GD655-5
GD675-5

Machine model Serial number


GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

00 Index and foreword


4

GD555-5,GD655-5,GD675-5 00-1
DRAFT

Table of contents

Table of contents
Composition of shop manual

00 Index and foreword


Table of contents .......................................................................................................................... 00 - 2
Table of contents ....................................................................................................................... 00 - 2
Foreword and general information ................................................................................................ 00 - 5
Safety notice .............................................................................................................................. 00 - 5
How to read the shop manual .................................................................................................... 00 - 10
Explanation of terms for maintenance standard ........................................................................ 00 - 12
Handling of electric equipment and hydraulic components........................................................ 00 - 14
Handling of connectors newly used for engines ........................................................................ 00 - 23
How to read electric wire code................................................................................................... 00 - 26
Precautions when carrying out work .......................................................................................... 00 - 29
Method of disassembling and connecting push-pull type coupler.............................................. 00 - 32
Standard tightening torque table................................................................................................ 00 - 35
List of Abbreviation .................................................................................................................... 00 - 39
Conversion table ........................................................................................................................ 00 - 43

01 Specification
Specification drawing ................................................................................................................. 01 - 3
Specifications............................................................................................................................. 01 - 4
Weight table ............................................................................................................................... 01 - 10
Table of fuel, coolant and lubricants .......................................................................................... 01 - 11

10 Structure, function and maintenance standard


Engine and Cooling....................................................................................................................... 10 - 4
Cooling system .......................................................................................................................... 10 - 4
Cooling fan pump....................................................................................................................... 10 - 6
Power train system ....................................................................................................................... 10 - 14
Power train system drawing....................................................................................................... 10 - 14
Power train piping drawing......................................................................................................... 10 - 16
Transmission control.................................................................................................................. 10 - 18
Torque converter........................................................................................................................ 10 - 20
Transmission.............................................................................................................................. 10 - 24
Transmission control valve ........................................................................................................ 10 - 46
ECMV......................................................................................................................................... 10 - 50
Main relief and torque converter relief valve .............................................................................. 10 - 58
Front axle ................................................................................................................................... 10 - 60
Final drive (no differential specification)..................................................................................... 10 - 64
Final drive (differential/ differential lock specification)................................................................ 10 - 66
Differential lock solenoid valve................................................................................................... 10 - 68
Tandem drive ............................................................................................................................. 10 - 70
Steering system ............................................................................................................................ 10 - 72
Steering piping diagram ............................................................................................................. 10 - 72
Priority valve .............................................................................................................................. 10 - 74
Steering valve ............................................................................................................................ 10 - 80
Brake system ................................................................................................................................ 10 - 88
Brake hydraulic piping diagram.................................................................................................. 10 - 88
Brake valve ................................................................................................................................ 10 - 89
Slack adjuster ............................................................................................................................ 10 - 96
Accumulator (for brake) ............................................................................................................. 10 - 98
Wheel brake............................................................................................................................... 10 -100

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Table of contents

Charge valve.............................................................................................................................. 10- 99


Wheel brake............................................................................................................................... 10 -100
Parking brake and bank control valve........................................................................................ 10 -102
Parking brake............................................................................................................................. 10 -104
Undercarriage frame ..................................................................................................................... 10 -106
Frame ........................................................................................................................................ 10 -106
Tire............................................................................................................................................. 10 -108
Hydraulic system .......................................................................................................................... 10 -110
Hydraulic system ....................................................................................................................... 10 -110
Work equipment hydraulic piping diagram................................................................................. 10 -114
Work equipment control............................................................................................................. 10 -118
Hydraulic tank ............................................................................................................................ 10 -120
Main pump ................................................................................................................................. 10 -122
Power train pump....................................................................................................................... 10 -134
Control valve.............................................................................................................................. 10 -136
CLSS ......................................................................................................................................... 10 -146
Functions and operation by valve .............................................................................................. 10 -150
Hydraulic cylinder ...................................................................................................................... 10 -160
Swivel joint................................................................................................................................. 10 -162
Pilot check valve ........................................................................................................................ 10 -164
Accumulator (for blade) ............................................................................................................. 10 -172
Work equipment............................................................................................................................ 10 -174
Circle and drawbar..................................................................................................................... 10 -174
Blade.......................................................................................................................................... 10 -176
Lifter........................................................................................................................................... 10 -178
Circle rotation motor .................................................................................................................. 10 -180
Circle rotation gear .................................................................................................................... 10 -182
Cab ............................................................................................................................................... 10 -184
Cab ............................................................................................................................................ 10 -184
Electrical ststem............................................................................................................................ 10 -186
Machine monitor ........................................................................................................................ 10 -186
Automatic shift control system ................................................................................................... 10 -190
Transmission controller.............................................................................................................. 10 -198
Engine controller........................................................................................................................ 10 -202
KOMTRAX system..................................................................................................................... 10 -206
Starting engine circuit ................................................................................................................ 10 -208
Stopping engine circuit .............................................................................................................. 10 -210
Preheating circuit ....................................................................................................................... 10 -212
Sensor ....................................................................................................................................... 10 -214
Engine power mode select circuit .............................................................................................. 10 -226
Cooling fan control function ....................................................................................................... 10 -228

20 Standard value table


Standard value table ..................................................................................................................... 20- 3
Standard value table for engine................................................................................................. 20- 3
Standard value table for machine .............................................................................................. 20- 5

30 Testing and adjusting


Tools for testing, adjusting, and troubleshooting .......................................................................... 30- 4
Tools for testing, adjusting, and troubleshooting ....................................................................... 30- 4
Engine and cooling system ........................................................................................................... 30- 10
Testing engine speed ................................................................................................................ 30- 10
Testing intake air pressure (boost pressure) ............................................................................. 30- 12
Testing exhaust gas temperature .............................................................................................. 30- 14

GD555-5,GD655-5,GD675-5 00-3
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Testing exhaust gas color .......................................................................................................... 30- 16


Adjusting valve clearance .......................................................................................................... 30- 18
Testing compression pressure................................................................................................... 30- 20
Testing blowby pressure ............................................................................................................ 30- 23
Testing engine oil pressure........................................................................................................ 30- 25
Handling fuel system device ...................................................................................................... 30- 26
Releasing remaining pressure from fuel system........................................................................ 30- 27
Testing fuel pressure ................................................................................................................. 30- 28
Bleeding air from fuel circuit....................................................................................................... 30- 29
Testing fuel circuit for leakage ................................................................................................... 30- 30
Cylinder cut-out test mode ......................................................................................................... 30- 31
No injection cranking.................................................................................................................. 30- 32
Handling voltage circuit of engine controller .............................................................................. 30- 33
Checking muffler body and muffler stack for looseness and damage ....................................... 30- 34
Checking muffler function .......................................................................................................... 30- 35
Checking cylinder head and manifolds for looseness................................................................ 30- 36
Checking engine piping for damage and looseness .................................................................. 30- 37
Checking fuel delivery, return rate and leakage......................................................................... 30- 38
Replacing alternator belt ............................................................................................................ 30- 41
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]. 30- 42
Power train.................................................................................................................................... 30- 44
Testing power train oil pressure................................................................................................. 30- 44
Adjusting transmission speed sensor ........................................................................................ 30- 56
Emergency escape method in case of transmission valve failure ............................................. 30- 60
Flushing torque converter and trasmission circuits.................................................................... 30- 64
Testing and adjusting toe-in....................................................................................................... 30- 66
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]......... 30- 68
Steering system ............................................................................................................................ 30- 70
Testing and adjusting steering oil pressure ............................................................................... 30- 70
Testing steering cylinder oil leakage.......................................................................................... 30- 71
Bleeding air from steering circuit................................................................................................ 30- 72
Brake system ................................................................................................................................ 30- 74
Testing and adjusting brake oil pressure ................................................................................... 30- 74
Releasing remaining pressure from brake circuit....................................................................... 30- 78
Bleeding air from brake circuit ................................................................................................... 30- 79
Testing wheel brake disc wear................................................................................................... 30- 80
Testing and adjusting parking brake .......................................................................................... 30- 82
Emergency release method of parking brake ............................................................................ 30- 84
Filling gas into brake accumulator ............................................................................................. 30- 86
Hydraulic system........................................................................................................................... 30- 88
Testing and adjusting work equipment oil pressure................................................................... 30- 88
Testing and adjusting pump LS differential pressure................................................................. 30- 91
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut] .................................. 30- 93
Testing work equipment cylinder oil leakage amount ................................................................ 30- 94
Bleeding air from work equipment circuit ................................................................................... 30- 97
Work equipment............................................................................................................................ 30- 98
Clearance adjustment of drawbar ball joint................................................................................ 30- 98
Testing and adjusting circle guide clearance ............................................................................. 30- 99
Testing and adjusting slip clutch type circle rotator ................................................................... 30- 101
Filling gas into blade accumulator [machine with blade accumulator] ....................................... 30- 103
Electrical system ........................................................................................................................... 30- 104
Procedure for testing diodes ...................................................................................................... 30- 104
Special functions of machine monitor (EMMS) .......................................................................... 30- 105
Handling high voltage circuit of engine controller ...................................................................... 30- 154

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How to start KOMTRAX terminal operations ............................................................................. 30- 156


Indicator lamps of KOMTRAX terminal...................................................................................... 30- 161
Preparation work for troubleshooting of electrical system ......................................................... 30- 164
Pm clinic ....................................................................................................................................... 30- 166
Pm Clinic- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-166
40 Troubleshooting
General information on troubleshooting........................................................................................ 40- 7
Points to remember when troubleshooting ................................................................................ 40- 7
Sequence of events in troubleshooting...................................................................................... 40- 8
Checks before troubleshooting .................................................................................................. 40- 9
Classification and procedures for troubleshooting..................................................................... 40- 29
Failure codes table .................................................................................................................... 40- 30
Failure and troubleshooting numbers ........................................................................................ 40- 37
Information in troubleshooting table........................................................................................... 40- 39
Troubleshooting method for open circuit in wiring harness of pressure sensor system ............ 40- 41
Connector list and layout ........................................................................................................... 40- 43
Connection table for connector pin numbers ............................................................................. 40- 58
T- branch box and T- branch adapter table ............................................................................... 40- 94
Locations of fuses...................................................................................................................... 40- 97
Troubleshooting by failurecode..................................................................................................... 40- 99
Failure code [1500LO] TORQUEFLOW transmission: Double engagement ............................. 40- 99
Failure code [15G0MW] Transmission R clutch: Slip ................................................................ 40- 100
Failure code [15H0MW] Transmission FH clutch: Slip .............................................................. 40- 101
Failure code [15J0MW] Transmission FL clutch: Slip ................................................................ 40- 101
Failure code [15K0MW] Transmission 1st clutch: Slip............................................................... 40- 102
Failure code [15L0MW] Transmission 2nd clutch: Slip.............................................................. 40- 103
Failure code [15M0MW] Transmission 3rd speed clutch: Slip ................................................... 40- 104
Failure code [15N0MW] Transmission 4th clutch: Slip .............................................................. 40- 105
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF .......... 40- 106
Failure code [15SBMA] ECMV R clutch: Malfunction ................................................................ 40- 108
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF ........ 40- 110
Failure code [15SCMA] ECMV FH clutch: Malfunction.............................................................. 40- 112
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF ........ 40- 114
Failure code [15SDMA] ECMV FL clutch: Malfunction .............................................................. 40- 116
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF ........ 40- 118
Failure code [15SEMA] ECMV 1st clutch: Malfunction.............................................................. 40- 120
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF ....... 40- 122
Failure code [15SFMA] ECMV 2nd clutch: Malfunction ............................................................. 40- 124
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF ....... 40- 126
Failure code [15SGMA] ECMV 3rd clutch: Malfunction ............................................................. 40- 128
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF........ 40- 130
Failure code [15SHMA] ECMV 4th clutch: Malfunction ............................................................. 40- 132
Failure code [15SJMA] ECMV lockup clutch: Malfunction......................................................... 40- 134
Failure code [15UONT] Inching clutch: Overheating ................................................................. 40- 134
Failure code [2G42ZG] Front accumulater: Oil pressure drop................................................... 40- 135
Failure code [2G43ZG] Rear accumulater: Pressure drop ........................................................ 40- 135
Failure code [AA1ANX] Air cleaner: Clogging ........................................................................... 40- 136
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched. .................. 40- 138
Failure code [AB00MA] Alternator: Malfunction......................................................................... 40- 140
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop ........................... 40- 142
Failure code: [B@BCNS] Engine coolant overheat ................................................................... 40- 142
Failure code: [B@CENS] Torque converter oil overheat ........................................................... 40- 143
Failure code: [B@CKNS] Differential case: Overheat ............................................................... 40- 144
Failure code: [B@HANS] Hydraulic oil: Overheating................................................................. 40- 146

GD555-5,GD655-5,GD675-5 00-3-2
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Table of contents

Failure code [CA111] Engine controller internal error................................................................ 40- 148


Failure code [CA115] Engine Ne, Bkup speed sensor error ...................................................... 40- 149
Failure code [CA122] Charge pressure sensor high error ......................................................... 40- 150
Failure code [CA123] Charge pressure sensor low error........................................................... 40- 152
Failure code [CA131] Throttle sensor high error........................................................................ 40- 154
Failure code [CA132] Throttle sensor low error ......................................................................... 40- 156
Failure code [CA144] Coolant sensor high error........................................................................ 40- 158
Failure code [CA145] Coolant sensor low error ......................................................................... 40- 160
Failure code [CA153] Charge temperature sensor high error.................................................... 40- 162
Failure code [CA154] Charge temperature sensor low error ..................................................... 40- 164
Failure code [CA155] Speed derating error by high charge temperature .................................. 40- 166
Failure code [CA187] Sensor power supply 2 low error............................................................. 40- 168
Failure code [CA221] Atmospheric pressure sensor high error ................................................. 40- 170
Failure code [CA222] Atmospheric pressure sensor low error .................................................. 40- 172
Failure code [CA227] Sensor power supply 2 high error ........................................................... 40- 174
Failure code [CA234] Engine overspeed ................................................................................... 40- 174
Failure code [CA238] Ne speed sensor power supply error ...................................................... 40- 175
Failure code [CA271] IMV/IMA: Short circuit ............................................................................. 40- 176
Failure code [CA272] IMV/IMA open circuit ............................................................................... 40- 178
Failure code [CA322] Injector #1 (L#1) open/short .................................................................... 40- 180
Failure code [CA323] Injector #5 (L#5) open/short .................................................................... 40- 182
Failure code [CA324] Injector #3 (L#3) open/short .................................................................... 40- 184
Failure code [CA325] Injector #6 (L#6) open/short .................................................................... 40- 186
Failure code [CA331] Injector #2 (L#2) open/short .................................................................... 40- 188
Failure code [CA332] Injector #4 (L#4) open/short .................................................................... 40- 190
Failure code [CA342] Data compatibility error in engine controller............................................ 40- 192
Failure code [CA351] Injector drive circuit error......................................................................... 40- 193
Failure code [CA352] Sensor power supply 1 low error............................................................. 40- 194
Failure code [CA386] Sensor power supply 1 high error ........................................................... 40- 195
Failure code [CA428] Water-in-fuel sensor high error ............................................................... 40- 196
Failure code [CA429] Water-in-fuel sensor low error................................................................. 40- 198
Failure code [CA431] Idle validation switch error....................................................................... 40- 200
Failure code [CA432] Idle validation action error ....................................................................... 40- 204
Failure code [CA435] Engine oil pressure switch error.............................................................. 40- 207
Failure code [CA441] Power supply voltage low error ............................................................... 40- 208
Failure code [CA442] Power supply voltage high error.............................................................. 40- 210
Failure code [CA449] Common rail pressure high error 2 ......................................................... 40- 211
Failure code [CA451] Common rail pressure sensor high error................................................. 40- 212
Failure code [CA452] Common rail pressure sensor low error .................................................. 40- 214
Failure code [CA488] Torque derating error by high charge temperature ................................. 40- 216
Failure code [CA553] Common rail pressure high error 1 ......................................................... 40- 217
Failure code [CA559] Supply pump pressure low error 1 .......................................................... 40- 218
Failure code [CA689] Engine Ne speed sensor error ................................................................ 40- 219
Failure code [CA731] Engine Bkup speed sensor phase error.................................................. 40- 221
Failure code [CA757] All continuous data lost error................................................................... 40- 222
Failure code [CA778] Engine Bkup speed sensor error............................................................. 40- 223
Failure code [CA1633] KOMNET (CAN communication) error .................................................. 40- 226
Failure code [CA2185] Throttle sensor power supply high error................................................ 40- 228
Failure code [CA2186] Throttle sensor power supply low error ................................................. 40- 230
Failure code [CA2249] Supply pump pressure low error 2 ........................................................ 40- 232
Failure code [CA2311] Abnormality in IMV (IMA) solenoid........................................................ 40- 233
Failure code [CA2555] Intake heater relay open circuit ............................................................. 40- 234
Failure code [CA2556] Intake heater relay short circuit ............................................................. 40- 236
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness..... 40- 238

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Table of contents

Failure code [D160KB] Backup lamp relay: Ground fault .......................................................... 40- 240
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault.................................. 40- 242
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state .......... 40- 244
Failure code [DAFRKR] CAN communication failure (monitor panel) ....................................... 40- 246
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input) ......... 40- 248
Failure code [DAQOKT] Transmission controller: Non-volatile memory error ........................... 40- 250
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)
................................................................................................................................................... 40- 252
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement
................................................................................................................................................... 40- 254
Failure code [DAQRKR] Transmission controller CAN communication: Communication error . 40- 256
Failure code [DAQRMA] Transmission controller option setting: Malfunction ........................... 40- 260
Failure code [DB2RKR] Engine controller CAN communication: Communication error ............ 40- 261
Failure code [DD1NLD] Fan reverse switch signal: Short circuit ............................................... 40- 268
Failure code [DD1PKB] RPM set switch power supply short circuit .......................................... 40- 270
Failure code [DD1QKB] RPM set mode switch short circuit ...................................................... 40- 272
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error ..................... 40- 274
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit .................................................. 40- 276
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit ................................................... 40- 276
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit .................................................. 40- 277
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit ................................................. 40- 277
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit ................................................. 40- 278
Failure code [DDTNKA] Fill switch for R clutch: Open circuit .................................................... 40- 279
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit .................................................. 40- 280
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input ................ 40- 281
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error . 40- 285
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range .......... 40- 288
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault................................... 40- 290
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range .... 40- 292
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault................................. 40- 294
Failure code [DJF1KA] Fuel level sensor: Open circuit ............................................................. 40- 296
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range.......................... 40- 298
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range............................. 40- 300
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit........................... 40- 302
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match 40- 303
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit............... 40- 304
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match
................................................................................................................................................... 40- 305
Failure code [DLM3KA] Fan speed sensor: Open circuit........................................................... 40- 306
Failure code [DLM3LC] Fan speed sensor: Short circuit ........................................................... 40- 307
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit ........................ 40- 308
Failure code [DV00KB] Buzzer: Short circuit ............................................................................. 40- 310
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit......................................... 40- 312
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit ......................................... 40- 314
Failure code [DW7BKA] Fan reverse solenoid: Open circuit ..................................................... 40- 315
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..................................................... 40- 316
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line .................... 40- 318
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit................................................. 40- 320
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit ................................................. 40- 321
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line ................ 40- 322
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit .................................................. 40- 324
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit .................................................. 40- 325
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line ................. 40- 326
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit .............................................. 40- 328

GD555-5,GD655-5,GD675-5 00-3-4
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Table of contents

Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit............................................... 40- 329
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line .............. 40- 330
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit ............................................... 40- 332
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit ............................................... 40- 334
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line............... 40- 336
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit............................................... 40- 338
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit............................................... 40- 340
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line .............. 40- 342
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit ............................................. 40- 344
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.............................................. 40- 346
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line............. 40- 348
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit .............................................. 40- 350
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit .............................................. 40- 352
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line.............. 40- 354
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit................................................. 40- 356
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit ................................................. 40- 357
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line ................ 40- 358
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit.............................................. 40- 360
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit .............................................. 40- 362
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line ............. 40- 364
Troubleshooting of electrical system (E-mode)............................................................................. 40- 366
E-1 Engine does not start (starting motor does not turn) ........................................................... 40- 366
E-2 Preheating does not work.................................................................................................... 40- 372
E-3 When starting switch is turned to ON position, machine monitor displays nothing ............. 40- 377
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen
................................................................................................................................................... 40- 380
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine mon-
itor does not display correct screen ........................................................................................... 40- 380
E-6 Emergency stop monitor lights up while engine is running ................................................. 40- 381
E-7 Speedometer or engine tachometer does not indicate correctly ......................................... 40- 385
E-8 Engine coolant temperature gauge does not indicate correctly .......................................... 40- 386
E-9 Articulation angle indicator does not indicate correctly ....................................................... 40- 388
E-10 Torque converter oil temperature gauge does not indicate correctly ................................ 40- 390
E-11 Fuel level gauge does not indicate correctly ..................................................................... 40- 392
E-12 Character display does not display correctly..................................................................... 40- 394
E-13 Centralized warning lamp does not light up or does not go off ......................................... 40- 396
E-14 Alarm buzzer does not sound or does not stop sounding ................................................. 40- 398
E-15 Machine monitor mode selector switch does not work...................................................... 40- 400
E-16 Transmission mode does not switch ................................................................................. 40- 404
E-17 Engine mode does not switch ........................................................................................... 40- 406
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock spec-
ification]...................................................................................................................................... 40- 408
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]
................................................................................................................................................... 40- 412
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator
specification] .............................................................................................................................. 40- 414
E-21 Horn does not sound or does not stop sounding............................................................... 40- 418
E-22 Backup alarm does not sound or does not stop sounding ................................................ 40- 420
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off ......................... 40- 423
E-24 Working lamp does not light up or does not go off ............................................................ 40- 430
E-25 Turn signal lamp and hazard lamp do not flash. ............................................................... 40- 436
E-26 Stop lamp does not light up or does not go off.................................................................. 40- 442
E-27 Backup lamp does not light up or does not go off ............................................................. 40- 444
E-28 Windshield wiper does not operate ................................................................................... 40- 446

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E-29 Window washer does not operate..................................................................................... 40- 454


E-30 KOMTRAX system does not operate correctly ................................................................. 40- 458
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40- 460
How to read troubleshooting matrix ........................................................................................... 40- 460
H-1 Engine speed lowers significantly or engine stalls.............................................................. 40- 466
H-2 Machine does not start........................................................................................................ 40- 467
H-3 Gear is not shifted............................................................................................................... 40- 468
H-4 Travel lacks speed or power. .............................................................................................. 40- 469
H-5 Torque converter lockup does not work or is not released. ................................................ 40- 474
H-6 A large time lag results at start or in gear shift.................................................................... 40- 475
H-7 Oil temperature of torque converter is high......................................................................... 40- 480
H-8 Differential lock-up function does not work or is not released............................................. 40- 485
H-9 Steering lacks speed or power............................................................................................ 40- 486
H-10 Steering wheel does not move.......................................................................................... 40- 487
H-11 Wheel brake does not work at all or sufficiently................................................................ 40- 488
H-12 Wheel brake cannot be released or drags ........................................................................ 40- 489
H-13 Parking brake does not work at all or insufficiently ........................................................... 40- 490
H-14 Parking brake (including emergency release system) cannot be released or drags. ....... 40- 491
H-15 All work equipment operation lacks speed or power......................................................... 40- 492
H-16 Work equipment does not work at all................................................................................ 40- 493
H-17 Unusual noise comes out from around hydraulic pump.................................................... 40- 494
H-18 Blade lift operation lacks speed or power ......................................................................... 40- 495
H-19 Hydraulic drift of blade lift cylinders is large...................................................................... 40- 496
H-20 Drawbar side shift operation lacks speed or power .......................................................... 40- 497
H-21 Blade side shift operation lacks speed or power............................................................... 40- 498
H-22 Power tilt operation lacks speed or power ........................................................................ 40- 499
H-23 Articulate operation lacks speed or power ........................................................................ 40- 500
H-24 Leaning operation lacks speed or power .......................................................................... 40- 501
H-25 Hydraulic drift of leaning cylinders (leaning) is large......................................................... 40- 502
H-26 Blade does not rotate........................................................................................................ 40- 503
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)
................................................................................................................................................... 40- 504
H-28 Blade accumulator function does not work or cannot be released (for machine with blade accumu-
lator float specification) .............................................................................................................. 40- 505
H-29 Blade float function does not work or cannot be released ................................................ 40- 506
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
................................................................................................................................................... 40- 507
Troubleshooting of engine (S-mode) ............................................................................................ 40- 508
Method of using troubleshooting chart....................................................................................... 40- 508
S-1 Startability is poor................................................................................................................ 40- 512
S-2 Engine does not start .......................................................................................................... 40- 513
S-3 Engine does not pick up smoothly ...................................................................................... 40- 516
S-4 Engine stops during operation ............................................................................................ 40- 517
S-5 Engine runs rough or is unstable ........................................................................................ 40- 518
S-6 Engine lacks power ............................................................................................................. 40- 519
S-7 Exhaust smoke is black (incomplete combustion) .............................................................. 40- 520
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................... 40- 521
S-9 Oil becomes contaminated early......................................................................................... 40- 522
S-10 Fuel consumption is excessive ......................................................................................... 40- 523
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) ........................................ 40- 524
S-12 Oil pressure drops............................................................................................................. 40- 525
S-13 Oil level rises (coolant or fuel in oil) .................................................................................. 40- 526
S-14 Coolant temperature rises too high (overheating)............................................................. 40- 527
S-15 Unusual noise is made...................................................................................................... 40- 528

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S-16 Vibration is excessive........................................................................................................ 40- 529

50 Disassembly and assembly


General information on disassembly and assembly ..................................................................... 50 - 4
How to read this manual ............................................................................................................ 50- 4
Coating materials list.................................................................................................................. 50- 6
Special tools list ......................................................................................................................... 50- 9
Sketches of special tools ........................................................................................................... 50- 13
Engine and cooling system ........................................................................................................... 50- 17
Removal and installation of fuel supply pump assembly ........................................................... 50- 17
Removal and installation of fuel injector assembly .................................................................... 50- 22
Removal and installation of cylinder head assembly ................................................................. 50- 32
Removal and installation of engine front oil seal........................................................................ 50- 50
Removal and installation of engine rear oil seal ........................................................................ 50- 53
Removal and installation of cooling fan pump assembly ........................................................... 50- 57
Removal and installation of cooling fan and fan motor assembly .............................................. 50- 59
Removal and installation of radiator assembly .......................................................................... 50- 63
Removal and installation of aftercooler assembly...................................................................... 50- 67
Removal and installation of power train oil cooler assembly ..................................................... 50- 70
Removal and installation of fuel tank assembly ......................................................................... 50- 73
Removal and installation of engine hood assembly................................................................... 50- 77
Power train.................................................................................................................................... 50- 79
Removal and installation of engine and transmission/torque converter assembly .................... 50- 79
Disassembly and assembly of engine and transmission/torque converter assembly ................ 50- 87
Disassembly and assembly of torque converter assembly ........................................................ 50- 89
Disassembly and assembly of transmission assembly .............................................................. 50- 97
Removal and installation of tandem drive and final drive assembly .......................................... 50- 135
Disassembly and assembly of tandem drive assembly ............................................................. 50- 139
Disassembly and assembly of final drive assembly................................................................... 50- 144
Steering system ............................................................................................................................ 50- 163
Removal and installation of steering valve (orbit-roll) assembly ................................................ 50- 163
Disassembly and assembly of steering valve (orbit-roll) assembly............................................ 50- 169
Brake system ................................................................................................................................ 50- 180
Disassembly and assembly of wheel brake assembly............................................................... 50- 180
Undercarriage and frame .............................................................................................................. 50- 185
Removal and installation of center hinge pin ............................................................................. 50- 185
Hydraulic system........................................................................................................................... 50- 198
Removal and installation of hydraulic tank, battery and frame assembly .................................. 50- 198
Removal and installation of hydraulic tank assembly ................................................................ 50- 205
Removal and installation of control valve assembly .................................................................. 50- 212
Disassembly and assembly of control valve assembly .............................................................. 50- 218
Disassembly and assembly of hydraulic cylinder assembly ...................................................... 50- 221
Work equipment............................................................................................................................ 50- 226
Removal and installation of blade assembly.............................................................................. 50- 226
Removal and installation of circle drawbar assembly ................................................................ 50- 228
Removal and installation of circle rotation gear assembly ......................................................... 50- 231
Disassembly and assembly of circle rotation gear assembly..................................................... 50- 238
Removal and installation of ripper assembly ............................................................................. 50- 238
Cab and its attachments ............................................................................................................... 50- 241
Removal and installation of operator cab assembly .................................................................. 50- 241
Removal and installation of floor frame assembly ..................................................................... 50- 253
Removal and installation of operator cab glass (adhered glass) ............................................... 50- 257
Removal and installation of air conditioner unit assembly ......................................................... 50- 267

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Electrical system ........................................................................................................................... 50- 273


Removal and installation of engine controller assembly............................................................ 50- 273
Removal and installation of machine monitor assembly............................................................ 50- 275
Removal and installation of transmission controller assembly .................................................. 50- 277
Removal and installation of KOMTRAX terminal assembly ....................................................... 50- 279

60 Maintenance standard
Engine and Cooling ...................................................................................................................... 60 - 4
Engine mount and transmission mount ..................................................................................... 60 - 4
Cooling system .......................................................................................................................... 60 - 6
Cooling fan motor ...................................................................................................................... 60 - 8
Power train system ....................................................................................................................... 60 - 12
Transmission control.................................................................................................................. 60 - 12
Torque converter ....................................................................................................................... 60 - 14
Transmission ............................................................................................................................. 60 - 16
Main relief valve and torque converter relief valve .................................................................... 60 - 24
Front axle................................................................................................................................... 60 - 26
Final drive (no differential specification) .................................................................................... 60 - 30
Final drive (differential/ differential lock specification) ............................................................... 60 - 32
Differential lock solenoid valve .................................................................................................. 60 - 34
Tandem drive............................................................................................................................. 60 - 36
Brake system ................................................................................................................................ 60 - 38
Slack adjuster ............................................................................................................................ 60 - 38
Wheel brake............................................................................................................................... 60 - 40
Parking brake............................................................................................................................. 60 - 42
Hydraulic system .......................................................................................................................... 60 - 44
Power train pump....................................................................................................................... 60 - 44
Control valve.............................................................................................................................. 60 - 46
Hydraulic cylinder ...................................................................................................................... 60 - 54
Work equipment............................................................................................................................ 60 - 56
Circle and drawbar..................................................................................................................... 60 - 56
Blade.......................................................................................................................................... 60 - 58
Lifter........................................................................................................................................... 60 - 60
Circle rotation gear .................................................................................................................... 60 - 62

80 Appendix
Air conditioner ............................................................................................................................... 80- 3
Precautions for refrigerant ......................................................................................................... 80- 3
Air Conditioner Components...................................................................................................... 80- 4
Structure and Function of Refrigeration System........................................................................ 80- 6
Overview of Refrigeration System ............................................................................................. 80- 7
Air Conditioner Unit.................................................................................................................... 80- 8
Compressor ............................................................................................................................... 80- 11
Condenser ................................................................................................................................. 80- 12
Receiver drier ............................................................................................................................ 80- 13
Air conditioner control panel ...................................................................................................... 80- 14
Procedure for check and troubleshooting .................................................................................. 80- 16
Circuit diagram and layout of connector pins............................................................................. 80- 18
System diagram......................................................................................................................... 80- 20
Detail of air conditioner unit ....................................................................................................... 80- 22
Parts and connectors layout ...................................................................................................... 80- 24
Testing air leakage (ducts) ........................................................................................................ 80- 26
Check with self-diagnosis (control panel display) ...................................................................... 80- 27
Testing temperature control....................................................................................................... 80- 28

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Testing Fresh/Recirc air changeover ......................................................................................... 80- 29


Testing evaporator temperature sensor..................................................................................... 80- 30
Testing relays............................................................................................................................. 80- 31
Testing blower amp.................................................................................................................... 80- 32
Troubleshooting Chart 1 ............................................................................................................ 80- 33
Troubleshooting Chart 2 ............................................................................................................ 80- 35
Information in troubleshooting table........................................................................................... 80- 37
Troubleshooting for power supply system (Air conditioner does not operate) ........................... 80- 38
Troubleshooting of compressor and refrigerant system (Air is not cooled)................................ 80- 40
Troubleshooting for blower motor system (Air does not come out or air flow is improper) ........ 80- 44
Troubleshooting for temperature control.................................................................................... 80- 46
Troubleshooting for FRESH/RECIRC air changeover ............................................................... 80- 48
Troubleshooting with gauge pressure........................................................................................ 80- 50
Connection of service tool.......................................................................................................... 80- 52
Precautions for disconnecting and connecting air conditioner piping ........................................ 80- 54
Handling compressor oil ............................................................................................................ 80- 56

90 Diagrams and drawings


Hydraulic diagrams and drawings................................................................................................. 90 - 3
Symbols used in hydraulic circuit diagrams ............................................................................... 90 - 3
Hydraulic circuit diagram............................................................................................................ 90 - 5
Power train hydraulic circuit diagram ......................................................................................... 90 - 9
Differential hydraulic circuit diagram .......................................................................................... 90 - 11
Electrical diagrams and drawings ................................................................................................. 90 - 13
Symbols used in electric circuit diagrams .................................................................................. 90 - 13
Electrical circuit diagram ............................................................................................................ 90 - 17

Index ............................................................................................................................................. 1

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Foreword and general information
Safety notice

Foreword and general information


Safety notice
(Rev. 2009/9)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific pur-
pose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.

1. General precautions
k Mistakes in operation are extremely dan- 7) If welding repairs are needed, always have a
gerous. Read the Operation and Mainte- trained and experienced welder carry out the
nance Manual carefully before operating work. When carrying out welding work,
the machine. In addition, read this manu- always wear welding gloves, apron, shielding
al and understand its contents before goggles, cap and other clothes suited for
starting the work. welding work.
1) Before carrying out any greasing or repairs, 8) Before starting work, warm up your body
read all the safety labels stuck to the thoroughly to start work under good condi-
machine. For the locations of the safety tion.
labels and detailed explanation of precau- 9) Avoid continuing work for long hours and
tions, see the Operation and Maintenance take rests at proper intervals to keep your
Manual. body in good condition.
2) Decide a place in the repair workshop to Take rests in specified safe places.
keep tools and removed parts. Always keep
the tools and parts in their correct places. Safety points
Always keep the work area clean and make 1 Good arrangement
sure that there is no dirt, water, or oil on the 2 Correct work clothes
floor. Smoke only in the areas provided for 3 Following work standard
smoking. Never smoke while working. 4 Making and checking signals
Prohibition of operation and handling by unli-
3) When carrying out any operation, always 5
censed workers
wear safety shoes and helmet. Do not wear 6 Safety check before starting work
loose work clothes, or clothes with buttons Wearing protective goggles(for cleaning or grind-
missing. 7
ing work)
q Always wear safety glasses when hitting Wearing shielding goggles and protectors(for
8
parts with a hammer. welding work)
q Always wear safety glasses when grind- 9 Good physical condition and preparation
ing parts with a grinder, etc. Precautions against work which you are not used
10
to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must carry out work
and operation which require license or quali-
fication.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones. Before starting work, thoroughly check
the tools, machine, forklift, service car, etc.

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Foreword and general information
Safety notice

2. Preparation work 6) When removing a cover which is under


1) Before adding oil or making any repairs, park internal pressure or under pressure from a
the machine on a hard and level ground, and spring, always leave 2 bolts in diagonal posi-
apply the parking brake and block the wheels tions. Loosen those bolts gradually and alter-
or tracks to prevent the machine from nately to release the pressure, and then
moving. remove the cover.
2) Before starting work, lower the work equip- 7) When removing components, be careful not
ment (blade, ripper, bucket, etc.) to the to break or damage the electrical wiring.
ground. If this is not possible, insert the lock Damaged wiring may cause electrical fires.
pin or use blocks to prevent the work equip- 8) When removing piping, stop the fuel or oil
ment from falling. In addition, be sure to lock from spilling out. If any fuel or oil drips onto
all the control levers and hang warning tag on the floor, wipe it up immediately. Fuel or oil
them. on the floor can cause you to slip and can
3) When disassembling or assembling, support even start fires.
the machine with blocks, jacks, or stands 9) As a general rule, do not use gasoline to
before starting work. wash parts. Do not use it to clean electrical
4) Remove all mud and oil from the steps or parts, in particular.
other places used to get on and off the 10)Be sure to assemble all parts again in their
machine. Always use the handrails, ladders original places. Replace any damaged parts
or steps when getting on or off the machine. and parts which must not be reused with new
Never jump on or off the machine. If it is parts. When installing hoses and wires, be
impossible to use the handrails, ladders or sure that they will not be damaged by contact
steps, use a stand to provide safe footing. with other parts when the machine is oper-
ated.
3. Precautions during work 11)When installing high pressure hoses and
1) Before disconnecting or removing compo- tubes, make sure that they are not twisted.
nents of the oil, water, or air circuits, first Damaged hoses and tubes are dangerous,
release the pressure completely from the so be extremely careful when installing
circuit. When removing the oil filler cap, a hoses and tubes for high pressure circuits. In
drain plug, or an oil pressure pickup addition, check that connections of them are
plug,loosen it slowly to prevent the oil from correct.
spurting out. 12)When assembling or installing parts, always
2) The coolant and oil in the circuits are hot tighten them to the specified torques. When
when the engine is stopped, so be careful not installing protective parts such as guards, or
to get scalded. Wait for the oil and coolant to parts which vibrate violently or rotate at high
cool before carrying out any work on the oil or speeds, be particularly careful to check that
water circuits. they are installed correctly.
3) Before starting work, stop the engine. When 13)When aligning 2 holes, never insert your
working on or around a rotating part, in partic- fingers or hand. Be careful not to get your
ular, stop the engine. When checking the fingers caught in a hole.
machine without stopping the engine 14)When measuring hydraulic pressure, check
(measuring oil pressure, revolving speed, that the measuring tools are correctly
temperature, etc.), take extreme care not to installed.
get caught in rotating parts or moving parts. 15)Take care when removing or installing the
4) Before starting work, remove the leads from tracks of track-type machines. When
the battery. Always remove the lead from the removing the track, the track separates
negative (–) terminal first. suddenly, so never let anyone stand at either
5) When raising a heavy component (heavier end of the track.
than 25kg), use a hoist or crane. Before 16)If the engine is operated for a long time in a
starting work, check that the slings (wire place which is not ventilated well, you may
ropes, chains, and hooks) are free from suffer from gas poisoning. Accordingly, open
damage. Always use slings which have the windows and doors to ventilate well.
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.

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Foreword and general information
Safety notice

4. Precautions for sling work and making signals


1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.) 8) When installing wire ropes to an angular
4) Measure the weight of the load by the eye load, apply pads to protect the wire ropes. If
and check its center of gravity. the load is slippery, apply proper material to
5) Use proper sling according to the weight of prevent the wire rope from slipping.
the load and method of slinging. If too thick 9) Use the specified eyebolts and fix wire ropes,
wire ropes are used to sling a light load, the chains, etc. to them with shackles, etc.
load may slip and fall. 10)Apply wire ropes to the middle portion of the
6) Do not sling a load with 1 wire rope alone. It hook.
may rotate and may slip out of the rope. q Slinging near the tip of the hook may
Install 2 or more wire ropes symmetrically. cause the rope to slip off the hook during
k Slinging with 1 rope may cause turn- hoisting. The hook has the maximum
ing of the load during hoisting, un- strength at the middle portion.
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 °, as a rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8kN
{1,000kg} vertically, at various hanging
11)Do not use twisted or kinked wire ropes.
angles. When the 2 ropes sling a load verti-
cally, up to 19.6kN {2,000kg} of total weight 12)When lifting a load, observe the following.
q Wind in the crane slowly until wire ropes
can be suspended. This weight is reduced to
9.8kN {1,000kg} when the 2 ropes make a are stretched. When settling the wire
hanging angle of 120 °. If the 2 ropes sling a ropes with the hand, do not grasp them
19.6kN {2,000kg } load at a lifting angle of but press them from above. If you grasp
150 ° , each of them is subjected to a force as them, your fingers may be caught.
q After the wire ropes are stretched, stop
large as 39.2kN {4,000kg}.
the crane and check the condition of the
slung load, wire ropes, and pads.

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Foreword and general information
Safety notice

qIf the load is unstable or the wire rope or 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift turn the power switch OFF. When turning on
it up again. a switch which was turned OFF by the
q Do not lift up the load at an angle. ground fault circuit interrupter, check that the
13)When lowering a load, observe the following. devices related to that switch are not in oper-
q When lowering a load, stop it temporarily ation state.
at 30cm above the floor, and then lower it 14)If you find an obstacle around the hoist, stop
slowly. the operation.
q Check that the load is stable, and then re- 15)After finishing the work, stop the hoist at the
move the sling. specified position and raise the hook to at
q Remove kinks and dirt from the wire least 2mabove the floor. Do not leave the
ropes and chains used for the sling work, sling installed to the hook.
and put them in the specified place.
7. Selecting wire ropes
5. Precautions for using mobile crane 1) Select adequate ropes depending on the
a Read the Operation and Maintenance Manu- weight of parts to be hoisted, referring to the
al of the crane carefully in advance and oper- table below.
ate the crane safely. Wire ropes
(Standard "Z" twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
kWhen raising a heavy part (heavier than Nominal diameter
Allowable load
25), use a hoist, etc. In Disassembly and of rope
assembly, the weight of a part heavier mm kN ton
than 25 is indicated after the mark of 4. 10 8.8 0.9
12 12.7 1.3
1) Before starting work, inspect the wire ropes, 14 17.3 1.7
brake, clutch, controller, rails, over wind stop 16 22.6 2.3
device, ground fault circuit interrupter, crane 18 28.6 2.9
collision prevention device, and power appli- 20 35.3 3.6
cation warning lamp, and check safety. 25 55.3 5.6
30 79.6 8.1
2) Observe the signals for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place. 50 221.6 22.6
4) Check the direction indicator plates (east, 60 318.3 32.4
west, south, and north) and the directions of a The allowable load is one-sixth of the
the control buttons without fail. breaking strength of the rope used (Safe-
5) Do not sling a load at an angle. Do not move ty coefficient: 6).
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting a load, stop it just after it leaves
the ground and check safety, and then lift it
up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch on a position where
it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.

