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

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 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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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

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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

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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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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

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

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 DRAFT
Foreword and general information
Safety notice
2. Preparation work
1) Before adding oil or making any repairs, park
the machine on a hard and level ground, and
apply the parking brake and block the wheels
or tracks to prevent the machine from
moving.
2) Before starting work, lower the work equip-
ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equip-
ment from falling. In addition, be sure to lock
all the control levers and hang warning tag on
them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup
plug,loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful not
to get scalded. Wait for the oil and coolant to
cool before carrying out any work on the oil or
water circuits.
3) Before starting work, stop the engine. When
working on or around a rotating part, in partic-
ular, stop the engine. When checking the
machine without stopping the engine
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to
get caught in rotating parts or moving parts.
4) Before starting work, remove the leads from
the battery. Always remove the lead from the
negative (–) terminal first.
5) When raising a heavy component (heavier
than 25kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
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.
00-6
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal posi-
tions. Loosen those bolts gradually and alter-
nately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10)Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with new
parts. When installing hoses and wires, be
sure that they will not be damaged by contact
with other parts when the machine is oper-
ated.
11)When installing high pressure hoses and
tubes, make sure that they are not twisted.
Damaged hoses and tubes are dangerous,
so be extremely careful when installing
hoses and tubes for high pressure circuits. In
addition, check that connections of them are
correct.
12)When assembling or installing parts, always
tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speeds, be particularly careful to check that
they are installed correctly.
13)When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
15)Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16)If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
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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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 DRAFT
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 Various pressure sensors and NE speed
sensor
Examples)
Intake air pressure sensor in intake manifold:
PIM(125,170,12V140 engines)
Oil pressure sensor:POIL(125,170,12V140
engines)
Oil pressure switch(95,107,114 engines)
Ne speed sensor of flywheel housing:
NE(95-170,12V140 engines)
Ambient pressure sensor:
PAMB(125,170,12V140 engines)