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Foreword and general information
Safety notice

8. Precautions for disconnecting and


connecting hoses and tubes in air condi-
tioner circuit
1) Disconnection
k For the environment, the air condition-
er of this machine uses the refrigerant
(air conditioner gas: R134a) which has
fewer factors of the depletion of the
ozone layer. However, it does not
mean that you may discharge the re-
frigerant into the atmosphere as it is.
Be sure to recover the refrigerant
when disconnecting the refrigerant
gas circuit and then reuse it. a For tightening torque, see the precau-
a Ask professional traders for collecting tions for installation in each section of
and filling operation of refrigerant "Disassembly and assembly".
(R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight and your skin may be fro-
zen. Accordingly, put on safety glass-
es, safety gloves and safety clothes
when recovering or adding the refrig-
erant.
Refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring (1) is not
damaged or deteriorated.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings (1).
a Example of O-ring (Fitted to every
joint of hoses and tubes)

GD555-5,GD655-5,GD675-5 00-9
DRAFT
Foreword and general information
How to read the shop manual

How to read the shop manual

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.

Composition of shop manual


This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.

00. Index and foreword


This section contains table of contents, and safety and basic information. If any revision of the shop man-
ual is made, the LIST OF REVISED PAGES will be added.

01. Specification
This section explains the specifications of the machine.

10. Structure, function and maintenance standard


This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.

20. Standard value table


This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.

30. Testing and adjusting


This section explains measuring instruments and measuring methods for testing and adjusting, and meth-
od of adjusting each part. The standard values and judgment criteria for testing and adjusting are ex-
plained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly


This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.

60. Maintenance standard


This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.

80. Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting fo the equipment.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

00-10 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
How to read the shop manual

Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.

q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)

q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.

Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are


a Caution
necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when selecting hoisting
Weight
wire, or when working posture is important, etc.

3 Tightening torque Places that require special attention for tightening torque during assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5 Oil, coolant Places where oil, etc. must be added, and capacity.

6 Drain Places where oil, etc. must be drained, and quantity to be drained.

Units
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

GD555-5,GD655-5,GD675-5 00-11
DRAFT
Foreword and general information
Explanation of terms for maintenance standard

Explanation of terms for maintenance standard


The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.

1. Standard size and tolerance


q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a tempo-
rary standard size is set and an allowable dif-
ference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "toler-
ance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard size.

Example:
Standard size Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

q Usually, the size of a hole and the size of the


shaft to be fitted to that hole are indicated by
the same standard size and different toler-
ances of the hole and shaft. The tightness of
fit is decided by the tolerance.
q Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
60
-0.076 0

00-12 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Explanation of terms for maintenance standard

2. Standard clearance and standard value 5. Clearance limit


q The clearance made when new parts are as- q Parts can be used until the clearance be-
sembled is called the "standard clearance", tween them is increased to a certain limit.
which is indicated by the range from the min- The limit at which those parts cannot be used
imum clearance to the maximum clearance. is called the "clearance limit".
q When some parts are repaired, the clearance q If the clearance between the parts exceeds
is generally adjusted to the standard clear- the clearance limit, they must be replaced or
ance. repaired.
q A value of performance and function of new
products or equivalent is called the "standard 6. Interference limit
value", which is indicated by a range or a tar- q The allowable maximum interference be-
get value. tween the hole of a part and the shaft of an-
q When some parts are repaired, the value of other part to be assembled is called the
performance/function is set to the standard "interference limit".
value. q The interference limit shows the repair limit of
the part of smaller tolerance.
3. Standard interference q If the interference between the parts exceeds
q When the diameter of a hole of a part shown the interference limit, they must be replaced
in the given standard size and tolerance table or repaired.
is smaller than that of the mating shaft, the
difference between those diameters is called
the "interference".
q The range (A – B) from the difference (A) be-
tween the minimum size of the shaft and the
maximum size of the hole to the difference
(B) between the maximum size of the shaft
and the minimum size of the hole is the "stan-
dard interference".
q After repairing or replacing some parts, mea-
sure the size of their hole and shaft and
check that the interference is in the standard
range.

4. Repair limit and allowable value or allowable


dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the per-
missible value is estimated from various tests
or experiences in most cases, however, it
must be judged after considering the operat-
ing condition and customer's requirement.

GD555-5,GD655-5,GD675-5 00-13
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

Handling of electric equipment and hydraulic components

To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Han-
dling hydraulic components" (particularly gear oil and hydraulic oil).

Points to remember when handling electric


equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about 10 times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated to cause defective
contact or the wire is broken.

00-14 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

3) Disconnections in wiring
If the harness is pulled to disconnect, or
components are lifted with a crane with the
harness still connected, or a heavy object
hits the harness, the crimping of the
connector may separate, or the soldering
may be damaged, or the harness may be
broken.

4) High-pressure water entering connector


The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.

GD555-5,GD655-5,GD675-5 00-15
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

3. Removing, installing, and drying connectors


and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips
q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.

q When removing a connector from a


clip, pull the connector in a parallel di-
rection to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the housing
may break.

3] Action to take after removing connectors


After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connector
portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.

00-16 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or water a If there is any damage or breakage,
stuck to the connector pins (mating replace the connector.
portion).
Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.

2] Fix the connector securely.


Position the connector correctly, and then
fit them securely. For connectors with the
lock stopper, push in the connector until
the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp has been re-
moved, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.

GD555-5,GD655-5,GD675-5 00-17
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

3) DT connector (DT 8-pole, 12-pole)


Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing both locks (a) and (b), pull out incomplete setting of
female connector (2). ((a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1)?Male connector
(2)?Female connector
(a),(b): Locks

00-18 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

4) Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with
air.

2] Dry the inside of the connector with a dryer.


If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.

3] Carry out a continuity test on the connector.


After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.

GD555-5,GD655-5,GD675-5 00-19
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

4. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
machine body, disconnect all wiring harness
connectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5. Points to remember when troubleshooting electric circuits


1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check all
the related connectors for half fit.
a Disconnect and connect the related con-
nectors several times to check.
3) Always connect any disconnected connec-
tors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary ab-
normality warning will be issued.
4) When carrying out troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there is probably
defective contact in that circuit.

00-20 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

Points to remember when handling hydraulic components


With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic components, it is necessary to be particularly careful.

1. Be careful of the operating environment


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the field
If disassembly or maintenance work is carried
out on hydraulic components in the field, there is
danger of dust entering the components. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.

4. Do not let any dirt or dust get in during refilling operations


Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.

GD555-5,GD655-5,GD675-5 00-21
DRAFT
Foreword and general information
Handling of electric equipment and hydraulic components

5. Change hydraulic oil when the temperature is high


When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic components (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning components is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.

00-22 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of connectors newly used for engines

Handling of connectors newly used for engines


a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3

Slide lock type Pull lock type (PACKARD-2)


(FRAMATOME-3,FRAMATOME-2) q 95–170,12V140 engines
q 95–170,12V140 engines q Various temperature sensors
q Various pressure sensors and NE speed Examples)
sensor Intake air temperature sensor in intake mani-
Examples) fold: TIM
Intake air pressure sensor in intake manifold: Fuel temperature sensor: TFUEL
PIM(125,170,12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor:POIL(125,170,12V140 Coolant temperature sensor: TWTR, etc.
engines)
Oil pressure switch(95,107,114 engines) Disconnect
Ne speed sensor of flywheel housing: Disconnect the connector by pulling lock (B) (on the
NE(95-170,12V140 engines) wiring harness side) of connector (2) outward.
Ambient pressure sensor:
PAMB(125,170,12V140 engines)

Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector(1)
toward you.
a Even if lock L2 is pressed, connector(1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while press lock
L2 , and then pull out connector(1) toward
you.

Connect
Insert the connector straight until it "clicks".

Connect
Insert the connector straight until it "clicks".

GD555-5,GD655-5,GD675-5 00-23
DRAFT
Foreword and general information
Handling of connectors newly used for engines

Push lock type (1)


q 95, 107, 114 engines While pressing up lock (C)of the connector with
Example) Fuel pressure sensor in common rail flat-head screwdriver [1], pull out connector (3) in
(BOSCH-03) the direction of the arrow.

Disconnect
While pressing lock (C), pull out connector (3) in the
direction of the arrow.

q 114 engine

Connect
Insert the connector straight until it "clicks".

Push lock type (2)


q 107, 114 engines
Example) Intake air pressure/temperature
q 107 engine sensor in intake manifold(SUMITOMO-04)

Disconnect
While pressing lock (D), pull out connector (4) in the
direction of the arrow.

a If the lock is on the underside, use flat-head


screwdriver[1]since you cannot insert your fin-
gers.

Connect
Insert the connector straight until it "clicks".

00-24 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Handling of connectors newly used for engines

Push lock type (3) Turn-housing type (Round green connector)


q 95, 125 – 170, 12V140 engines q 140 engine
Example) Intake air pressure sensor in intake
Disconnect manifold.
While pressing lock (E) of the connector, pull out (CANNON-04): PIM etc.
connector (5) in the direction of the arrow.
Disconnect
Example) Fuel pressure sensor in common rail: 1) Turn housing (H1) in the direction of the
PFUEL etc. (AMP-3) arrow.
a When connector is unlocked, housing
(H1)becomes heavy to turn.
2) Pull out housing (H1)in the direction of the
arrow.
a Housing (H1)is left on the wiring harness
side.

Example) Injection pressure control valve of fuel


supply pump: PCV (SUMITOMO-2)

Connect
1) Insert the connector to the end, while setting
its groove.
2) Turn housing (H1)in the direction of the arrow
until it "clicks".

Examples) Speed sensor of fuel supply pump:G


(SUMITOMO-3)
a Pull the connector straight up.

Connect
Insert the connector straight until it "clicks".

GD555-5,GD655-5,GD675-5 00-25
DRAFT
Foreword and general information
How to read electric wire code

How to read electric wire code


a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85

Indicates color of wire by color code.


Color codes are shown in Table 3.

Indicates size of wire by nominal No.


Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.


Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their
symbols are not indicated on the diagram.)

1. Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thick-
ness and outside diameter and different from AV and AVS in material of the cover.

(Table 1)
Using tem-
Type Symbol Material perature Example of use
range (°C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above.)
bile Insulator Soft polyvinyl chloride
-30 to +60
Annealed copper for electric
Thin-cover Conductor
appliance General wiring
low-voltage wire AVS
(nominal No. 3 and below.)
for automobile Insulator Soft polyvinyl chloride
Annealed copper for electric
Heat-resistant Conductor General wiring in extremely cold
appliance
low-voltage wire AEX -50 to +110 district, wiring at high ambient tem-
Heat-resistant crosslinked
for automobile Insulator perature place
polyethylene

00-26 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
How to read electric wire code

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0

AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 ―


Cov-er D

AV Standard ― ― ― ― ― ― ― 4.6

AEX Standard 2.0 2.2 2.7 3.0 3.1 ― 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6

AVS Standard ― ― ― ― ― ― ― ― ―
Cov-er D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

"f" of nominal No. denotes "flexible".

GD555-5,GD655-5,GD675-5 00-27
DRAFT
Foreword and general information
How to read electric wire code

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG ― ― ― ― R ―
Ground B ― ― ― ― ―- B ―
Start R ― ― ― ― ― R ―
Light RW RB RY RG RL ― D ―
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB ― L ―
Type of cir-
Br BrW BrR BrY BrB ― ― ―
cuit
Lg LgR LgY LgB LgW ― ― ―
O ― ― ― ― ― ― ―
Others Gr ― ― ― ― ― ― ―
P ― ― ― ― ― ― ―
Sb ― ― ― ― ― ― ―
Dg ― ― ― ― ― ― ―
Ch ― ― ― ― ― ― ―

00-28 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Precautions when carrying out work

Precautions when carrying out work

When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the work.

1. Precautions when carrying out removal work


q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789-20210
03 07376 - 70315 02789-20315
04 07376 - 70422 02789-20422
05 07376 - 70522 02789-20522
06 07376 - 70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234

2) Split flange type hoses and tubes


Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 27 22.5 34

GD555-5,GD655-5,GD675-5 00-29
DRAFT
Foreword and general information
Precautions when carrying out work

2. Precautions when carrying out installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) .
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with liquid gasket.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps
and other hydraulic component removed for repair, always bleed the air as follows:
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4] After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing work


1) Refilling with coolant, oil and grease
q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run
the engine to circulate the coolant through the system . Then check the coolant level again.
q If the hydraulic component has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
q If the piping or hydraulic component have been removed, always bleed the air from the system after
reassembling the parts.
a For details, see Testing and adjusting, "Bleeding air".
q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.

2) Checking cylinder head and manifolds for looseness


Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loose, retighten it.
q For the tightening torque, see "Disassembly and assembly" .

3) Checking engine piping for damage and looseness


Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loose or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
If any part is loose or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
If any part is loose or damaged, retighten or repair it.

00-30 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Precautions when carrying out work

4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loose, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

GD555-5,GD655-5,GD675-5 00-31
DRAFT
Foreword and general information
Method of disassembling and connecting push-pull type coupler

Method of disassembling and connecting push-pull type coupler

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3) . (Fig. 1)
a The adapter can be pushed in approxi-
mately 3.5 mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.

2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose ap-
proximately 3.5 mm. This does not indi-
cate abnormality, however.

00-32 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Method of disassembling and connecting push-pull type coupler

Type 2

1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)

2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 9)

GD555-5,GD655-5,GD675-5 00-33
DRAFT
Foreword and general information
Method of disassembling and connecting push-pull type coupler

Type 3

1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 10)
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)

2. Connection
q Hold the tightening portion and push body (9)
straight until the sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 13)

00-34 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Standard tightening torque table

Standard tightening torque table


1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.

a The following table applies to the bolts in Fig. A.


Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 –196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370

a The following table applies to the bolts in Fig. B.


Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2

a Fig. A a Fig. B

Remarks: The widths across flats by thread


diameter of flanged bolts (marked with "*") in
Fig. A are the ones indicated in the table for
bolts shown in Fig. B.
(Values of tightening torques shown in the
table for Fig. A are applied.)

GD555-5,GD655-5,GD675-5 00-35
DRAFT
Foreword and general information
Standard tightening torque table

2. Table of tightening torques for split flanged bolts


a Unless there are special instructions, tighten split flanged bolts to the torque below.
Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diam- Width across
Tightening torque Nm {kgm}
Nominal No. eter flats
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
Varies
03,04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05,06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10,12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
nector.
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}

4. Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Thread diam- Width across
Tightening torque Nm {kgm}
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

00-36 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Standard tightening torque table

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
No. of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16 – 18UNF 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

6. Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats –Number of
Range Target (mm)
(mm) (mm) threads, type of
(Reference)
thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification.

GD555-5,GD655-5,GD675-5 00-37
DRAFT
Foreword and general information
Standard tightening torque table

7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 ― ―

8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine se-
ries to the torque below.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 en-
gine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

00-38 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
List of Abbreviation

List of Abbreviation
q This list of abbreviations is taken from the abbre- q Special abbreviations that appear infrequently
viations used in the text of the shop manual for are marked in the text with an *.
parts, components, and functions whose mean- q This list of abbreviations consists of two
ing is not immediately clear. The spelling is given parts.The first part is a list of abbreviations used
in full with an outline of the meaning. in the text of the manual, and the second part is
q Abbreviations that are used in general society a list of abbreviations used in circuit diagrams.
may not be included.
List of abbreviations used in the shop manual
Purpose of use (major
Abbreviation Full Spelling applicable machine (*), or Explanation
component/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idling speed.
System
Instead of a steering wheel, a lever is used to carry
Advanced Joystick Steer- Steering
A.J.S.S. out the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Accel- Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
erator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Speed Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load Sens-
C.L.S.S. Hydraulic actuators regardless of the load (provides better
ing System
ease of combined operation than O.L.S.S.).
Uses engine controller to carry out electronic con-
trol of supply pump, common rail, and injector.
C.R.I. Common Rail Injection Engine
Functions to maintain optimum fuel injection
amount and fuel injection timing.
Electronic control device that uses the signals from
E.C.M. Electronic Control Module Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electronic Control Modula- Transmission
E.C.M.V. increases oil pressure to engage clutch and
tion (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA )
absorb vibration of machine during travel.
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
E.G.R. Exhaust Gas Recirculation Engine bustion chamber in order to reduce combustion
temperature, controls emission of Nox.

GD555-5,GD655-5,GD675-5 00-39
DRAFT
Foreword and general information
List of Abbreviation

Purpose of use (major


Abbreviation Full Spelling applicable machine (*), or Explanation
component/system)
System that allows data (filter, oil replacement
Equipment Management interval, abnormalities on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S. Global Positioning System
(KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of left and right tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Transmission
H.S.T. Hydro Static Transmission nation of hydraulic pump and hydraulic motor to
(D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actuator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
Valve installed at inlet port of pump to adjust fuel
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging Ser-
M.M.S. Communication short messages consisting of characters or voice
vice
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electronic and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electronic and hydraulic
cuits that are normally open if not actuated.
Open-center Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and carries
P.C.C.S.
System (D) out optimum electronic control of the engine and
HST.
Valve installed at inlet port of pump to adjust fuel
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Con- Control system that moves an actuator in propor-
P.P.C. Hydraulic
trol tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
A device to take off power of the engine in order to
P.T.O. Power Take Off Power train
drive a hydraulic pump, an air compressor, etc.
Power Tilt and power Pitch Work equipment Function that carries out hydraulic control of the tilt
P.T.P.
dozer (D) and pitch of the bulldozer blade.

00-40 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
List of Abbreviation

Purpose of use (major


Abbreviation Full Spelling applicable machine (*), or Explanation
component/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale d’Unites) is
the modern form of the metric system, and is the
Le Systeme International world’s most widely used system of measure-
S.I. Unit
d’ Unites ment. There’re seven base units: meter (m), kilo-
gram (kg), second (s), ampere (A), kelvin (K),
candela (cd), and mole (mol). The derived units
include Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electronic
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electronic Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communi-
daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring cation
V.H.M.S. sumption, radiator water temperature, oil or filter
System (D, HD, PC, WA : Large
replacement interval, to make it possible to collect
size)
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader

GD555-5,GD655-5,GD675-5 00-41
DRAFT
Foreword and general information
List of Abbreviation

List of abbreviations used in the circuit drawings


Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actruator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission

00-42 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Conversion table

Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)


1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

GD555-5,GD655-5,GD675-5 00-43
DRAFT
Foreword and general information
Conversion table

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 5 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons


1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

00-44 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Conversion table

Liters to U.K. Gallons


1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

GD555-5,GD655-5,GD675-5 00-45
DRAFT
Foreword and general information
Conversion table

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

00-46 GD555-5,GD655-5,GD675-5
DRAFT
Foreword and general information
Conversion table

Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 47 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


–19.4 –3 26.6 0 32 89.6 19.4 68 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 69 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

GD555-5,GD655-5,GD675-5 00-47
DRAFT
Foreword and general information
Conversion table

00-48 GD555-5,GD655-5,GD675-5
DRAFT

GD555-5,GD655-5,GD675-5
SEN0521504-00

MOTOR GRADER
Shop Manual

GD555-5
GD655-5
GD675-5

Machine model Serial number


GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

01 Specification
4

Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
2
Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
3
Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
4
Weight table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
10
Table of fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
11

GD555-5,GD655-5,GD675-5 01-1
DRAFT

Contents

Contents
01 Specification
Specification drawing ................................................................................................................... 01 - 3
Specifications............................................................................................................................... 01 - 4
Weight table ................................................................................................................................. 01 - 10
Table of fuel, coolant and lubricants ............................................................................................ 01 - 11

01-2 GD555-5,GD655-5,GD675-5
DRAFT

Specification drawing

Specification drawing

Item Unit GD555-5 GD655-5 GD675-5


Operating mass (including weight of 110 kg of two opera-
tors)
kg 15160 15520 16000
Komatsu Komatsu Komatsu
SAA6D107E-1 SAA6D107E-1 SAA6D107E-1
Engine model —
Diesel engine Diesel engine Diesel engine
E-mode: 104-118-131 E-mode: 108-134-149 E-mode: 108-134-149
(141-160-178) (147-182-203) (147-182-203)
P-mode: 118-131-144 P-mode: 134-149-163 P-mode: 134-149-163
Engine rated output
kW (160-178-196) (182-203-222) (182-203-222)
q Net [ISO 9249/JIS D0006-1]
{PS}/rpm E-mode: 107-120-134 E-mode: 110-137-152 E-mode: 110-137-152
q Gross [SAE J1995]
(145-163-182) (150-186-206) (150-186-206)
P-mode: 120-134-146 P-mode: 137-152-165 P-mode: 137-152-165
(163-182-199) (186-206-224) (186-206-224)
A Overall length mm 8970 9065 9065
B Overall height (including light diffusing type warning lamp) mm 3200 3200 3200
C Height up to the tip of the exhaust pipe mm 2995 2995 2995
D Overall width mm 2485 2485 2630
Minimum ground clearance (up to the lower surface of the
mm 390 390 390
final drive case)
Minimum turning radius (outside of machine) mm 7300 7400 7400
Travel speed 1st (forward/reverse) 3.4/4.5 3.4/4.5 3.4/4.5
2nd (forward/reverse) 5.0/9.2 5.0/9.2 5.0/9.2
3rd (forward/reverse) 7.0/20.3 7.0/20.3 7.0/20.3
4th (forward/reverse) 10.2/40.3 10.2/40.3 10.2/40.3
km/h
5th (forward/reverse) 15.4/- 15.4/- 15.4/-
6th (forward/reverse) 22.3/- 22.3/- 22.3/-
7th (forward/reverse) 30.6/- 30.6/- 30.6/-
8th (forward/reverse) 44.3/- 44.3/- 44.3/-

a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output mea-
sured of an independent engine. While, net denotes the value measured of an engine under the condition
essentially the same as that when it is installed on machine.

GD555-5,GD655-5,GD675-5 01-3
DRAFT

Specifications

Specifications
Machine model Unit GD555-5 GD655-5 GD675-5
Serial number ― 55001 and up 55001 and up 55001 and up
Machine weight kg 15160 15520 16000
(including respec- (including respec- (including respec-
Weight

tive weight of 75 kg tive weight of 75 kg tive weight of 75 kg


of 1 operator) of 1 operator) of 1 operator)
Load on front axle kg 4155 4220 4390
Load on rear axle kg 11005 11300 11610
Travel speed
q Forward 1st 3.1 3.1 3.1
q Forward 2nd 5.0 5.0 5.0
q Forward 3rd 7.0 7.0 7.0
q Forward 4th km/h 10.2 10.2 10.2
q Forward 5th 15.4 15.4 15.4
q Forward 6th 22.3 22.3 22.3
q Forward 7th 30.6 30.6 30.6
Performance

q Forward 8th 44.3 44.3 44.3

Reverse 1st 4.5 4.5 4.5


Reverse 2nd 9.2 9.2 9.2
km/h
Reverse 3rd 20.3 20.3 20.3
Reverse 4th 40.3 40.3 40.3
Maximum drawbar pull kN {kg} 86.3 88.6 91.1
Gradeability deg. 24 24 24
Minimum turning radius (center of out-
mm 7300 7400 7400
side tire)
Static stability deg. 35 35 35
Overall length mm 8970 9065 9065
Overall height mm 3200 3200 3200
Height up to tip of exhaust pipe mm 2995 2995 2995
Wheelbase mm 6270 6480 6480
Dimensions

Tandem wheelbase mm 1525 1525 1525


Thread
q Front wheels mm 2070 2070 2070
q Rear wheels mm 2060 2060 2060
Blade base mm 2380 2580 2580
Min. ground clearance mm 390 390 390

01-4 GD555-5,GD655-5,GD675-5
DRAFT

Specifications

Machine model Unit GD555-5 GD655-5 GD675-5


Serial number ― 55001 and up 55001 and up 55001 and up
Komatsu Komatsu Komatsu
Model
SAA6D107E-1 SAA6D107E-1 SAA6D107E-1
4-cycle, 4-cycle, 4-cycle,
water-cooled, verti- water-cooled, verti- water-cooled, verti-
cal and straight cal and straight cal and straight
Type
type, direct injec- type, direct injec- type, direct injec-
tion, turbocharged tion, turbocharged tion, turbocharged
and air-aftercooled and air-aftercooled and air-aftercooled
Number of cylinders - bore x stroke mm 6 - 107 x 124 6 - 107 x 124 6 - 107 x 124
Total piston displacement l(cc) 6.69 (6690) 6.69 (6690) 6.69 (6690)
Rated output E-mode: E-mode: E-mode:
q Net [ISO 9249/JISD 0006-1] 104-118-131 108-134-149 108-134-149
(141-160-178) (147-182-203) (147-182-203)
kW(PS)/rpm
P-mode: P-mode: P-mode:
118-131-144 134-149-163 134-149-163
(160-178-196) (182-203-222) (182-203-222)
q Gross [SAE J1995] (*1) E-mode: E-mode: E-mode:
107-120-134 110-137-152 110-137-152
(145-163-182) (150-186-206) (150-186-206)
Engine

kW(PS)/rpm
P-mode: P-mode: P-mode:
Performance

120-134-146 137-152-165 137-152-165


(163-182-199) (186-206-224) (186-206-224)
Maximum torque Nm
q Low output {kgm}/rpm 700 {71.4}/1450 845{86.2}/1450 845 {86.2/1450
Nm
q Medium output 815 {83.1}/1450 941 {96.0}/1450 941 {96.0}/1450
{kgm}/rpm
Nm
q High output 880 {89.7}/1450 941 {96.0}/1450 941 {96.0}/1450
{kgm}/rpm
Fuel consumption ratio at rated g/Kwh 231 {170} (at high 231 {170} (at high 231 {170} (at high
output {g/PSh} output) output) output)
High idle speed rpm 2200 2200 2200
Low idle speed rpm 800 800 800
Starting motor 24 V, 5.5 kW 24 V, 5.5 kW 24 V, 5.5 kW
Alternator 24 V, 60 A 24 V, 60 A 24 V, 60 A
(*3) 24 V, 90A (*3) 24 V, 90A (*3) 24 V, 90A
Battery 12 V, 140 Ah 12 V, 140 Ah 12 V, 140 Ah
Corrugated (alumi- Corrugated (alumi- Corrugated (alumi-
Type of radiator core
num) num) num)
*1: Indicates the value of the engine alone (without cooling fan).
*2: The battery capacity (Ah) is the value on the 5-hour rate.
*3: It indicates the value of the large-capacity battery.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.

GD555-5,GD655-5,GD675-5 01-5
DRAFT

Specifications

Machine model Unit GD555-5 GD655-5 GD675-5


Serial number ― 55001 and up 55001 and up 55001 and up
Torque converter ― 3-element, 3-element, 3-element,
1-stage, 2-phase 1-stage, 2-phase 1-stage, 2-phase
With hydrauli- With hydrauli- With hydrauli-
cally-actuated wet cally-actuated wet cally-actuated wet
disc for lockup disc for lockup disc for lockup
Transmission ― Counter-shaft type Counter-shaft type Counter-shaft type
Full automatic Full automatic Full automatic
Electronically-con- Electronically-con- Electronically-con-
trolled automatic trolled automatic trolled automatic
gear shift gear shift gear shift
Pump pres- Pump pres- Pump pres-
Power train

sure-lubricated sure-lubricated sure-lubricated


type type type
8-speed in for- 8-speed in for- 8-speed in for-
ward, 4-speed in ward, 4-speed in ward, 4-speed in
reverse reverse reverse
Final reduction gear ― Spiral bevel gear Spiral bevel gear Spiral bevel gear
type, planetary type, planetary type, planetary
reduction splash reduction splash reduction splash
lubrication type lubrication type lubrication type
Tandem device ― Double row, Double row, Double row,
chain-drive type, chain-drive type, chain-drive type,
splash lubrication splash lubrication splash lubrication
type type type
Reverse Elliot Reverse Elliot Reverse Elliot
Front axle type, nonlinear, type, nonlinear, type, nonlinear,

q Type hydraulic leaning hydraulic leaning hydraulic leaning
Axle

type type type


q Maximum leaning angle deg. 16 16 16
Rear axle Full floating, tan- Full floating, tan- Full floating, tan-

q Type dem type dem type dem type
Size ― 14.00 -24 -10PR 14.00 -24 -12PR 17.5R - 25
Rim size ― 9.00/1.5 x 24 9.00/1.5 x 24 13.00/1.5 x 24
Tire

Inflation pressure
q Front wheels
kPa {kg/cm2} 250 {2.5} 275 {2.8} 250 {2.55}
q Rear wheels kPa {kg/cm2 } 250 {2.5} 275 {2.8} 250 {2.55}

01-6 GD555-5,GD655-5,GD675-5
DRAFT

Specifications

Machine model Unit GD555-5 GD655-5 GD675-5


Serial number ― 55001 and up 55001 and up 55001 and up
Braking of rear four Braking of rear four Braking of rear four
Brake system
wheels wheels wheels
Survice

Wet multiple disc Wet multiple disc Wet multiple disc


Brake type
type type type
Hydraulically-actu- Hydraulically-actu- Hydraulically-actu-
Operating system
ated ated ated
Brake

Braking of final Braking of final Braking of final


Brake system reduction gear reduction gear reduction gear
Parking

input shaft input shaft input shaft


Dry single-disc Dry single-disc Dry single-disc
Brake type
type type type
Full hydraulic Full hydraulic Full hydraulic
Operating system
power steering power steering power steering
Type ―
Steering

Steering angle deg. 49 49 49


Machine articulation angle deg. 25 25 25
Work equipment, brake, steering
pump
― Variable displace- Variable displace- Variable displace-
ment swash plate ment swash plate ment swash plate
Hydraulic pump

q Type piston type piston type piston type


q Delivery cm3/rev 90 90 90
Power train pump
q Type Gear type Gear type Gear type
Hydraulic system

q Delivery cm3/rev 63 63 63
Differential lock pump

q Type Gear type Gear type Gear type
q Delivery cm3/rev 10.5 10.5 10.5
Control valve
q Type 9-spool type 9-spool type 9-spool type
Control valve

q Set pressure MPa {kg/cm2} 20.6 {210} 20.6 {210} 20.6 {210}
Steering valve

Orbit-roll type Orbit-roll type Orbit-roll type
q Type
q Set pressure MPa {kg/cm2} 18.1 {185} 18.1 {185} 18.1 {185}

GD555-5,GD655-5,GD675-5 01-7
DRAFT

Specifications

Machine model Unit GD555-5 GD655-5 GD675-5


Serial number ― 55001 and up 55001 and up 55001 and up
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 50 50 50
Steering

Piston rod outside diameter mm 35 35 35


Stroke mm 330 330 330
Maximum distance between
mm 911.5 911.5 911.5
centers of pins
Min. distance between cen-
mm 581.5 581.5 581.5
ters of pins
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 70 80 80
Leaning

Piston rod outside diameter mm 35 40 40


Stroke mm 160 160 160
Maximum distance between
mm 608.5 613 613
centers of pins
Min. distance between cen-
mm 448.5 453 453
ters of pins
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Hydraulic system

Cylinder bore mm 80 80 80
Articulate
Cylinder

Piston rod outside diameter mm 45 45 45


Stroke mm 418 418 418
Maximum distance between
mm 1128 1128 1128
centers of pins
Min. distance between cen-
mm 710 710 710
ters of pins
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 80 80 80
Blade lift

Piston rod outside diameter mm 50 50 50


Stroke mm 1160 1160 1160
Maximum distance between
mm 1690 1690 1690
centers of pins
Min. distance between cen-
mm 530 530 530
ters of pins
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 80 80 80
Blade shift

Piston rod outside diameter mm 50 50 50


Stroke mm 1250 1250 1250
Maximum distance between
mm 2770 2770 2770
centers of pins
Minimum distance between
mm 1520 1520 1520
centers of pins

01-8 GD555-5,GD655-5,GD675-5
DRAFT

Specifications

Machine model Unit GD555-5 GD655-5 GD675-5


Serial number ― 55001 and up 55001 and up 55001 and up
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 80 80 80
Power tilt

Piston rod outside diameter mm 40 40 40


Stroke mm 300 300 300
Maximum distance between
mm 890 890 890
Hydraulic system

centers of pins
Minimum distance between
Cylinder

mm 590 590 590


centers of pins
Double acting pis- Double acting pis- Double acting pis-
Type
ton ton ton
Cylinder bore mm 80 80 80
Drawbar shift

Piston rod outside diameter mm 45 45 45


Stroke mm 550 550 550
Maximum distance between
mm 1560 1560 1560
centers of pins
Minimum distance between
mm 1010 1010 1010
centers of pins
Blade length mm 3710 3710 4320
Blade height mm 645 645 645
Blade thickness mm 19 19 19
Cutting edge length mm 1829 1829 2134
Cutting edge width mm 152 152 152
Cutting edge width mm 15.9 15.9 15.9
Maximum lift above ground mm 480 480 480
Maximum digging depth mm 615 615 615
Work equipment

Blade load kN {kg} 65.7 68.7 71.5


Turing angle deg. 360 360 360
Blade side shift quantity
(Corresponds to the cylinder move
quantity)
mm
q Left 586 586 586
q Right mm 664 664 664
Blade side shift quantity
(Corresponds to the adjustment done
195 195 500
on the bolt)
mm
q Left
q Right mm 195 195 500
Angle
q Forward deg. 40 40 40
q Reverse deg. 5 5 5

GD555-5,GD655-5,GD675-5 01-9
DRAFT

Weight table

Weight table
k Use the weight table when handing individual parts or when transporting the entire machine.

Unit: kg
Machine model GD555-5 GD655-5 GD675-5
Serial Number 55001 and up
Engine assembly (dry) 585 585 585
Cooling assembly (dry) 186 186 186
Transmission assembly (dry) 896 896 896
Transmission pump (with Diff) 11 11 11
Final drive assembly 922 922 922
Tandem drive assembly 785 785 785
Front axle assembly, expect leaning cylinder 501 553 553
Parking brake assembly (with Disk) 23 23 23
Wheel assembly (front) 153 × 2 153 × 2 195 × 2
Wheel assembly (rear) 153 × 4 153 × 4 195 × 4
Scarifier assembly 644 644 644
Hydraulic pump 39 39 39
Fuel tank (dry) 205 205 205
Hydraulic tank (dry) 80 80 80
Circle rotation motor 10 10 10
Steering cylinder assembly 12 × 2 12 × 2 12 × 2
Leaning cylinder assembly 11 11 11
Articulating cylinder assembly 22 × 2 22 × 2 22 × 2
Blade lift cylinder assembly 51 × 2 53 × 2 53 × 2
Blade side-shift cylinder assembly 48 48 48
Blade power tilt cylinder assembly 19 19 19
Drawbar side shift cylinder assembly 30 32 32
Scarifier cylinder assembly 23 23 23
Drawbar assembly 618 638 638
Blade assembly 701 701 727
Circle assembly 532 532 532
Circle rotation gear assembly 200 200 200
Front frame assembly 1875 1965 1965
Rear frame assembly 1275 1275 1275
Ripper (with 3 SHANKS) 950 950 950
operator's compartment assembly and controls 273 273 273
Cab assembly 795 795 795

01-10 GD555-5,GD655-5,GD675-5
DRAFT

Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants


a For details of the notes (Notes 1, Note 2... ) in the table, see Operation and Maintenance Manual.

GD555-5,GD655-5,GD675-5 01-11
DRAFT

Table of fuel, coolant and lubricants

Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 25 23
Transmission case 60 45
Hydraulic oil system 132 69
Final drive case With differential lock 17 17
57 each on the left 57 each on the left
Tandem case
and right and right
Blade rotating machine gear case Slip clutch type 7 7
Cooling system 25 25
Fuel tank 400 —

01-12 GD555-5,GD655-5,GD675-5
GD555-5,GD655-5,GD675-5
SEN0521506-00

MOTOR GRADER
Shop Manual

GD555-5
GD655-5
GD675-5

Machine model Serial number


GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

10 Structure, function and


4
maintenance standard

GD555-5,GD655-5,GD675-5 10-1
Contents

Contents
10 Structure, function and maintenance standard
Engine and Cooling........................................................................................................................ 10 - 4
Cooling system ........................................................................................................................... 10 - 4
Cooling fan pump........................................................................................................................ 10 - 6
Power train system ........................................................................................................................ 10 - 14
Power train system drawing........................................................................................................ 10 - 14
Power train piping drawing.......................................................................................................... 10 - 16
Transmission control................................................................................................................... 10 - 18
Torque converter......................................................................................................................... 10 - 20
Transmission............................................................................................................................... 10 - 24
Transmission control valve ......................................................................................................... 10 - 46
ECMV.......................................................................................................................................... 10 - 50
Main relief and torque converter relief valve ............................................................................... 10 - 58
Front axle .................................................................................................................................... 10 - 60
Final drive (no differential specification)...................................................................................... 10 - 64
Final drive (differential/ differential lock specification)................................................................. 10 - 66
Differential lock solenoid valve.................................................................................................... 10 - 68
Tandem drive .............................................................................................................................. 10 - 70
Steering system ............................................................................................................................. 10 - 72
Steering piping diagram .............................................................................................................. 10 - 72
Priority valve ............................................................................................................................... 10 - 74
Steering valve ............................................................................................................................. 10 - 80
Brake system ................................................................................................................................. 10 - 88
Brake hydraulic piping diagram................................................................................................... 10 - 88
Brake valve ................................................................................................................................. 10 - 89
Slack adjuster ............................................................................................................................. 10 - 96
Accumulator (for brake) .............................................................................................................. 10 - 98
Charge valve............................................................................................................................... 10 - 99
Wheel brake................................................................................................................................ 10 -100
Parking brake and bank control valve......................................................................................... 10 -102
Parking brake.............................................................................................................................. 10 -104
Undercarriage frame ...................................................................................................................... 10 -106
Frame.......................................................................................................................................... 10 -106
Tire.............................................................................................................................................. 10 -108
Hydraulic system............................................................................................................................ 10 -110
Hydraulic system......................................................................................................................... 10 -110
Work equipment hydraulic piping diagram.................................................................................. 10 -114
Work equipment control .............................................................................................................. 10 -118
Hydraulic tank ............................................................................................................................. 10 -120
Main pump .................................................................................................................................. 10 -122
Power train pump........................................................................................................................ 10 -134
Control valve ............................................................................................................................... 10 -136
CLSS........................................................................................................................................... 10 -146
Functions and operation by valve ............................................................................................... 10 -150
Hydraulic cylinder........................................................................................................................ 10 -160
Swivel joint .................................................................................................................................. 10 -162
Pilot check valve ......................................................................................................................... 10 -164
Accumulator (for blade)............................................................................................................... 10 -172
Work equipment............................................................................................................................. 10 -174
Circle and drawbar...................................................................................................................... 10 -174
Blade........................................................................................................................................... 10 -176
Lifter ............................................................................................................................................ 10 -178

10-2 GD555-5,GD655-5,GD675-5
(05)
Contents

Circle rotation motor ................................................................................................................... 10 -180


Circle rotation gear ..................................................................................................................... 10 -182
Cab ................................................................................................................................................ 10 -184
Cab ............................................................................................................................................. 10 -184
Electrical system ............................................................................................................................ 10 -186
Machine monitor ......................................................................................................................... 10 -186
Automatic shift control system .................................................................................................... 10 -190
Transmission controller............................................................................................................... 10 -198
Engine controller......................................................................................................................... 10 -202
KOMTRAX system...................................................................................................................... 10 -206
Starting engine circuit ................................................................................................................. 10 -208
Stopping engine circuit ............................................................................................................... 10 -210
Preheating circuit ........................................................................................................................ 10 -212
Sensor ........................................................................................................................................ 10 -214
Engine power mode select circuit ............................................................................................... 10 -226
Cooling fan control function ........................................................................................................ 10 -228

GD555-5,GD655-5,GD675-5 10-3
(05)
Engine and Cooling
Contents

Engine and Cooling


Cooling system

10-4 GD555-5,GD655-5,GD675-5
Engine and Cooling
Contents

A: Radiator inlet D: Power train oil cooler outlet


B: Radiator outlet E: Aftercooler inlet
C: Power train oil cooler inlet F: Aftercooler outlet

1. Fan guard 7. Shroud


2. Radiator inlet hose 8. Radiator cap
3. Drain valve 9. Radiator
4. Radiator outlet hose 10. Power train oil cooler
5. Reservoir tank 11. Condenser
6. Aftercooler 12. Oil cooler

Specifications
Power train oil
Radiator Aftercooler
cooler
Core type CF68-4 CF40-1 CF69

Fin pitch (mm) 3.5/2 3.5/2 4.0/2

Total heat dissipation area (m2) 44.59 4.07 x 2 14.78


Cracking pressure of pressure
70 ± 15
valve ― ―
{0.7 ± 0.15}
(kPa {kg/cm2})
Cracking pressure of vacuum
0–5
valve ― ―
{0 – 0.05}
(kPa {kg/cm2})

GD555-5,GD655-5,GD675-5 10-5
Engine and Cooling
Cooling fan pump

Cooling fan pump


Type: LMF16

P: From pump through charge valve Specifications


T: To hydraulic tank through return filter Type: LMF28
TC: To tank Capacity: 28 cm3/rev
Rated speed: 1575 rpm
1. Terminal ER Rated delivery: 56.5 l/min
2. Terminal EF
3. Proportional solenoid pilot valve
4. ON/OFF pilot valve

10-6 GD555-5,GD655-5,GD675-5
Engine and Cooling
Cooling fan pump

1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
18. Speed sensor

GD555-5,GD655-5,GD675-5 10-7
Engine and Cooling
Cooling fan pump

1. Hydraulic motor

Function
q This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.

Principle of operation
q The pressurized oil sent from the pump flows
through valve plate (7) into cylinder block (5).
q This pressurized oil can flow on only to one side
of the (Y - Y) line connecting the top dead center
and bottom dead center of the stroke of piston
(4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (two or three pistons).
q A single piston generates force F1 [F1 (kg) = P

(kg/cm2) x xD2/4 (cm2)].


q This force works on thrust plate (2).
q Since thrust plate (2) is fixed with the specific an-
gle (a) to output shaft (1), the force is divided into
components (F2) and (F3).
q Among them, radial component (F3) generates
torque (T = F3 x ri) against the (Y - Y) line con-
necting the top dead center and bottom dead
center.
q Total torque of the component force [T = Σ(F3 x
ri)] rotates cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.

10-8 GD555-5,GD655-5,GD675-5
Engine and Cooling
Cooling fan pump

2. Suction safety valve (2) When engine is stopped


q When the engine stops, the pump speed be-
1) Suction function comes 0 rpm.
q The pressurized oil from the pump is not sup-
Function plied to port (P).
q If the fan pump stops, the pressurized oil does q As the pressurized oil is not supplied to (MA)
not flow into the motor. side of the motor, the motor speed decreases
q Since the motor continues to rotate with the force gradually to stop.
of inertia, the pressure on the outlet side of the q If the motor shaft is rotated by the force of inertia
motor increases. while the oil flow in port (P) is reducing, the pres-
q When the pressurized oil stops flowing in from surized oil in port (T) on the outlet side is sent by
inlet port (P), suction safety valve (1) sucks in the suction safety valve (1) to (MA) side to prevent
pressurized oil on the outlet side and supplies it cavitation.
to port (MA) where there is not sufficient oil to
prevent cavitation.

Operation
(1) When engine is started
q The pressurized oil from the pump is supplied to
port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
and the motor starts rotating.
q The pressurized oil on the motor outlet (MB) side
returns through port (T) to the tank.

GD555-5,GD655-5,GD675-5 10-9
Engine and Cooling
Cooling fan pump

2) Safety function

Function
q When the engine is started, the pressure in port
(P) of the fan motor is increased in some cases.
q Suction safety valve (1) is installed to protect the
fan system circuit.

Operation
q If the pressure in port (P) increases above the
cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to re-
lease the pressurized oil into port (T).
q By this operation, the generation of the abnor-
mally high pressure in port (P) is prevented.

10-10 GD555-5,GD655-5,GD675-5
Engine and Cooling
Cooling fan pump

3. Operation of reversible valve

1) When ON/OFF solenoid is de-energized 2) When ON/OFF solenoid is energized


q When ON/OFF solenoid (1) is "de-energized", q When ON/OFF solenoid (1) is "energized", valve
the pressurized oil from the pump is shut off by (2) is switched.
valve (2). q The pressurized oil from the pump flows to spool
q Port (C) opens for the hydraulic tank circuit. chamber (D) through port (C).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil flowed in chamber (D) com-
q Port (MA) opens and pressurized oil flows in to presses spring (4).
rotate the motor in normal direction (clockwise). q Spool (3) moves to the left.
q Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse direction (counter-
clockwise).

GD555-5,GD655-5,GD675-5 10-11
Engine and Cooling
Cooling fan pump

4. Flow control valve (continuously-variable


type)

Function
This valve supplies the required pump delivery to
the motor, and returns the excessive oil to the hy-
draulic tank.

q The motor speed increases in proportion to the


increase of the incoming oil (Q) as shown in Fig
1.
q When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
q In order to reduce noise and performance loss of
the motor, this valve keeps the fan speed con-
stant independent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed con-
stant between points (A) and (C).

Operation
q For the flow control valve, the upstream pres-
sure through the orifice is applied to the right
side of spool (1) and the downstream pressure
through the orifice is applied to its left side.
q The differential pressure before and after orifice
(E) by the incoming flow rate to the motor works
on spring (2).
q In Fig. 1, when the incoming flow rate becomes
more than (Q0), the differential pressure before
and after spool (1) becomes larger than the in-
stalled load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig 1 flows to
the hydraulic tank through the flow control valve,
and the motor speed is kept constant from (A) to
(C).
q This flow control valve is a continuously-variable
type.
q As shown in Fig 2, it is possible to change the
flow control valve continuously while maintaining
the motor speed constant between (A') to (C') by
changing the command current between the mo-
tor speed (A) and (C).

10-12 GD555-5,GD655-5,GD675-5
Engine and Cooling
Cooling fan pump

5. Speed sensor

1. Speed sensor
2. O-ring
3. Connector
4. Wire

Function
q Speed sensor which is installed to case of the
motor detects fan motor speed as pulse signals
from cylinder block spline inside the motor and
sends them as converted electric signals to the
controller.
q Since the clearance between sensor and spline
is specified according to the parts dimensions,
adjustment at installation is not necessary.

GD555-5,GD655-5,GD675-5 10-13
Power train system
Cooling fan pump

Power train system


Power train system drawing

1. Engine Outline
2. Torque converter q The power from engine (1) is transmitted
3. Transmission through torque converter (3) to transmission (4).
4. Drive shaft q Transmission (4) is of counter-shaft type, con-
5. Final drive trolled hydraulically, and has "8 forward and 4 re-
6. Shaft verse gear speeds".
7. Tandem drive q The power from transmission (4) is transmitted
8. Chain through drive shaft (5) to final drive (6).
9. Wheel brake q The power speed reduced by final drive (6) is
10. Tier transmitted through shaft (7) to tandem drive (8).
q The power from shaft (7) is transmitted through
chain (9) in tandem drive (8) to hub shaft (10).
q The power transmitted to hub shaft (10) is trans-
mitted to tires (11) to drive the machine.

10-14 GD555-5,GD655-5,GD675-5
Power train system
Cooling fan pump

GD555-5,GD655-5,GD675-5 10-15
Power train system
Power train piping drawing

Power train system


Power train piping drawing

1. Transmission oil filler/oil level gauge 6. Power train oil cooler


2. Power train oil filter outlet hose 7. Power train oil cooler inlet hose
3. Power train oil filter 8. Power train pump
4. Power train pump outlet hose 9. Power train pump inlet tube
5. Power train oil cooler outlet hose 10. Transmission

10-16 GD555-5,GD655-5,GD675-5
Power train system
Power train piping drawing

GD555-5,GD655-5,GD675-5 10-17
Power train system
Transmission control

Transmission control

1. Gear shift lever


2. Transmission mode selector switch
3. Transmission controller

10-18 GD555-5,GD655-5,GD675-5
Power train system
Transmission control

GD555-5,GD655-5,GD675-5 10-19
Power train system
Torque converter

Torque converter

10-20 GD555-5,GD655-5,GD675-5
Power train system
Torque converter

1. PTO drive gear (number of teeth: 70) Specifications


2. Pump 3-element, 1-stage, 2-phase
Type
3. Race With lockup clutch
4. Drive case Wet-type single-disc clutch
5. Stator Lockup clutch Hydraulic control
6. Turbine (with modulation mechanism)
Stall torque ratio 2.17
7. Lockup clutch piston
8. Lockup clutch housing (number of teeth: 72)
9. Pilot
10. Boss
11. Lockup clutch disc
12. Free wheel
13. Guide
14. Stator shaft
15. Transmission input shaft

GD555-5,GD655-5,GD675-5 10-21
Power train system
Torque converter

Power transmission route

When lockup clutch is "disengaged" When lockup clutch is "engaged"

Drive case (3), boss (9) and turbine (8) are discon- Drive case (3), boss (9) and turbine (8) are connect-
nected and the torque converter works as an ordi- ed and the lockup function works.
nary torque converter. Engine power
Engine power O
O Flywheel (1)
Flywheel (1) O
O Clutch housing (2)
Clutch housing (2) O
O Drive case (3), pump (5) and PTO drive gear (6) ro-
Drive case (3), pump (5) and PTO drive gear (6) ro- tate together
tate together O
O Lockup clutch (4)
Oil is used as a medium O
O Boss (9)
Turbine (8) and turbine boss (9) O
O Transmission input shaft (10)
Transmission input shaft (10)
q The power transmitted to PTO drive gear (6) is
q The power transmitted to PTO drive gear (6) is used as power for driving the hydraulic pumps
used as power for driving the hydraulic pumps after being transmitted through PTO idler gear
after being transmitted through PTO idler gear (7).
(7).

10-22 GD555-5,GD655-5,GD675-5
Power train system
Torque converter

Flow of oil

q The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. The oil then
flows through inlet port (A) and the oil passage of
stator shaft (1) and guide (2) to pump (3).
q The oil is given centrifugal force by pump (3) and
flows into turbine (4) to transmit its energy to tur-
bine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again. And part of the oil
flows through the space between turbine (4) and
stator (5) to outlet port (B). The oil is then con-
ducted to the oil cooler for cooling and used for
lubricating the transmission.

GD555-5,GD655-5,GD675-5 10-23
Power train system
Transmission

Transmission

10-24 GD555-5,GD655-5,GD675-5
Power train system
Transmission

A: From power train pump


B: To oil cooler
C: From oil cooler
D: To power train pump

1. Main pump mounting location


2. Power train, differential lock pump mounting location
3. Transmission control valve
4. Transmission oil temperature sensor
5. Oil filler pipe mounting location
6. Transmission case (front)
7. Transmission case (rear)
8. Transmission output shaft speed sensor
9. Main relief, torque converter relief valve
10. Torque converter oil temperature sensor
11. Transmission input shaft speed sensor
12. Transmission intermediate shaft speed sensor

GD555-5,GD655-5,GD675-5 10-25
Power train system
Transmission

10-26 GD555-5,GD655-5,GD675-5
Power train system
Transmission

GD555-5,GD655-5,GD675-5 10-27
Power train system
Transmission

1. Torque converter
2. Input shaft
3. FL clutch
4. Upper shaft
5. FH clutch
6. Lower shaft
7. 3rd clutch
8. Coupling
9. 4th clutch
10. Output shaft
11. 2nd clutch
12. 1st clutch
13. R clutch
14. PTO idler gear A (number of teeth: 67)
15. PTO gear A shaft
16. PTO gear A (number of teeth: 62)

10-28 GD555-5,GD655-5,GD675-5
Power train system
Transmission

GD555-5,GD655-5,GD675-5 10-29
Power train system
Transmission

10-30 GD555-5,GD655-5,GD675-5
Power train system
Transmission

1. PTO gear B (number of teeth: 62) Outline


2. PTO idler gear B (number of teeth: 53) q The transmission adopted is a "forward 8-gear
3. R idler gear (number of teeth: 37) range and reverse 4-gear range" transmission
4. Strainer which consists of the counter-shaft type, con-
5. Drain plug stant mesh spur gear mechanisms and the disc
6. Drain plug clutches.
q The transmission selects a rotating direction and
rotating speed by fixing the counter-shaft type,
constant mesh spur gear mechanisms and two
out of seven sets of disc clutches with the oil
pressure by ECMV operation.
q The transmission transfers the power received
by the transmission input shaft to the output
shaft while changing the gear speed (forward 1st
- 8th or reverse 1st - 4th) by any combination of
the FL, FH, R clutches and four speed clutches.

Number of plates and discs used


Clutch No. Number of plate Number of disc
FL clutch 9 8
FH clutch 13 12
R clutch 9 8
1st clutch 6 5
2nd clutch 15 14
3rd clutch 8 7
4th clutch 7 6

Combinations of clutches at each gear speed


and reduction ratio
Operating
Gear range Reduction ratio
clutches
Forward 1st FL × 1st 9.950
Forward 2nd FH × 1st 6.865
Forward 3rd FL × 2nd 4.879
Forward 4th FH × 2nd 3.367
Forward 5th FL × 3rd 2.222
Forward 6th FH × 3rd 1.533
Forward 7th FL × 4th 1.118
Forward 8th FH × 4th 0.772
Neutral ― ―
Reverse 1st R × 1st 7.549
Reverse 2nd R × 2nd 3.702
Reverse 3rd R × 3rd 1.686
Reverse 4th R × 4th 0.848

GD555-5,GD655-5,GD675-5 10-31
Power train system
Transmission

FL and R clutches

A: R clutch oil port C: Lubricating oil port


B: FL clutch oil port D: Lockup clutch oil port

1. R clutch gear (Number of teeth: 25) 5. FL clutch gear (number of teeth: 28)
2. R clutch 6. Input gear (number of teeth: 36)
3. FL and R cylinders 7. Input shaft
4. FL clutch

10-32 GD555-5,GD655-5,GD675-5
Power train system
Transmission

FH and 1st clutches

A: FH clutch oil port C: Lubricating oil port


B: 1st clutch oil port

1. Upper gear (number of teeth: 42) 5. FH clutch


2. 1st clutch gear (number of teeth: 26) 6. FH clutch gear (number of teeth: 55)
3. 1st clutch 7. Upper shaft
4. FH and 1st cylinders (number of teeth: 62)

GD555-5,GD655-5,GD675-5 10-33
Power train system
Transmission

2nd and 3rd clutches

A: 2nd clutch oil port C: Lubricating oil port


B: 3rd clutch oil port

1. Lower gear (number of teeth: 29) 5. 3rd clutch


2. 2nd clutch gear (number of teeth: 61) 6. 3rd clutch gear (number of teeth: 55 and 41)
3. 2nd clutch 7. Lower shaft
4. 2nd and 3rd cylinders (number of teeth: 77)

10-34 GD555-5,GD655-5,GD675-5
Power train system
Transmission

4th clutch

A: 4th clutch oil port C: Lubricating oil port


B: Lubricating oil port

1. Output gear (number of teeth: 44) 3. 4th cylinders (number of teeth: 42)
2. 4th clutch 4. Output shaft

GD555-5,GD655-5,GD675-5 10-35
Power train system
Transmission

Operation of disc clutch

When clutch is "engaged" (fixed) When clutch is "disengaged" (released)

q The oil sent from the ECMV flows through the oil q When the oil sent from the ECMV is shut off, the
passage of shaft (1), is pressure-fed to the back pressure of the oil exerted on the back of piston
of piston (2), and pushes piston (2) to the right. (2) goes down.
q Piston (2) compresses plates (3) and discs (4) q Piston (2) is pushed back to the left by reactive
and the rotation of discs (4) is stopped by the force of wave spring (7).
frictional force. q The friction force between plates (3) and discs
q As the internal teeth of discs (4) are meshed with (4) is eliminated and shaft (1) and clutch gear (5)
clutch gear (5), shaft (1) and clutch gear (5) are released.
transfer the power in a body. q When the clutch is released, the oil on the back
q The oil is drained from oil drain hole (6), but the of piston is drained by the centrifugal force
drain amount is less than the amount of oil sup- through oil drain hole (6) to prevent the clutch
plied, so there is no influence on the actuation of from being partially engaged.
the clutch.
a Oil drain hole (6) is provided only with the 2nd,
3rd, and 4th clutches.

10-36 GD555-5,GD655-5,GD675-5
Power train system
Transmission

Power transmitting route


Forward 1st gear speed

FL clutch (3) and 1st clutch (11) are fixed hydraulically.


Power from torque converter o(from left bottom) o(from center bottom)
O O O
Input shaft (1) 1st clutch (11) Output gear (25)
O O O
FL and R cylinders (2) 1st clutch gear (14) Output shaft (26)
O O
FL clutch (3) 2nd and 3rd cylinders (20)
O O
FL clutch gear (5) Lower shaft (21)
O O
FH and 1st cylinders (12) Lower gear (22)
O O
(To center top)o (To right top) o

GD555-5,GD655-5,GD675-5 10-37
Power train system
Transmission

Forward 2nd gear speed

FH clutch (10) and 1st clutch (11) are fixed hydraulically.


Power from torque converter o(from left bottom)
O O
Input shaft (1) 1st clutch gear (14)
O O
Input gear (7) 2nd and 3rd cylinders (20)
O O
FH clutch gear (9) Lower shaft (21)
O O
FH clutch (10) Lower gear (22)
O O
FH and 1st cylinders (12) Output gear (25)
O O
1st clutch (11) Output shaft (26)
O
(To right top) o

10-38 GD555-5,GD655-5,GD675-5
Power train system
Transmission

Forward 3rd gear speed

FL clutch (3) and 2nd clutch (18) are fixed hydraulically.


Power from torque converter o(from left bottom) o(from center bottom)
O O O
Input shaft (1) Upper gear (15) Output gear (25)
O O O
FL and R cylinders (2) 2nd clutch gear (16) Output shaft (26)
O O
FL clutch (3) 2nd clutch (18)
O O
FL clutch gear (5) 2nd and 3rd cylinders (20)
O O
FH and 1st cylinders (12) Lower shaft (21)
O O
Upper shaft (13) Lower gear (22)
O O
(To center top)o (To right top) o

GD555-5,GD655-5,GD675-5 10-39
Power train system
Transmission

Forward 4th gear speed

FH clutch (10) and 2nd clutch (18) are fixed hydraulically.


Power from torque converter o(from left bottom) o(from center bottom)
O O O
Input shaft (1) Upper gear (15) Output gear (25)
O O O
Input gear (7) 2nd clutch gear (16) Output shaft (26)
O O
FH clutch gear (9) 2nd clutch (18)
O O
FH clutch (10) 2nd and 3rd cylinders (20)
O O
FH and 1st cylinders (12) Lower shaft (21)
O O
Upper shaft (13) Lower gear (22)
O O
(To center top)o (To right top) o
Forward 5th gear speed

10-40 GD555-5,GD655-5,GD675-5
Power train system
Transmission

FL clutch (3) and 3rd clutch (19) are fixed hydraulically.


Power from torque converter o(from left bottom)
O O
Input shaft (1) 3rd clutch (19)
O O
FL and R cylinders (2) 2nd and 3rd cylinders (20)
O O
FL clutch (3) Lower shaft (21)
O O
FL clutch gear (5) Lower gear (22)
O O
FH and 1st cylinders (12) Output gear (25)
O O
3rd clutch gear (17) Output shaft (26)
O
(To right top) o

GD555-5,GD655-5,GD675-5 10-41
Power train system
Transmission

Forward 6th gear speed

FH clutch (10) and 3rd clutch (19) are fixed hydraulically.


Power from torque converter o(from left bottom)
O O
Input shaft (1) 3rd clutch (19)
O O
Input gear (7) 2nd and 3rd cylinders (20)
O O
FH clutch gear (9) Lower shaft (21)
O O
FH clutch (10) Lower gear (22)
O O
FH and 1st cylinders (12) Output gear (25)
O O
3rd clutch gear (17) Output shaft (26)
O
(To right top) o

10-42 GD555-5,GD655-5,GD675-5
Power train system
Transmission

Forward 7th gear speed

FL clutch (3) and 4th clutch (24) are fixed hydraulically.


Power from torque converter o(from left bottom)
O O
Input shaft (1) 4th clutch gear (23)
O O
FL and R cylinders (2) 4th clutch (24)
O O
FL clutch (3) Output shaft (26)
O
FL clutch gear (5)
O
FH and 1st cylinders (12)
O
3rd clutch gear (17)
O
(To right top) o

GD555-5,GD655-5,GD675-5 10-43
Power train system
Transmission

Forward 8th gear speed

FH clutch (10) and 4th clutch (24) are fixed hydraulically.


Power from torque converter o(from left bottom)
O O
Input shaft (1) 4th clutch gear (23)
O O
Input gear (7) 4th clutch (24)
O O
FH clutch gear (9) Output shaft (26)
O
FH clutch (10)
O
FH and 1st cylinders (12)
O
3rd clutch gear (17)
O
(To right top) o

10-44 GD555-5,GD655-5,GD675-5
Power train system
Transmission

Reverse 1st gear speed

R clutch (4) and 1st clutch (11) are fixed hydraulically.


Power from torque converter o(from left bottom) o(from center bottom)
O O O
Input shaft (1) Upper gear (15) Lower shaft (21)
O O O
FL and R cylinders (2) Upper shaft (13) Lower gear (22)
O O O
R clutch (4) FH and 1st cylinders (12) Output gear (25)
O O O
R clutch gear (6) 1st clutch (11) Output shaft (26)
O O
R idler gear (8) 1st clutch gear (14)
(Output rotation is reversed through O
R idler gear (8).) 2nd and 3rd cylinders (20)
O O
(To center top)o (To right top) o

GD555-5,GD655-5,GD675-5 10-45
Power train system
Transmission control valve

Transmission control valve

10-46 GD555-5,GD655-5,GD675-5
Power train system
Transmission control valve

A: From power train pump


B: FL clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: FH clutch oil pressure pickup port
E: 1st clutch oil pressure pickup port
F: 2nd clutch oil pressure pick-up port
G: 3rd clutch oil pressure pickup port
H: 4th clutch oil pressure pickup port
J: Lockup clutch oil pressure pickup port

1. FL clutch ECMV
2. R clutch ECMV
3. FH clutch ECMV
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. 4th clutch ECMV
8. Seat
9. Last chance filter
10. Lockup clutch ECMV

GD555-5,GD655-5,GD675-5 10-47
Power train system
Transmission control valve

Outline
q The oil from the pump flows to the transmission front case block through the oil filter and then the flow
diverges, one flowing toward the main relief circuit and another toward the clutch operating circuit.
q The oil regulated by the main relief valve flowed in the clutch operating circuit, operates the clutch through
the last chance filter. The oil relieved by the main relief valve is supplied to the torque converter.
q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. The ECMV
keeps the clutch pressure constant during travel.
q When the FL, FH, or R, and one of 1st to 4th ECMVs are selected, the pressure regulated oil is supplied
to the selected clutches and the desired gear range is obtained.
q Three types of ECMVs are used, which are identified and have differences as shown below.
Identifi- Fill switch
Stamp on name plate cation Stamp (Operating pressure: MPa Clutch to be
Flow detecting valve
(A) color (C) used
(B) {kg/cm2})
(*1) Equipped
E******* — None 2nd, 3rd, 4th
Pink (0.26 {2.7})
(*1) Equipped
A******* — None FL, FH, R, 1st
Yellow (0.26 {2.7})
K******* — — None None L/U

L/U: Indicates lockup clutch ECMV.


*1: Since the transmission assembly is painted, each ECMV cannot be identified by identification color.
(Each ECMV can be identified by identification color only when it is not assembled and painted.)
Table of ECMV operation
ECMV
Gear FL FH R 1st 2nd 3rd 4th
speed
F1 Q Q
F2 Q Q
F3 Q Q
F4 Q Q
F5 Q Q
F6 Q Q
F7 Q Q
F8 Q Q
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
N

10-48 GD555-5,GD655-5,GD675-5
Power train system
Transmission control valve

GD555-5,GD655-5,GD675-5 10-49
Power train system
ECMV

ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve
For lockup clutch
a Don't try to disassemble the ECMVs since the adjustment for maintaining the performance will be required.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch pressure pickup port

1. Proportional solenoid connector


2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Name plate

10-50 GD555-5,GD655-5,GD675-5
Power train system
ECMV

Outline of ECMV Operation


q This valve is used to switch the clutch in addition Clutch is "disengaged"
to regulating the clutch oil pressure to the set
pressure.
Since the pressure application characteristics to
the clutch is used for the modulation waveform,
ECMV is capable of connecting the lockup clutch
smoothly, thereby reducing the shocks resulting
from gear shift. In addition, the above prevents
the generation of peak torque in the power train.
As a result, it provides a comfortable ride for the
operator and increases the durability of the
power train.

When changing from torque converter mode to


direct drive mode

q Under the condition where any current is not


When changing gear range (in direct travel) sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).

GD555-5,GD655-5,GD675-5 10-51
Power train system
ECMV

Clutch is "engaged"

q When current is passed to proportional solenoid


(1), the hydraulic force balanced with the sole-
noid force is applied to chamber (B) and pushes
pressure control valve (3) to the left. As a result,
pump port (P) and clutch port (A) are opened
and oil starts filling the clutch.
q If the clutch is filled with oil, this thrust of the so-
lenoid is balanced with the sum of the thrust gen-
erated by the oil pressure in clutch port and the
reactive force of pressure control valve spring
(2), and then the pressure is settled.

10-52 GD555-5,GD655-5,GD675-5
Power train system
ECMV

For F, R, 1st, 2nd, 3rd, and 4th clutches


a Don't try to disassemble ECMV since the adjustment for maintaining the performance will be required.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port

1. Fill switch connector


2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Name plate

GD555-5,GD655-5,GD675-5 10-53
Power train system
ECMV

Outline of ECMV a The logic is designed so that the controller does


q The ECMV consists of a pressure control valve not recognize the completion of filling even if the
and a fill switch. fill switch is turned "ON" during triggering (Range
q Pressure control valve D).
The proportional solenoid receives the current
from the transmission controller, and the valve
converts it into oil pressure.
q Fill switch
This switch detects that the clutch is filled with oil
and has the following functions.
1. Outputs a signal (a fill signal) to the controller to
notify that filling is completed when the clutch is
filled with oil.
2. Keeps outputting the signals (fill signals) to the
controller to notify it of the oil pressure actually
applied while oil pressure is applied to the clutch.

Range A: Before shifting gear (when draining)


Range B: During filling
Range C: Pressure regulation
Range D: During filling (during triggering)
Point E: Start of filling
Point F: End of filling

10-54 GD555-5,GD655-5,GD675-5
Power train system
ECMV

ECMV and proportional solenoid


q Each ECMV is equipped with a proportional so-
lenoid.
The proportional solenoid generates thrust
shown below according to the command current
from the controller.
The thrust generated by the proportional sole-
noid is applied to the pressure control valve
spool to generate oil pressure as shown in the
figure below. Accordingly, the thrust is changed
by controlling the command current to operate
the pressure control valve to control the flow and
pressure of the oil.

Current of proportional solenoid - thrust charac-


teristics

Thrust of proportional solenoid - characteristics


of hydraulic pressure

ECMV and fill switch


q Each ECMV is equipped with a fill switch.
When the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. The oil
pressure is built up according to this signal.

GD555-5,GD655-5,GD675-5 10-55
Power train system
ECMV

Operation of ECMV Before shifting gear [when draining] (range A in


q ECMV is controlled by the command current chart)
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relation between the proportional solenoid
command current for ECMV, clutch input pres-
sure, and fill switch output signal is shown below.

q Under the condition where any current is not


sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
At this time, fill switch (5) is turned "OFF"
Range A: Before shifting gear (when draining) because oil pressure is not applied to pressure
Range B: During filling detecting valve (4).
Range C: Pressure regulation
Range D: During filling (during triggering)
Point E: Start of filling
Point F: End of filling

a The logic is designed so that the controller does


not recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).

10-56 GD555-5,GD655-5,GD675-5
Power train system
ECMV

During filling (range B in chart) Pressure regulation (range C in chart)

q When current is applied to proportional solenoid q When current is passed to proportional solenoid
(1) with no oil in the clutch, the hydraulic force (1), the solenoid generates thrust in proportion to
balanced with the solenoid force is applied to the current. This thrust of the solenoid is bal-
chamber (B) and pushes pressure control valve anced with the sum of the thrust generated by
(3) to the left. As a result, pump port (P) and the oil pressure in clutch port and the reactive
clutch port (A) are opened and oil starts filling the force of pressure control valve spring (2), and
clutch. When the clutch is filled with oil, pressure the pressure is settled.
detecting valve (4) actuates to turn "ON" fill
switch (5).

GD555-5,GD655-5,GD675-5 10-57
Power train system
Main relief and torque converter relief valve

Main relief and torque converter relief valve

1. Body A: Drain (torque converter relief)


2. Piston B: Drain
3. Torque converter relief valve C: From pump
4. Piston D: Drain
5. Main relief valve E: To torque converter
6. Seat P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port

10-58 GD555-5,GD655-5,GD675-5
Power train system
Main relief and torque converter relief valve

Outline Operation of main relief valve

Torque converter relief valve


q The torque converter relief valve constantly reg-
ulates the torque converter inlet circuit pressure
below the set pressure to protect the torque con-
verter from abnormally high pressure.
Set pressure: 1.02 MPa {10.4 kg/cm2}
(Cracking pressure)

Main relief valve


q The main relief valve regulates the pressure in
the transmission and parking brake hydraulic cir-
cuits to the set pressure.
Set pressure: 2.48 MPa {25.3 kg/cm2}
(At rated engine speed) q The oil from the hydraulic pump flows to port (C)
through the filter. Then it flows to chamber (F)
Operation through orifice (a) in main relief valve (1).

Operation of torque converter relief valve

q When the oil pressure in the circuit increases be-


q The oil relieved through the main relief valve yond the set pressure, the oil in chamber (F)
flows through port (E) into the torque converter. pushes piston (2) and the resulting pushing force
It also flows through orifice (b) in torque convert- against the spring force pushes main relief valve
er relief valve (3) into chamber (G). (1) leftward. This connects ports (C) and (E).
q When the oil pressure to the torque converter Then, the oil from pump flows through port (E)
goes beyond the set pressure, the oil conducted into the torque converter.
to chamber (G) pushes piston (4) and the result-
ing pushing force pushes torque converter relief
valve (3) rightward. This connects ports (E) and
(A).
Then, the oil in port (E) is drained through port
(A).

GD555-5,GD655-5,GD675-5 10-59
Power train system
Front axle

Front axle

1. Tie rod Specifications


2. Steering cylinder Toe-in angle (°) -5 – 0
3. Support axle Camber angle (°) 0
4. Leaning rod Leaning angle (°) (*1) 13
5. Leaning cylinder *1: Leaning angle of center of tire from perpendicular
6. Bracket line to axle
7. Hub shaft

10-60 GD555-5,GD655-5,GD675-5
Power train system
Front axle

Function of front axle Unless the whole oscillating range (16° on


the right and left) for the front axle is used,
1. Lessening blade inclination and vertical move- the blade moves up and down keeping its
ment posture horizontal.
q The front axle is installed to the frame in the
center with the center pin and can oscillate
16°. This mechanism is employed to reduce
vertical movement of the blade similarly to
the tandem system when the wheels on ei-
ther side ride over an object or fall into a hole.
When the front wheel rides over an object
(height H), the center point of the front axel
rises by H/2 as shown in the figure.
Since the front axle can oscillate, the blade
moves by H/4 while keeping its posture hori-
zontal.

2. Sideways slip Prevention of the front wheels


from slipping sideways (leaning system)
q The front wheels can lean to the right and left.
This mechanism is called the leaning system
and is employed to prevent the front wheels
from slipping sideways and to reduce the
turning radius.
The blade is usually angled during grading
work. The larger the blade angle is, the larger
sideward slipping force is applied to the
blade.

q The machine weight is distributed to the front


and rear wheels at a ratio of about 3:7. When
the blade digs into the ground, the load on
the front wheels decreases and the front
wheels slip easily.
The front wheels are leaned to brace against
the sideways force and to move the center of
the front wheel load and the center of gravity
of the machine to prevent sideways slip.

GD555-5,GD655-5,GD675-5 10-61
Power train system
Front axle

q Since the motor grader has a long wheelbase


and does not have a differential system, its
turning radius is very large.
If the wheels are leaned, the distance tires =
2xr made by turning the tire larger on the
larger load radius side is larger than that on
the smaller load radius side, and accordingly
the tire on the larger load radius side moves
more. As a result, the machine moves in the
leaning direction.

The turning radius can be reduced by using


this characteristic of the leaning operation.

q When the motor grader travels in reverse, the


wheels are leaned in the opposite direction to
the turning direction of the steering wheel
(opposite direction to the direction in the for-
ward travel).

10-62 GD555-5,GD655-5,GD675-5
Power train system
Front axle

GD555-5,GD655-5,GD675-5 10-63
Power train system
Final drive (no differential specification)

Final drive (no differential specification)

1. Coupling (Figure indicates holder.) 6. Planetary gear (number of teeth: 20)


2. Bevel pinion (number of teeth: 12) 7. Ring gear (number of teeth: 66)
3. Bevel gear (number of teeth: 43) 8. Planetary carrier
4. Cage 9. Shaft
5. Sun gear (number of teeth: 24) 10. Sprocket (number of teeth: 20)

10-64 GD555-5,GD655-5,GD675-5
Power train system
Final drive (no differential specification)

Outline
q When the motor grader travels to work with the
blade angled or with its body leaned, its front
portion receives a sideway force and tends to
turn to the right or left by the reaction force. To
maintain the straight travel performance against
the above force, the motor graders are not usu-
ally equipped with differential system.

Operation
q The power transmitted from the engine to the
transmission is then transmitted to sprocket (10)
by means of engaged bevel pinion (2) and bevel
gear (3) through cage (4) o sun gear (5) o plan-
etary gear (6) o planetary (carrier) (8) o and
shaft (9).

GD555-5,GD655-5,GD675-5 10-65
Power train system
Final drive (differential/ differential lock specification)

Final drive (differential/ differential lock specification)

1. Coupling 6. Pinion gear (number of teeth: 10)


2. Bevel pinion (number of teeth: 12) 7. Side gear (number of teeth: 20)
3. Bevel gear (number of teeth: 43) 8. Sun gear (number of teeth: 24)
4. Differential case 9. Planetary gear (number of teeth: 20)
5. Shaft 10. Ring gear (number of teeth: 66)
11. Planetary carrier
12. Shaft
13. Sprocket (number of teeth: 20)
14. Disk
15. Plate

10-66 GD555-5,GD655-5,GD675-5
Power train system
Final drive (differential/ differential lock specification)

Outline
q When the motor grader travels to work with the
blade angled or with its body leaned, its front
portion receives a sideway force and tends to
turn to the right or left by the reaction force. To
maintain the straight travel performance against
the above force, motor graders are not usually
equipped with differential system.
q When the motor grader grades the ground while
turning, the rear wheels slip more because of the
difference in track.
In this case, the tire service life is lengthened, if
the machine is equipped with lock-type differen-
tial final drives.

Operation
q The power transmitted from the engine to the
transmission is then transmitted to sprocket (13)
by means of engaged bevel pinion (2) and bevel
gear (3) through differential case (4) o shaft (5)
o pinion gear (6) o side gear (7) o sun gear (8)
o planetary gear (9) o planetary carrier (11) o
shaft (12).
The differential system is set to ON or LOCK
(OFF) by hydraulically pressing disc (14) and
plate (15) together or separately.
q While the machine is traveling at high speed (F6
to F8), the controller cancels the differential lock
automatically even if it is switch to ON.

GD555-5,GD655-5,GD675-5 10-67
Power train system
Differential lock solenoid valve

Differential lock solenoid valve


With differential lock
(Option)

10-68 GD555-5,GD655-5,GD675-5
Power train system
Differential lock solenoid valve

GD555-5,GD655-5,GD675-5 10-69
Power train system
Tandem drive

Tandem drive

1. Sprocket (number of teeth: 20)


2. Hub shaft
3. Disc
4. Plate
5. Breather
6. Oil level plug
7. Drain plug

10-70 GD555-5,GD655-5,GD675-5
Power train system
Tandem drive

Outline
q The power from the final drive is transmitted to
the front and rear wheels by the chains of the
tandem drive.
q Since the tandem case can rock in the direction
of the front up 11° and in the direction of the front
down 13°, the rear four wheels are kept in con-
tact with the ground even if it is uneven, thus the
blade move up and down less.

Operation
q When the rear wheels of the motor grader ride
on a bump, the blade moves as follows.

1. If both of the right and left wheels ride on the


bump (height: H), the height at the center
between the rear hub shafts is H/2. Since the
blade is located at almost the center between the
front and rear axles, its height at the center of the
rear axles is H/4.

2. If only one of the left rear wheels rides on the


bump (height: H), the height at the center
between the rear hub shafts is H/2, as shown in
the figure, and the height at the center of the
machine on the rear axle is reduced to a half, or
H/4. The height of the center of the blade is
reduced to a half again, or H/8.

GD555-5,GD655-5,GD675-5 10-71
Steering system
Steering piping diagram

Steering system
Steering piping diagram
GD555-5

1. Steering valve
2. Steering wheel
3. Main pump
4. Hydraulic tank
5. Hydraulic oil line filter
6. Priority valve
7. Steering sylinder
8. LS pressure control valve

10-72 GD555-5,GD655-5,GD675-5
Steering system
Steering piping diagram

GD655-5, GD675-5

1. Steering valve
2. Steering wheel
3. Main pump
4. Hydraulic tank
5. Hydraulic oil line filter
6. Priority valve
7. Steering sylinder
8. LS pressure control valve

GD555-5,GD655-5,GD675-5 10-73
Steering system
Priority valve

Priority valve

P: From pump 1. Relief valve


EF: To work equipment circuit 2. Orifice
CF: To steering valve 3. Spring
LS: To pilot circuit 4. Spool
T: To hydraulic tank 5. Orifice
6. Orifice
7. Accumulator charge valve mounting face

10-74 GD555-5,GD655-5,GD675-5
Steering system
Priority valve

Outline
q If the work equipment and steering hydraulic
systems are powered with only one pump, it be-
comes very dangerous when all the pump deliv-
ery is consumed by the work equipment circuit
and sufficient oil is not supplied to the steering
circuit.
q The valve secures the oil flow for the steering cir-
cuit first.
q If a large flow of oil is sent to the steering circuit
even when the steering is at neutral , the oil flow
to the work equipment circuit will be reduced and
poor efficiency results.
q To prevent this situation and to ensure a quick
response when operatiing the steering , this
valve keeps the steering circuit oil flow to a min-
imun (approx. 1 l/min) when the steering is at
neutral, and to send the rest of the oil to the work
equipment circuit.
q The built-in relief valve regulates the steering cir-
cuit pressure to prevent generation of abnormal
pressure.

GD555-5,GD655-5,GD675-5 10-75
Steering system
Priority valve

Operation
While engine is stopped
q Spool (1) is pressed to the right by the reaction
force of spring (2), and consequently port (EF) is
closed and the open area of port (CF) increases
to the maximum.

When engine is started


(Control valve and steering valve are in neutral)
q The oil from the main pump flows through ports
(A) and (CF) to the steering circuit.
q Since the steering valve is in neutral, the oil pres-
sure in port (CF) increases.
q The oil in chamber (A) flows through orifice (a) of
spool (1) to chamber (B) and pushes spool (1) to
the left.
q The oil in port (CF) is drained through the steer-
ing valve.
q The oil flow to the LS circuit is usually about 1
l/min.
q When the oil in the LS circuit passes orifices (b)
and (e), the differential pressure across the ori-
fices is approximately 0.98 MPa {10 kg/cm2} and
Pressure in chamber (B) = Pressure in chamber
(C) +0.98 MPa {10 kg/cm2}, and spool (1) moves
to the left to start closing portion (d).
q If the open area of portion (d) decreases, the
drain rate through orifice (b) decreases and the
pressure difference across orifice (b) decreases.
q If spool (1) is pushed to the right by the reaction
force of spring (2), portion (d) opens and the oil
flow increases to move spool (1) to the left again.
q Balance is maintained by repeating these opera-
tions.
q Force in left direction (converted to hydraulic
force)
: Pressure in chamber (B) (= 1.57 MPa {16
kg/cm2})
q Force in right direction
: Pressure in chamber (C) + 0.98 MPa {10
kg/cm2}
(=1.57 MPa {16 kg/cm2})
(0.98 MPa {10 kg/cm2} is the hydraulic force
converted for spring (2))

10-76 GD555-5,GD655-5,GD675-5
Steering system
Priority valve

When machine is steered


(Control valve is in neutral)
q If the steering wheel is operated, port (CF) is
connected to the steering cylinder and port (LS).
q Spool (1) is pushed to the right by the increase
of the oil pressure in chamber (C) and the reac-
tion force of spring (2), and the open area of por-
tion (d) increases.
q While the steering wheel is operated, the oil from
the main pump flows through port (CF) and
steering valve to the steering cylinder according
to the operation.
q If the steering wheel is operated quickly, the area
of the variable orifice of the steering valve is in-
creased.
q If the pressure difference across the variable or-
ifice in the steering valve decreases, the oil pres-
sure in the (LS) circuit increases (and the oil
pressure in chamber (B) decreases) and the oil
pressure in chamber (C) increases.
q Spool (1) moves to the right further and the open
area of portion (d) increases further to increase
the oil flow to the steering cylinder.
q If the steering wheel is operated slowly, the area
of the variable orifice of the steering valve is de-
creased.
q If the area of the variable orifice in the steering
valve decreases, the differential pressure across
the orifice increases and the pressure in cham-
ber (C) increases for that in chamber (B).
q Spool (1) moves to the left and the open area of
portion (d) decreases to decrease the oil flow to
the steering cylinder.
q Spool (1) is balanced according to the operation
of the steering wheel.
q Spool (1) is so controlled that the open area of
portion (d) will correspond to the flow rate neces-
sary to port (CF) while the differential pressure
between chambers (A) and (B) is maintained at
0.98 MPa {10 kg/cm2}. (All the oil, except for the
part necessary to the steering operation, flows
through port (EF) to the control valve)
q If a load is applied to the oil flowing through port
(CF) to the steering cylinder, the oil pressure in
the (PLS) line increases.
q If the oil pressure in the (PLS) line increases, it is
applied to the servo valve of the main pump.
q The swash plate angle of the main pump is con-
trolled to increase the delivery to increase the oil
pressure in the circuit.
q The oil pressure in the (PLS) line is fed back to
the main pump by sensing the load in the steer-
ing circuit.

GD555-5,GD655-5,GD675-5 10-77
Steering system
Priority valve

When steering cylinder is at stroke end


q If the steering wheel is kept operated after the
steering cylinder reaches the stroke end, the oil
flowing stops with the connection between the
steering valve and the steering cylinder main-
tained.
q If the oil flowing stops, the oil pressure in the
(CF) and (LS) circuits increases to the oil pres-
sure level in pump port (P).
q The pressure in both chambers (B) and (C) in-
creases and spool (1) moves to the right.
q If the oil pressure in chamber (C) increases

above 15.2 MPa {155 kg/cm2}, the steering relief


valve opens to drain the oil in chamber (C).
q A pressure difference is generated across orific-
es (b) and the pressure in chamber (C) decreas-
es for that in chamber (B) and spool (1) moves to
the left.
q Spool (1) is balanced at a point where the open
area of portion (d) is decreased to the level of the
flow rate of 1 l/min to prevent a large loss of the
oil flow when the oil is relieved.
q If spool (1) moves to the left too much, portion (d)
closes and oil does not flow to orifice (b).
q If the oil pressures in chambers (C) and (B) be-
come the same, spool (1) is moved to the right
by the reaction force of spring (2) to open portion
(d).
q The oil pressure in the steering circuit is kept be-

low 15.2 MPa {155 kg/cm2} by repeating these


operations.

When steering valve is in neutral and work


equipment control lever is operated
q If the work equipment control lever is operated,
the oil pressure in chamber (A) changes within
the range of 1.96 - 24.5 MPa {20 - 250 kg/cm2}
according to the load.
q Since the steering valve is in neutral, the opera-
tion is the same with the case when charging the
accumulator with pressure is completed in
"When engine is started (Control valve and
steering valve are in neutral)".
q The force applied to spool (1) is constant, re-
gardless of the pressure in chamber (A).
q If the pressure in chamber (A) increases, portion
(d) opens momentarily and the oil pressure in the
(CF) circuit increases and more oil flows through
orifice (b) and the pressure difference across or-
ifice (b) increases.
q Spool (1) moves to the left to reduce the open
area of portion (d) and limits the flow rate auto-
matically to 1 l/min.

10-78 GD555-5,GD655-5,GD675-5
Steering system
Priority valve

When steering system and work equipment are


operated simultaneously
1. When load on steering circuit is heavier than that
on work equipment circuit
q Actuation is the same with "Steering opera-
tion (Control valve is in neutral)".
q If the oil pressures in port (CF) and chamber
(A) become the same, portion (f) is choked
until the oil pressure flowing through port
(EF) to the control valve is adjusted to the
level necessary to the operation of the work
equipment.
q The oil pressure in the main circuit of the
main pump is controlled by the oil pressure in
the steering circuit.

2. When load on steering circuit is lighter than that


on work equipment circuit
q If the oil pressure in port (EF) is higher for
that in port (CF) while the oil flow and oil pres-
sure in port (CF) are sufficient for the steering
operation, the oil flowing through portion (d)
is increased to increase the oil pressure in
chamber (B).
q Spool (1) moves to the left to reduce the open
area of portion (d) to adjust the oil flow and oil
pressure to levels necessary to port (CF).
q Necessary oil flows to the steering circuit
first, regardless of the oil pressures in the
steering circuit and work equipment circuit.

GD555-5,GD655-5,GD675-5 10-79
Steering system
Steering valve

Steering valve
(Q/Amp manual Orbit-roll type)

1. Bushing Outline
2. Valve body q The Q/Amp manual orbit-roll consists of a direc-
3. Check valve tion control valve and a flow amplifier orifice.
4. Gerotor q This valve controls the steering delivery accord-
5. Spacer ing to the operating speed of the steering wheel.
6. Cover Particularly in the high-speed operation range,
7. Spacer this valve has the flow characteristic amplified to
8. Drive shaft above the metering flow rate of the gerotor.
9. Sleeve (Variable ratio steering function)
10. Spool q The Q/Amp manual orbit-roll has the following
11. Center pin features.
12. Centering spring q Fine compensation of the steering is possible
at high speed to ensure stable steering.
q Quick turns are possible when the machine is
traveling at low speed or when it is stationary.
q Emergency steering is possible with the Or-
bitroll control used independently.

10-80 GD555-5,GD655-5,GD675-5
Steering system
Steering valve

Variable ratio steering function

q The steering pump delivery varies with the turn- q If the steering wheel is turned slowly during
ing speed of the steering wheel. high-speed travel, the steering pump delivery is
q The steering pump delivery is reduced when the reduced and fine compensation of the steering is
steering wheel is turned at low speed, and the possible, thus high steering performance is ob-
former is increased when the latter is turned at tained during high-speed travel.
high speed. q If the steering wheel is turned quickly while the
machine is stationary or traveling at a low speed,
large steering pump delivery is obtained easily,
thus the machine can be turned quickly.

Flow amplification function


q Since the orbit-roll has the bypass flow control
function with the built-in flow amplifier orifice in
addition to the metering function with the gero-
tor, it can supply a large quantity of oil to the
steering cylinder.
q Even a small orbit-roll can supply a large quanti-
ty of oil to the steering cylinder during the
high-speed steering operation.

GD555-5,GD655-5,GD675-5 10-81
Steering system
Steering valve

Q/Amp manual Orbit-roll

q An Orbit-roll with an emergency steering func-


tion using a Q/Amp Orbit-roll is called a Q/Amp
manual Orbit-roll.
q The emergency steering function is obtained by
closing the bypass orifice characteristics (the
characteristics of the flow amplifier orifice (AA)
which do not pass through the metering system
(gerotor) in an emergency steering state (when
the valve is at the maximum movement position).
q The Q/Amp manual orbit-roll has large advan-
tages when it is used in the steering system of a
medium-sized machine.
q Only a small-capacity orbit-roll can use its emer-
gency steering function by itself. A large-capaci-
ty orbit-roll needs a separate emergency
hydraulic pressure source to use its emergency
steering function.
q The steering system is simplified and its reliabil-
ity is improved by employing the Q/Amp manual
orbit-roll.

10-82 GD555-5,GD655-5,GD675-5
Steering system
Steering valve

Structure
q Spool (10) is connected to the drive shaft of the
steering wheel and further connected to sleeve
(9) through center pin (7) (which is not in contact
with the spool while the steering wheel is in "neu-
tral") and centering spring (4).
q The top of drive shaft (3) is engaged with center
pin (7) and united with sleeve (9), and the bottom
is engaged with the spline of rotor (1) of the gero-
tor set (assembly of rotor (1) and stator (11)).
q The valve body has four ports, which are con-
nected respectively to the pump circuit, tank cir-
cuit, circuit on the steering cylinder head side,
and circuit on the steering cylinder bottom side.
The ports on the pump side and tank side are
connected by the check valve in the body. If the
pump or engine fails, the oil can be sucked
through this check valve directly from the tank.

GD555-5,GD655-5,GD675-5 10-83
Steering system
Steering valve

Connection of hand pump and sleeve


q If the pump or engine fails, the suction and dis-
charge of this hand pump is performed forcibly
and oil is sent to the steering cylinder.Thus, it is
still possible to steer the machine.

q Above figure shows the suction and discharge


ports of the gerotor and connections with the
sleeve ports.
q If the steering wheel is turned to the right, ports
(a), (c), (e), (g), (i) and (k) will be connected to
the pump side by the vertical grooves in the
spool. Likewise, ports (b), (d), (f), (h), (j) and (l)
are connected to the L.H. steering cylinder head
side.
q In the figure above left , ports (1), (2) and (3) are
related to the discharge state of the gerotor and
connected to ports (l), (b) and (d), and the oil is
sent to the steering cylinder. Ports (5), (6) and
(7) are also connected each other and the oil
from the pump flows into them.
q The right of the above figure shows the state that
has resulted from 90 ° turning of the steering
wheel as an operation continued from the above
state. Under this state, ports (1), (2) and (3) are
in the suction state, and connected to ports (i),
(k) and (c). Ports (5), (6) and (7) are in the dis-
charge state and connected to ports (d), (f) and
(h).
q As shown above, the ports which are in the dis-
charge state of the hand pump are connected to
the ports being connected to the steering cylin-
der. The ports which are in the suction state are
connected to the pump circuit.

10-84 GD555-5,GD655-5,GD675-5
Steering system
Steering valve

GD555-5,GD655-5,GD675-5 10-85
Steering system
Steering valve

q The delivery is controlled according to the turning angle of the steering wheel. That is, the oil from the
pump always passes through this hand pump. The internal gear of the hand pump rotates forward by one
tooth for 1/7 turn of the steering wheel, and the oil is delivered by the quantity corresponding to the internal
gear position. Accordingly, the oil delivery is in direct proportion to the turning angle of the steering wheel.
q When the pump or engine has a trouble, the oil is delivered similarly to the above, or the normal delivery
is obtained.

Difference between trochoid pump and hand pump for steering pump

Trochoid pump

q The inlet port and outlet port are parted from


each other. If the shaft rotates, the oil is sucked
in to the inlet side and discharged to the outlet
side as shown in (2) - (6) of the above figure.

Hand pump for steering pump

q The hand pump has the outlet and inlet at the in-
ternal teeth bottom of the stator. If the shaft ro-
tates, the port is connected to the steering pump
and oil is sucked in as shown in (2) - (3) of the
above figure. If the shaft rotates further, the port
is connected to the steering cylinder to send the
oil to the cylinder as shown in (5) - (6). This op-
eration is performed in each port.

10-86 GD555-5,GD655-5,GD675-5
Steering system
Steering valve

Role of centering spring

q Centering spring (2) is composed of four


X-shaped leaf springs and two flat leaf springs
and installed between spool (9) and sleeve(8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular differ-
ence (a) is generated between spool (9) and
sleeve (8).
As a result, the ports of spool (9) and sleeve (8)
are connected and the oil is sent to the steering
cylinder. When the steering wheel stops , the
gerotor also stops turning. Then, the oil is not
sent to the steering cylinder any more and its
pressure increases. To prevent this, when the
steering wheel turning stops, gerotor is turned by
the reaction force of centering spring (2) by
angular difference (a) of spool (9) and sleeve (8)
to return the steering wheel to the "neutral" posi-
tion.

GD555-5,GD655-5,GD675-5 10-87
Brake system
Brake hydraulic piping diagram

Brake system
Brake hydraulic piping diagram

1. Brake pedal 10. Wheel brake (front)


2. Brake valve 11. Parking brake cylinder
3. Slack adjuster (right) 12. Slack adjuster (left)
4. Main pump 13. Stop lamp oil pressure switch
5. Brake accumulator (right) 14. Accumulator charge valve
6. Brake accumulator (left) 15. Hydraulic oil line filter
7. Hydraulic tank 16. Parking brake, bank control valve
8. Priority valve
9. Wheel brake (rear)

10-88 GD555-5,GD655-5,GD675-5
Brake system
Brake valve

Brake valve

PA: From charge valve port ACC1 TA: Plug


PB: From charge valve port ACC2 TB: Drain
A: To front slack adjuster SA: Stop lamp oil pressure switch
B: To rear slack adjuster SB: Plug

1. Piston 4. Spool (in each of the rear two wheels)


2. Spool (in each of the front two wheels) 5. Cylinder (in each of the rear two wheels)
3. Cylinder (in each of the front two wheels)

GD555-5,GD655-5,GD675-5 10-89
Brake system
Brake valve

Outline
q The brake valve is installed in the lower front
side of the operator's cab. Depressing the brake
pedal conducts oil to the brake piston, operating
the brake.

Operation
When the brake pedal is depressed

q Brake pedal (1) depressing effort is transmitted


to spool (5) through rod (2), piston (3) and spring
(4).
q As spool (5) is pushed to the right, port (TA) is
closed and the oil from the pump activates the
brakes on the front two wheels after being con-
ducted through accumulator, port (PA), port (A)
and the brake piston on the front two wheels.
q As spool (5) is pushed to the right, spool (6) is
also pushed to the right and port (TB) is closed.
The oil from the pump activates the brakes on
the rear two wheels after being conducted
through accumulator, port (PB), port (B) and the
brake piston on the rear two wheels.

10-90 GD555-5,GD655-5,GD675-5
Brake system
Brake valve

When brake of one side is operated


(When the other brake failed)

q Even when only one of the brakes can work due


to leakage of oil in the rear brake system, brake
pedal (1) depressing effort is capable of me-
chanically moving spools (5) and (6) to the right.
Thus, the oil from the pump is normally supplied
to the brake piston working normally, enabling it
to continue the operation. The brake, therefore,
is capable of stopping the machine as needed to
ensure the intended safety level.

GD555-5,GD655-5,GD675-5 10-91
Brake system
Brake valve

Balancing operation

q When the brake cylinders in the front two wheels


are filled with oil and the oil pressure increases
between port (PA) and port (A), the oil being
transmitted to chamber (E) through orifice (c) of
spool (5) pushes spool (5) to the left against the
reactive force of spring (4). As a result, port (PA)
is disconnected from port (A).
At this time, port (TA) remains closed. Thus, the
oil from the front slack adjuster is retained and
the brake remains applied.
q At the same time as spool (5) is moved to the
left, the brake cylinders in the rear two wheels
are filled up with oil, increasing the oil pressure
between port (PB) and port (B). Thus, the oil
transmitted to chamber (F) through orifice (d) of
spool (6) pushes back spool (6) leftwards by the
move distance of spool (5). As a result, port (PB)
and port (B) are disconnected.
Port (TB) remains closed. Thus, the oil from the
rear slack adjuster is retained and the brake
remains applied.
q Oil pressure in the brake circuit [port (A) side] for
the front two wheels and the brake pedal de-
pressing effort are balanced and oil pressure in
the brake circuit [port (B) side] for the rear two
wheels and oil pressure in the brake circuit [port
(A) side] for the two front wheels are balanced.
When spools (5) and (6) are moved to the right
to the stroke end, port (PA) and port (A) as well
as port (PB) and port (B) are opened completely.
Thus, pressure of oil to the front side and rear
side brake circuits becomes equal to the oil pres-
sure from the pump.
Thus, the braking force is adjustable by
adjusting the brake pedal depressing amount
until spools (5) and (6) are moved to the right to
the stroke end.

10-92 GD555-5,GD655-5,GD675-5
Brake system
Brake valve

GD555-5,GD655-5,GD675-5 10-93
Brake system
Brake valve

When brake pedal is released

q Releasing brake pedal (1) releases the pedal de-


pressing effort being applied to spool (5).
q As spool (5) is pushed back to the left by back
pressure of brake piston in each of the front two
wheels and reactive force of spring (7), port (PA)
is closed and the oil in the brake piston in each
of the front two wheels is transmitted through
port (A) to port (TA) and then drained from port
(TB) to the hydraulic tank. As the result, the
brakes on the front two wheels are released.
q At the same time as spool (5) is moved to the
left, spool (6) is also pushed back to the left by
back pressure of the brake piston in each of the
rear two wheels and reactive force of spring (7).
Thus, port (PB) is closed and the oil in the brake
piston in each of the rear two wheels is transmit-
ted through port (B) to port (TB) and then drained
from port (TB) to the hydraulic tank. As a result,
the brakes on the rear two wheels are released.

10-94 GD555-5,GD655-5,GD675-5
Brake system
Brake valve

GD555-5,GD655-5,GD675-5 10-95
Brake system
Slack adjuster

Slack adjuster

A: Inlet port Function


B: Outlet port q The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston and
1. Bleeder used to keep the brake operation time lag con-
2. Check valve stant.
3. Piston q Suppress the peak pressure by equalizing the
amount of oil per charge.
Specifications
Piston operating pressure
0.01 {0.1}
(MPa {kg/cm2})
Check valve cracking pres-
sure 0.93 {9.5}

Check valve closing pressure


0.59 {6.0}
(MPa {kg/cm2})

10-96 GD555-5,GD655-5,GD675-5
Brake system
Slack adjuster

Operation

When the brake pedal is depressed

q Pistons (4) before the brake pedal is depressed q When the pressure of the oil fed when the brake
are returned as much as the distance corre- pedal is depressed exceeds the set pressure of
sponding to stoke (S) (full stroke). check valve (3), check valve (3) opens to pres-
q When the brake pedal is depressed, the oil flow surize port (C), which acts on brake piston (7) as
from the brake valve is divided from slack adjust- a braking force.
er port (P) to the left and right cylinders (2). q A time lag that is generated when braking stays
q Left and right pistons (4) moves to the left or right constant by the action of the slack adjuster.
as much as the distance corresponding to stroke
(S). When the brake pedal is released

q When the brake pedal is released, pistons (4)


q The oil flow from port (C) to brake piston (7) are returned as much as the amount of oil corre-
moves brake piston (7) as much as the distance sponding to stroke (S) by return spring (8) of the
corresponding to stroke (S). brake and the brake is released.
q As slack adjuster pistons (4) alone move, no q Return stroke (T) of brake pistons (7) is decided
braking force is generated between the brake by the oil volume for stroke (S) of the slack ad-
piston and the disc; instead the clearance be- juster and the time lag when braking is kept con-
tween them is reduced to zero. stant, regardless of wear of the brake disc.

GD555-5,GD655-5,GD675-5 10-97
Brake system
Accumulator (for brake)

Accumulator (for brake)


1. Valve
2. Top cover
3. Cylinder
4. Free piston

Function
q The accumulator is installed between the accu-
mulator charge valve and brake valve.
q Cylinder (3) is filled with nitrogen gas and the
pressure that is stored by free piston (4) by com-
pressing the nitrogen gas maintains the braking
force after the engine has stopped.
Specification
Gas to be used Nitrogen gas
Volume of gas (cc) 3,750
Charge pressure 3.4 ± 0.1 {35 ± 1.0}
(MPa {kg/cm2}) (at 20°C)
Max. pressure applied
20.6 {210}
(MPa {kg/cm2})

10-98 GD555-5,GD655-5,GD675-5
Brake system
Charge valve

Charge valve

P: From pump
PA: To cooling fan motor
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain

GD555-5,GD655-5,GD675-5 10-99
(05)
Brake system
Charge valve

1. Valve body Function


2. Relief valve (R2) q The charge valve maintains the oil pressure
3. Shuttle valve (S1) from the pump to the set pressure and accu-
4. Priority valve mulates it in the accumulator.
5. Main relief valve (R1) q When the pressure is accumulated in the accu-
mulator, the circuit to the cooling fan motor
opens and the oil from the pump is output as
cooling fan motor drive pressure.
q When the oil pressure rises above the preset
pressure, the oil from the pump is led to the
drain circuit to reduce the load on the pump.
q The charge valve reduces the pressure of the
oil from the pump and outputs the basic pres-
sure of the pilot circuit.

10-99-1
10-100 GD555-5,GD655-5,GD675-5
(05)
Brake system
Charge valve

Operation

When oil is not supplied to accumulator (cut-out state)

q Plunger (1) is moved in the right direction by


the accumulator pressure, and maintains
unload
q The oil in the spring chamber of unload valve
(3) is drained to the hydraulic tank through port
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the right direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).

GD555-5,GD655-5,GD675-5 10-99-2
10-101
(05)
Brake system
Charge valve

When oil is supplied to accumulator


1. Cut-in state

q As the accumulator pressure goes low, pres-


sure on port (E) goes low, allowing plunger (1)
to move in the left direction and unload relief
valve (2) to close the drain circuit.
q Since the oil pressure in port (F) and the spring
chamber of unload valve (3) increases, unload
valve (3) moves in the left direction.
q Port (C) and port (B) are opened, conducting
the oil from the pump to port (B).
q As oil pressure in port (B) increases beyond
the set pressure of check valve (4), check
valve opens, allowing the oil to be supplied to
the accumulator through port (E). The pressure
for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.

10-99-3
10-102 GD555-5,GD655-5,GD675-5
(05)
Brake system
Charge valve

2. When pressure reaches cut-out pressure

q As pressure in port (F) reaches the set pres-


sure (cut-out pressure of unload relief valve
(2)), oil in the spring chamber of unload valve
(3) is drained to the hydraulic tank through port
(F), unload relief valve (2) and port (T).
q Plunger (1) is moved in the right direction by
the accumulator pressure, and maintains
unload relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the right direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).

GD555-5,GD655-5,GD675-5 10-99-4
10-103
(05)
Brake system
Charge valve

Main relief valve (R1) Shuttle valve (S1)

q If the pressure in port (P) (pump pressure) q When the pressure in port (ACC2) is higher
rises above the set pressure, it compresses than that in port (ACC1), shuttle valve (1)
spring (1) and moves ball (2) to the left. moves to the left to disconnect port (ACC2)
q The pressure of the oil from the pump is from oil passage (B).
reduced across orifice (a), and the resulting q The open area between port (ACC1) and oil
pressure difference compresses spring (3) and passage (B) is increased and the oil is supplied
moves valve (4) to the left largely. to the accumulator on port (ACC1) side.
q Port (P) being connected to port (T) drains the q When the pressure in port (ACC1) is higher
pump pressure and, thereby, regulates the than that in port (ACC2), the oil is supplied to
maximum pressure in the charge circuit in the accumulator on port (ACC2) side.
order to protect the circuit. The oil from the pump is supplied first to the
low-pressure side of the 2 systems.

10-99-5
10-104 GD555-5,GD655-5,GD675-5
(05)
Brake system
Charge valve

GD555-5,GD655-5,GD675-5 10-99-6
10-105
(05)
Brake system
Wheel brake

Wheel brake

1. Cage
2. Piston
3. Guide pin
4. Gear

10-100 GD555-5,GD655-5,GD675-5
Brake system
Wheel brake

GD555-5,GD655-5,GD675-5 10-101
Brake system
Parking brake and bank control valve

Parking brake and bank control valve

P: From accumulator Outline


B1: To bank control cylinder q The parking brake and bank control valve con-
B2: To bank control cylinder tains a parking brake solenoid valve and a bank
PB: To parking brake control solenoid valve.
T: To hydraulic tank q If the parking brake solenoid is energized, the oil
G2: Accumulator pressure pickup port is transmitted to the parking brake to release the
parking brake.
1. Bank control solenoid valve q If the bank control solenoid is energized, the oil
2. Parking brake solenoid valve is transmitted to the bank control lock pin cylin-
3. Filter der to move the lock pin in the pulling out direc-
4. Check valve tion.

10-102 GD555-5,GD655-5,GD675-5
Brake system
Parking brake and bank control valve

GD555-5,GD655-5,GD675-5 10-103
Brake system
Parking brake

Parking brake

1. Piston 3. Caliper
2. Adjustment bolt 4. Disc

Outline
q The parking brake is a disc type, and is installed
to the final drive.
q The parking brake is applied mechanically by the
force of the spring inside the caliper, and is re-
leased by hydraulic force.
q The parking brake caliper is secured to the final
drive case.
q The disc is installed to the final drive coupling
and rotates together with the coupling.
q If the gear shift lever is moved to a position other
than P (parking) with the oil pressure in the ac-
cumulator being high enough, the oil pressure
acts on the chamber to release the parking
brake.

10-104 GD555-5,GD655-5,GD675-5
Brake system
Parking brake

GD555-5,GD655-5,GD675-5 10-105
Undercarriage frame
Frame

Undercarriage frame
Frame

1. Articulate cylinder Outline


2. Front frame q Front frame (2) and rear frame (3) are coupled
3. Rear frame with each other by hinge pins (4) and (5).
4. Upper-center hinge pin q Articulate cylinder (1) on the left and right sides
5. Lower-center hinge pin connects the front frame (2) and rear frame (3).
6. Articulate lock pin The extension or retraction of the cylinders
causes the frames to bent 25° on each of the left
and right sides at the center hinge pin.
q An articulated mechanism is effective in reduc-
ing the swing radius, in offset operations, in es-
caping from mud and in operations using blade
corners.

10-106 GD555-5,GD655-5,GD675-5
Undercarriage frame
Frame

GD555-5,GD655-5,GD675-5 10-107
Undercarriage frame
Tire

Tire
The radial tires (if equipped) of this machine have the following features.
q High grip q Better operator q Reduced of tire punc- q Less uneven
comfort ture rate wear
q Improvement of q Long life q Less damage on ma- q Less generation
fuel consumption chine of heat
rate

Comparison of structures and characteristics of tires


Radial tire Bias tire

Structure Structure
q The cords of carcass (1) are arranged at right q The cords of carcass (1) are arranged bias
angles to the center line of tread (T) (radially). against the center line of tread (T).
q Tread (T) is stabilized and protected by several q Side wall (W) and tread (T) are integral.
strong belts (2).
q Side wall (W) and tread (T) are independent from Ground contact characteristics
each other. q If the tire is deformed by a load, the ground con-
tact surface is also deformed, leading to wasteful
Ground contact characteristics behavior. As a result, the ground contact surface
q Even if the tire is deformed by a load, it avoids becomes unstable.
wasteful behavior for ground contact surface,
and uniform ground contact surface is secured Deformation characteristics
stably. q Side wall (W) which receives loads and tread (T)
move together as one unit.
Deformation characteristics
q Only side wall (W) is deformed as load is applied
and tread (T) made of strong belts (2) keeps sta-
bility independently.

10-108 GD555-5,GD655-5,GD675-5
Undercarriage frame
Tire

GD555-5,GD655-5,GD675-5 10-109
Hydraulic system
Hydraulic system

Hydraulic system
Hydraulic system

Outline of system

Main pump
1. The hydraulic oil in the hydraulic tank is fed 3. Pressure loss due to the resistance to flow along
through the main pump to the priority valve. the way varies with temperature and, when there
is not enough control pressure at low tempera-
2. The main pump serving as a hydraulic source for tures, required flow may not be ensured. To
the steering system and the work equipment prevent this, oil pressure (PP) in the vicinity of
generates required pressure and oil flow each component is introduced to the main pump
according to the demand ( LS pressure) from and the main pump delivery is controlled so that
relevant components. the differential pressure between (PP) and (LS)
Pump pressure = LS pressure + Control pres- is 2.35 MPa {24 kg/cm2}.
sure of 2.35 MPa {24 kg/cm2}
When the control levers are in NEUTRAL, the 4. Using the PQ control in which the pressure and
pressure is set as follows : Steering LS pressure delivery of the main pump are controlled to keep
of 0.8 – 1.1 MPa {8 –11 kg/cm2} + 2.35 MPa {24 the value PQ constant, the engine assuredly
provides a high torque at low rpms under
kg/cm2} +Pipe pressure loss = 3.24 – 3.63 MPa
increased load or during combined operations.
{33 – 37 kg/cm2}
5. In a neutral condition in which there is no flow
request from the steering system or work equip-
ment, the main pump sets the swash plate at the
minimum angle to provide a quick response to
the sudden steering operation or a quick
response to the work equipment operation.

10-110 GD555-5,GD655-5,GD675-5
Hydraulic system
Hydraulic system

Steering circuit
1. The priority valve is designed to give flow priority 4. As the pressure of the brake accumulator is
to the steering system that is closely related to decreased, the parking brake release pressure
safety over the work equipment. is decreased, which causes the parking brake to
be automatically applied by the force of spring. If
2. The steering valve of closed center hydraulic the machine is stopped for a certain period of
system allows flow of hydraulic oil only when time, the parking brake will be automatically
necessary and does not allow it when the applied, making it impossible to release the
steering wheel is not operated for energy saving brake until the engine is started.
operation.
When the steering wheel is operated, pressure 5. The bank control lock pin is inserted or removed
(LS pressure) is transmitted to the servo valve of to change the work equipment posture (to set the
the main pump through the LS regulating valve. blade to bank-cutting or shoulder reach posture).
The main pump ensures required flow and The pressure of the brake accumulator is used
develops the Pb pressure (= LS + 25 +Pipe pres- as a hydraulic source for these operations.
sure loss ). At the same time, the LS pressure is
transmitted to the priority valve and causes the 6. The brake pump is also hydraulic source for the
spool of the priority valve to stay at a position cooling fan motor.
where the required flow for the steering cylinder
circuit is ensured regardless of whether a flow LS pressure regulating valve
request from the work equipment is present, 1. Since the main pump keeps delivering a
minimum flow to maintain quick response in the
3. The steering valve of Q-Amp type features quick steering operation and a quick response of
excellent controllability during high speed travel- the work equipment, the control valve has an
ling and ensures steering performance even if unload valve.
the engine stops or the main pump fails.
2. During steering operations, the LS pressure of
4. Unlike the work equipment circuit pressure, the the steering circuit increases and the main pump
maximum pressure of the steering circuit is delivery increases. This causes the Pb pressure
determined by the relief valve that is built in the of the steering circuit and the priority valve func-
priority valve. tions to deliver the remaining flow that has not
been taken up for steering to the control valve. If
Brake circuit the unload valve is open at this point in time, the
1. The oil pressure from the brake pump is boosted remaining flow is returned to the hydraulic tank
to a required value by the charge valve and to result in loss of energy. When the work equip-
stored in the brake accumulator that is installed ment is not use, a signal pressure is transmitted
in each of the dual brake circuits. to the unload valve and the contral valve is put in
an loaded condition .As a result, the flow of oil to
2. If the brake is applied and the pressure of the the hydraulic tank is shut, and the remaining flow
brake circuit falls below the set pressure of 9.36 is returned to the steering circuit, preventing loss
MPa {95 kg/cm2}, the charge valve is activated of energy.
to accumulate pressure until the pressure of the
brake accumulator reaches its set pressure of
13.8 MPa {141 kg/cm2}.

3. After the engine has stopped, the oil pressure in


the accumulator allows braking for a given
period of time.

GD555-5,GD655-5,GD675-5 10-111
Hydraulic system
Hydraulic system

Control valve
1. Since the control valve is a closed center type
valve, the oil is returned from the unload valve to
the hydraulic tank when the contral valve is at
NEUTRAL position where the work equipment is
not use.
[Unload pressure]
Engine at low idle: 3.14 MPa {32 kg/cm2}
Engine at full speed: 3.43 MPa {35 kg/cm2}

2. When the work equipment control lever is oper-


ated, the pressure at the inlet of the valve is
transmitted to the main pump as Pb and the
highest load pressure of the work equipment is
transmitted to the main pump through the LS
circuit. This allows the main pump to deliver the
required flow.

3. During hydraulic relief, the upper limit of the LS


pressure is determined by the LS relief valve.
The control valve is closed center load sensing
type valve with pressure compensation function
for proportional flow distribution and is equipped
with an unload valve, an LS relief valve and a
serge pressure absorbing valve.
The control valve has the following features.
q Requires less operating effort and less lever
stroke.
q Optimum cylinder speed can be adjusted for
each work equipment.
q Blade lifting height can be adjusted with the
same RAISE and LOWER speed of lift cylin-
ders (extension and retraction of cylinder) .
q Broad spool range for fine control.
q Spool positionn where work equipment starts
to move is constant regardless of load.
q Requires less spool stroke to move work
equipment and allows easy fine control.
q The valve spools are securely activated dur-
ing combined operation.
q Allows combined operation even if oil flow is
not enough.
q During hydraulic relief of a circuit, other work
equipment can be operated.
The control valve combined with the CLSS
hydraulic pump provides the following
features.
q Constant work equipment speed is ensured
regardless of engine rpm.
q Reduced hydraulic pressure loss with control
valve in NEUTRAL position.
q Reduced hydraulic pressure loss in relief.
q Engine is less likely to stop under a large load
during combined operation.

10-112 GD555-5,GD655-5,GD675-5
Hydraulic system
Hydraulic system

GD555-5,GD655-5,GD675-5 10-113
Hydraulic system
Work equipment hydraulic piping diagram

Work equipment hydraulic piping diagram

1. L.H. blade lift cylinder


2. Accumulator for L.H. blade lift cylinder (if
equipped)
3. R.H. blade lift cylinder
4. Power tilt cylinder
5. Blade side shift cylinder
6. Drawbar shift cylinder
7. Circle rotation motor

10-114 GD555-5,GD655-5,GD675-5
Hydraulic system
Work equipment hydraulic piping diagram

1. Accumulator for R.H. blade lift cylinder (if


equipped)
2. Leaning cylinder
3. Swivel joint

GD555-5,GD655-5,GD675-5 10-115
Hydraulic system
Work equipment hydraulic piping diagram

1. Control valve
2. R.H. articulate cylinder
3. Accumulator charge valve
4. Priority valve
5. Main pump
6. Hydraulic tank
7. Hydraulic oil line filter
8. L.H. articulate cylinder
9. LS pressure control valve
10. Parking brake and bank control valve

10-116 GD555-5,GD655-5,GD675-5
Hydraulic system
Work equipment hydraulic piping diagram

GD555-5,GD655-5,GD675-5 10-117
Hydraulic system
Work equipment control

Work equipment control

10-118 GD555-5,GD655-5,GD675-5
Hydraulic system
Work equipment control

1. Control valve
2. Angle adjustment knob for steering wheel and
machine monitor
3. Steering wheel
4. L.H. blade lift control lever
5. Ripper or scarifier control lever (if equipped)
6. Blade shift control lever
7. Power tilt control lever
8. Circle rotation control lever
9. Machine monitor
10. Drawbar shift control lever
11. Articulate control lever
12. Leaning control lever
13. R.H. blade lift control lever
14. Gas spring
15. Accelerator pedal
16. Brake pedal
17. Steering console tilt pedal
18. Inching pedal

Outline
q Work equipment control levers are mounted on
the shaft of steering console, and connected to
the control valve via rods.
q The lock can be released by loosening angle ad-
justment knob (2) for the steering wheel and ma-
chine monitor. Then the angle of the steering
wheel and machine monitor can be adjusted,
and fixed by tightening control knob (2).
q Steering console tilt mechanism
The lock can be released by depressing steering
console tilt pedal (17). Then the tilt angle of the
steering console can be adjusted, and fixed by
releasing pedal (17).

GD555-5,GD655-5,GD675-5 10-119
Hydraulic system
Hydraulic tank

Hydraulic tank

1. Oil filler cap Specification


2. Hydraulic tank
3. Sight gauge Tank capacity (l) 93
4. Drain plug
5. Bypass valve Oil level in tank (l) 69
6. Filter element Set pressure of bypass valve 103 ± 20
7. Suction strainer
(kPa {kg/cm2}) {1.05 ± 0.2}
Cracking pressure of pressure
valve 38 ± 15
{0.39 ± 0.15}
(kPa {kg/cm2})
Actuating pressure of vacuum
valve 0 – 4.5
{0 – 0.046}
(kPa {kg/cm2})

10-120 GD555-5,GD655-5,GD675-5
Hydraulic system
Hydraulic tank

GD555-5,GD655-5,GD675-5 10-121
Hydraulic system
Main pump

Main pump
Type: LPV90

P1: Pump discharge port PD6: Drain port


P1L: Pump pressure input port PEN: Control pressure pickup plug
PD: Drain port PLS: Load pressure input port
PD2: Drain plug PS: Pump suction port

1. Pump unit 2. Servo valve

10-122 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

1. Pump unit

PA: Control source pressure output port


PD4: Drain port
PD5: Drain port
PE: Control pressure input port

GD555-5,GD655-5,GD675-5 10-123
Hydraulic system
Main pump

1. Bearing 9. End cap


2. Shaft 10. Shoe retainer
3. Case 11. Servo piston
4. Rocker cam 12. Spring
5. Shoe 13. Sleeve
6. Piston 14. Oil seal
7. Cylinder block 15. Ball retainer
8. Valve plate

10-124 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

Function q The pressurized oil is sucked into and dis-


q The pump converts the engine rotation and charged from each cylinder chamber in cylinder
torque transmitted to its shaft into oil pressure block (6) through valve plate (7).
and delivers pressurized oil corresponding to the
load.
q The delivery of this pump can be changed by
changing swash plate angle.

Structure
q Cylinder block (6) is jointed to shaft (1) by splines
(a), and shaft (1) is supported by the front and
rear bearings
q The tip of piston (5) has a concave ball that grips
shoe (4) to form one unit. Piston (5) and shoe (4)
form a spherical bearing.
q Rocker cam (3) is supported on case (2) and ball
retainer (9), and has plane (A). Shoe (4) is kept
pressed against the plane of rocker cam (3) and
slides circularly. Since high-pressure oil is rout-
ed to the plane, shoe (4) forms a static pressure
bearing and slides.
q Piston (5) in each cylinder chamber of cylinder
block (6) moves relatively in the axial direction.
q Cylinder block (6) rotates while sealing in pres-
surized oil against valve plate (7).
q This pump is designed so that the pressure bal-
ance on the sides of the plate is maintained cor-
rectly.

GD555-5,GD655-5,GD675-5 10-125
Hydraulic system
Main pump

Operation

1) Operation of pump
q Cylinder block (6) rotates together with shaft (1), q As center line (X) of rocker cam (3) matches the
and shoe (4) slides on plane (A). axis of cylinder block (6) (swash plate angle = 0),
q Rocker cam (3) pivots on ball retainer (9), and the difference between volumes (E) and (F) in-
accordingly angle (a) between center line (X) of side cylinder block (6) equals 0.
rocker cam (3) and the axis of cylinder block (6) q The hydraulic oil is not sucked or discharged.
changes. (Actually, however, the swash plate angle is not
q Angle (a) is called the swash plate angle. set to 0)
q The pump delivery is in proportion to swash plate
angle (a).

q If angle (a) is made between center line (X) of


rocker cam (3) and the axis of cylinder block (6),
plane (A) functions as a cam against shoe (4).
q In this way, piston (5) slides inside the cylinder
block (6), so a difference between volumes (E)
and (F) is created inside cylinder block (6).
q A single piston (5) suctions and discharges the
oil by the amount subtracting (E) from (F).
q As cylinder block (6) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is
sucked.

10-126 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

2) Delivery control
q If swash plate angle (a) increases, the difference
between volumes (E) and (F) increases, increas-
ing delivery (Q).
q Swash plate angle (a) is changed by servo pis-
ton (11).
q Servo piston (11) reciprocates straight according
to the signal pressure from the CO and LS
valves.
q This straight line movement is transmitted to
rocker cam (3).
q Rocker cam (3) supported with ball retainer (9)
slides around ball retainer (9).

GD555-5,GD655-5,GD675-5 10-127
Hydraulic system
Main pump

2. Servo valve

P1: Pump discharge pressure port


PE: Control pressure output port
T: Drain port

10-128 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

PC valve LS valve
T: Drain PA: Pump pressure input
PA: Pump pressure input PE: Control piston pressure
PPL: PC valve output pressure PLS: LS pressure input
PPL: PC valve output pressure
1. Lever PPLS: LS pump pressure input
2. Spring
3. Retainer 10. Nut
4. Seat 11. Plate
5. Spool 12. Plug
6. Sleeve 13. Spring
7. Piston 14. Seat
8. Seal 15. Plug
9. Piston 16. Spool
17. Plug

GD555-5,GD655-5,GD675-5 10-129
Hydraulic system
Main pump

3. LS valve 4. PC valve

Function Function
q The LS valve controls the pump delivery accord- q The PC valve limits the oil flow to a certain level
ing to the travel of the control lever, or the flow (depends on the discharge pressure) even if the
demanded by the actuator. travel of the control valve is increased extremely
q The LS valve detects the flow demanded by the so that the horsepower absorbed by the pump
actuator by using the differential pressure does not exceed the engine horsepower, when
(dPLS) between control valve inlet pressure pump discharge pressure (PA) is high.
(PPLS) and control valve outlet pressure (PLS), q In other words, the PC valve decreases the
and controls main pump delivery (Q). ((PPLS) pump delivery when the actuator load is in-
stands for the LS pump pressure, (PLS) the LS creased and the pump discharge pressure rises,
pressure, and (dPLS) the LS differential pres- and increases it when the pump discharge pres-
sure.) sure lowers.
q In other words, pressure loss [= LS differential q The relationship between the pump pressure
pressure (dPLS)], which occurs when oil flows and pump delivery is shown below.
through the passage in control valve spool, is de-
tected, and pump delivery (Q) is controlled to
maintain the pressure loss at a constant level.
Through this operation, pump can deliver the
proper volume of oil as demanded by the actua-
tor.
q Main pump discharge pressure (PP), LS pump
pressure (PPLS) and LS pressure (PLS) are in-
troduced into the LS valve. Pump delivery (Q)
changes as shown in the following diagram ac-
cording to the LS differential pressure (dPLS).

Operation

1) Function of spring
q The spring force of spring (2) in the PC valve is
decided by the position of the swash plate.
q If servo piston (6) moves to the right, spring (2)
is compressed through lever (1) and the spring
force changes.

2) When pump pressure (PA) is low


q The pressing force of piston (5) is decreased and
spool (3) is a little to the right (Fig. 1). At this time,
port (C) is connected to port (D) and the pres-
sure introduced in the LS valve becomes drain
pressure (PT).
q At this time, port (F) is connected to port (G) of
the LS valve. As a result, the pressure in port (J)
becomes drain pressure (PT) and servo piston
(6) moves to the left.
q Consequently, the pump delivery is increased.
q As servo piston (6) moves to the left, lever (1)
moves to the left and spring (2) expands and the
spring force is decreased. Consequently, spool
(3) moves to the left to disconnect port (C) from
port (D), and pump discharge port (B) is connect-
ed to port (C).

10-130 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

q As a result, the pressure in port (C) rises and the


piston pressure is increased and servo piston (6)
stops moving to the left.

3) When pump pressure (PA) is high


q The pressing force of piston (5) is increased and
spool (3) is a little to the left (Fig. 2). At this time,
port (C) is connected to port (B) and the pressure
introduced in the LS valve becomes pump pres-
sure (PA).
q At this time, port (F) is connected to port (G) of
the LS valve. As a result, the pressure in port (J)
becomes pump pressure (PA) and servo piston
(6) moves to the right.
q Consequently, the pump delivery is decreased.
q As servo piston (6) moves to the right, lever (1)
moves to the right and spring (2) is compressed
and spring force is increased. Consequently,
spool (3) moves to the right to disconnect port
(C) from port (B), and drain pressure port (D) is
connected to port (C).
q As a result, the pressure in port (C) lowers and
the piston pressure is decreased and servo pis-
ton (6) stops moving to the right.
q Accordingly, the stop position (= pump delivery)
of servo piston (6) is determined by the position
where the thrust caused by pressure (PA) ap-
plied to piston (5) is balanced with the spring
force of spring (2) acting through spool (3). (Fig.
3)

GD555-5,GD655-5,GD675-5 10-131
Hydraulic system
Main pump

When load is light


(Fig. 1)

When load is heavy


(Fig. 2)

10-132 GD555-5,GD655-5,GD675-5
Hydraulic system
Main pump

When servo piston is balanced


(Fig. 3)

GD555-5,GD655-5,GD675-5 10-133
Hydraulic system
Power train pump

Power train pump


Single pump type
SAR (2) 63

10-134 GD555-5,GD655-5,GD675-5
Hydraulic system
Power train pump

Double pump type


(if equipped)
SAR (2) 63 + SB (1) 10

GD555-5,GD655-5,GD675-5 10-135
Hydraulic system
Control valve

Control valve

9-spool valve
Outside view

A1: To R.H. blade lift cylinder bottom B4: To articulate cylinder


A2: To leaning cylinder head B5: To power tilt cylinder head
A3: To drawbar shift cylinder head B6: To circle motor
A4: To articulate cylinder B7: To blade shift cylinder head
A5: To power tilt cylinder bottom B8: To L.H. blade lift cylinder head
A6: To circle motor B9: To optional actuator
A7: To blade shift cylinder bottom LS: To LS pressure reducing valve LS (V) port
A8: To L.H. blade lift cylinder bottom P1: From pump 1
A9: To optional actuator P2: From pump 2
B1: To R.H. blade lift cylinder head PP: To pump
B2: To leaning cylinder bottom T1, T2: To tank
B3: To drawbar shift cylinder bottom TS: To tank (seal drain)

10-136 GD555-5,GD655-5,GD675-5
Hydraulic system
Control valve

10-spool valve
Outside view

A1: To optional actuator B6: To power tilt cylinder head


A2: To R.H. blade lift cylinder bottom B7: To circle motor
A3: To leaning cylinder head B8: To blade shift cylinder head
A4: To drawbar shift cylinder head B9: To L.H. blade lift cylinder head
A5: To articulate cylinder B10: To optional actuator
A6: To power tilt cylinder bottom LS: To LS pressure reducing valve LS (V) port
A7: To circle motor P1: From pump 1
A8: To blade shift cylinder bottom P2: From pump 2
A9: To L.H. blade lift cylinder bottom PP: To pump
A10: To optional actuator T1, T2: To tank
B1: To optional actuator TS: To tank (seal drain)
B2: To R.H. blade lift cylinder head
B3: To leaning cylinder bottom
B4: To drawbar shift cylinder bottom
B5: To articulate cylinder

GD555-5,GD655-5,GD675-5 10-137
Hydraulic system
Control valve

Sectional view

1. Centralized safety valve


2. Individual safety valve (on the optional actuator B
side)
3. Individual safety valve (on the blade shift A side)
4. Individual safety valve (on the blade shift A side)
5. Blind plug (on the optional actuator A side)

10-138 GD555-5,GD655-5,GD675-5
Hydraulic system
Control valve

Sectional view

6. Spool (Optional actuator)


7. Spool (L.H. blade lift)
8. Spool (blade shift)
9. Spool (circle)
10. Spool (power tilt)
11. Spool (articulate)
12. Spool (drawbar shift)
13. Spool (leaning)
14. Spool (R.H. blade lift)
15. Main relief valve

GD555-5,GD655-5,GD675-5 10-139
Hydraulic system
Control valve

Sectional view

16. LS relief valve 31. Pressure compensation valve F (articulate)


17. Pressure compensation valve R (Optional actu- 32. Pressure compensation valve F (drawbar shift)
ator) 33. Pressure compensation valve F (leaning)
18. Pressure compensation valve R (L.H. blade lift) 34. Pressure compensation valve F (R.H. blade lift)
19. Pressure compensation valve R (blade shift) 35. LS bypass valve
20. Pressure compensation valve R (circle) 36. Unload valve
21. Pressure compensation valve R (power tilt)
22. Pressure compensation valve R (articulate)
23. Pressure compensation valve R (drawbar shift)
24. Pressure compensation valve R (leaning)
25. Pressure compensation valve R (R.H. blade lift)
26. Pressure compensation valve F (Optional actu-
ator)
27. Pressure compensation valve F (L.H. blade lift)
28. Pressure compensation valve F (blade shift)
29. Pressure compensation valve F (circle)
30. Pressure compensation valve F (power tilt)

10-140 GD555-5,GD655-5,GD675-5
Hydraulic system
Control valve

Sectional view

37. Centralized safety valve filter


38. Pressure release plug (A9, B8, B5, B1)
39. Pilot check valve (if equipped)
40. Pressure release plug (B9)

GD555-5,GD655-5,GD675-5 10-141
Hydraulic system
Control valve

Sectional view

41. Pilot check valve (L.H. and R.H. blade lift)


42. Check valve (centralized safety valve circuit)

10-142 GD555-5,GD655-5,GD675-5
Hydraulic system
Control valve

Sectional view

43. Pilot check valve (power tilt)


44. Check valve (centralized safety valve circuit)
45: P circuit filter

GD555-5,GD655-5,GD675-5 10-143
Hydraulic system
Control valve

Sectional view

46. Pilot check valve (articulate)


47. Pilot check valve (drawbar shift)
48. Pilot check valve (leaning)

10-144 GD555-5,GD655-5,GD675-5
Hydraulic system
Control valve

GD555-5,GD655-5,GD675-5 10-145
Hydraulic system
CLSS

CLSS
a CLSS: Abbreviation for Closed center Load Sensing System

Outline of CLSS

Features Configuration
q Fine control not influenced by load q CLSS consists of variable capacity piston pump,
q Controllability enabling digging even with fine control valve, and actuators.
control q The main pump consists of pump unit, PC valve
q Ease of combined operation ensured by flow di- and LS valve.
vider function depending on area of openings of
spools
q Energy saving by variable pump control

10-146 GD555-5,GD655-5,GD675-5
Hydraulic system
CLSS

Basic principle

Pump swash plate angle control q If it becomes higher than the set pressure (when
q Pump swash plate (pump delivery) is controlled the actuator load pressure is low), the pump
so that LS differential pressure (dPLS), a differ- swash plate angle shifts toward the minimum an-
ential pressure between pump discharge pres- gle.
sure (PP) and LS pressure (PLS) (actuator load [LS differential pressure (dPLS) and pump
pressure) at the control valve outlet, is kept at a swash plate
constant level.
q [LS differential pressure (dPLS) = Pump dis-
charge pressure (PP) - LS pressure (PLS)]

a For details of the function, see "Main pump".

q The pump swash plate angle shifts toward the


maximum angle if LS differential pressure
(dPLS) is lower than the set pressure of the LS
valve (when the actuator load pressure is high).

GD555-5,GD655-5,GD675-5 10-147
Hydraulic system
CLSS

Pressure compensation control

q The valve (pressure compensation valve) is in-


stalled to the inlet side of each control valve
spool to balance the loads.
q When actuators are operated simultaneously,
the pressure difference (dP) between upstream
(inlet port) and downstream (outlet port) of each
valve spool is controlled to be the same regard-
less of the size of load (pressure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve spool.

10-148 GD555-5,GD655-5,GD675-5
Hydraulic system
CLSS

GD555-5,GD655-5,GD675-5 10-149
Hydraulic system
Functions and operation by valve

Functions and operation by valve

Hydraulic circuit diagram and name of valves


9-spool valve

1. Unload valve 6. Suction safety valve (individual safety valve: B9)


2. Pressure compensation valve Set pressure: 17.2 MPa {175 kg/cm2}
3. LS relief valve 7. Centralized safety valve
Set pressure: 19.8 MPa {202 kg/cm2} Set pressure: 24.5 MPa {250 kg/cm2}
4. Main relief valve
Set pressure: 23.4 MPa {239 kg/cm2}
5. Suction safety valve
Set pressure: 24 MPa {245 kg/cm2}

10-150 GD555-5,GD655-5,GD675-5
Hydraulic system
Functions and operation by valve

10-spool valve

1. Unload valve 6. Suction safety valve (individual safety valve: B1,


2. Pressure compensation valve B10)
3. LS relief valve Set pressure: 17.2 MPa {175 kg/cm2}
Set pressure: 19.8 MPa {202 kg/cm2} 7. Centralized safety valve
4. Main relief valve Set pressure: 24.5 MPa {250 kg/cm2}
Set pressure: 23.4 MPa {239 kg/cm2}
5. Suction safety valve
Set pressure: 24 MPa {245 kg/cm2}

GD555-5,GD655-5,GD675-5 10-151
Hydraulic system
Functions and operation by valve

Unload valve
When control valve is in NEUTRAL

A: To each valve
B: To pump LS valve
PLS: LS circuit
PP: Pump circuit
T: Tank circuit

Function
q When the control valve is in NEUTRAL, the un-
load valve drains pump delivery (Q) with the
swash plate at the minimum angle to the tank cir-
cuit.
q Pump discharge pressure (PP) is set to 2.9 MPa

{30 kg/cm2} by spring (2) in the valve.


[LS pressure (PLS) is 0 MPa {0 kg/cm2}]

Operation
q Pump pressure (PP) is applied to the left end
face of spool (1) having an area of (S1). Pump
pressure (PP) is also applied to the right end
face having an area of (S2) and LS pressure
(PLS) is applied to the area of (S3).
q When the control valve is in NEUTRAL, LS pres-
sure (PLS) is not generated, and only pump dis-
charge pressure (PP) that is determined by the
spring force of spring (2) acts on the spool.
q As pump discharge pressure (PP) increases,
spool (1) moves to the right until [(PP) x (S1) =
(PP) x (S2) + Force of spring (2)] holds, and
pump circuit (PP) is connected to tank circuit (T)
through the drill hole in spool (1).
q Pump discharge pressure (PP) is set to 2.9 MPa

{30 kg/cm2}.

10-152 GD555-5,GD655-5,GD675-5
Hydraulic system
Functions and operation by valve

When control valve is in fine control range

A: To each valve q Pump discharge pressure (PP) is set to the pres-


B: To pump LS valve sure of [Force of spring (2) (2.9 MPa {30
PLS: LS circuit kg/cm2}) + LS pressure (PLS)], and LS differen-
PP: Pump circuit tial pressure (dPLS) is kept at 2.9 MPa {30
T: Tank circuit
kg/cm2}.
Function
q When the control valve is in fine control range, if
actuator demand flow is less than the pump de-
livery with the swash plate at the minimum angle,
the unload valve set pump discharge pressure
(PP) to [LS pressure (PLS) + 2.9 MPa {30
kg/cm2}].
q When the differential pressure between pump
discharge pressure (PP) and LS pressure (PLS)
reaches the spring force of spring (2) (2.9 MPa
{30 kg/cm2}), the unload valve opens and LS dif-
ferential pressure (dPLS) is kept at 2.9 MPa {30
kg/cm2}.

Operation
q If the control valve is moved into the fine control
range, LS pressure (PLS) is generated and ap-
plied to the right end face area (S3) of spool (1).
At this time, LS differential pressure (PLS) differs
substantially from pump discharge pressure
(PP) because the opening area of the control
valve spool is small.
q When the differential pressure between pump
discharge pressure (PP) and LS pressure (PLS)
reaches the spring force of spring (2), spool (1)
moves to the right and pump circuit (PP) is con-
nected to tank circuit (T).

GD555-5,GD655-5,GD675-5 10-153
Hydraulic system
Functions and operation by valve

When control valve is operated

A: To each valve
B: To pump LS valve
PLS: LS circuit
PP: Pump circuit
T: Tank circuit

Function
q When the control valve is operated, if the actua-
tor demand flow exceeds the pump delivery with
the swash plate at the minimum angle, the un-
load valve blocks the flow to tank circuit (T) and
allows all of pump delivery (Q) to flow to the ac-
tuator circuit.

Operation
q If the control valve is operated by a large stroke,
LS pressure (PLS) is generated and applied to
the right end face area (S3) of spool (1).
q LS pressure (PLS) differs not so much from
pump discharge pressure (PP) because the
opening area of control valve spool is wide.
q Since the differential pressure between pump
discharge pressure (PP) and LS pressure (PLS)
does not reach the spring force of spring (2) (2.9
MPa {30 kg/cm2}), spool (1) is pushed to the left
by spring (2).
q Pump circuit (PP) is disconnected from tank cir-
cuit (T) and all of pump delivery (Q) flows to the
actuator circuit.

10-154 GD555-5,GD655-5,GD675-5
Hydraulic system
Functions and operation by valve

Introduction of LS pressure

Function q Actuator circuit pressure (PA) (= A) is applied to


q The LS pressure means actuator load pressure the right end of pressure reducing valve (3), and
on the control valve outlet side. reduced pump discharge pressure (PP) is ap-
q Actually, pump discharge pressure (PP) is re- plied to the opposite end.
duced by pressure reducing valve (3) of the q Pressure reducing valve (3) balances at the po-
pressure compensation valve to the same pres- sition where actuator circuit pressure (PA) and
sure as actuator circuit pressure (A) and intro- the pressure in spring chamber (PLS1) are
duced to LS circuit (PLS). equal.
q Thus, pump discharge pressure (PP) reduced by
Operation notch (c) turns to be equal to actuator circuit
q When spool (1) is operated, the oil at pump dis- pressure (A) and is introduced to LS circuit
charge pressure (PP) flows through flow control (PLS).
valve (2), notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q Since pressure reducing valve (3) moves to the
right, pump discharge pressure (PP) is reduced
by the pressure loss at notch (c) and introduced
to LS circuit (PLS). The pressure is also intro-
duced to spring chamber (PLS1).
q LS circuit (PLS) is connected to tank circuit (T)
through LS bypass valve (4). (See "LS bypass
valve")

GD555-5,GD655-5,GD675-5 10-155
Hydraulic system
Functions and operation by valve

LS bypass valve

A: To each valve
B: To pump LS valve
PLS: LS circuit
PP: Pump circuit
T: Tank circuit

Function
q This valve releases residual LS pressure (PLS).
q This valve serves to lower the rising speed of LS
pressure (PLS). In addition, the discarded flow
causes a pressure loss when throttled in the
spool and shuttle valve, and that lowers the ef-
fective LS differential pressure to improve the
stability.

Operation
q Pressurize oil in LS circuit (PLS) flows through
filter (a) and orifice (b) of LS bypass valve (1) into
tank circuit (T).

10-156 GD555-5,GD655-5,GD675-5
Hydraulic system
Functions and operation by valve

LS relief valve

Function Operation
q Even when LS pressure introduction and throttle q If LS circuit pressure (PLS) increases and reach-
functions work, if other actuator relieves during es the set pressure of LS relief valve (1), (PLS)
combined operation, the speed of the actuator is is kept at a constant level.
slower than that in single operation. q Pump circuit (PP) pressure is set by [Spring
q LS relief is adopted to prevent significant drop of force + (PLS)] of unload valve (2).
the actuator speed due to the relief of other ac- q Pump circuit (PP) relief flow runs into tank circuit
tuator, that affects operation. (T) through unload valve (2). (Corresponding to
q Compact pilot relief valve mounted on LS circuit the minimum swash plate angle flow)
controls the maximum pressure. q Relief valve (3) functions as backing up LS relief
q Unload valve mounted on control valve works as valve and as surge pressure absorbing valve.
a relief valve to release the flow.
q In addition, the LS differential pressure corre-
sponding to set unload valve pressure is se-
cured, so the relief actuator does not slow down
the operation.

GD555-5,GD655-5,GD675-5 10-157
Hydraulic system
Functions and operation by valve

LS pressure reducing valve

A: To main valve
B: To pump port (LS)
C: From steering valve port (LS)
D: From steering valve port (P)
E: To pump port (PP)

Function Operation
q LS differential pressure (dPLS) for the control q Pump port pressure (PCF) and LS pressure
valve is set higher than that for the steering (PLS) (ST) are introduced from the steering
valve. valve.
q With this hydraulic circuit, if steering operation is q Using pump port pressure (PCF) as a source
performed, the pump delivery reaches the maxi- pressure, LS pressure (PLS) (V) is produced by
mum, and the excessive flow is drained through reducing the pressure corresponding the force of
the unload valve of the control valve. This spring (1) from LS pressure (PLS) (ST) and, is
causes a large energy loss. introduced to the control valve.
q The LS pressure reducing valve reduces steer- q Check valve (2) prevents oil from flowing into the
ing LS pressure to the same level as the LS dif- steering valve through port (PP) when the work
ferential pressure of the control valve in order to equipment is operated.
reduce the energy loss.

10-158 GD555-5,GD655-5,GD675-5
Hydraulic system
Functions and operation by valve

Pressure compensation valve

Function q Flow control valve (2) and pressure reducing


q When the load pressure of an actuator is lower valve (1) stop at a position where the pressure
than that of other actuator and the flow to the ac- difference between (PA) and (PLS), that act on
tuator is going to increase during combined op- the both end faces of the pressure reducing
eration, this valve allows the load pressure to be valve (1) respectively, is the same as the pres-
compensated. sure loss generated across flow control valve (2)
q Assume that the load pressure of the other actu- between (PP) and (PPA).
ator (on the right) is higher than that of the actu- q The pressure differences between upstream
ator on the left side during combined operation. pressure (PPA) and downstream pressure (PA)
of both spools operated for combined operation
Operation is the same and pump delivery is divided in pro-
q When the load pressure of the other actuator (on portion to the opening area of notch (a) of each
the right) rises during combined operation, flow spool.
to actuator circuit (A) on the left side is apt to in-
crease.
q LS pressure (PLS) of the other actuator is ap-
plied to spring chamber (PLS1) and pushes
pressure reducing valve (1) and flow control
valve (2) to the left.
q Flow control valve (2) throttles the opening area
between pump circuit (PP) and spool upstream
(PPA) to generate a pressure loss between (PP)
and (PPA).

GD555-5,GD655-5,GD675-5 10-159
Hydraulic system
Hydraulic cylinder

Hydraulic cylinder

10-160 GD555-5,GD655-5,GD675-5
Hydraulic system
Hydraulic cylinder

GD555-5,GD655-5,GD675-5 10-161
Hydraulic system
Swivel joint

Swivel joint

a: To power tilt cylinder head 1. Plug


b: To power tilt cylinder bottom 2. Plate
c: To blade shift cylinder head 3. Cover
c: To blade shift cylinder bottom 4. Shaft
5. Rotor

10-162 GD555-5,GD655-5,GD675-5
Hydraulic system
Swivel joint

GD555-5,GD655-5,GD675-5 10-163
Hydraulic system
Pilot check valve

Pilot check valve


Pilot check valve (Hydraulic drift prevention valve)

Function
q When work equipment control lever is not operated, pressurized oil flowing from the cylinder can leak from
spool (1) and cause the hydraulic drift of work equipment cylinder. Pilot check valve prevents this problem.

(1) When control lever is in NEUTRAL

Operation
q When the work equipment control lever is in NEUTAL, the cylinder is held at the current position because
check valve (2) is closed by the cylinder holding pressure.
(No hydraulic drift caused)

10-164 GD555-5,GD655-5,GD675-5
Hydraulic system
Pilot check valve

(2) When control lever is operated

(1): Spool
(2): Valve
(3): Valve
(5): Piston
(6): Pressure compensation valve

Operation
q When the spool is moved to the left, pressurized oil from the pump passes through a passage within the
valve, shifts check valve (3) on the A side to the right, and flows into the cylinder.
q Because the pump pressure is applied to pilot circuit (4), pistons (5) shift to the left and right respectively.
q Piston (5) shifts check valve (2) on the B side, allowing pressurized oil returned from the cylinder to flow
into the valve, then into the tank through the spool notch to make cylinder move to the right.

GD555-5,GD655-5,GD675-5 10-165
Hydraulic system
Pilot check valve

Blade FLOAT with detent function (FLOAT position): (left and right blade lift cylinders)

Function
q When the blade lift lever is moved further than the blade LOWER position, the lever enters in FLOAT po-
sition.
The detent (retention) function is provided on FLOAT position, enabling the lever to be kept in the current
position even if it is released.
To cancel FLOAT condition, pull the lever back with stronger force to return the lever to RAISE and
NEUTRAL position.

(1) Blade LOWER position

Operation
q When the spool is moved to the left, pressurized oil from the pump passes through a passage within the
valve, shifts check valve (3) on the A side to the right, and flows into the cylinder.
q Because the pump pressure is applied to pilot circuit (4), pistons (5) shift to the left and right respectively.
q Piston (5) shifts check valve (2) on the B side, allowing pressurized oil returned from the cylinder to flow
into the valve, then into the tank through the spool notch to make the cylinder move to the right.

10-166 GD555-5,GD655-5,GD675-5
Hydraulic system
Pilot check valve

(2) FLOAT position

(1): Spool
(2): Valve
(3): Valve
(5): Piston
(6): Pressure compensation valve
F: Notch A
G: Notch B

Function
q When the spool is moved to the left further than LOWER position, the spool enters into FLOAT position.
(Because a force equivalent to the force of spring (9) is applied to the control lever when ball (8) runs over
notch (7), corresponding force is required for this operation.)
q The pressurized oil from the pump passes through notches A and B of the spool, and flows to the tank.
q Pressure of the pilot circuit increases according to the opening area balance of notches A and B of the
spool, causing check valves (2) and (3) to shift to the left and right respectively, and both the head and
bottom ends of the cylinder are connected to the tank circuit to put the cylinder into FLOAT condition.
q Due to notch (7), the lever is kept in FLOAT position even after it is released.

GD555-5,GD655-5,GD675-5 10-167
Hydraulic system
Pilot check valve

Cylinder pressure release plug (Function to drop work equipment manually in an emergency)

Function
q When the work equipment piping is removed for valve replacement or other purposes, loosening plug (1)
allows for returning pressurize oil in the piping to the tank and lowering the work equipment to the ground
for safe operation.

Operation
q As for the following section, the cylinder circuit can be connected to the tank to lower the work equipment
by loosening pressure release plug (1).
1. A9 (Optional actuator)
2. B8 (L.H. blade lift cylinder head)
3. B5 ( Power tilt cylinder head)
4. B1 (R.H. blade lift cylinder head)
q After the operation, tighten plug (1) to the speci-
fied torque.

10-168 GD555-5,GD655-5,GD675-5
Hydraulic system
Pilot check valve

Relief valve for scarifier (if equipped)

Function
q When the scarifier and drawbar accidentally interfere with each other, the relief valve protects the cylinder
and piping.

Operation
q When external force extends the scarifier cylinder, a high pressure is generated at the A2 port on the head
end.
When the pressure at the A2 port reaches 24.5 MPa {250 kgm/cm2}, the relief valve opens and releases
the pressure to A1 port on the bottom end to protect the cylinder and piping.

GD555-5,GD655-5,GD675-5 10-169
Hydraulic system
Pilot check valve

Blade accumulator solenoid

A1: To accumulator
B1: From control valve
B2: To blade lift cylinder bottom

Outline
q The blade accumulator solenoid is installed in the circuit on the bottom end of the blade lift cylinder. By
turning on the blade accumulator switch, the solenoid is energized, connecting the accumulator and cyl-
inder bottom circuit.
q This prevents upthrust and overload on the blade, improving durability of the work equipment and frame,
and reducing the fatigue of operator.

10-170 GD555-5,GD655-5,GD675-5
Hydraulic system
Pilot check valve

GD555-5,GD655-5,GD675-5 10-171
Hydraulic system
Accumulator (for blade)

Accumulator (for blade)


(if equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston

Function
q If high pressure is generated in the blade cylin-
der due to impacts applied to the blade, high
pressurized oil flows through the solenoid valve
to the accumulator.
q The high pressurized oil compresses nitrogen
gas in cylinder (3) by pushing up free piston (4).
q The pressure of the nitrogen gas in cylinder (3)
absorbs the pressure to the blade cylinder to
protect the machine from impacts applied to the
blade.

Specification
Gas Nitrogen gas
Amount of gas (cc) 1,000
Charged pressure 2.0 ± 0.10 {20 ± 1.0}
(MPa {kg/cm2}) (at 20°C)
Max. operating pressure
20.6 {210}
(MPa {kg/cm2})

10-172 GD555-5,GD655-5,GD675-5
Hydraulic system
Accumulator (for blade)

GD555-5,GD655-5,GD675-5 10-173
Work equipment
Circle and drawbar

Work equipment
Circle and drawbar

10-174 GD555-5,GD655-5,GD675-5
Work equipment
Circle and drawbar

1. Circle (number of teeth: 64) Outline


2. Drawbar q Drawbar (9) is an important device used for sup-
3. Blade lift cylinder porting the circle and blade.
4. Drawbar shift cylinder q Play of drawbar (9) that can result from wear of
5. Ball stud ball stud (12) can be adjusted by adjusting the
6. Guide plate shims of the ball joint portion.
7. Adjustment bolt q The clearance between circle (8) and drawbar
8. Guide bushing (9) can be adjusted by adjusting the shims of the
9. Guide guide installation portion and adjustment bolt
(14) .

GD555-5,GD655-5,GD675-5 10-175
Work equipment
Blade

Blade

10-176 GD555-5,GD655-5,GD675-5
Work equipment
Blade

1. Blade Function
2. Adjuster q The side edge installed to the blade is structured
3. Blade rail guide in such that it can be used twice if it is reversed
4. Drawbar shift cylinder horizontally and vertically.
5. Blade side shift cylinder q The blade rail guide functions as a bushing for
6. Power tilt cylinder the sliding part when the blade is shifted side-
ways. Adjustment of the shims or replacement of
blade guide rail (7) will be required if the targeted
finishing accuracy is not expectable due to an
excessive clearance in the sliding portion.
q The power tilt control lever on the power tilt
mechanism allows freely adjusting the bank cut-
ting angle by blade (5) in the range of 32° to 80°.

GD555-5,GD655-5,GD675-5 10-177
Work equipment
Lifter

Lifter

1. Cap
2. Bushing
3. Yoke
4. Bank control lock pin
5. Bushing
6. Case
7. Cover
8. Shaft
9. Upper lifter bracket
10. Lower lifter bracket

10-178 GD555-5,GD655-5,GD675-5
Work equipment
Lifter

Outline
q The work equipment can be rotated by using lift-
er brackets (9) and (10) installed on the guide,
which is welded to the front frame.
q Bank control lock pin (4) can be inserted or
pulled back by using the lift arm lock switch.
q Lifter brackets (9) and (10) can be rotated
around the guide welded to the front frame by re-
moving bank control lock pin (4).
q In addition to the standard position (a), bank con-
trol lock pin (4) for stopping the rotation of the lift-
er has four more insertion holes at positions (b),
(c), (d) and (e) in order to support the bank cut
posture and shoulder reach posture.
q Bushing (5) is installed to the insertion hole of
bank control lock pin (6) to minimize the clear-
ance between bank control lock pin (4) and the
insertion hole.
q An increased clearance between bank control
lock pin (4) and the insertion hole increases ver-
tical play of the blade.
q The clearance between the guide welded to the
front frame and lifter brackets (9) and (10) can be
adjusted by adjusting the thickness of the shims
inserted between lifter brackets (9) and (10).

GD555-5,GD655-5,GD675-5 10-179
Work equipment
Circle rotation motor

Circle rotation motor

1. Output shaft
2. Flange
3. Shaft seal
4. Taper-roller bearing for heavy load
5. Main drive
6. O-ring
7. Gerotor
8. Valve drive
9. Valve on wear compensation mechanism
10. PF1/2 O-ring port
11. Check valve
12. Valve plate

10-180 GD555-5,GD655-5,GD675-5
Work equipment
Circle rotation motor

Outline
q The circle rotation motor is a low-speed,
high-torque motor and the gerotor on it perform
planetary movement to provide the torque equiv-
alent to that results when the speed of general
hydraulic motors is reduced to 1/6 by a reducer.
q Oil leakage is minimized thanks to the oil pres-
sure balancing type disc valve employed for the
valve mechanism and the high-precision gero-
tor.
q Accurate valve timing and stable performance
over a long period of time are available because
the valve parts are assembled independently
from the power train.
q The taper-roller bearing installed to the output
shaft enables resisting high radial load and high
thrust load.

Operation

q The high pressure oil flows to the motor, then en-


ters into gerotor (2) through disc valve (1) to
cause planetary motion of the star of gerotor (2).
Main drive (3) extracts only the rotation on its
axis of the gerotor from this planetary motion to
rotate output shaft (4).
q Disc valve (1) is driven by the valve drive, so the
positional relationship between twelve ports in
disc valve (1) and seven ports in valve plate (5)
is changed. As a result, flowing-in position of hy-
draulic oil into gerotor (2) is sequentially
changed.

GD555-5,GD655-5,GD675-5 10-181
Work equipment
Circle rotation gear

Circle rotation gear


Slip clutch type

1. Worm wheel (number of teeth: 40) 9. Shim


2. Collar 10. Shaft
3. Shim 11. Floating seal
4. Spring 12. Worm
5. Plate 13. Oil filler plug
6. Disc 14. Drain plug
7. Case 15. Circle rotation motor
8. Pinion (number of teeth: 6)

10-182 GD555-5,GD655-5,GD675-5
Work equipment
Circle rotation gear

Outline
q The circle rotation motor (15) is connected to
worm (12) and rotates the circle rotation gear.
q The clutch mechanism is provided for shaft (10)
and its discs (6) will slip in order to protect the
blade from getting damage when abnormal rota-
tive force is transmitted from the blade.
q Clutching pressure of the clutch mechanism is
adjustable by changing the thickness of shim (3).

GD555-5,GD655-5,GD675-5 10-183
Cab
Cab

Cab
Cab

1. Cab-mounted working lamp 6. Door wiper (right)


2. Light diffusion type warning lamp 7. Air conditioner fresh air filter
3. Door wiper (left) 8. Radio antenna
4. Front wiper 9. Rear wiper
5. Orbcomm GPS antenna

10-184 GD555-5,GD655-5,GD675-5
Cab
Cab

GD555-5,GD655-5,GD675-5 10-185
Electrical system
Machine monitor

Electrical system
Machine monitor

10-186 GD555-5,GD655-5,GD675-5
Electrical system
Machine monitor

1. Engine coolant temperature gauge 20. Emergency steering pilot lamp (*1)
2. Torque converter oil temperature gauge 21. RPM set pilot lamp
3. Shift indicator 22. Water separator monitor
4. Fuel gauge 23. Maintenance caution lamp
5. Engine speed indicator 24. Fan reverse rotation pilot lamp
6. Articulation indicator 25. Differential lock pilot lamp (*2)
7. Speedometer 26. Inching clutch overheat caution lamp
8. Meter display indicator 27. Economy operation pilot lamp
9. Character display 28. Turn signal pilot lamp (left)
10. Parking brake pilot lamp 29. Headlamp high beam pilot lamp
11. Brake oil pressure caution lamp 30. Front working lamp pilot lamp (*1)
12. Engine coolant temperature caution lamp 31. Working lamp pilot lamp
13. Engine oil pressure caution lamp 32. Turn signal pilot lamp (right)
14. Engine oil level caution lamp (*1) 33. Centralized warning lamp
15. Engine pre-heating pilot lamp 34. Blade float pilot lamp
16. Battery charge circuit caution lamp 35. Blade accumulator pilot lamp (*2)
17. Torque converter oil temperature caution lamp 36. Lift arm lock pin pilot lamp
18. Differential oil temperature caution lamp (*2) 37. P-mode pilot lamp
19. Hydraulic oil temperature caution lamp

*1: Not used by this model


*2: if equipped

Monitoring items and display


Central-
ized Warning
Display cate- Display
No. Display item Display range Display method warning buzzer Remarks
gory color
lamp output
output
Refer to the figure Corresponding and
1 Gauge given in the previous lower segments all — — Black LCD
Engine coolant page light up
temperature Below 102°C Off Off OFF
12 Caution 102°C – 105°C ON ON OFF Red LED
Min. 105°C ON ON ON
Corresponding and
2 Gauge Torque con- See figure at left. lower segments all — — Black LCD
verter oil tem- light up
perature Below 120°C Off Off OFF
17 Caution Red LED
Min. 120°C ON ON ON
Corresponding seg-
3 Indicator Shift indicator See figure at left. ment alone lights — —
up
Corresponding and
4 Gauge Fuel level See figure at left. lower segments all — —
light up
Corresponding and
5 Engine speed See figure at left. lower segments all — —
light up
Corresponding and Black LCD
6 Articulation lower segments all — —
Indicator
light up
9 segments x 2 dig-
7 Speedometer 0 – 99 — —
its
MPH Corresponding unit
8 Meter display — —
km/h lights up
[*1]
Character dis- While engine is run-
9 Service meter 0 – 99999.9 h — —
play ning
odometer
*1: For details of the display in the service mode, see "Special functions of monitor panel (EMMS)" in Testing and adjust-
ing.

GD555-5,GD655-5,GD675-5 10-187
Electrical system
Machine monitor

Central-
ized Warning Dis-
Display cat-
No. Display item Display range Display method warning buzzer play Remarks
egory
lamp Output Color
Output
10 Pilot Parking brake During operation ON — —
Brake oil pres- Specified value or lower
11 ON ON ON
sure (4.4 MPa {45 kg/cm2})
Lamp is OFF
Red
Caution (while engine is Off OFF
Engine oil Specified value or lower
13 stopped)
pressure (49 kPa {0.5 kg/cm2}) Lamp is ON (while
ON ON
engine is running)
15 Pilot Preheating While preheating ON — — Green
Lamp is OFF
(while engine is Off OFF
Battery
16 When charging is defective stopped)
charge circuit
Caution Lamp is ON (while Red
ON ON
engine is running) LED
Differential oil
18 Min. 120°C ON ON ON
temperature
21 Pilot RPM set During operation ON — — Green
Before the 30-hour point Off
Between the 30-hour point
23 Caution Maintenance Flashes Off OFF Red
to the replacement time
After the replacement time ON
Differential When the differential lock Yel-
ON — —
lock switch signal is input low
25 Blinks (when the
Differential Yel-
Oil temperature Max. 25°C differential lock is — —
lock low
"ON"
Economy
27 Economy operation ON — —
operation
Turn signal
28 When turn signal lever and — — Green
(left)
Pilot hazard lamp switch signal Flashes
Turn signal
32 is input — —
(right)
When headlamp high
beam signal is input
High beam of
29 (when headlamp switch is ON — — Blue
head lamp
"ON" and dimmer switch is
"ON")
When working lamp switch
31 Working lamp ON — — Green
signal is input
Centralized See the column "Centralized warning lamp Bulb
33 Caution — — Red
warning Output" of this table.
When the blade lift cylin-
34 Blade float der control lever is at ON — —
"Float" position
Blade accu- When blade accumulator
35 ON — —
mulator switch signal is input
Pilot Green
Lift arm lock When lift arm lock switch
36 ON — —
pin signal is input
When power mode selector
37 Power mode switch is set to "P-mode" ON — —
position

10-188 GD555-5,GD655-5,GD675-5
Electrical system
Machine monitor

GD555-5,GD655-5,GD675-5 10-189
Electrical system
Automatic shift control system

Automatic shift control system

Outline
q In the automatic shift control system, the trans-
mission controller automatically sets the trans-
mission to an optimal gear speed responding to
the incoming lever position signal from the gear
shift lever, electrical potential signal from the ac-
celerator pedal and inching pedal, speed signal
from the transmission and signals from the other
switches and sensors.
q Other than controlling the transmission gear
speed, the transmission controller controls the
torque converter lockup, too.

10-190 GD555-5,GD655-5,GD675-5
Electrical system
Automatic shift control system

Shift lever positions

Shift lever positions and automatic gear shift


range
q The following table shows the relationship between the gear shift lever positions and the gear speeds.
q The transmission mode selector switch allows switching the pattern of the gear shift as well as lockup pat-
tern.
q When the transmission mode selector switch is at "MANU" (manual mode) position, the gera is engaged
according to the gear shift lever position. When, however, the gear shift lever is at R3 or R2 position, au-
tomatic gear shifting is performed according to the travel speed.
q When the transmission mode selector switch is at "T/C AUTO" (auto mode) position and the gear shift le-
ver is at any of F1 - F4 or R1 - R4 positions, gera shifting is performed manually. When the gear shift lever
is at any of F5 - F8 or R3, R4, automatic gear shifting is performed automatically according to the travel
speed.
a Regardless of the position of the transmission mode selector switch, switching to the selected gear speed
may not take place immediately when the transmission is in the manual shift range. This arrangement is
intended for preventing overrun of the engine.

MANU mode
Gear shift lever Gear speed
position N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
N A
F1 B
F2 B
F3 B
F4 B
F5 B
F6 B
F7 B
F8 B
R1 A
R2 A
R3 A C
R4 A C C

T/C AUTO mode


Gear shift lever Gear speed
position N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 Rmax
N A
F1 A
F2 A
F3 A
F4 A
F5 A C
F6 A C C
F7 A C C C
F8 A C C C C
R1 A
R2 A
R3 A C
Rmax A C C

A: Torque converter lockup function is disabled.


B: Torque converter is locked up unconditionary re-
gardless of the travel speed and engine speed.
C: Torque converter is locked up automatically ac-
cording to the travel speed and engine speed.

GD555-5,GD655-5,GD675-5 10-191
Electrical system
Automatic shift control system

Overrun prevention function q If the machine decelerates, the overrun preven-


q While traveling a downhill or if a sudden shifting tion function is released and the gear speed au-
is tried, a gear inconsistent with the gear shift le- tomatically switched to the one specified with the
ver position may be selected in order to prevent gear shift lever position.
overrun of the engine.
q If the engine overrun is detected, warning
sounds will be issued for a limited period of time
to alert the operator.
Ultra-low speed travel control
q The ultra-low speed travel control mode is actu-
ated when the gear shift lever is set to "F1", the
transmission mode selector switch to "T/C AU-
TO", the accelerator pedal is released, the travel
speed is below 1.8 km/h, the inching pedalis re-
leased, and the engine speed to below 1,000
rpm. In this mode, travel speed is maintained at
1 km/h.

VHPC control
q The transmission controller and engine control- q The engine power mode switching always takes
ler exchange signals using CAN communication. place after gear shift is completed.
i CAN communication o
Transmission controller Engine controller
(VHPC signal o)

High i Priority in judgment o Low


Normal gear shift mode
Torque converter stall mode
(VHPC control)
Gear speed ALL
Engine power See the following table
MID
Mode

Table 1 Table 2
Direct drive mode T/C auto mode
Engine power mode switch Engine power mode switch
Q:E Mode Q:E Mode
q:P Mode q:P Mode
Engine power mode Engine power mode
ECO LOW MID HIGH ECO LOW MID HIGH
F1 Q q F1 Q q
F2 Q q F2 Q q
F3 Q q F3 Q q
F4 Q q F4 Q q
F5 Q q F5 Q q
Gear speed
Gear speed

F6 Q q F6 Q q
F7 Q q F7 Q q
F8 Q q F8 Q q
P, N Qq P, N Qq
R1 Q q R1 Q q
R2 Q q R2 Q q
R3 Q q R3 Q q
R4 Q q R4 Q q

The following shows the engine output power value (net value) in respective engine power modes.
GD555-5 GD555-5/675-5
ECO : 106.7 kw (145 PS) 110.4 kw (150 PS)
LOW : 120.1 kw (163 PS) 136.5 kw (185 PS)
MID : 133.5 kw (181 PS) 151.5 kw (206 PS)
HIGH : 146.2 kw (198 PS) 164.8 kw (224 PS)

10-192 GD555-5,GD655-5,GD675-5
Electrical system
Automatic shift control system

GD555-5,GD655-5,GD675-5 10-193
Electrical system
Automatic shift control system

Schematic of input and output signals


Transmission input shaft speed sensor Po oA Solenoid (ECMV) for FL

Transmission output shaft speed sensor Po oA Solenoid (ECMV) for FH

Transmission intermediate shaft speed sensor A o oA Solenoid (ECMV) for R

Transmission oil temperature sensor Ao oA Solenoid (ECMV) for lockup

Torque converter outlet oil temperature sensor D o oA Solenoid (ECMV) for 1st

FL clutch pressure switch Do oA Solenoid (ECMV) for 2nd

FH clutch pressure switch Do oA Solenoid (ECMV) for 3rd

R clutch pressure switch Do oA Solenoid (ECMV) for 4th

1st clutch pressure switch Do

2nd clutch pressure switch Do Machine monitor


q Speedometer
3rd clutch pressure switch Do q Tachometer
Transmission controller

q Articulation indicator
4th clutch pressure switch Do oC
q Transmission oil temperature gauge
q Parking signal
F (forward) signal Do q Differential oil temperature signal
q Real-time monitor signal
R (reverse) signal Do

Neutral signal Do
Engine controller
NOT parking signal Do q VHPC selector signal
oC q Engine speed signal
Parking signal Do q Error information
q Throttle lower limit signal
Signal 1 Do q Coolant temperature signal for fan
control
Signal 2 Do

Signal 3 Do

Signal 4 Do

Signal 5 Do

Signal 6 Do oD Parking brake release signal

Signal 7 Do oD Differential control relay

Signal 8 Do oD Backup alarm relay

Inching potentiometer Ao oD RPMset switch 1

Differential selector switch Do oD RPMset switch 2

10-194 GD555-5,GD655-5,GD675-5
Electrical system
Automatic shift control system

Engine mode switch Do oD Fan reverse rotation switch

Transmission mode switch Do oD Air conditioner clutch

Transmission controller
Articulate sensor Ao oP Fan speed

Alternator R Ao oA Motor flow controller

Starting switch C Do oA Fan reverse rotation solenoid

Brake oil signal (oil pressure switch) Do oC Failure code

Hydraulic oil temperature sensor Ao

Differential oil temperature sensor Ao

Manual preheating signal Do

A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal

GD555-5,GD655-5,GD675-5 10-195
Electrical system
Automatic shift control system

System circuit diagram


a Items marked with "*1" in drawing may or may
not installed.

10-196 GD555-5,GD655-5,GD675-5
Electrical system
Automatic shift control system

GD555-5,GD655-5,GD675-5 10-197
Electrical system
Transmission controller

Transmission controller

10-198 GD555-5,GD655-5,GD675-5
Electrical system
Transmission controller

GD555-5,GD655-5,GD675-5 10-199
Electrical system
Transmission controller

Input/Output signal
TM39
Input/Out- Input/out
Pin No. Signal name Pin No. Signal name put sig-
put signal
nal
1
13
2
14 Differential oil temperature sensor Input
3 Transmission oil temperature sen- Input
15 Alternator R terminal Input
4 GND (SIG) —
16 Sensor power Output
5 AC compressor actuation, for fan Input
17 RPMset MODE-MANU Input
6 Engine mode selector switch Input
18 Gear shift mode switch Input
7 Inching potentiometer Input
19 Memory set switch Input
8 Articulation sensor Input
20 Hydraulic oil temperature sensor Input
Torque converter outlet oil tempera-
9 Input 21 GND (analog GND) —
ture sensor
22 Output
10 GND (SIG) —
23 RPMset MODE-AUTO Input
11 Stop lamp signal Input
24 Engine manual pre-heating Input
12 Fan reverse rotation SW Input

TM40
Input/Ou Input/Ou
Pin No. Signal name tput sig- Pin No. Signal name tput sig-
nal nal
1 — — 21 S_NET —
2 T/M FILL 3 Input 22 CAN0_L —
3 T/M FILL 2 Input 23 CAN1_L —
4 232C_RxD Input 24 Service connector input Input
5 1st speed signal (shifter) Input 25 F (forward) signal (shifter) Input
6 5th speed signal (shifter) Input 26 3rd speed signal (shifter) Input
7 T/M FILL FH Input 27 T/M FILL R Input
8 — — 28 Differential lockup switch Input
9 — — 29 GND (Pulse GND) Input
10 Fan speed sensor Input Transmission output shaft speed
30 Input
11 — — sensor
12 — 31 —
13 T/M FILL Input 32 CAN0_H —
14 232C_TxD Output 33 CAN1_H —
15 R (reverse) signal (shifter) Input 34
16 4th speed signal (shifter) Input 35 Neutral signal (shifter) Input
17 T/M FILL FL Input 36 2nd speed signal (shifter) Input
18 37
19 38 T/M FILL 4 Input
Transmission intermediate shaft 39 GND (Pulse GND) Input
20 Input
sensor Transmission input shaft speed
40 Input
sensor

10-200 GD555-5,GD655-5,GD675-5
Electrical system
Transmission controller

TM41
Input/Ou Input/Ou
Pin No. Signal name tput sig- Pin No. Signal name tput sig-
nal nal
1 VB (controller power) Input 21 GND (controller GND) Input
2 VIS (solenoid power) Input 22 VIS (solenoid power) Input
SOL_COM (solenoid common SOL_COM (solenoid common
3 Input 23 Input
GND) GND)
4 — — 24 KEY_SIG Input
5 T/M 1 Output 25 T/M 3 Output
6 — 26 T/M FL Output
7 Parking brake solenoid Output 27
28 Fan reverse mode Output
8 Differential control solenoid Output
29 8th speed signal (shifter) Input
9 6th speed signal (shifter) Input 30 RPM-DECEL/RESUME Input
10 Starting switch C terminal signal Input 31 GND (controller GND) Input
11 VB (controller power) Input 32 GND (controller GND) Input
12 VIS (solenoid power) Input 33 GND (controller GND) Input
SOL_COM (solenoid common 34 Potentiometer power Output
13 Input
GND) 35 T/M 4 Output
14 KEY_SIG Input 36 T/M FH Output
15 T/M 2 Output 37 Hydraulic drive fan speed variable Output
16 T/M R Output 38 T/M torque converter L/U Output
17 39 Parking signal (shifter) Input
18 Backup lamp relay Output 40 Not (EXC.) P signal (shifter) Input
19 7th speed signal (shifter) Input
20 RPMset-ACCEL/SET sensor Input

GD555-5,GD655-5,GD675-5 10-201
Electrical system
Engine controller

Engine controller

Input/Output signal
q The following is the list of the symbols used for signal classification in the input/output signal chart.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication

DTP06-4P [CN-EC3]
Signal
Pin No. Signal name classifi-
cation
1 GND C
2 GND C
3 Unswitched power supply (+24 V) A
4 Unswitched power supply (+24 V) A

10-202 GD555-5,GD655-5,GD675-5
Electrical system
Engine controller

GD555-5,GD655-5,GD675-5 10-203
Electrical system
Engine controller

DRC26-60P [CN-EC1]
Signal Signal
Pin No. Signal name classifica- Pin No. Signal name classifi-
tion cation
1 NC — 31 NC —
2 Power supply for IMA D 32 IMA return C
3 Ambient pressure sensor B 33 Sensor power supply (+5V) A
4 NC — 34 NC —
5 NC — 35 NC —
6 CAN (-) E 36 NC —
7 NC — 37 Sensor power supply (+5 V) A
8 CAN (+) E 38 GND C
9 NC — 39 NC —
10 NC — 40 NC —
11 NC — 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 WIF sensor B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
Crankshaft speed sensor power
16 A 46 Injector #5 (+) D
supply (+5 V)
47 G sensor ground C
17 NC —
18 NC — 48 Ne sensor ground C
19 NC — 49 NC —
20 NC — 50 NC —
21 NC — 51 Injector #2 (–) C
22 NC — 52 Injector #3 (–) C
23 Charge air temperature sensor B 53 Injector #1 (–) C
24 NC — 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 G sensor (+) B 56 Injector #4 (+) D
27 Ne sensor (+) B 57 Injector #6 (+) D
28 NC — 58 Injector #4 (–) C
29 NC — 59 Injector #6 (–) C
30 NC — 60 Injector #5 (–) C

10-204 GD555-5,GD655-5,GD675-5
Electrical system
Engine controller

DRC26-50P [CN-EC2]
Signal Signal
Pin No. Signal name classifi- Pin No. Signal name classifi-
cation cation
1 Idle validation signal 2 B 26 NC —
2 NC — 27 NC —
3 NC — 28 NC —
4 NC — 29 NC —
5 NC — 30 NC —
6 NC — 31 NC —
7 NC — 32 Idle validation signal (-) C
8 NC — 33 GND C
Accelerator pedal potentiometer 34 NC —
9 B
signal 35 NC —
10 NC — 36 NC —
11 Idle validation signal 1 B 37 NC —
12 NC — 38 NC —
13 NC — 39 Starting switch ACC signal B
14 NC — 40 Intake air heater actuation signal D
15 NC — 41 NC —
16 NC — 42 NC —
17 NC — 43 NC —
18 NC — 44 NC —
19 NC — 45 NC —
20 NC — 46 CAN_H E
21 NC — 47 CAN_L E
Accelerator pedal potentiometer
22 A 48 NC —
power supply(+5 V)
23 Accelerator pedal potentiometer (-) C 49 PWM OUTPUT D
24 NC — 50 NC —
25 NC —

GD555-5,GD655-5,GD675-5 10-205
Electrical system
KOMTRAX system

KOMTRAX system
q Standard specification

q KOMTRAX terminal transmits various machine information by use of the radio communication. The
KOMTRAX operator is allowed to reference these information in the office and offer the customer various
services.

a To receive the service, a separate procedure for starting the KOMTRAX service is required.

The information transmitted from the


KOMTRAX terminal includes the following.
1. Operation map
2. Service meter reading
3. Position information
4. Failure history
and others.

10-206 GD555-5,GD655-5,GD675-5
(03)
Electrical system
KOMTRAX system

KOMTRAX terminal
Type: TC301
q The KOMTRAX system uses satellite communi-
cation technology.

1. Communication antenna connection


2. GPS antenna connection
3. Machine harness connection (DEUTSCH-40P)

Input and output signals


DEUTSCH-40P [CN-G01]
Input Input
and out- and out-
Pin No. Signal name Pin No. Signal name
put sig- put sig-
nals nals
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN L Input/out 27 Starting switch C signal Input
8 CAN H Input/out 28 Alternator R signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Unswitched power supply (24 V) Input
20 Immobilize signal Output 40 Unswitched power supply (24 V) Input
Outline
q The KOMTRAX terminal can send information q There are LED lamp and the 7-segment indica-
via wireless communication antenna, acquiring tor lamp in the display area, and these lamps are
various information on the machine from the net- used for the testing and the troubleshooting.
work signal in the machine and the input signal.
The controller has a CPU (Central Processing
Unit), and provides the wireless communication
function and the GPS function.
q The use of the KOMTRAX terminal is limited to
the countries where such communication is al-
lowed by the contract.

GD555-5,GD655-5,GD675-5 10-207
Electrical system
KOMTRAX system

q Chinese specification

q KOMTRAX terminal transmits various machine information by use of the radio communication. The
KOMTRAX operator is allowed to reference these information in the office and offer the customer various
services.

a To receive the service, a separate procedure for starting the KOMTRAX service is required.

The information transmitted from the


KOMTRAX terminal includes the following.
1. Operation map
2. Service meter reading
3. Position information
4. Failure history
and others.

10-207-1
10-208 GD555-5,GD655-5,GD675-5
(03)
Electrical system
KOMTRAX system

KOMTRAX terminal
Type: TC411
q The KOMTRAX system uses ground wave com-
munication technology.

1. Communication antenna connection


2. GPS antenna connection
3. Machine harness connection (AMP(18+12+12P))

Input and output signals


AMP(18+12) [CN-V1] [CN-V4]
Input and Input and
Pin No. Signal name output Pin No. Signal name output
signals signals
1 5V_OUT Output 1 GND —
2 GND — 2 GND —
3 SNET Input/output 3 CTR KEY Input
4 GND — 4 AIS V 0 Input
5 DIS H 4 Input 5 AIS V 1 Input
6 DIS H 3 Input 6 POWER Input
7 DIS L 2 Input 7 POWER Input
8 DIS L 1 Input 8 DOS L 0 Output
9 CAN SH — 9 DIS L CHK0 Input
10 CAN_H Input/output 10 DIS L CHK1 Input
11 CAN_L Input/output 11 DIS H 0 Input
12 DIS H 7 Input 12 AIS V 2 Input
13 DIS H 6 Input
14 DIS H 5 Input
15 GND —
16 AIS V 3 Input
17 AIS V 4 Input
20 AIS V 5 Input

Outline
q The KOMTRAX terminal can send information q There are LED lamp and the 7-segment indica-
via wireless communication antenna, acquiring tor lamp in the display area, and these lamps are
various information on the machine from the net- used for the testing and the troubleshooting.
work signal in the machine and the input signal. a This terminal is dedicated to China, When using
The controller has a CPU (Central Processing the KOMTRAX system in Japan, the terminal
Unit), and provides the wireless communication dedicated to Japan must be mounted.
function and the GPS function.
q The use of the KOMTRAX terminal is limited to
the countries where such communication is al-
lowed by the contract.

GD555-5,GD655-5,GD675-5 10-207-2
10-209
(03)
Electrical system
Starting engine circuit

Starting engine circuit


a Items marked with "*1" in drawing may or may not installed.

Function
1. The parking safety circuit employed ensures 3. The engine cannot be started while the "blade lift
safety when the engine is started. lever" of the work equipment levers is set to the
q The engine can not be started if the gear shift "blade float" mode. This arrangement is
lever is not set to "P" (Parking). intended for preventing the blade from inadver-
tent drop due to the engine start-up.
2. The KOMTRAX engine cutoff circuit is employed
to disable the engine from starting if the
KOMTRAX terminal receives an engine cutoff
command issued through external operation.

10-208 GD555-5,GD655-5,GD675-5
Electrical system
Starting engine circuit

Operation
1. When starting switch is turned to ON position 4. After engine is started
q When the starting switch is turned to ON po- q If the starting switch is returned to the "ON"
sition, terminals B and BR on the starting position, the current of the starting switch ter-
switch are connected and the current flows minal C is cut off. Therefore, the current from
from the battery through the starting switch the safety relay to the starting switch is cut
and the battery relay coil to the ground, there- off.
by closing the contact of the battery relay.
As a result, the power is supplied to each
circuit of the machine. At this time, the ACC
signal is sent from the terminal ACC on the
starting switch to the engine controller,
readying the engine for startup.

2. Parking safety circuit


q As long as the gear shift lever is set to "P
(Parking)", the current flows from the gear
shift lever terminal 6 to the coil on the safety
relay, activating the safety relay.
q While the safety relay is activated, the self
holding relay works by setting the starting
switch to the "START" position. It enables to
hold the safety relay even if "P" signals from
gear shift lever stop due to voltage drop.
q When the gear shift lever is not set to "P
(Parking)", the current from the gear shift le-
ver terminal 6 to the safety relay is cut off, re-
sulting in the current to the safety relay coil
being cut off. As a result, the starting circuit is
cut off.

3. When starting switch is set to START position


q When the starting switch is set to the START
position, the current flows from the starting
switch terminal C through the KOMTRAX en-
gine cut-off relay, the safety relay, and the
float ENG cancel relay to the starting switch
safety relay to start the engine.
q When the gear shift lever is set to any posi-
tion other than P (Parking), the parking relay
is not activated, and the engine will not start.
q When KOMTRAX terminal receives the ex-
ternally-issued engine cut-off command,
KOMTRAX engine cut-off relay is activated,
shutting down the circuit to the parking relay
from the starting switch terminal C. Thus, the
engine will not crank.
q The float ENG cancel relay remains active as
long as the blade lift lever is set to the "blade
float" position, which prevents the engine
from starting.

GD555-5,GD655-5,GD675-5 10-209
Electrical system
Stopping engine circuit

Stopping engine circuit


a Items marked with "*1" in drawing may or may
not installed.

Operation
q When the starting switch is set to the OFF posi-
tion, ACC signal from the starting switch terminal
ACC to the engine controller is cut off and the
supply of fuel to the engine is stopped.
q As the fuel supply to the engine is stopped, the
engine speed drops and eventually the engine
stops.
q After the engine has stopped, the alternator
stops to generate the power, which cuts off the
voltage supply from the alternator terminal R.
q Since the current from the starting switch termi-
nal BR is cut off, the contact of the battery relay
is opened. Consequently, the supply of power to
each circuit of the machine is stopped.

10-210 GD555-5,GD655-5,GD675-5
Electrical system
Stopping engine circuit

GD555-5,GD655-5,GD675-5 10-211
Electrical system
Preheating circuit

Preheating circuit

Outline Operation
q The automatic preheating system is installed so q Set the starting switch to ON position to start the
that the engine will start easily in cold weather. engine controller. In this case, if the engine cool-
q The automatic preheating system is capable of ant temperature is below the set value, the en-
cutting the preheating time short when the start- gine controller activates the intake air heater
ing switch is set to "ON" position. This system is relay to start preheating immediately after the
capable of automatically setting the preheating. starting switch is turned to the ON position.
q When the starting switch is set to the ON posi- q The automatic preheating time is set as shown in
tion, the preheater pilot lamp on the machine the figure below.
monitor lights and the intake air heater starts
preheating intake air.
The engine controller sets the preheating time
referring to the temperature detected by the
engine coolant temperature.
q The pilot lamp remains turned on as long as pre-
heating is continued. Keep the starting switch in
the ON position during this time. Turning the
starting switch to START position from this state
cancels preheating.
q The automatic preheating system turns itself on
or off by detecting the engine coolant tempera-
ture.
In such a case, set the starting switch to the "R
(Preheat)" position to manually start the system.
q Setting the starting switch to the "R (Pre-
heat)"position activates the heater relay inde-
pendent of external air temperature to start
preheating by the intake air heater.
Manual preheating time must be in the range of
5 - 30 seconds.

10-212 GD555-5,GD655-5,GD675-5
Electrical system
Preheating circuit

GD555-5,GD655-5,GD675-5 10-213
Electrical system
Sensor

Sensor
Engine oil pressure switch

1. Connector
2. Sensor
3. O-ring

Coolant temperature sensor


Fuel temperature sensor

1. Connector
2. Sensor
3. O-ring

10-214 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

Engine speed sensor

1. Connector
2. Sensor
3. O-ring

Ambient pressure sensor

1. Connector
2. Pressure inlet port

GD555-5,GD655-5,GD675-5 10-215
Electrical system
Sensor

Boost pressure sensor

1. O-ring
2. Sensor
3. Connector

Boost temperature sensor

1. Connector
2. Sensor
3. O-ring

10-216 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

WIF (water-in-fuel) sensor

1. Connector
2. Tube
3. Sensor
4. O-ring

GD555-5,GD655-5,GD675-5 10-217
Electrical system
Sensor

Accelerator pedal sensor

1. Pedal Output characteristics


2. Connector
3. Sensor

Function
q This sensor is installed to the surface of the cab
floor. It outputs the accelerator signal or idle val-
idation signal corresponding to the accelerator
pedal depressing angle.

Accelerator signal
q The position of the accelerator pedal detected by
the potentiometer inside the sensor is output in
variable voltage from pin No. 2.

Idle validation signal


q In order to detect a failure of potentiometer, the
"ON" and "OFF" signals are output from the pin
No. 5 and No. 6 according to the operated con-
ditions of accelerator pedal.

10-218 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

Inching pedal potentiometer

1. Pedal Relationship between the pedal operating angle


2. Return spring and lever stroke (location a)
3. Potentiometer
4. Arm assembly
5. Lever assembly
6. Spring

Function
q This sensor is installed on the cab floor surface.
It detects the inching pedal depressing angle
and outputs the angle after converting it to the
corresponding electric signal.

Relationship between the pedal operating angle


and output voltage

GD555-5,GD655-5,GD675-5 10-219
Electrical system
Sensor

Blade lift control lever proximity switch

1. Switch 3. Pilot lamp


2. Locknut 4. Connector

Function
q This sensor is installed to the linkage located at the base of the right and left blade lift control levers.
q If the plate is positioned over the detector plane, this sensor lights up the pilot lamp and turns the switch
to the "OFF" position.

10-220 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

Potentiometer

1. Shaft Output characteristics


2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function
q This sensor is installed on the front frame side of
the joint of the front frame and rear frame.
q This sensor detects the articulation angle of the
front and rear frames, and then outputs an elec-
tric signal corresponding to the angle.

GD555-5,GD655-5,GD675-5 10-221
Electrical system
Sensor

Torque converter oil temperature sensor


Transmission oil temperature sensor
Hydraulic oil temperature sensor
Differential lock oil temperature sensor (if equipped)

1. Connector 3. Thermistor
2. Plug

Function
q The torque converter oil temperature sensor is installed in the torque converter outlet port at the top of the
transmission front case. The transmission oil temperature sensor is installed in the lubricating line in the
front side of the transmission case. The hydraulic oil temperature sensor is located in the front side of the
hydraulic tank. The differential lock oil temperature sensor is installed in the rear side of the rear axle.
q These sensors detect the oil temperatures and output them after converting them to the corresponding
electric signals.

Brake oil pressure switch

1. Pressure sensor 3. Connector


2. Cable

Function
q This switch is installed on the brake accumulator pipe.
q This switch senses the brake oil pressure (accumulator pressure) and turns to the "ON" position if the pres-
sure goes below the set pressure.

10-222 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

Transmission input shaft speed sensor


Transmission shaft speed sensor
Transmission output shaft speed sensor

1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal

Function
q These sensors are installed to the input shaft, shaft and output shaft sections of the transmission case.
q These sensors sense the gear speeds and output them after converting them to the corresponding pulse
signals.

GD555-5,GD655-5,GD675-5 10-223
Electrical system
Sensor

Air cleaner clogging sensor

1. Indicator 3. Adapter
2. Spring 4. Connector

Function
q The sensor is installed on the air cleaner outlet side. It outputs the signal when the air cleaner is clogged
and the pressure level drops to the specified level (negative pressure).

10-224 GD555-5,GD655-5,GD675-5
Electrical system
Sensor

Fuel level sensor

1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body

Function
q This sensor is installed on the side face of the fuel tank.
q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
q The float moves up and down according to the
fuel level.
q The movement of the float operates the variable resistor through the arm.

GD555-5,GD655-5,GD675-5 10-225
Electrical system
Engine power mode select circuit

Engine power mode select circuit

1. Power mode selector switch


2. Transmission controller
3. Engine controller

Function
q When setting the power mode selector switch to
"P mode", the engine output can have priority.
When setting it to "E mode", the fuel consump-
tion can have priority.
q The switch signal is input to the transmission
controller to select the power curve compatible
to the selected engine power mode.

Operation
q Setting the power mode selector switch to
"P-mode" sends the switch signal to the trans-
mission controller. Then, the transmission con-
troller sends a CAN signal to the engine
controller to change the engine torque curve into
"P-mode". At the same time, the switch signal
lights up "P-mode indicator."

10-226 GD555-5,GD655-5,GD675-5
Electrical system
Engine power mode select circuit

GD555-5,GD655-5,GD675-5 10-227
Electrical system
Cooling fan control function

Cooling fan control function

1. Transmission controller Input and output signals


2. Machine monitor Transmission controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan motor flow rate control signal
5. Cooling fan motor c. Cooling fan reverse rotation signal
5a. Cooling fan motor flow rate control EPC valve d. Cooling fan rotation speed signal
5b. Cooling fan reverse rotation solenoid valve
6. Cooling fan reverse rotation switch Machine monitor
7. Machine monitor mode selector switch 1 e. Cooling fan manual reverse rotation signal
8. Machine monitor mode selector switch 2 f. CAN signal
9. Engine g. "U" switch signal
10. Radiator h. "t" switch signal
11. Transmission i. ">" switch signal
j. "<" switch signal

Engine controller
k. CAN signal
l. Boost pressure and temperature signal
m. Engine speed signal
n. Coolant temperature signal

10-228 GD555-5,GD655-5,GD675-5
Electrical system
Cooling fan control function

Fan control
q Employment of the hydraulically driven cooling fan and the control of the oil flow rate of the hydraulic motor
allow reducing the engine horsepower loss and noises as well as cutting the warm-up operation time in a
low temperature environment.
q The transmission controller receives the engine speed, coolant temperature and boost temperature sig-
nals that the engine controller received via the network.
q Based on the received information, the transmission controller sends the signal current to the cooling fan
motor flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tem-
perature levels and the engine speed.

Fan speed in accordance with temperature

*1: The target fan speed is determined based on the highest temperature among the coolant temperature,
torque converter temperature and boost air temperature.
*2: Within this range, the fan speed is set according to the coolant temperature, torque converter oil temper-
ature and boost air temperature.
*3: When the boost air temperature is at the lower limit or when the torque converter oil temperature is low,
the fan speed is decreased to increase the oil and coolant temperature (heater blow out temperature) and
cut the warm-up operation time.
(The fan speed in this range is controlled based on the hysteresis of each temperature.)

GD555-5,GD655-5,GD675-5 10-229
Electrical system
Cooling fan control function

Control at start of engine


q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan
speed is temporarily increased immediately after the engine is started to aid start of the fan rotation.
q After the operation is switched to basic control, normal fan control is carried based on the procedure de-
scribed in the section of "Fan speed and temperature".
a The fan control (restriction of the minimum fan speed) at start of the engine is conducted only once after
the starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once and
then turned "ON" again, the control is implemented one more time if the control starting conditions are met.

The control (restriction of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.
Condition 1 Starting switch is turned to ON position.

Condition 2 Engine speed is 800 rpm or above.


Fan is rotating in normal direction.
Condition 3 [The above does not include the case where the controller recognizes that the fan rotation direction
switching operation is being performed, even if the fan is rotating in normal direction]
After the starting switch is turned to ON position, the control at start of engine has not been carried
Condition 4
out yet.

*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20°C or above.

Point A: Starting switch is in ON position (engine is


stopped)
Point B : Control starting conditions are met
Range C : Minimum fan speed is restricted
Range D : Under basic control

10-230 GD555-5,GD655-5,GD675-5
Electrical system
Cooling fan control function

Fan reverse rotation function


q When the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated to rotate the fan in reverse.

1. Fan manual reverse rotation function


The operator can select the desired fan rotation direction by holding down the fan reverse rotation switch
for 0.5 seconds or longer.
When the fan rotation direction switching operation is being performed, the pilot lamp on the machine
monitor keeps blinking to inform the operator that the switching is underway. When the reverse rotation is
suspended due to the high engine speed, high coolant or oil temperature, this lamp also keeps on blinking
until the preparation for switching is completed.
When the fan rotation switching condition is met, this function sends the throttle opening-restricting signal
to the engine controller so that the engine speed does not exceed 1,200 rpm while the switching work is
underway. The above control, however, is not applicable when the hydraulic oil temperature is 30°C or
above.
The pilot lamp on the machine monitor keeps on blinking as long as the reverse rotation of the fan
continues.

The fan rotation is switched from "normal" to "reverse" when every condition in the following table is met.
Condition 1 The fan reverse rotation switch is held down for 0.5 seconds or longer.
Condition 2 Engine speed is over 500 rpm below 1,200 rpm.
(*1) [In order to prevent generation of peak oil pressure at switching of the rotation direction.]
Coolant temperature is below 90°C.
Condition 3
[In order to prevent overheat.]
Hydraulic oil temperature is below 100°C.
Condition 4
[In order to prevent overheat.]
Boost air temperature is below 80°C.
Condition 5
[In order to prevent overheat.]
30 seconds have passed after the engine is started (30 seconds after engine speed reached 500
Condition 6 rpm or above).
[In order to ensure that enough oil is fed to the brake accumulator.]
Torque converter oil temperature is below 102°C.
Condition 7
[In order to prevent overheat]
Condition 8 Gear shift lever is set to "P (Parking)" position.

The fan rotation is switched from "reverse" to "normal" if any of the following conditions is met.
Condition 1 The fan reverse rotation switch is pressed again while the fan is rotating in reverse, and the
(*1) engine speed goes below 1,200 rpm.
Condition 2
The engine speed goes below 1,200 rpm after 10 minutes from start of the fan reverse rotation.
(*1)
Condition 3 Engine has stopped.

*1: The engine speed-related requirement (1,200 rpm) is not applied when the hydraulic oil temperature
is 30°C or above.

2. Overheat prevention function


If overheat in the coolant temperature, hydraulic oil temperature or boost air temperature is recognized
while the fan is rotating in reverse, the reverse rotation is forcibly stopped and switched to the normal rota-
tion in order to increase the air flow to the radiator.

3. Fan speed during reverse rotation


While the reverse fan rotation continues, this function sets the fan speed to the maximum by cutting off the
command current (sets the command current to 0 mA) to the fan motor flow rate control EPC valve.
Setting the fan speed to the maximum increases air flow to the radiator core to the maximum, making the
core cleaning work easier.

GD555-5,GD655-5,GD675-5 10-231
Electrical system
Cooling fan control function

10-232 GD555-5,GD655-5,GD675-5
GD555-5,GD655-5,GD675-5
SEN0521508-00 20-1

MOTOR GRADER
Shop Manual 20-1

GD555-5
GD655-5
GD675-5

Machine model Serial number


GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

20 Standard value table 20-1

GD555-5,GD655-5,GD675-5 20-1
(01)
Table of contents

Table of contents 20-2


20 Standard value table
Standard value table ............................................................................................................... 20- 3
Standard value table for engine ........................................................................................... 20- 3
Standard value table for machine ........................................................................................ 20- 5

20-2 GD555-5,GD655-5,GD675-5
(01)
Standard value table
Standard value table for engine

Standard value table 20-3


Standard value table for engine 20-3
Machine model GD555/GD655/675-5
Engine SAA6D107E-1
Category

Standard value Service limit


Item Measurement condition Unit
for new machine value

High E-mode rpm 1850 ± 50 1850 ± 50


idle P-mode rpm 2200 ± 25 2200 ± 25

q Coolant temperature: Low idle rpm 800(+50/0) 800(+50/0)


Engine speed
Within operating range In E-mode/
Rated speed Other than P-mode F7, F8
rpm P-mode F7, F8
2000 2100

GD555-5
q At rated output kPa Min. 153 Min. 127
Boost pressure
q Aftercooler outlet {mmHg} Min. {1150} Min. {950}
GD655/675-5

Exhaust tempera-
q Whole speed range
ture
q Outside air temperature: 20°C °C Max. 650 700
(Turbocharger inlet
q Turbocharger inlet
temperature)
At sudden acceler- %
ation (discolor- Max. 25 35
q Coolant temperature: (LowoHigh) ation)
Exhaust gas color
Within operating range %
At high idle (discolor- – –
ation)
Intake valve mm 0.25 ± 0.05 0.152–0.381
Valve clearance q Normal temperature
Engine

Exhaust valve mm 0.51 ± 0.05 0.381–0.762

q Engine oil temperature: Compression pres- MPa


Min. 2.41 1.69
Compression pres- sure {Min. 24.6} {20}
40–60°C
sure
q Engine speed Engine speed rpm 250–280 -
q Coolant temperature:
kPa Max. 0.98 1.96
Blowby pressure Within operating range
{mmHg0} {Max. 100} {200}
q At rated output

MPa 0.34–0.59 0.25


q SAW At high idle
{kg/cm2} {3.5–6.0} {2.5}
15W40DH
q Engine coolant tempera-
Engine oil pressure
ture:
Within operating
MPa Min. 0.10 0.07
range At low idle
{kg/cm2} {Min. 1.0} 0.7

Oil temperature q Whole speed range (inside oil pan) °C 80–110 120
q Deflection when pressed Between idler pul- Auto tensioner Auto tensioner
with finger force of ap- ley and Crankshaft (auto adjust- (auto adjust-
prox. 58.8 N {6 kg} pulley ment) ment)
Belt tension Between air condi- mm
q Deflection when pressed
tioner compressor
with finger force of ap- 11–15 11–15
and Crankshaft pul-
prox. 98 N {10 kg}
ley

GD555-5,GD655-5,GD675-5 20-3
(01)
Standard value table
Standard value table for engine

a The following should be noted when using the standard value table to make judgments during testing, ad-
justing and troubleshooting, etc.
1. The standard values for new machines specified in the table are based on data at the time of factory ship-
ment. These values should be used as judgment criteria for evaluating wear resulting from operation, and
as goals when making repairs.
2. The permissible values and failure criterion specified in the table are estimates based on various test data
results of machines at the time of factory shipment. These values should be used as reference for trouble-
shooting while taking into account conditions such as the repair frequency and operating history of the
particular machine.
3. The standard value table will not support a claim.

20-4 GD555-5,GD655-5,GD675-5
(01)
Standard value table
Standard value table for machine

Standard value table for machine 20-5


Applicable models GD555/655/675-5
Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine
Neutral a For details, see Fig.
A at the end of this 45 ± 2 –
Depressed (α1) °
Accelerator pedal section.
angle (degrees)
Stroke (α) q Engine started 17 ± 2 –
q α = α1 - α2

Travel mm 85 ± 5 –
q Engine stopped
q Tip of pedal
q Travel: Between released position Play mm Max. 5 –
Inching pedal and fully depressed posidtion
q Play: At released position Height
mm 175 ± 5 –
q Height: Released position and de- (released)
pressed position above floor level Height
mm 90 ± 5 –
(depressed)

PoN mm 28.5 ± 5 –

N o F1 mm 28.5 ± 5 –

F1 o F2 mm 28.5 ± 5 –
Travel of levers, pedal and steering wheel

F2 o F3 mm 28.5 ± 5 –

F4 o F5 mm 28.5 ± 5 –

q Engine stopped F5 o F6 mm 28.5 ± 5 –


Gear shift lever q At position 24 mm downward from
lever tip F6 o F7 mm 28.5 ± 5 –

F7 o F8 mm 28.5 ± 5 –

N o R1 mm 28.5 ± 5 –

R1 o R2 mm 28.5 ± 5 –

R2 o R3 mm 28.5 ± 5 –

R3 o MAX mm 28.5 ± 5 –

q Engine at low speed


q Front wheels raised off the ground Engine
Turns 6.0–7.0 –
q No. of turns: Between steering speed
Steering wheel stroke ends
q Play: Between rotation starting
point of steering wheel and point Play mm 0–25
where machine start steering
q Engine stopped
q Tip of pedal Stroke mm 55 ± 10 –
Brake pedal q Stroke: Between released position
and breaking position Play mm Max. 5 –
q Play: At released position

GD555-5,GD655-5,GD675-5 20-5
(01)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine
L.H. blade lift cyl- N o Front
mm 22 ± 5 –
inder control lever N o Rear
Attachment control N o Front
mm 22 ± 5 –
N o Rear
Travel of lever, pedal and steering wheel

lever
Blade rotation con- N o Front
mm 22 ± 5 –
trol lever N o Rear
Articulate control N o Front
mm 22 ± 5 –
lever N o Rear
Drawbar side shift q Engine stopped N o Front
mm 22 ± 5 –
control lever q Center of lever knob N o Rear
Power tilt control N o Front
mm 22 ± 5 –
lever N o Rear
Leaning control N o Front
mm 22 ± 5 –
lever N o Rear
Blade side shift N o Front
mm 22 ± 5 –
control lever N o Rear
R.H. blade lift cyl- N o Front
mm 22 ± 5 –
inder control lever N o Rear
At begin- q Engine started
24.5–37.8
ning of q Measured at 150 mm –
{2.5–3.9}
Accelerator pedal Pedal effort depressing away from pedal ful- N {kg}
Engine at crum 45.5–58.8
{4.6–6.0} –
full speed
q Engine stopped
40–80
Inching pedal q 150 mm from pivot N {kg} –
{4–9}
q Max. value to stroke end
Operating effort of lever, pedal and steering wheel

29.4 ± 4.9
PoN N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
N o F1 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
F1 o F2 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
F2 o F3 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
F3 o F4 N {kg} –
q Engine stopped {3.0 ± 0.5}
q At position 24 mm downward from
29.4 ± 4.9
Gear shift lever lever knob end F4 o F5 N {kg} –
{3.0 ± 0.5}
q Max. value in travel to just before
finish of gear shifting 29.4 ± 4.9
F5 o F6 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
F6 o F7 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
F7 o F8 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
R1 o R2 N {kg} –
{3.0 ± 0.5}
29.4 ± 4.9
PoN N {kg} –
{3.0 ± 0.5}

20-6 GD555-5,GD655-5,GD675-5
(01)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine

q Engine stopped 29.4 ± 4.9


R2 o R3 N {kg} –
q Center of lever knob {3.0 ± 0.5}
Gear shift lever
q Max. value in operating effort to just 29.4 ± 4.9
before finish of gear shifting R3 o MAX N {kg} –
{3.0 ± 0.5}
q Engine running at low idle Max. 29.0 Max. 49.0
Steering wheel N {kg}
q When driving in F1 {Max. 3} {Max. 5}
q Engine at high idle
276 ± 28
Brake pedal q 150 mm from rotation center N {kg} –
Operating effort of lever, pedal and steering wheel

{28.1 ± 2.8}
q Max. value until machine is fully braked

L.H. blade lift cyl- N o Front Max. 26.0


N {kg} –
inder control lever N o Rear {Max. 2.7}

Attachment control N o Front Max. 26.0


N {kg} –
lever N o Rear {Max. 2.7}
Blade rotation con- N o Front Max. 26.0
N {kg} –
trol lever N o Rear {Max. 2.7}
Articulate control N o Front Max. 26.0
N {kg} –
lever N o Rear {Max. 2.7}
Drawbar side shift q Engine stopped N o Front Max. 26.0
N {kg} –
control lever q Max. reading up to stroke end N o Rear {Max. 2.7}
Power tilt control N o Front Max. 26.0
N {kg} –
lever N o Rear {Max. 2.7}
Leaning control N o Front Max. 25.0
N {kg} –
lever N o Rear {Max. 2.5}
Blade side shift N o Front Max. 26.0
N {kg} –
control lever N o Rear {Max. 2.7}

R.H. blade lift cyl- N o Front Max. 26.0


N {kg} –
inder control lever N o Rear {Max. 2.7}
Engine speed

q Torque converter stall function


Torque converter
q Torque converter oil temperature: 60–80°C rpm 1689 ± 100 –
stall speed
q Engine at full speed

GD555-5,GD655-5,GD675-5 20-7
(01)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine
2.30 ± 0.20 2.30 ± 0.20
Low speed
Transmission main {23.5 ± 2.0} {23.5 ± 2.0}
relief pressure 25.1 ± 0.20 25.1 ± 0.20
Full speed
{25.6 ± 2.0} {25.6 ± 2.0}
Torque converter 0.93 ± 0.10 0.93 ± 0.10
Full speed
inlet pressure {9.5 ± 1.0} {9.5 ± 1.0}
Torque converter 0.65 ± 0.10 0.65 ± 0.10
Power train oil pressure and pump performance

Full speed
outlet pressure {6.6± 1.0} {6.6± 1.0}
Torque converter
20.6 ± 0.20 20.6 ± 0.20
lockup clutch pres- Full speed
{21.0 ± 2.0} {21.0 ± 2.0}
sure q Torque converter oil temperature:
60–80°C
Transmission FL 1.96–2.45 1.96–2.45
q Engine at low speed or full speed Full speed MPa
clutch pressure {20–25} {20–25}
q During idle-running of tires with {kg/cm2}
Transmission R shift lever in P position or each gear 2.06–2.45 2.06–2.45
Full speed
clutch pressure speed {21–25} {21–25}
Transmission FH 1.96–2.45 1.96–2.45
Full speed
clutch pressure {20–25} {20–25}
Transmission 1st 1.96–2.45 1.96–2.45
Full speed
clutch pressure {20–25} {20–25}
Transmission 2nd 1.96–2.45 1.96–2.45
Full speed
clutch pressure {20–25} {20–25}
Transmission 3rd 1.96–2.45 1.96–2.45
Full speed
clutch pressure {20–25} {20–25}
Transmission 4th 1.96–2.45 1.96–2.45
Full speed
clutch pressure {20–25} {20–25}
Power train pump q Torque converter oil temperature: 60–80°C
l/min 210 –
delivery q Engine at high idle
F1 km/h 3.4 ± 0.2 3.4 ± 0.2
F2 km/h 5.0 ± 0.3 5.0 ± 0.3
F3 km/h 7.0± 0.4 7.0± 0.4
Power train performance

F4 km/h 10.2 ± 0.5 10.2 ± 0.5


q In manual mode F5 km/h 15.4 ± 0.8 15.4 ± 0.8
q In P-mode
q Torque converter oil temperature: F6 km/h 22.3 ± 1.1 22.3 ± 1.1
Travel speed
60–80°C F7 km/h 32.1 ± 1.6 32.1 ± 1.6
q While running at engine rated
speed (2000-2100 rpm) F8 km/h 46.5 ± 2.3 46.5 ± 2.3
R1 km/h 4.5 ± 0.2 4.5 ± 0.2
R2 km/h 9.2 ± 0.5 9.2 ± 0.5
R3 km/h 20.3 ± 1.0 20.3 ± 1.0
R4 km/h 40.3 ± 2.0 40.3 ± 2.0
Differential

Differential lockup
q Final drive oil temperature: 60–80°C 3.05(+0.1/-0.
oil pressure MPa 2.7(+0.2/0)
q Engine at high idle 294)
[Machine with dif-
q Differential lockup operating {kg/cm2} {31.2(+1/0)}
{31.2(+1/-3)}
ferential lockup]

20-8 GD555-5,GD655-5,GD675-5
(01)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine

q Hydraulic oil temperature: 45-55°C


Steering oil pres- MPa 17.2 ± 1.0 17.2 ± 1.0
q Engine at full speed
sure
q When steering cylinder is relieved {kg/cm2} {175 ± 10} {175 ± 10}

q Hydraulic oil temperature: 45-55°C


Steering cylinder
q Engine at full speed cc/min Max. 10 Max. 10
oil leakage
q When steering cylinder is relieved

q
Steering and tire

Camber Flat paved road surface ° 0 –


q Camber: Kingpin inclination
q Toe-in: Difference in tire distances measured at
Toe-in front and rear of tires mm -5 ± 5 –

q Measured with a dial indicator set at tire side wall


Tire deflection mm Max. 7 –
(both front and rear tires)
kPa 250 ± 20
14.00-24-10PR –
{kg/cm2} {2.5}
kPa 275 ± 20
Tire air pressure: 14.00-24-12PR –
{kg/cm2} {2.75}
kPa 250 ± 20
17.5R25TG –
{kg/cm2} {2.5}
Cut-in pres- MPa 9.36(0/-0.5)

Brake accumulator q Hydraulic oil temperature: 45-55°C sure {kg/cm2} {95.5(0/5)}
charge pressure q Engine at full speed Cut-out pres- MPa 13.8(0/-0.5)

sure {kg/cm2} {140(0/5)}
q Hydraulic oil temperature: 45-55°C
Wheel brake oper- MPa 3.95 ± 0.4 3.95 ± 0.4
q Engine stopped (after accumulator is charged)
ating pressure
q Brake pedal depressed {kg/cm2} {40.3 ± 4.1} {40.3 ± 4.1}
Brake

q Hydraulic oil temperature: 45-55°C


Wheel brake oper- MPa
q Engine stopped (after accumulator is charged) 98 98
ating pressure
q Pressure drop in 5 minutes with brake pedal de- {kg/cm2} {1.0} {1.0}
drop
pressed
q Hydraulic oil temperature: 45-55°C
Parking brake q Engine stopped (after accumulator is charged) MPa 9.36–13.24 9.36–13.24
relief pressure q Starting switch ON and gear shift lever in N posi- {kg/cm2} {95.5–135} {95.5–135}
tion.
Wheel brake brak- q Hydraulic oil temperature: 45-55°C
m Max. 14 Max. 14
ing distance q Braking distance from 35 km/h
Stroke and operating effort to control valve

Blade rota-
mm 6 –
q Engine stopped tion only
Spool stroke
q N o RAISE side, N o Lower side Blade not
mm 6 –
rotating
Blade rota- N Max. 117.6

tion only {kg} {Max. 12}

Control valve q Engine stopped


spool operating q N o RAISE side, N o Lower side
effort q Max. value to stroke end Blade not N Max. 73.6

rotating {kg} {Max. 7.5}

GD555-5,GD655-5,GD675-5 20-9
(04)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine

q Hydraulic oil temperature: 45-55° Unload pres- MPa


Work equipment oil pressure and pump performance

3.3
C –
sure {kg/cm2} {34}
q Engine at full speed
Work equipment
q Unload pressure: When all work
oil pressure
equipment in neutral Work equip-
q Work equipment relief pressure: ment relief MPa 23.4
2} –
When leaning cylinder relieved {kg/cm {250}
pressure

q Hydraulic oil temperature: 45-55°C


q Engine at full speed
LS differential q Blade rotation operating MPa 2.35±0.1
2 –
pressure (Pa=14.7 MPa {150 kg/cm }) {kg/cm2} {24 ± 1}
q LS differential pressure = Pump pressure – LS
pressure
q Hydraulic oil temperature: 45-55°C
Steering/Work
q Engine at low speed
equipment pump l/min 77 –
q Blade rotation operation (measured during opera-
delivery
tion)
Fan and brake q Hydraulic oil temperature: 45-55°C
l/min 21.5 –
pump delivery q Engine at low speed
RAISE 2.7±0.4 4.0
Blade lifting speed
LOWER 2.7±0.4 4.0

Blade side shift q Hydraulic oil temperature: 45-55° Shift to left 9.1±1.1 11.0
speed C
Shift to right 9.1±1.1 11.0
q Engine at full speed
q Blade lift: While cylinder travels Shift to left 7.3±1.1 10.0
Drawbar side shift 350 mm, left/right operated inde-
speed pendently Shift to right 7.5±1.1 10.0
q Blade side shift: Cylinder travelling
Blade rotating from end to end Left rotation 8.8±1.3 12.0
Work equipment speed

speed q Drawbar side shift: Height of blade


bottom 100 mm, cylinder travelling Right rotation 8.8±1.3 12.0
from end to end Large cut-
3.5±0.7 7.0
q Blade rotation: Start of rotation to ting angle
Power tilt speed sec
90°(degrees) Small cutting
3.8±0.8 7.0
q Power tilt: Cylinder travelling from angle
end to end Left swing 7.0±1.1 14.0
Articulate speed q Articulate: Cylinder travelling from
end to end Right swing 7.0±1.1 14.0
(while travelling)
q Leaning: Cylinder travelling from Left leaning 1.8±0.3 6.0
Leaning speed end to end
q Rippert: While cylinder travels 100 Right leaning 1.8±0.3 6.0
mm
RAISE 1.7±0.2 3.0
q Scarifier elevation: While cylinder
Ripper speed
travels 180 mm LOWER 1.4±0.2 3.0

Scarfier elevating RAISE 2.0±0.3 3.0


speed LOWER 2.0±0.3 3.0

20-10 GD555-5,GD655-5,GD675-5
(01)
Standard value table
Standard value table for machine

Applicable models GD555/655/675-5


Work equipment hydraulic drift and oil leakage Category

Standard value
Service limit
Item Measurement condition Unit for new
value
machine
q Right and left blade hydraulic lift cylinder: RAISE
Blade hydraulic
stroke end
drift
q Hydraulic oil temperature: 45-55°C mm 10 20
(no load on cylin-
q Engine stopped
der)
q Cylinder extension in 10 minutes after setting
q Right and left blade hydraulic lift cylinder: LOWER
Blade hydraulic stroke end (machine lifted)
drift q Hydraulic oil temperature: 45-55°C mm 20 35
(machine lifted) q Engine stopped
q Cylinder retraction in 10 minutes after setting

Work equipment q Hydraulic oil temperature: 45-55°C


cylinder oil leak- q Engine at full speed cc/min Max. 3 Max. 3
age amount q Cylinder relieved

a The following should be noted when using the standard value table to make judgments during testing, ad-
justing and troubleshooting, etc.
1. The standard values for new machines specified in the table are based on data at the time of factory ship-
ment. These values should be used as judgment criteria for evaluating wear resulting from operation, and
as goals when making repairs.
2. The permissible values and failure criterion specified in the table are estimates based on various test data
results of machines at the time of factory shipment. These values should be used as reference for trouble-
shooting while taking into account conditions such as the repair frequency and operating history of the
particular machine.
3. The standard value table will not support a claim.

GD555-5,GD655-5,GD675-5 20-11
(01)
Standard value table
Standard value table for machine

Posture of machine for measuring performance


and measurement procedure 20-12

a Fig. A

20-12 GD555-5,GD655-5,GD675-5
(01)
GD555-5,GD655-5,GD675-5
SEN0521510-00 30-1

MOTOR GRADER
Shop Manual 30-1

GD555-5
GD655-5
GD675-5

Machine model Serial number


GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

30 Testing and adjusting 30-1

GD555-5,GD655-5,GD675-5 30-1
(01)
Table of contents

Table of contents 30-2


30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting .................................................................... 30- 4
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 4
Engine and cooling system ..................................................................................................... 30- 10
Testing engine speed........................................................................................................... 30- 10
Testing intake air pressure (boost pressure) ....................................................................... 30- 12
Testing exhaust gas temperature ........................................................................................ 30- 14
Testing exhaust gas color .................................................................................................... 30- 16
Adjusting valve clearance .................................................................................................... 30- 18
Testing compression pressure............................................................................................. 30- 20
Testing blowby pressure ...................................................................................................... 30- 23
Testing engine oil pressure.................................................................................................. 30- 25
Handling fuel system device ................................................................................................ 30- 26
Releasing remaining pressure from fuel system.................................................................. 30- 27
Testing fuel pressure ........................................................................................................... 30- 28
Bleeding air from fuel circuit................................................................................................. 30- 29
Testing fuel circuit for leakage ............................................................................................. 30- 30
Cylinder cut-out test mode ................................................................................................... 30- 31
No injection cranking............................................................................................................ 30- 32
Handling voltage circuit of engine controller ........................................................................ 30- 33
Checking muffler body and muffler stack for looseness and damage ................................. 30- 34
Checking muffler function .................................................................................................... 30- 35
Checking cylinder head and manifolds for looseness.......................................................... 30- 36
Checking engine piping for damage and looseness ............................................................ 30- 37
Checking fuel delivery, return rate and leakage................................................................... 30- 38
Replacing alternator belt ...................................................................................................... 30- 41
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]30- 42
Power train.............................................................................................................................. 30- 44
Testing power train oil pressure........................................................................................... 30- 44
Adjusting transmission speed sensor .................................................................................. 30- 56
Emergency escape method in case of transmission valve failure ....................................... 30- 60
Flushing torque converter and trasmission circuits.............................................................. 30- 64
Testing and adjusting toe-in................................................................................................. 30- 66
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]... 30- 68
Steering system ...................................................................................................................... 30- 70
Testing and adjusting steering oil pressure ......................................................................... 30- 70
Testing steering cylinder oil leakage.................................................................................... 30- 71
Bleeding air from steering circuit.......................................................................................... 30- 72
Brake system .......................................................................................................................... 30- 74
Testing and adjusting brake oil pressure ............................................................................. 30- 74
Releasing remaining pressure from brake circuit................................................................. 30- 78
Bleeding air from brake circuit ............................................................................................. 30- 79
Testing wheel brake disc wear............................................................................................. 30- 80
Testing and adjusting parking brake .................................................................................... 30- 82
Emergency release method of parking brake ...................................................................... 30- 84
Filling gas into brake accumulator ....................................................................................... 30- 86
Hydraulic system..................................................................................................................... 30- 88
Testing and adjusting work equipment oil pressure............................................................. 30- 88
Testing and adjusting pump LS differential pressure........................................................... 30- 91
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut] ............................ 30- 93
Testing work equipment cylinder oil leakage amount .......................................................... 30- 94

30-2 GD555-5,GD655-5,GD675-5
(03)
Table of contents

Bleeding air from work equipment circuit............................................................................. 30- 97


Work equipment...................................................................................................................... 30- 98
Clearance adjustment of drawbar ball joint.......................................................................... 30- 98
Testing and adjusting circle guide clearance....................................................................... 30- 99
Testing and adjusting slip clutch type circle rotator ............................................................. 30- 101
Filling gas into blade accumulator [machine with blade accumulator] ................................. 30- 103
Electrical system ..................................................................................................................... 30- 104
Procedure for testing diodes................................................................................................ 30- 104
Special functions of machine monitor (EMMS).................................................................... 30- 105
Handling high voltage circuit of engine controller ................................................................ 30- 154
How to start KOMTRAX terminal operations ....................................................................... 30- 156
Indicator lamps of KOMTRAX terminal................................................................................ 30- 161
Preparation work for troubleshooting of electrical system ................................................... 30- 164
Pm clinic ................................................................................................................................. 30- 166
Pm Clinic.............................................................................................................................. 30- 166

GD555-5,GD655-5,GD675-5 30-3
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

Tools for testing, adjusting, and troubleshooting 30-4


Tools for testing, adjusting, and troubleshooting 30-4
Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
1 799-205-2200 Tachometer kit 1 6.0 – 99999.9 r/min
Testing engine speed A
2 6210-81-4111 Gearbox 1
1 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
Testing boost pressure B
2 790-301-1530 Elbow 1 R1/8xR1/8, 90°

Testing exhaust gas tem- C


799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
perature
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color D Available on the Bosch index: 0 – 9
2 Smoke meter 1
market
1 795-799-1131 Gear 1
Adjusting valve clearance E Available on the
2 Clearance gauge 1 Intake: 0.33 mm, Exhaust: 0.71 mm
market
1 795-502-1590 Puller 1
Testing compression 2 795-799-6700 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
F
pressure 3 795-790-4410 Adapter 1 107E-1 engine
4 6754-11-3130 Gasket 1 107E-1 engine
Testing blowby pressure G 799- 201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mm H2O}
Pressure gauge 2.5, 6, 40, 60 MPa
799-101- 002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing engine oil pres- 1
H Pressure gauge: 60 MPa {600
sure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101- 002 Hydraulic tester 1
1
790-261-1204 Digital hydraulic tester 1 In common with H
Testing fuel pressure K 2 799-401-2320 Hydraulic tester 1
799-101-5220 Nipple 1
3 Size:10 x 1.25 mm
07002-11023 O-ring 1
799-101- 002 Hydraulic tester 1
Testing power train oil 1
K 790-261-1204 Digital hydraulic tester 1 In common with H
pressure
2 799-401-2320 Hydraulic tester 1
Emergency escape 794-423-1190 Plug 3
method in case of trans- L
mission valve failure 07002-22034 O-ring 3
799-101- 002 Hydraulic tester 1
1
Testing differential lock-up 790-261-1204 Digital hydraulic tester 1 In common with H
oil pressure
M 2 799-401-2320 Hydraulic tester 1
Machine with differential
lock-up 799-101-5220 Nipple 1
3 Size:10 x 1.25 mm
07002-11023 O-ring 1
799-101- 002 Hydraulic tester 1
1 In common with H1
Testing steering oil pres- 790-261-1204 Digital hydraulic tester 1
N
sure 799-203-2410 Adapter 1
2 Size:10 x 1.25 mm
07002-11023 O-ring 1
Testing steering cylinder Available on the
P Measuring cylinder 1
oil leakage amount market

30-4 GD555-5,GD655-5,GD675-5
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-101- 002 Hydraulic tester 1 In common with H1
1
790-261-1204 Digital hydraulic tester 1
Testing and adjusting
Q 793-520-1805 Brake test kit 1 0 – 20 MPa {0 – 200 kg/cm2}
brake oil pressure 2
790-438-1060 Nipple 1
3 799-401-3100 Adapter 1 In common with N2
Filling gas into brake
R 792-610-1700 Charging tool 1 Intake: 0.33 mm, Exhaust: 0.71 mm
accumulator
Testing and adjusting 799-101- 002 Hydraulic tester 1
work equipment oil pres- S In common with H1
sure 790-261-1204 Digital hydraulic tester 1
799-101- 002 Hydraulic tester 1 In common with H1
1
790-261-1204 Digital hydraulic tester 1
Testing and adjusting
Differential pressure
pump LS differential pres- T 2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
sure
799-101-5220 Nipple 2
3
07002-11023 O-ring 2 Size:10 x 1.25 mm
799-101- 002 Hydraulic tester 1 In common with H1
Checking lift arm lock cyl- 1
U 790-261-1204 Digital hydraulic tester 1
inder circuit oil pressure
2 799-401-3100 Adapter 2 Size: 02
Testing work equipment Available on the
V Measuring cylinder 1 In common with P
cylinder oil leakage market
1 795-790-4700 Multimeter kit 1
6754-71-5340 Connector 1
2
6754-71-5350 Washer 1
Available on the
3 Measuring cylinder 1
Testing fuel return rate market
W
and leakage amount Available on the
4 Stopwatch 1
market
Available on the Hose (inner diameter 14
5 1
market mm)
Available on the Hose (inner diameter 8
6 1
market mm)
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

effort 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring travel and Available on the
– Ruler 1
hydraulic drift market
Measuring work equip- Available on the
– Stopwatch 1
ment speed market
Measuring voltage and Available on the
– Multimeter 1
resistance market

GD555-5,GD655-5,GD675-5 30-5
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-4130 T-adapter – For NE sensor
799-601-4130 T-adapter – For oil pressure sensor
799-601-4240 Socket – For ambient pressure sensor
799-601-4250 Socket – For boost pressure sensor
799-601-4330 Socket – For G sensor
799-601- 9020 T-adapter – For injector
Troubleshooting for
engine controller, sen- – 799-601-9030 T-adapter – For CAN
sors and actuators 799-60 -9040 T-adapter – For EGR valve position sensor
799-601-9430 Socket – For supply pump
For engine coolant temperature sen-
795-799-5530 Socket –
sor/fuel temperature sensor
795-799-5540 Socket – For boost temperature sensor
799 -601-4211 T-adapter – Controller (50 poles)
799-601-4220 T-adapter – Controller (60 poles)

30-6 GD555-5,GD655-5,GD675-5
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

Sym-

Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-4101
or
799-601-4201
or T-adapter assembly 1 For DT adapter
799-601-9000
or
799-601-9200
799-601- 9020 q Adapter for DT 1 For DT2P
For DT3P (excluding 799-601-4100
799-601-9030 q Adapter for DT 1
and 799-601-4200)
799-60 -9040 q Adapter for DT 1 For DT4P
For DT6 (excluding 799-601-4100
799-60 -9050 q Adapter for DT 1
and 799-601-4200)
For DT12GR (excluding
799-601-9110 q Adapter for DT 1
799-601-4100 and 799-601-4200)
For DT12B (excluding 799-601-4100
799-601-9120 q Adapter for DT 1
and 799-601-4200)
For DT12G (excluding 799-601-4100
799-601-9130 q Adapter for DT 1
and 799-601-4200)
For DT12BR (excluding
799-601-9140 q Adapter for DT 1
799-601-4100 and 799-601-4200)
799-601-7000
or
799-601-7100
Troubleshooting for chas- or T-adapter assembly 1 Adapter for X, SWP, M
sis sensors and wiring – 799-601-7400
harnesses or
799-601-8000
For X1P (excluding 799-601-7000
799-601-7010 q Adapter for X 1
and 799-601-7100)
799-601-7020 q Adapter for X 1 For X2P
799-601-7050 q Adapter for SWP 1 For SW6P (excluding 799-601-8000)
For SW14P (excluding 799-601-7000
799-601-7070 q Adapter for SWP 1
and 799-601-7100)
For M1P (excluding 799-601-7000
799-601-7080 q Adapter for M 1
and 799-601-7100)
799 -601-7090 q Adapter for M 1 For M2P
799-601-7110 q Adapter for M 1 For M3P
799-601-7120 q Adapter for M 1 For M4P
799-601-7130 q Adapter for M 1 For M6P
799-601-7310 q Adapter for SWP 1 For SW12P
799-601-7500 T-adapter assembly 1 Adapter for 070
799-601-7520 q Adapter for 070 1 For 070-12P
799-601-7550 q Adapter for 070 1 For 070-20P
799-601-9300 T-adapter assembly 1 For DRC adapter
799-601-9350 q Adapter for DRC 1 For DRC-40P
799-601-9360 q Adapter for DRC 1 For DRC-24P
Removal and installation
of engine coolant temper- – 795T-981-1010 Socket 1
ature sensor
a For the model names and part Nos. of the T-adapters and T-boxes used for troubleshooting the machine
monitor, controllers, actuators and wiring harnesses, see Troubleshooting, "T-box and T-adapter list."

GD555-5,GD655-5,GD675-5 30-7
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

-: Socket

30-8 GD555-5,GD655-5,GD675-5
(01)
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting

GD555-5,GD655-5,GD675-5 30-9
(01)
Engine and cooling system
Testing engine speed

Engine and cooling system 30-10


Testing engine speed 30-10
Testing method by using tachometer kit
a Testing tools for engine speed (for measurement 1) Open the left engine side cover (1).
by a tachometer kit)
Symbol Part No. Part name
A 1 799-205-2200 Tachometer kit
k Stop the machine on the level ground, set the
gear shift lever to the P position, and set
chocks to the tires.
a Measure the engine speed under the following
condition.
q Coolant temperature: within operating range
q Torque converter oil temperature:
within operating range
q Hydraulic oil temperature: 45 - 55°C

1. Preparatory work
(for low idle and high idle speed test) 2) Attach a reflecting seal to the fan drive pulley
Testing method by using machine monitor and measure by using a tachometer kit A1.
Prepare for the testing of engine speed by
turning the starting switch to ON position and
switching the machine monitor function to the
display of "Real-time monitoring".
a For the operating method, see "Special func-
tion of machine monitor (EMMS)".
q Monitoring code:
01001- ENG SPEED (MONITOR
PANEL)
01001- ENG SPEED (ENGINE)

30-10 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing engine speed

2. Testing low idle speed 3) While firmly depressing the brake pedal, set
1) Start the engine and hold the gear shift lever the gear shift lever to the F8 position.
in the P position. 4) Slowly depress the accelerator pedal to run
2) Measure the engine speed with the acceler- the engine at high speed with the torque
ator pedal released. converter stalled.
k Keep the brake pedal firmly de-

3. Testing high idle speed pressed.


1) Start the engine and hold the gear shift lever 5) When the torque converter oil temperature
in the P position. (lower row) reaches 90°C, return the accel-
2) Measure the engine speed with the acceler- erator pedal to the low idle position immedi-
ator pedal depressed to the stroke end. ately and return also the gear shift lever to
the P position.
k Do not operate the gear shift lever with
4. Testing torque converter stall speed
the accelerator pedal depressed. Oth-
1) Start the engine and hold the gear shift lever
erwise, the inside of the transmission
in the P position.
can be broken.
2) Switch the machine monitor function to the
6) While holding the gear shift lever in the P
display of "Torque converter stall" to prepare
position, run the engine at medium speed.
for the torque converter stalled operation.
When the torque converter oil temperature
a The operating method, see "Special func-
decreases to approximately 80°C, return
tion of machine monitor (EMMS)".
the engine to low idle.
a The engine speed is displayed on the up-
7) Repeat the procedure 3) to 6) to make the oil
per row and torque converter oil tempera-
temperature of the torque converter and
ture on the lower row.
transmission equal.
8) Repeat the procedure 3) to 6) and at the
same time, measure the torque converter
stall speed when the torque converter oil
temperature is 80°C.
a Measure the torque converter stall speed
in the same procedure two to three times.
<Reference>
The torque converter stall speed varies due to
the following conditions. Be sure to measure it at
the time of delivery.
q Variation due to engine serial number
q Variation due to atmospheric pressure and
temperature
q Variation due to power consumed by auxilia-
ry equipment
q Variation due to torque converter indivisual
difference
q Variation due to measuring method

5. Work after finishing testing


After completing testing, remove the testing
tools and return the machine to the original
condition (only at the time of testing by using a
tachometer kit).

GD555-5,GD655-5,GD675-5 30-11
(01)
Engine and cooling system
Testing intake air pressure (boost pressure)

Testing intake air pressure (boost pressure) 30-12


3. Start the engine and run it at middle or higher
a Testing tools for intake air pressure (boost pres- speed and discharge the oil from the hose.
sure) a Insert the gauge connection into the hose
Sym-
Part No. Part name
halfway and open the self-seal in the hose
bol connector. Repeating this action will drain
1 799-201-2202 Boost gauge kit the oil.
B
2 790-301-1530 Elbow (R1/8xR1/8, 90°)
a If Pm kit (A) is available, you may use the
air-bleeding coupling (790-261-1130) in that
k Stop the machine on the level ground, set the kit.
gear shift lever to the P position, and set a If oil is left in the hose, the gauge does not
chocks to the tires. work. Be sure to drain the oil.
k When installing and removing the testing in-
strument, take care not to touch a hot part of 4. Hold the gear shift lever in the P position and the
the engine. fuel control lever in the low idle position.
a Measure the intake air pressure (boost pres-
sure) under the following condition. 5. Switch the machine monitor function to the
q Coolant temperature: within operating range display of "Torque converter stall" to prepare for
q Torque converter oil temperature: the torque converter stalled operation.
within operating range a For the operating method, see "Special func-
q Hydraulic oil temperature: 45 – 55°C tion of machine monitor (EMMS)".
a The engine speed is displayed on the upper
1. Open the right engine side cover and remove row and torque converter oil temperature on
intake air pressure pickup port plug (1) from the the lower row.
intake connector.

2. Install the elbow B2 and nipple [1] of boost


gauge kit B1 and connect gauge [2].

30-12 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing intake air pressure (boost pressure)

6. While firmly depressing the brake pedal, set the


gear shift lever to the F8 position.

7. Slowly depress the accelerator pedal and


measure the intake air pressure (boost pres-
sure) when the engine is running at high speed
with the torque converter stalled.
k Keep the brake pedal firmly depressed.

8. After completing measuring, immediately return


the accelerator pedal to the low idle position and
return also the gear shift lever to P position.
k Do not operate the gear shift lever with
the accelerator pedal depressed. Other-
wise, the inside of the transmission can
be broken.

9. After completing measuring, remove the testing


tools and return the machine to the original
condition.

GD555-5,GD655-5,GD675-5 30-13
(01)
Engine and cooling system
Testing exhaust gas temperature

Testing exhaust gas temperature 30-14


4. Procedure when conducting periodic testing
a Testing tools for exhaust temperature for Pm clinic, etc.
Symbol Part No. Part name a In order to prevent the torque converter over-
C 799-101-1502 Digital thermometer heat, stabilize the exhaust temperature by a
k Stop the machine on the level ground, set the full stall (torque converter stall + oil pressure
gear shift lever to the P position, and set relief) operation, then run the engine with
chocks to the tires. only the torque converter stalled to perform
k Install or remove the testing instrument after test.
the exhaust manifold temperature has low- 1) Start the engine and hold the gear shift lever
ered. in the P position and the accelerator pedal in
a Measure the exhaust temperature under the fol- the low idle position.
lowing condition. 2) Bring the right and left blade lift cylinders to
q Coolant temperature: within operating range the RAISE storke end by the right and left
q Torque converter oil temperature: blade lift control levers.
within operating range 3) Switch the machine monitor function to the
q Hydraulic oil temperature: 45 – 55°C display of "Torque converter stall" to prepare
for the torque converter stalled operation.
1. Open the left engine side cover and remove the a For the operating method, see "Special
heat insulation cover from the turbocharger. function of machine monitor (EMMS)".
a The engine speed is displayed on the up-
2. Remove exhaust temperature pickup port plug per row and torque converter oil tempera-
(1) from the exhaust manifold. ture on the lower row.

3. Install sensor [1] of digital thermometerC and


connect it to meter [2].
a Fix the harness of the digital thermometer to
the appropriate position so that it does not
contact a hot part during measurement.

30-14 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing exhaust gas temperature

4) While firmly depressing the brake pedal, set 5. Procedure when measuring the maximum
the gear shift lever to the F8 position. value in troubleshooting
5) Slowly depress the accelerator pedal and run Measure the maximum value of the exhaust
the engine at high speed with the torque temperature when actually conducting work.
converter stalled. At the same time, operate a The highest temperature is automatically re-
the right and left blade lift control levers to the corded if the PEAK mode of the digital ther-
lifting side to relieve oil pressure (bring the mometer is used.
machine to full stall condition). a As the exhaust temperature differs greatly
k Keep the brake pedal firmly de- depending on the ambient air temperature
pressed. (intake air temperature of the engine), correct
a Continue this operation until the exhaust the value using the following formula if an ab-
temperature reaches the standard value, normal value is recorded.
approx. 670°C. q Compensation value [°C] = Measured value

6) When the exhaust temperature stabilizes + 2 x (20 - ambient air temperature)


near the target temperature, return the right
and left blade lift control levers to the neutral
position and measure the exhaust tempera-
ture when only the torque converter is
stalled.
7) After completing measuring, immediately
return the accelerator pedal to the low idle
position and return also the gear shift lever to
P position.
k Do not operate the gear shift lever with
the accelerator pedal depressed. Oth-
erwise, the inside of the transmission
can be broken.

6. After completing measurement, remove the


measuring tools and return the machine to the
original condition.

GD555-5,GD655-5,GD675-5 30-15
(01)
Engine and cooling system
Testing exhaust gas color

Testing exhaust gas color 30-16


1) Insert probe [1] of smoke meter D2 in the
a Testing tools for exhaust gas color outlet of the exhaust pipe (1) and fix it to the
Symbol Part No. Part name exhaust pipe by using a clip.
1 799-201-9001 Handy smoke checker
D 2 Commercially
Smoke meter
available

k Stop the machine on the level ground, set the


gear shift lever to the P position, and set
chocks to the tires.
k Be careful not to touch any hot part when re-
moving or installing the testing tools.
a Check the exhaust gas color under the following
condition.
q Coolant temperature: within operating range
a If an air source and an electric power source are
not available in the field, use handy smoke
checker D1. When recording official data, use
2) Connect the probe hose, plug of the acceler-
smoke meter D2.
ator switch, and air hose to smoke meter D2.
a Limit the supplied air pressure to 1.5 MPa
1. Testing by using handy smoke checker D1
{15 kg/cm2} or below.
1) Stick a sheet of filter paper to smoke checker
3) Connect the power cable to an 100V AC
D1.
receptacle.
2) Insert the exhaust gas intake pipe in exhaust
a Before connecting the cable, check that
pipe (1).
the power switch of the smoke meter is
3) Start the engine and hold the gear shift lever turned OFF.
in the P position.
4) Loosen the cap nut of the suction pump and
4) Operate the handle of smoke checker D1 fit the filter paper.
when the engine is accelerated suddenly or a Fit the filter paper securely so that the ex-
when it is running at high idle so that the filter haust gas will not leak.
paper absorbs the exhaust gas.
5) Turn ON the power switch of smoke meter
a Absorbing time: 1.4 ± 0.2 seconds
D2.

5) Remove the filter paper and compare it with


6) Start the engine and hold the gear shift lever
the attached scale.
in the P position.
6) After completing test, remove the testing
7) Depress the accelerator pedal of smoke
tools and return the machine to the original
meter D2 when the engine is accelerated
condition.
suddenly or when it is running at high idle in
order to collect the exhaust gas into the filter
2. Checking by using smoke meter D2
paper.

30-16 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing exhaust gas color

8) Place the contaminated filter paper on the


clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After completing measurement, remove the
measuring tools and return the machine to
the original condition.

GD555-5,GD655-5,GD675-5 30-17
(01)
Engine and cooling system
Adjusting valve clearance

Adjusting valve clearance 30-18


5. Rotate the crankshaft in normal direction by
a Adjusting tools for valve clearance using tool E1 and align a wide slit (b) in the disc,
Symbol Part No. Part name which has slits for speed sensor and is installed
1 795-799-1131 Gear at the rear of the crank pulley, with top face (a) of
E Commercially the protrusion of the front cover.
2 Feeler gauge
available
a It is acceptable if top face (a) of the protrusion
is within wide slit (b) when viewed from the
1. Remove the hood assembly and air cleaner intake manifold side.
assembly (1).
See "Disassembly and assembly of hood
assembly" of "Disassembly and Assembly".

2. Remove muffler assembly (2).

3. Remove cylinder head cover (3).

k Note that either of No. 1 and No. 6 cylin-


ders are not at top dead center when this
alignment is made. (The cylinder is at 76 –
88° before top dead center.)

4. Remove plug (4) located above the starting


motor and install tool E1.

30-18 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Adjusting valve clearance

6. Adjust the valve clearance in the following 7. In the same manner as in procedure 5, rotate the
procedure. crankshaft in normal direction one turn by using
a When the rocker arm for the exhaust valve tool E1 and align wide slit (b) with top face (a) of
(EX side) of No. 1 cylinder is not moved by the protrusion.
hand, adjust valves with Q mark in the valve
layout drawing. 8. Adjust the clearance of the remaining valves
q When the rocker arm of the exhaust valve according to procedure 6.
(EX side) of No. 1 cylinder is moved by the a When having adjusted valves with Q mark in
amount of valve clearance by hand, adjust the layout drawing in procedure 4, adjust
valves with q mark in the valve layout draw- valves with q mark. (When valves with q
ing. mark has been adjusted, adjust valves with Q
mark.)

9. After completing adjustment, remove the


adjusting tools and return the removed parts to
their original condition.
k Be careful not to forget removal of tool E1.
3 Cylinder head cover mounting bolt :
20 – 28 Nm {2.04 – 2.86 kgm}

1) Insert feeler gauge E2 into clearance


between rocker arm (5) and cross head (6).
2) Loosen locknut (7) and adjust valve clear-
ance by adjustment screw (8).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you
can move the feeler gauge with some re-
sistance.
3) Fix adjustment screw (8) and tighten locknut
(7).
3 Locknut:
20 – 28 Nm {2.04 – 2.86 kgm}
a After tightening the lock nut, check the
valve clearance again.

GD555-5,GD655-5,GD675-5 30-19
(01)
Engine and cooling system
Testing compression pressure

Testing compression pressure 30-20


4. Loosen injector terminal nuts (4) and remove the
a Testing tools for compression pressure harness terminal from the injector.
Symbol Part No. Part name
1 795-502-1590 Puller 5. Bring the cylinder to be tested to the compres-
2 795-799-6700 Compression gauge
F sion top dead center.
3 795-790-4410 Adapter
4 6754-11-3130 Gasket a See "Adjusting valve clearance".

k
6. Remove rocker arm assembly (5).
When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a ro-
tating part.
a Measuring the compression pressure when the
engine is warm.
(Engine oil temperature: 40 – 60°C)

1. Remove cylinder head cover (1).

2. Disconnect injector harness connector (2) and


shift the harness.

3. Disconnect high pressure fuel tube (3).


7. Remove retainer (6) and remove fuel inlet
connector (7).

8. Remove injector holder (8).

9. Remove injector (9).


a Remove the injector using tool F1 and apply-
ing impact with a slide hammer.
a Do not pry the upper part of the injector to re-
move the injector.

30-20 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing compression pressure

15. Set the engine to the no injection cranking mode


by using the machine monitor.
a See "Special functions of machine moitor".
k If the engine is not set to the no injection
mode, it will start, which may cause per-
sonal injury. Be sure to set the engine to
this mode.
16. Test the compression while cranking the engine
by the starting motor.
a Read the pressure when the gauge pointer is
stabilized.

17. After completing the test, remove the testing


tools and return the machine to the original
10. Install a gasket F4 to the end of the adapter F3 condition.
and then insert the adapter into the injector a Install the injector and high pressure fuel
mounting bore. tube according to the following procedure.
1) Align the projection (a) on the injector with
11. Fix adapter F3 by using injector holder (8). the notch (b) in the holder, and install the
a Tighten the holder mounting bolts alternately. injector in the cylinder head.
3 Holder mounting bolt: a Install the injector with the above-men-
8 ± 0.8 Nm {0.8 ± 0.08 kgm} tioned mating part faced toward the fuel
inlet connector inserting side.
12. Connect gauge assembly F2 to adapter F3.
a Air leakage may be reduced by applying a
small amount of engine oil to the adapter and
gauge connecting surfaces.

13. Install rocker arm assembly (5).


3 Rocker arm assembly mounting bolt :
36 ± 5 Nm {3.67 ± 0.51 kgm}

14. Adjust the valve clearances.


a See "Adjusting valve clearance".

2) Screw in the injector holder mounting bolts


(10) by 3 or 4 threads.
3) Set the fuel inlet connector (7).
a Press fuel inlet connector in until you feel
the O-ring snap in place.
4) Loosely install the fuel inlet connector (7) by
retainer (6).
3 Retainer: 15 ± 5.0 Nm {1.5 ± 0.5
kgm}
5) Tighten injector holder mounting bolts (10)
alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
6) Tighten the fuel inlet connector retainer (6).
3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}

GD555-5,GD655-5,GD675-5 30-21
(01)
Engine and cooling system
Testing compression pressure

7) Tighten the high pressure fuel tube (3) sleeve


nuts from the head side first, and then the
common rail side.
3 Sleeve nut :
35 ± 3.5 Nm {3.6 ± 0.4 kgm}

18. After installing the rocker arm assembly, see


"Adjusting valve clearance" to adjust valve clear-
ance.
3 Rocker arm assembly mounting bolt :
36 ± 5 Nm {3.67 ± 0.51 kgm}

19. Install the injector harness.


3 Terminal nut: 1.5 ± 0.25 Nm {0.15 ±
0.025 kgm}
a Check that the injector harness does not in-
terfere with the rocker arm.

20. Install the head cover.


3 Head cover mounting nut :
24 ± 4 Nm {2.45 ± 0.41 kgm}

30-22 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing blowby pressure

Testing blowby pressure 30-23


a Testing tools for blowby pressure
Sym-
Part No. Part name
bol
G 799-201-1504 Blowby checker
k Stop the machine on the level ground, set the
gear shift lever to the P position, and set
chocks to the tires.
a Test the blowby pressure under the following
condition.
q Coolant temperature: within operating range
q Torque converter oil temperature:
within operating range
q Hydraulic oil temperature: within operating
range 5. While firmly depressing the brake pedal, set the
gear shift lever to the F8 position.
1. Open the right engine side cover and pull out
blowby hose (1) outside. 6. Slowly depress the accelerator pedal and
measure the blowby pressure when the engine
2. Install nozzle [1] of blowby checker G to the tip of is running at high speed with the torque
blowby hose (1) and connect it to gauge [2]. converter stalled.
k Keep the brake pedal firmly depressed.
a Although it is desirable to test blowby pres-
sure during operation at rated horsepower,
an approximate value can be obtained by
performing the torque converter stalled oper-
ation.
a When rated horsepower operation or torque
converter stalled operation cannot be per-
formed, test with high idle operation. In this
case, a blowby measurement value equiva-
lent to approx. 80% of the value during oper-
ation at rated horsepower can be obtained.
a Blowby pressure can change greatly de-
pending on the engine condition. When a
3. Start the engine and hold the gear shift lever in measured value is judged to be abnormal,
the P position and the fuel control lever in the low check for the problems related to faulty blow-
idle position. by such as excessive oil consumption, im-
proper exhaust gas color or deterioration or
4. Switch the machine monitor function to the premature dirt of oil.
display of "Torque converter stall" to prepare for
the torque converter stalled operation.
a For the operating method, see "Special func-
tion of machine monitor (EMMS)".
a The engine speed is displayed on the upper
row and torque converter oil temperature on
the lower row.

GD555-5,GD655-5,GD675-5 30-23
(01)
Engine and cooling system
Testing blowby pressure

7. After completing measuring, immediately return


the accelerator pedal to the low idle position and
return also the gear shift lever to P position.
k Do not operate the gear shift lever with
the accelerator pedal depressed. Other-
wise, the inside of the transmission can
be broken.

8. Return the hose to guide (2).

9. Pass the blowby hose guide (3) from the bottom


of the chassis so that it does not interfere with
the parking brake.
10. Check the blowby hose for twist, bend and so on.

11. After completing measurement, remove the


measuring tools and return the machine to the
original condition.

30-24 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing engine oil pressure

Testing engine oil pressure 30-25


3. Start the engine and measure engine oil pres-
a Testing tools for engine oil pressure sure when engine is running at low idle and high
Sym-
Part No. Part name
idle.
bol
799-101-002 Hydraulic tester
1
H 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

k Stop the machine on the level ground, set the


gear shift lever to the P position, and set
chocks to the tires.
a Measure the engine oil pressure under the fol-
lowing condition.
q Coolant temperature: within operating range

1. Open the right engine side cover (1).

4. After completing measurement, remove the


measuring tools and return the machine to the
original condition.

2. Install adapter [1] of hydraulic tester H1 and


connect it to hydraulic tester H2.

GD555-5,GD655-5,GD675-5 30-25
(01)
Engine and cooling system
Handling fuel system device

Handling fuel system device 30-26


a Precautions for checking and maintaining fuel
system
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzles. If foreign
matter enters this system, it can cause a
problem.
When checking and maintaining the fuel system,
take care more than ever before. If dust, etc.
sticks to any part, wash that part thoroughly with
clean fuel.
a Precautions for replacing the fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzles. To
prevent entry of foreign matter, a special filter
with a highly-efficient filtering performance is
used.
Therefore, never use a non-genuine filter which
may cause a problem in the fuel system.

30-26 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Releasing remaining pressure from fuel system

Releasing remaining pressure from fuel system 30-27


a Pressure of the fuel system is generated in the
low-pressure circuit and the high-pressure circuit
while the engine is running.
Low-pressure circuit: Feed pump – Fuel filter –
Fuel supply pump
High-pressure circuit: Fuel supply pump –
Common rail – Fuel injectors
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level au-
tomatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is checked and its parts
are removed, the remaining pressure in the fuel
circuit must be released completely. According-
ly, observe the following.
k Before checking the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the remaining pressure
in the fuel circuit is released. (Do not start the
work just after stopping the engine because
there is remaining pressure.)

GD555-5,GD655-5,GD675-5 30-27
(01)
Engine and cooling system
Testing fuel pressure

Testing fuel pressure 30-28


3. Start the engine and test the fuel pressure with
a Testing tools for fuel pressure the engine at low idle.
Symbol Part No. Part name a If the fuel pressure is in the following range, it
799-101- 002 Hydraulic tester is proper.
1
J 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester 0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

k Stop the machine on the level ground, set the


gear shift lever to the P position, and set
chocks to the tires.
a For fuel pressure, test only the low-pressure cir-
cuit from the feed pump through the fuel filter to
the fuel supply pump.
k The pressure in the high-pressure circuit
from the fuel supply pump through the com-
mon rail to the fuel injectors is very high, so
it cannot be tested.

1. Open the right engine side cover and remove


fuel pressure pickup port plug (1) from the fuel
filter head. 4. After completing measurement, remove the
measuring tools and return the removed parts.
3 Fuel pressure pickup port plug:
10 ± 2 Nm {1 ± 0.2 kgm}

2. Install nipple [1] of hydraulic tester J1 and


connect it to hydraulic tester J2.

30-28 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Bleeding air from fuel circuit

Bleeding air from fuel circuit 30-29


a If fuel is used up or if a fuel circuit part is removed
and installed, bleed air from the fuel circuit ac-
cording to the following procedure.

1. Loosen the knob of the priming pump (1) and


move it back and forth.

a Continue moving the knob until it becomes


hard to move.
(If the main filter is empty, move the knob 60
– 70 times, and the air is bled)

2. Crank the engine in order to start it.


a The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
a If the engine does not start, air may not be
bled from the low-pressure circuit. In this
case, repeat the above work.

GD555-5,GD655-5,GD675-5 30-29
(01)
Engine and cooling system
Testing fuel circuit for leakage

Testing fuel circuit for leakage 30-30


9. Check the fuel piping and devices for fuel
k Stop the machine on the level ground, set the leakage.
gear shift lever to the P position, and set a Check the high-pressure circuit parts coated
chocks to the tires. with the color checker and their peripheries
k Very high pressure is generated in the for fuel leakage.
high-pressure circuit of the fuel system. If a If any fuel leakage is detected, repair it and
fuel leaks while the engine is running, it pres- check again from step 1.
ents a danger that could result in fire. a If no fuel leakage is detected, check is com-
a Clean and degrease the engine and the parts pleted.
around it in advance so that you can check it
easily for fuel leakage.

1. Spray color checker (fuel leak detector) over the


fuel supply pump, common rail, fuel injectors,
and joints of the high-pressure fuel piping.

2. Start the engine, keep its speed at 1,000 rpm or


below, and stop it when its speed is stabilized.

3. Check the fuel piping and devices for fuel


leakage.
a Check the high-pressure circuit parts coated
with the color checker and their peripheries
for fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

4. Run the engine at low idle.

5. Check the fuel piping and devices for fuel


leakage.
a Check the high-pressure circuit parts coated
with the color checker and their peripheries
for fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

6. Run the engine at high idle.

7. Check the fuel piping and devices for fuel


leakage.
a Check the high-pressure circuit parts coated
with the color checker and their pheripheries
for fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

8. Run the engine at high idle, then load it.


a Perform right and left blade lift cylinder circuit
relief.

30-30 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Cylinder cut-out test mode

Cylinder cut-out test mode 30-31


a The cylinder cut-out test mode operation means
to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.

1. This mode is used to find out a cylinder which


does not output power properly (or, combustion
in it is abnormal).

2. When a cylinder is cut out, if the engine speed


and output power do not change from the normal
operation (all-cylinder operation), that cylinder
has one or more defects.
The following problems can be considered:
q Compression leak from cylinder head gasket
q Defective injection from injector
q Defective piston, piston rings and cylinder lin-
er
q Defective valve mechanism
q Defective electrical system

3. The injector of each cylinder is separately


controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a defec-
tive cylinder easily.
a The cylinder cut-out test mode operation is
set by the service mode of the machine mon-
itor.
For details, see "5. Engine cylinder cut-out
function" of "Special function of machine
monitor (EMMS)".

GD555-5,GD655-5,GD675-5 30-31
(01)
Engine and cooling system
No injection cranking

No injection cranking 30-32


a No-injection cranking means to crank the engine
by using the starting motor while all the injections
are stopped electrically. The purpose and effect
of this operation are as follows.
q Before the engine is started after the engine or
the machine has been stored for a long period,
the no injection cranking is performed to lubri-
cate the engine parts and protect them from sei-
zure.
a No injection cranking is set in service mode of
the machine monitor.
For details, see "Special function of monitor
panel (EMMS)" in "6. No injection cranking func-
tion".

30-32 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Handling voltage circuit of engine controller

Handling voltage circuit of engine controller 30-3


1. Before disconnecting or connecting the engine
harness connector from/to the engine controller,
be sure to turn the starting switch to OFF posi-
tion.

2. If a T-adapter is inserted in or connected to the


connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You may turn the starting switch to the OFF
or ON position, but must not turn it to the
START position.

GD555-5,GD655-5,GD675-5 30-33
(01)
Engine and cooling system
Checking muffler body and muffler stack for looseness and damage

Checking muffler body and


muffler stack for looseness and
damage 30-34
1. Visually check the muffler and muffler stack for
cracks and damages. If any part is damaged,
replace it.

2. Check the mounting bolts and nuts of the muffler


and muffler stack for looseness. If any part has
worked loose, retighten it.

30-34 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Checking muffler function

Checking muffler function 30-35


q Check the muffler for unusual noise or different
noise from that of a new muffler. If any unusual
noise is heard, repair the muffler, referring to
"Troubleshooting".

GD555-5,GD655-5,GD675-5 30-35
(01)
Engine and cooling system
Checking cylinder head and manifolds for looseness

Checking cylinder head and mani-


folds for looseness 30-36
Check the cylinder head and intake and exhaust
manifolds for looseness. If any part has worked
loose, retighten it.
a For the tightening torque, see "Disassembly and
assembly" .

30-36 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Checking engine piping for damage and looseness

Checking engine piping for


damage and looseness 30-37
Intake and exhaust system: Check the piping for
damage, the mounting bolts and nuts for
looseness, and the joints for air suction
and exhaust gas leakage. If any part has
worked loose or is damaged, retighten or
repair it.

Cooling system: Check the piping for damage, the


mounting bolts and nuts for looseness,
and the joints for coolant leakage. If any
part has worked loose or is damaged, re-
tighten or repair it.

Fuel system: Check the piping for damage, the


mounting bolts and nuts for looseness,
and the joints for fuel leakage. If any part
has worked loose or is damaged, retighten
or repair it.

GD555-5,GD655-5,GD675-5 30-37
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage

Checking fuel delivery, return rate


and leakage 30-38 3) Crank the engine for 30 seconds, and then
measure the delivery rate using the
a Tools for inspecting fuel delivery, return, and measuring cylinder W4.
leakage rates a Arrange the test hose so that it does not
Symbol Part No. Part name slacken and put its end in a container.
1 795-790-4700 Tester kit a Do not crank the engine for more than 30
6754-71-5340 Connector seconds to protect the starting motor in
3
6754-71-5350 Washer any case other than this measurement.
4
Commercially
Measuring cylinder a If the supply pump delivery is in the fol-
available lowing standard range, it is proper.
W Commercially
5 Stopwatch When cranking at 125 rpm 75 cc minimum
available
When cranking at 150 rpm 90 cc minimum
Commercially Hose (14-mm internal
6
available diameter)
Commercially Hose (8-mm internal
7
available diameter)

a Prepare a container of approximately 20 l to re-


ceive the fuel leaking during the test.

1. Testing supply-pump delivery rate


1) Loosen the clamp (2) on delivery tube (1) of
the supply pump and disconnect the tube (1).

4) After completing testing, remove the testing


tools and return the machine to the original
condition.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}

2. Testing supply-pump return rate


2) Connect the test hose W6 to the delivery 1) Disconnect the return hose (3) from the
nipple of the supply pump. supply pump.
a Fix the hose with a wire etc.
a Adjust the route of the test hose so that it
does not slacken, and put its end in a con-
tainer.

2) Install the connector W3 and the cap nut [1]


from the tester kit W1 to the return-hose end
in order to stop the outflow of fuel.

30-38 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage

3) Connect the test hose [2] from the tester kit 3. Testing the leak rate from the pressure
W1 to the supply pump. limiter
a Arrange the test hose so that it does not 1) Disconnect the return hose (4) from the pres-
slacken and put its end in a container. sure limiter section.
a Install the seal washer to the connector
bolt.

4) Start the engine, and over a low-idling dura-


tion of 25 seconds, measure the return rate
from the supply pump using the measuring 2) Install the disconnected connector bolt (5)
cylinder W4. and the cap nut [1] from the tester kit W1 to
a If the return rate from the supply pump is the return hose end in order to stop the
in the following range, it is proper. outflow of fuel.
3) At the common rail side, install the connector
At low idle 400 cc
W3 and connect the test hose [2] from the
tester kit W1.
a Arrange the test hose so that it does not
slacken and put its end in a container.

5) After completing the measurement, remove


the testing tools and return the machine to
the original condition.

GD555-5,GD655-5,GD675-5 30-39
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage

4) Start the engine, and over a low-idling dura- 2) At the cylinder head side, install the
tion of 1 minute, measure the leak rate using connector W3 and connect the test hose [2]
the measuring cylinder W4. from the tester kit W1, and put the end of the
a If the leakage from the pressure limiter is hose in a container.
in the following range, it is proper. 3) Install the disconnected connector bolt (7)
At low idle
0 cc and the cap nut [1] from the tester kit W1 to
(no leakage) the return hose end in order to stop the leak
of fuel.
4) Start the engine, and over a low-idling dura-
tion of 1 minute, measure the return rate from
the injector using the measuring cylinder W4
.
a If the return rate from the injector is in the
following range, it is proper.
At low idle Max. 180 cc/min
During cranking Max. 90 cc/min

5) After completing measurement, remove the


measuring tools and return the machine to
the original condition.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

4. Testing the return rate from injectors


1) Disconnect the return hose (6) from the
cylinder head. k If the engine cannot be started, you
a Install the seal washer to the connector may measure the fuel return rate
bolt. while rotating the engine by using
the starting motor. Do not rotate for
more than 30 seconds continuous-
ly, however, for protection of the
starting motor.

5) After completing measurement, remove the


measuring tools and return the machine to
the original condition.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

30-40 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Replacing alternator belt

Replacing alternator belt 30-41


a As an auto tensioner is used for the alternator
belt, belt tension check and adjustment are not
necessary.
a Remove air conditioner compressor belt before
replacing the alternator belt.
k Stop the machine on the level ground and
lower the work equipment to the ground.

1. Open the left engine side cover (1).

2. Apply a wrench (a) to the section "A" of


tensioner assembly (2) and turn the wrench
toward the engine in order to loosen tension of
alternator belt (3).
k Apply the wrench (a) to section "A" of ten-
sioner assembly securely before turning
it. (The spring of tensioner assembly (2) is
strong, and if it is turned with the wrench
applyed loosely, the wrench comes off,
which may cause personal injury.)
k After removing alternator belt (3), slowly
and carefully return tensioner assembly
(2).
k Be careful not to get your fingers pinched
between the pulley and alternator belt (3)
during work.

3. Replace alternator belt (3).


q Check each pulley for breakage and crack.

GD555-5,GD655-5,GD675-5 30-41
(03)
Engine and cooling system
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]

Testing and adjusting air condi- Adjusting 30-42


tioner compressor belt tension 1. Loosen locknut (1).
[machines with air conditioner] 30-42
2. Turn adjusting nut (2) and displace compressor
k Stop the machine on the level ground, set the (3) with the bracket as one to adjust belt tension.
gear shift lever to the P position, and set a Be careful of overtension of the belt.
chocks to the fires.
3. Tighten locknut (1) and fix compressor (3).
Testing 30-42 a Check each pulley for breakage, wear of the
1. Open the right engine side cover. V-groove, and contact of the V-belt with
V-groove.
2. Measure deflection (a) when pressing the a When the V-belt has so elongated that no al-
midpoint of the compressor pulley and crank lowance for adjustment is left or it has a cut
pulley belt by a thumb. or crack, replace it with a new one.
q Belt pressing force: 98 N {10 kg}
a When the V-belt is replaced, perform testing
q Deflection (a): 17 - 19 mm (when the belt is
and adjustment again in a few days.
retightened)
15 - 16 mm (when the belt is new)

4. After completing adjustment, return the machine


to original condition.

30-42 GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]

GD555-5,GD655-5,GD675-5 30-43
(01)
Power train
Testing power train oil pressure

Power train 30-4


Testing power train oil pressure 30-4
a The following diagram shows the various points on the transmission where hydraulic pressure can be in-
spected.

30-44 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

a Testing instruments for power train hydraulic a Gear speed and clutch combinations
pressure Operating clutch pack No.
Symbol Part No. Part name FL FH R 1st 2nd 3rd 4th
1
799-101- 002 Hydraulic tester F1 w w
790-261-1204 Digital hydraulic tester F2 w w
K 2 799-401-2320 Hydraulic tester F3 w w
799-101-5220 Nipple (10 x 1.25 mm) F4 w w
3
07002-11023 O-ring
w w

Gear speed
F5
a Hydraulic pressure inspection points and gaug- F6 w w
es to be used F7 w w
Hydraulic pres- F8 w w
No. Measured hydraulic pressure sure gauge R1 w w
(MPa {kg/cm2}) R2 w w
Powertrain main relief pressure R3 w w
1 6.0 {60} R4 w w
(Main)
Torque converter inlet pressure
2 2.5 {25} Reference
(In)
q In order to protect the transmission, it is provided
Torque converter outlet pressure
3 1.0 {10} with functionality that prevents it jumping two
(Out)
Torque converter lockup clutch gear positions even if the gear shift lever does
4 6.0 {60} this.
pressure (L/U)
Transmission FL clutch pres- a) Example of gear shift lever action: F1 o F4
6 6.0 {60}
sure (FL) b) Transmission action: F1 o F3 o F4
6 Transmission FH clutch (FH) 6.0 {60} q The transmission only moves directly to the in-
Transmission R clutch pressure tended gear speed when the gear shift lever is
7 6.0 {60}
(R)
moved to the corresponding position from N.
Transmission 1st clutch pressure
8
(1st)
6.0 {60} a) Example of gear shift lever action: N o F4
Transmission 2nd clutch pres- b) Transmission action: N o F4
9 6.0 {60}
sure (2nd)
Transmission 3rd clutch pres-
10 6.0 {60}
sure (3rd)
Transmission 4th clutch pres-
11 6.0 {60}
sure (4th)

GD555-5,GD655-5,GD675-5 30-45
(01)
Power train
Testing power train oil pressure

Preparation work (for idle running of wheel) 30-46 k If the wheels are run and the brakes ap-
k Park the machine on flat, level ground, set plied with the rear wheels raised above
the gear shift lever to the P position, and se- the ground, there is a danger that the tan-
cure the wheels with chocks. dem could rotate as a result of brake reac-
a Test the power train oil pressure under the fol- tion. Accordingly, the brakes must not be
lowing condition. applied.
q Torque converter oil temperature:
Within operating range
k Whenever required to measure the torque
converter's lockup clutch pressure and any
of the transmission's clutch pressures as
part of hydraulic pressure inspection, follow
the procedure outlined below to prepare for
idle running of wheel by raising the rear
wheels off the ground.

1. Place chocks (21) in front of and behind each of


the front wheels in order to prevent the machine
from moving.

2. Start the engine, operate the right and left blade


lift cylinder levers, and place the blade down on
level ground.

3. Move the left blade lift cylinder in the direction of


lowering, and with the rear left wheel raised off
the ground, setup a block (22) or stand at the
bottom of the center of the left tandem case.

4. Next, move the right blade lift cylinder in the


direction of lowering, and with the rear right
wheel raised off the ground, setup a block or
stand at the bottom of the center of the right
tandem case.

5. Raise the blade off the ground temporarily, and


check that the rear wheels remain fully off the
ground. Following this, lower the blade to the
ground again and stop the engine.
k When the rear wheels have been raised
off the ground, setup notices or the like to
prevent anyone from approaching the
wheels.

30-46 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

Testing 30-47 2. Testing torque converter inlet pressure (In)


1. Testing powertrain main relief pressure (Main) k Ensure that the engine is stopped when
k Ensure that the engine is stopped when testing tools are being installed or re-
testing tools are being installed or re- moved.
moved. 1) Remove the cover from the top of the trans-
1) Remove the cover from the top of the trans- mission.
mission. 2) Connect the hydraulic tester K1 to the oil
2) Connect the hydraulic tester K1 to the oil pressure testing nipple (2) on the main relief
pressure testing nipple (1) on the main relief and torque converter relief valves.
and torque converter relief valves. a Use an oil pressure gauge of 2.5 MPa {25
a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
kg/cm2} .

3) Start the engine and keep the gear shift lever


3) Start the engine, keep the gear shift lever in in the P position.
the P position, and raise the torque converter 4) Test the torque converter inlet pressure with
oil temperature to the operating range. the engine at full speed.
4) Test the powertrain main relief pressure with
the engine at low speed and full speed.

5) After finishing measurement, remove the


testing tools and return the removed parts to
5) After finishing measurement, remove the their original position.
testing tools and return the removed parts to
their original position.

GD555-5,GD655-5,GD675-5 30-47
(01)
Power train
Testing power train oil pressure

3. Testing torque converter outlet pressure 4. Testing torque converter lockup clutch pres-
(Out) sure (L/U)
k Ensure that the engine is stopped when k Ensure that the engine is stopped when
testing tools are being installed or re- testing tools are being installed or re-
moved. moved.
1) Remove the cover from the top of the trans- 1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup mission and remove the oil pressure pickup
port plug (3) from the transmission case. port plug (4) from the lockup clutch valve
2) Install the hydraulic tester's nipple K3 and (ECMV).
connect the hydraulic tester K2. 2) Install the hydraulic tester's nipple K3 and
a Use an oil pressure gauge of 1 MPa {10 connect the hydraulic tester K1.
kg/cm2}. a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

3) Start the engine, keep the gear shift lever in 3) Start the engine and raise the torque
the P position, and raise the torque converter converter oil temperature to the operating
oil temperature to the operating range. range.
4) Test the torque converter outlet pressure 4) Set the transmission mode selector switch in
with the engine at full speed. lockup mode.
5) Operate the gear shift lever and run the rear
wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torque
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
a The gear shift lever can be selected to
any position other than P, N, or R1 to R4.
6) Run the rear wheels idle with the engine at
full speed, and test the lockup clutch oil pres-
5) After finishing measurement, remove the sure.
testing tools and return the removed parts to
their original position.

30-48 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

6) Run the rear wheels idle with the engine at


full speed, and test the FL clutch oil pressure.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position. 7) After finishing measurement, remove the
5. Testing transmission FL clutch pressure (FL) testing tools and return the removed parts to
k Ensure that the engine is stopped when their original position.
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (5) from the FL clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F1 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torque
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.

GD555-5,GD655-5,GD675-5 30-49
(01)
Power train
Testing power train oil pressure

6. Testing transmission FH clutch pressure


(FH)
k Ensure that the engine is stopped when
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (6) from the FH clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F2 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torque
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
6) Run the rear wheels idle with the engine at
full speed, and test the FH clutch oil pres-
sure.

30-50 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

7. Testing transmission R clutch pressure (R)


k Ensure that the engine is stopped when
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (7) from the R clutch valve (ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the R1 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
6) Run the rear wheels idle with the engine at
full speed, and test the R clutch oil pressure.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

GD555-5,GD655-5,GD675-5 30-51
(01)
Power train
Testing power train oil pressure

8. Testing transmission 1st clutch pressure


(1st)
k Ensure that the engine is stopped when
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (8) from the 1st clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F1 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torgue
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
6) Run the rear wheels idle with the engine at
full speed, and test the 1st clutch oil pres-
sure.

30-52 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

9. Testing transmission 2nd clutch pressure


(2nd)
k Ensure that the engine is stopped when
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (9) from the 2nd clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F3 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torgue
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
6) Run the rear wheels idle with the engine at
full speed, and test the 2nd clutch oil pres-
sure.

GD555-5,GD655-5,GD675-5 30-53
(01)
Power train
Testing power train oil pressure

10. Testing the transmission 3rd clutch pressure


(3rd)
k Ensure that the engine is stopped when
testing tools are being installed or re-
moved.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (10) from the 3rd clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F5 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torgue
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
6) Run the rear wheels idle with the engine at
full speed, and test the 3rd clutch oil pres-
sure.

30-54 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure

11. Testing transmission 4th clutch pressure


(4th)
k Ensure that the engine is stopped when
inspection devices are being installed or
removed.
1) Remove the cover from the top of the trans-
mission and remove the oil pressure pickup
port plug (11) from the 4th clutch valve
(ECMV).
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

7) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

3) Start the engine and raise the torque


converter oil temperature to the operating
range.
4) Set the transmission mode selector switch to
lockup mode.
5) Operate the gear shift lever to the F7 position
and run the rear wheels idle.
k Before starting the engine, check that
the rear wheels are completely raised
off the ground.
a When operating in lockup mode, torgue
converter mode will be adopted immedi-
ately before an engine stall, and there-
fore, the brake pedal should not be
applied.
6) Run the rear wheels idle with the engine at
full speed, and test the 4th clutch oil pres-
sure.

GD555-5,GD655-5,GD675-5 30-55
(01)
Power train
Adjusting transmission speed sensor

Adjusting transmission speed sensor 30-56


a The drawing shows installed positions of each speed sensor on the transmission.

k Park the machine on a level ground, place the 1. Input shaft speed sensor (connector: TM19)
gear shift lever in the P position, and put 2. Intermediate shaft speed sensor (connector:
chocks under the wheels. TM20)
a When the transmission speed sensors are re- 3. Output shaft speed sensor (connector: TM22)
moved and installed or the transmission is disas-
sembled and assembled, adjust each speed
sensor in the following procedure.

30-56 GD555-5,GD655-5,GD675-5
(01)
Power train
Adjusting transmission speed sensor

1. Adjusting input shaft speed sensor 2. Adjusting intermediate shaft speed sensor
1) Remove input shaft speed sensor (1), and 1) Remove intermediate shaft speed sensor (4),
after checking that there is no adhesion of and after checking that there is no adhesion
iron powder or flaws on the tip of the sensor, of iron powder or flaws on the tip of the
temporarily assemble it in its original posi- sensor, temporarily assemble it in its original
tion. position.
2 Threads of sensor: Liquid gasket 2 Threads of sensor: Liquid gasket
(LG-5) (LG-5)
2) Tighten sensor (1) until its tip lightly contacts 2) Tighten sensor (4) until its tip lightly contacts
the tooth tip of gear (2) of the input shaft. the tooth tip of gear (5) of the intermediate
3) Loosen sensor (1) 1/2 to one turn from the shaft.
position and besides, adjust so that the angle 3) Loosen sensor (4) 1/2 to one turn from the
formed by the lead wire of sensor (1) is within position and besides, adjust so that the angle
the angle shown in the drawing below. formed by the lead wire of sensor (4) is within
a Gap (a) of 0.75 to 1.5 mm is created be- the angle shown in the figure below.
tween the sensor tip and gear tooth tip. a Gap (b) of 0.75 to 1.5 mm is created be-
tween the sensor tip and gear tooth tip.

4) While fixing sensor (1), tighten nut (3).


3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} 4) While fixing sensor (4), tighten nut (6).
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

GD555-5,GD655-5,GD675-5 30-57
(01)
Power train
Adjusting transmission speed sensor

3. Adjusting output shaft speed sensor 4. Check of sensor input signal


1) Remove input shaft speed sensor (7), and Check that signals from each speed sensor are
after checking that there is no adhesion of normally inputted with "Real time monitoring
iron powder or flaws on the tip of the sensor, function" of the machine monitor.
temporarily assemble it in its original posi- a For the operating method, see "Special func-
tion. tions of machine monitor (EMMS)".
2 Threads of sensor: Liquid gasket q Monitoring code (all TRANSMISSION 1):
(LG-5) Input shaft: 31200-T/M SPEED:IN
2) Tighten sensor (7) until its tip lightly contacts Intermediate shaft: 31300-T/M SPEED:MID1
the tooth tip of gear (8) of the input shaft. Output shaft: 31400-T/M SPEED:OUT
k The speed other than that of the input
3) Loosen sensor (7) 1/2 to one turn from the
position and besides, adjust so that the angle shaft cannot be checked unless actual
formed by the lead wire of sensor (7) is within traveling of the machine or idle running of
the angle shown in the figure below. the rear wheels is performed.
a Gap (C) of 0.75 to 1.5 mm is created be- a For the method for idle running of the rear
tween the sensor tip and gear tooth tip. wheels, see the section of "Testing power-
train oil pressure".

4) While fixing sensor (7), tighten nut (9).


3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

30-58 GD555-5,GD655-5,GD675-5
(01)
Power train
Adjusting transmission speed sensor

GD555-5,GD655-5,GD675-5 30-59
(01)
Power train
Emergency escape method in case of transmission valve failure

Emergency escape method in case of transmission valve failure 30-60


a The drawing shows installed positions of each clutch valve (ECMV) on the transmission.

30-60 GD555-5,GD655-5,GD675-5
(01)
Power train
Emergency escape method in case of transmission valve failure

a Tools for emergency escape 3. Remove two solenoids (1) of the clutch valve to
Sym- be engaged.
Part No. Part name
bol a The solenoid is of hexagonal shape (width
1 794-423-1190 Plug across flat: 33 mm) and turn the solenoid
L
2 07002-22034 O-ring body to remove.
a Travel direction and clutch to be engaged
k Park the machine on a level ground, place the Forward and
Gear speed
gear shift lever in the P position, and put reverse Gear speed
Clutch
chocks under the wheels. Clutch
a If the clutch valve (ECM) of the transmission fails When travel-
FL 2nd F3
and the machine does not move, engage the ing forward
When travel-
transmission clutch in the following procedure R 2nd R2
ing reverse
for emergency escape.
k The engagement of the clutch in this method a As the lockup clutch (L/U) of the torque con-
must not be performed except for emergency verter is not engaged, the torque converter
escape. After completing emergency escape, turns into a torque converter mode regard-
immediately restore the condition to the orig- less of selection of the transmission mode
inal condition. selector switch.

1. Remove the transmission cover (upper and


lower) and clean around the clutch valve.
a Remove mud and dust clean so that foreign
material is not mixed in the clutch valve dur-
ing work.

2. Disconnect eight connectors on the solenoid


side of the torque converter and transmission
clutch valve.
k Leave all connectors disconnected so
that the clutch is not engaged suddenly
during travel.
a Connector No. of solenoid
q T24: FL clutch 4. Install plug L into a mounting hole of the sole-
q T25: FH clutch noid.
q T26: R clutch a Clean the plug completely to prevent foreign
q T27: 1st clutch material from being mixed and check that the
q T28: 2nd clutch O-ring is fitted before installation.
q T29: 3rd clutch a As the plug pushes the inside spool spring, it
q T30: 4th clutch becomes slightly heavy halfway, but tighten it
q T31: Lockup clutch until the stepped portion of the plug hits the
valve body.
3 Plug: 49.0 ± 5.0 Nm {5.0 ± 0.5 kgm}

GD555-5,GD655-5,GD675-5 30-61
(01)
Power train
Emergency escape method in case of transmission valve failure

5. Remove tire chocks and start the engine.


k As the transmission is engaged with F3 or
R2 when the engine is started, if the gear
shift lever is carelessly moved from the P
position, the parking brake is released
and the machine starts.

6. Operate the gear shift lever to the N position with


the brake pedal depressed and gradually
release the brake pedal to move to a safe place.
a If the parking brake cannot be released, see
"Emergency release method of parking
brake" to release it.
a After moving the machine, return the gear
shift lever to the P position, stop the engine
and put chocks under the tires.

7. When the work is completed, return the clutch


valve to its original condition promptly.

30-62 GD555-5,GD655-5,GD675-5
(01)
Power train
Emergency escape method in case of transmission valve failure

GD555-5,GD655-5,GD675-5 30-63
(01)
Power train
Flushing torque converter and trasmission circuits

Flushing torque converter and 3. Replacing transmission oil filter


trasmission circuits 30-64 1) Open the left side cover.
2) Loosen center bolt (4) to remove case (5).
k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
a Dust such as metal powder in the hydraulic cir-
cuits of the torque converter and transmission
shortens the life of the torque converter and
transmission and causes internal breakage.
To remove dust in the hydraulic circuit, perform
flushing in the following procedure.
a For measuring of the oil level and refilling of the
transmission case, see Operation and Mainte-
nance Manual.

1. When performing flushing


1) When metal powder flows into the circuit 3) Install a new cartridge for flushing.
because of damage to the torque converter,
transmission and hydraulic components.
4. Refilling transmission case
2) When the torque converter and transmission
1) Refill new oil through filler port (6) of the
are overhauled or modified.
transmission case up to the specified level
with the engine stopped.
5 Transmission case: 45 l (specified
2. Oil drain of transmission case
When oil remains in the transmission case, capacity)
remove drain plug (1) on the right side of the
2) After starting the engine and circulating oil,
machine and loosen drain plug (2) to drain oil.
recheck the level and adjust the oil level so
After drain, remove drain plug (3) to drain.
6 Transmission case
that it is at the specified level when the
engine runs at low idle.
45 l (refill capacity) 60 l (specified ca-
pacity)
a After drain is completed, tighten the drain
plugs.
3 Drain plug (1):
58.8 – 78.4 Nm {6.0 – 8.0 kgm}
3 Drain plug (2):
49.0 – 78.4 Nm {5.0 – 8.0 kgm}
3 Drain plug (3): 9.8 – 12.7 Nm {1.0 – 1.3
kgm}

30-64 GD555-5,GD655-5,GD675-5
(01)
Power train
Flushing torque converter and trasmission circuits

5. Performing flushing 8. Checking oil level in transmission case


1) Start the engine and repeat the gear shift After starting the engine and circulating oil,
lever operation at low idle for approximately recheck the level.
20 minutes.
a Set the transmission mode selector
switch into the torque converter mode.
k While firmly pressing the brake pedal,
slowly and securely operate the gear
shift lever between N and F8, and be-
tween N and R4.
a Increase the engine speed up to approxi-
mately 1,500 rpm from time to time.
a If the outside air temperature is low and
the engine coolant temperature gauge
does not rise to the white range, continue
the operation further.
2) Perform idle running of the vear wheels or
actual traveling of the machine for approxi-
mately 20 minutes.
a For the method for idle running of rear
wheels, see the section of "Testing pow-
ertrain oil pressure".
a Use all gear speeds from F1 to F8.
3) Repeat the same operation as in Item 1) for
approximately 20 minutes.

6. Replacing transmission oil filter


Replace the cartridge of the transmission oil filter
with a new one in the same procedure as in
Section 3.
q 714-07-28713: Cartridge
7. Replacing transmission last chance filter
1) Turn and remove filter case (7) and remove
element (8).
2) Replace element (8) with a new one and
install filter case (7).
q 569-15-51732 : Element
q 07000-A2060: O-ring
a If there is dust in the filter case, clean it.
a Apply a small amount of grease to the
outer circumference of the O-ring.
3 Filter case:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}

GD555-5,GD655-5,GD675-5 30-65
(01)
Power train
Testing and adjusting toe-in

Testing and adjusting toe-in 30-6

a When the front axle is disassembled and assembled or when straight travel stability is poor, test and adjust
toe-in in the following procedure.

Testing 30-6 Adjusting 30-6


1. Place the steering and leaning at the center posi- 1. If toe-in is not normal, adjust it with joint (1).
tion and park the machine on a level ground. a When the joint is rotated one turn, toe-in in-
a When parking, be sure to travel forward by creases or decreases by approximately 3
several meters before stopping so that un- mm.
necessary force is not applied to tires. 3 Lock nut: 490 – 686 Nm {50 – 70 kgm}
2. Measure height (h) from the road surface to the
center of the front wheel. 2. After completing adjustment, check toe-in again.
3. Put marks with a white marker pen on right and
left front wheels at the height measured in
section 2.
a Put cross (+) marks so that height and width
can be measured.
4. Measure dimension (a) between marks put on
the right and left front wheels.
5. Slowly move the machine forward, and when the
marks put on the right and left front wheels rotate
backward and are at the same height as that
measured in Section 2, stop the machine.
a Be sure to move the machine in the forward
direction.
6. Measure dimension (b) between marks of the
right and left front wheels.
7. Check toe-in (c).
q Specified toe-in (c) = (a) – (b) = -5 ± 1 mm

30-66 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing and adjusting toe-in

GD555-5,GD655-5,GD675-5 30-67
(01)
Power train
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]

Testing and adjusting differential 3) Start the engine and set the differential lock
lock-up oil pressure [machine with switch to ON (I position).
differential lock-up] 30-68 4) Test the outlet pressure of the differential
lock-up pump with the engine at full speed.
a Testing and adjusting tools for differential lock oil
pressure
Symbol Part No. Part name
799-101- 002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M 2 799-401-2320 Hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring

k Park the machine on a level ground, place the


gear shift lever in the P position, and put
chocks under the wheels.
a Test and adjust the differential lock oil pressure
under the following condition. 5) After finishing measurement, remove the
q Final drive case oil temperature: 60 – 80°C
testing tools and return the removed parts to
their original position.
Testing 30-68
1. Testing outlet pressure of differential lock-up 2. Measuring outlet pressure of differential
pump lock-up valve
1) Remove hose (1) of the differential lock valve 1) Remove hose (2) of the differential lock-up
inlet piping and use an adapter. valve inlet piping and use an adapter.

2) Install nipple M2 and connect oil pressure


gauge [1] of hydraulic tester M1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm 2}.

30-68 GD555-5,GD655-5,GD675-5
(01)
Power train
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]

2) Install nipple M2 and connect oil pressure Adjusting 30-69


gauge [1] of hydraulic tester M1. Adjusting differential lock-up relief valve
a Use an oil pressure gauge of 6 MPa {60 a Neither the outlet pressure of the differential
kg/cm2}. lock-up pump nor the outlet pressure of the valve
is normal (2.7 – 3.1 MPa {27.5 – 31.5 kg/cm2}),
adjust differential lock-up relief valve (3) in the
following procedure.

3) Start the engine and set the differential


lock-up switch to ON (I position).
4) Test the outlet pressure of the differential
lock-up pump with the engine at full speed. 1. While fixing adjustment screw (4), loosen lock
nut (5).
2. Adjust the pressure by turning adjustment screw
(4).
a If the adjustment screw is
q Turned clockwise, the pressure is in-
creased
q Turned counter clockwise, the pressure is
decreased.

3. While fixing adjustment screw (4), tighten lock


nut (5).

5) After finishing measurement, remove the


testing tools and return the removed parts to
their original position.

4. After completing adjustment, check that the oil


pressure is normal in the above-mentioned
testing procedure.

GD555-5,GD655-5,GD675-5 30-69
(01)
Steering system
Testing and adjusting steering oil pressure

Steering system 30-70


Testing and adjusting steering oil pressure 30-70
a Testing and adjusting tools for steering oil pres- 3. Start the engine and operate the steering
sure cylinder to the stroke end.
Symbol Part No. Part name
799-101- 002 Hydraulic tester 4. Measure the oil pressure when the steering
1
790-261-1204 Digital hydraulic tester
N cylinder is relieved with the engine at full speed.
799-203-2410 Adapter (M10 x 1.5)
2
07002-11023 O-ring

k Stop the machine on a flat ground, place the


gear shift lever in the P position, and put
chocks under the wheels.
a Test and adjust the steering oil pressure under
the following condition.
q Hydraulic oil temperature: 45 – 55°C

Testing 30-70
1. Remove pressure pickup port plugs (1) and (2)
of steering oil pressure and install adapter N2.

5. After finishing measurement, remove the


measuring tools and return the removed parts to
their original position.

Adjust 30-70
a Steering oil pressure (relief valve of the priority
valve) cannot be adjusted.

2. Install nipple [1] of hydraulic tester N1 and


connect it to oil pressure gauge [2].
a Use an oil pressure gauge of 40 MPa {400
kg/cm 2}.

30-70 GD555-5,GD655-5,GD675-5
(01)
Steering system
Testing steering cylinder oil leakage

Testing steering cylinder oil


leakage 30-71
a Testing tools for oil leakage amount from steer-
ing cylinder
Symbol Part No. Part name
Available on the
P 1 Measuring cylinder
market
k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
a Test and adjust the steering oil pressure under
the following condition.
q Hydraulic oil temperature: 45 – 55°C

1. Start the engine and extend the cylinder to be


tested so that it reaches the stroke end.

2. Disconnect hose (1) on the cylinder head side


and block the hose side by using a plug.
k Take care not to disconnect the hose on
the cylinder bottom side.
a Use the following part to block the hose side.
07376-70422 (plug #04)

3. Start the engine and relieve the steering at full


speed.
k Operate so that the cylinder to be tested is
relieved in the extending direction and be
careful not to operate in the opposite di-
rection.

4. Start testing the oil leakage 30 seconds after


relieving is started, and test for 1 minute.

5. After completing testing, return the condition to


its original condition.

GD555-5,GD655-5,GD675-5 30-71
(01)
Steering system
Bleeding air from steering circuit

Bleeding air from steering circuit 30-72


a If the steering cylinder was removed and in-
stalled or its piping was disconnected and con-
nected, bleed air in the following procedure.
a Be careful that during air bleeding work the oil
level in the hydraulic oil tank does not fall below
the specified level.

1. Perform extension and retraction operation of


the cylinder at engine low speed four to five
times.
k Stop the piston rod approximately 50 mm
before each stroke end. Do not cause the
relief.

2. While running the engine at low speed, move the


piston rod to the stroke end and relieve the oil.

30-72 GD555-5,GD655-5,GD675-5
(01)
Steering system
Bleeding air from steering circuit

GD555-5,GD655-5,GD675-5 30-73
(01)
Brake system
Testing and adjusting brake oil pressure

Brake system 30-74


Testing and adjusting brake oil pressure 30-74
a Testing and adjusting tools for brake oil pressure 3) Install the adaptor [1] (M14 x 1.5) of the
Symbol Part No. Part name hydraulic tester Q1 and connect it to the oil
799-101- 002 Hydraulic tester pressure gauge [2].
1
790-261-1204 Digital hydraulic tester a Use elbow (790-261-1231) or the equiva-
Q 793-520-1805 Brake test kit lent to ensure that the quick coupler does
2
790-438-1060 Nipple
not interfere with the frame.
3 799-401-3100 Adapter (Size 02)
a Use an oil pressure gauge of 40 MPa
k Park the machine on level ground, place the {400 kg/cm2}.
gear shift lever in the P position, and put
chocks under the wheels.
a Test and adjust the brake pressure under the fol-
lowing condition.
q Hydraulic oil temperature: 45 – 55°C

Testing 30-74
1. Measuring charge valve cut-in and cut-out
pressures
1) Release the remaining pressure in the wheel
brake circuit. For details, see "Releasing
remaining pressure from brake circuit".
k As high pressure remains in the accu-
mulator, the release of remaining pres-
sure must be carried out before
preparing for measurement. 4) Start the engine at low speed and build up
pressure inside the accumulator.
2) Remove the oil pressure pickup port plug (1)
a When the machine monitor's brake pres-
from the charge valve.
sure caution lamp turns off, the cut-in
pressure will still not have been reached;
therefore, continue operation at low
speed for another 1 to 2 minutes.
5) Measure the cut-in pressure with the engine
at full speed.
1] Repeatedly depress and release the
brake pedal to gradually lower the pres-
sure in the accumulator.
2] Measure the oil pressure at which the
needle on the pressure gauge [2] stops
dropping and starts to rise.

30-74 GD555-5,GD655-5,GD675-5
(01)
Brake system
Testing and adjusting brake oil pressure

6) Measure the cut-off pressure with the engine 2) Install the brake test kit Q2.
at full speed. 3) Bleed the air in the wheel brake circuit. For
1] Stop operating the brake pedal when the details, see "Bleeding air from brake circuit".
pressure starts to rise above the cut-in a Air bleeding is performed using the air
point. bleeder from the brake test kit Q2.
2] Measure the oil pressure at which the
needle on the pressure gauge [2] stops
rising.
7) After finishing measurement, remove the
testing tools and return the removed parts to
their original position.

4) Test the wheel brake's operation pressure.


1] Operate the engine at low speed for
several minutes, build up pressure inside
the accumulator, and then stop the
engine.
2] Measure the operation pressure corre-
2. Testing wheel brake operation pressure and sponding to full depression of the brake
pressure reduction pedal.
a The same procedure is used to test the 5) Inspect the degree of reduction in the wheel
brakes for all four wheels. brake's operation pressure.
1) Remove the brake piping cover from the a Before performing the test, check that the
tandem case and remove the air bleeder (2). wheel brake operation pressure is nor-
k As high pressure remains in the accu- mal.
mulator, operation of the brake pedal 1] Operate the engine at low speed for
must not be carried out when install- several minutes, build up pressure inside
ing or removing testing tools. the accumulator, and then stop the
engine.
2] Fully depress the brake pedal and
measure the corresponding brake pres-
sure.
a Keep the brake pedal in the de-
pressed condition for 5 minutes.
3] Test the hydraulic pressure after the five
minutes and calculate the degree of pres-
sure reduction.
6) After finishing measurement, remove the
measuring tools and return the removed
parts to their original position.
k Bleed air from the wheel brake circuit
after the testing tools have been re-
moved.

GD555-5,GD655-5,GD675-5 30-75
(01)
Brake system
Testing and adjusting brake oil pressure

3. Testing parking brake operating pressure 4) Operate the engine at low speed for several
1) Disconnect the parking brake valve's outlet minutes, build up pressure inside the accu-
hose (3). mulator, and then stop the engine.
k As high pressure remains in the accu- 5) Turn on the starter switch and test the opera-
mulator, operation of the gear shift le- tion pressure when the gear shift lever is
ver to any position other than P must moved to any position other than P.
not be carried out when installing or
removing the testing tools.

6) After finishing measurement, remove the


measuring tools and return the removed
2) Install adapter Q3 and connect the discon- parts to their origimal position.
nected hose again. k Bleed air from the parking brake cir-
3) Install the nipple [1] of the hydraulic tester Q1 cuit after the testing tools have been
and connect it to the oil pressure gauge [2]. removed.
a Use an oil pressure gauge of 40 MPa
{400 kg/cm2}.

30-76 GD555-5,GD655-5,GD675-5
(01)
Brake system
Testing and adjusting brake oil pressure

Adjusting 30-7
Adjusting charge valve cutout pressure
a If the cutout pressure for the charge valve (4) is
abnormal, adjust the PU relief valve (5) of the
charge valve (4) as described below.
a Adjustment of the PU relief valve (5) causes the
cutout pressure to change.

1. With the adjustment screw (6) fixed in place,


loosen the lock nut (7).

2. Adjust the oil pressure by turning adjustment


screw (6).
a If the adjustment screw is
q Turn clockwise to increase the pressure.
q Turn counter clockwise to reduce the
pressure.
a Amount of pressure adjustment per turn of
adjustment screw:
2.49 MPa {25.4 kg/cm2}
3. With the adjustment screw (6) fixed in place,
tighten the lock nut (7).
3 Lock nut: 11.8 – 16.7 Nm {1.2 – 1.7
kgm}

4. After finishing adjustment, check the hydraulic


pressure once again according to the above
procedure.

GD555-5,GD655-5,GD675-5 30-77
(04)
Brake system
Releasing remaining pressure from brake circuit

Releasing remaining pressure from brake circuit 30-78


k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
k High pressure in the accumulator normally
acts to the charge valve, accumulator , brake
valve and the parking brake valve in the
brake circuit. Therefore, discharge remaining
pressure in the following procedure before
disconnecting and connecting piping and re-
moving and installing component.
k Hydraulic oil in the accumulator acts be-
tween the brake valve and wheel brake only
when the brake pedal is depressed.
k Hydraulic oil in the accumulator acts be-
tween the parking brake valve and parking
brake only when the starting switch is turned
ON and the gear shift lever is set to other po-
sition other than the P position.

1. Repeat the depressing and releasing operation


of the brake pedal until no operating sound of the
brake is made.

2. After no operating sound of the brake is made,


repeat the depressing and releasing operation of
the brake pedal dozens of times further.

a The above operation completes remaining pres-


sure discharge, and to check that no remaining
pressure is left, slowly disconnect piping.

30-78 GD555-5,GD655-5,GD675-5
(01)
Brake system
Bleeding air from brake circuit

Bleeding air from brake circuit 30-79


k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
a When removing and installing the brake circuit
equipment, bleed air from the brake circuit in the
following procedure.
a For the wheel brake circuit, be sure to bleed air
in the order of the slack adjuster section and
wheel brake section.

1. Bleeding air from slack adjuster section of


wheel brake circuit
a Bleed air in the same procedure for both the 2) Run the engine at low speed.
front brake circuit and rear brake circuit.
3) Depress the brake pedal and hold it as it is.
1) Remove the upper cover of the left battery
4) Loosen air bleeder (2) approximately a half
case and connect an air bleeding hose to air
turn and drain oil mixed with air.
bleeder (1) of the slack adjuster.
5) When oil mixed with no air starts to flow out,
tighten air bleeder (2).
6) After completing air bleeding, return the
condition to its original condition.

3. Breeding air from parking brake circuit


1) Connect air bleeding hose [1] to air bleeder
(3) of the parking brake caliper.

2) Run the engine at low speed.


3) Depress the brake pedal and hold it as it is.
4) Loosen air bleeder (1) approximately a half
turn and drain oil mixed with air.
5) When oil mixed with no air starts to flow out,
tighten air bleeder (1).
6) After completing air bleeding, return the
condition to its original condition.
2) Run the engine at low speed.
3) Set the gear shift lever to the N position and
2. Bleeding air from wheel brake section of
hold it as it is.
wheel brake circuit
a Bleed air in the same procedure for front and 4) Loosen air bleeder (3) approximately a half
rear and right and left brakes. turn and drain oil mixed with air.
1) Remove the piping cover of the tandem case 5) When oil mixed with no air starts to flow out,
tighten air bleeder (3).
3 Air bleeder:
and connect air bleeding hose [1] to air
bleeder (2).
22.6 – 28.3 Nm {2.3 – 2.9 kgm}
(Target: 25.5 Nm {2.6 kgm})
6) After completing air bleeding, return the
condition to its original condition.

GD555-5,GD655-5,GD675-5 30-79
(01)
Brake system
Testing wheel brake disc wear

Testing wheel brake disc wear 30-80 3. Run the engine at low speed for a few minutes to
accumulate pressure in the accumulator and
k Park the machine on a level ground, place the then, stop the engine.
gear shift lever in the P position, and put
chocks under the wheels. 4. Depress the brake pedal with the engine
a Tests front and rear and right and left brakes in stopped and hold it as it is for a while.
the same procedure.
1. Remove the tire of the brake to be tested. 5. Push shaft (2) of the wear gauge into the tandem
case in a state of Section 4, and determine a
2. Loosen cap (1) of the wear gauge. wear amount by measuring its protrusion
a Do not loosen the nut on the tandem case amount (a).
side because it is for fixing the wear gauge. a When a brake disc is new, protrusion amount
(a) is set to approximately 5 mm.
a When protrusion amount (a) becomes zero,
the brake disc has reached the wear limit. It
is necessary to disassemble it and replace it
with a new one.

6. After finishing measurement, return the removed


parts to their original position.

<Reference>
q The wear gauge of the brake disc is set with ref-
erence to a new brake disc. Therefore, do not
make an adjustment without the brake disc re-
placed.
q For the adjusting method after replacement of
the brake disc, see the section of "Disassembly
and assembly of wheel brake assembly" in the
disassembly and assembly volume.

30-80 GD555-5,GD655-5,GD675-5
(01)
Brake system
Testing wheel brake disc wear

GD555-5,GD655-5,GD675-5 30-81
(01)
Brake system
Testing and adjusting parking brake

Testing and adjusting parking brake 30-82

k Park the machine on a level ground, place the 3. Adjusting pad clearance
gear shift lever in the P position, and put 1) Start the engine, accumulate pressure in the
chocks under the wheels. accumulator, and stop the engine.
2) Turn the starting switch ON and set the gear
1. Testing pad thickness shift lever to the N position.
1) Start the engine, accumulate pressure in the 3) Remove plug (3) and loosen lock nut (4).
accumulator, and stop the engine. 4) Set the brake caliper free once in the
2) Turn the starting switch ON and set the gear following procedure.
shift lever to the N position. 1] Loosen double nut (5) and loosen bolt (6)
3) Test front and rear pad (1) thickness (a)(b). approximately five times.
q When thickness (a)(b) is 3 mm or more:
2] Loosen lock nut (7) and loosen bolt (8)
The pads can be used as they are. approximately three times.
q When thickness (a)(b) is less than 3 mm:
a Pull the lock nut to the mount bracket
The pads cannot be used. Replace. side.
5) Screw in adjustment bolt (9) until front and
2. Testing pad clearance rear pads (1) hit disc (2).
1) Start the engine, accumulate pressure in the 6) Screw in bolt (8) until it hits urethane spring
accumulator, and stop the engine. (10) and further screw it in a half turn.
2) Turn the starting switch ON and set the gear 7) Tighten lock nut (7) to the mount bracket
shift lever to the N position. side.
3) Measure clearance (c) and (d) between front 3 Lock nut:
and rear pads (1) and disc (2). 242 – 302 Nm {24.7 – 30.8 kgm}
4) Calculate the total value of clearance. (Target: 272 Nm {27.7 kgm})
a If the total value of clearance (c+d) is 2.5
mm or more, adjustment of clearance is
necessary.
q Total value of clearance (c+d) when new:
0.5 – 0.8 mm

30-82 GD555-5,GD655-5,GD675-5
(01)
Brake system
Testing and adjusting parking brake

8) Loosen adjustment bolt (9) and adjust the


total value of clearance (a+b) of front and
rear pads (1).
q Total value of clearance (a+b): 0.5 – 0.8
mm
9) While applying the tip of bolt (6) to bracket
(11), adjust with double nut (5) so that clear-
ance (a)(b) between front and rear pads (1)
and disc (2) is equal, and fix double nut (5).
3 Double nut:
24.1 – 30.1 Nm {2.46 – 3.07 kgm}
(Target: 27.1 Nm {27.6 kgm})
10)Fix adjustment bolt (9) with lock nut (4).
3 Lock nut:
102.8 – 128.2 Nm {10.5 – 13.1 kgm}
(Target 115.5 Nm {11.8 kgm})
11)Re-check clearance (a)(b) between front and
rear pads (1) and disc (2).
12)Install plug (3).
13)Operate the gear shift lever to the P position
and check that there is no clearance between
front and rear pads (1) and disc (2).
a If the adjustment work exceeds 15 min-
utes, perform the operation of 1) - 2) half-
way, and after accumulating pressure in
the accumulator, continue the work.
14)Turn the starting switch OFF.

GD555-5,GD655-5,GD675-5 30-83
(01)
Brake system
Emergency release method of parking brake

Emergency release method of parking brake 30-84


3. Move the machine to a safe place by self-propel-
a If a malfunction arises in the electrical system or ling or towing it.
hydraulic system of the parking brake and the a After moving the machine, securely put
parking brake is not released, it can be released chocks under the tires.
temporarily in the following procedure.
k If a malfunction arises in the hydraulic sys- 4. After completing the parking brake repair, make
tem, it is probable that the brake does not a pad clearance adjustment, referring to the
function normally. Therefore, after releasing section of "Testing and adjustment parking
the parking brake, be sure to tow the ma- brake".
chine at low speed.
k Check surroundings for safety on a level
ground before performing the parking brake
release operation. When releasing the park-
ing brake on a downhill unavoidably in case
of emergency, be sure to securely put
chocks under the tires.

1. Remove plug (1).

2. Loosen locknut (2) and turn adjustment bolt (3)


counterclockwise.
a Turn the adjustment bolt until clearance is
created between the brake pads and disc.

30-84 GD555-5,GD655-5,GD675-5
(01)
Brake system
Emergency release method of parking brake

GD555-5,GD655-5,GD675-5 30-85
(01)
Brake system
Filling gas into brake accumulator

Filling gas into brake accumulator 30-86


3. Installation of charging tool R
a Gas filling tool of brake accumulator 1) Remove cover (1) of the accumulator and
Sym- remove the cap of valve (2).
Part No. Part name
bol
R 792-610-1700 Charging tool

a When gas in the accumulator is released or the


pressure of gas lowers, fill nitrogen gas in the fol-
lowing procedure.

1. Releasing remaining pressure in brake


circuit
1) Release the remaining pressure inside the
brake circuit. For details, see Testing and
adjusting, "Releasing remaining pressure
from brake circuit".
a This work is not necessary when gas fill-
ing work is performed with an accumula- 2) Screw charging tool R into valve (2) of the
tor alone. accumulator.
3) Connect hose [3] to charging tool R and
2. Preparation for chargin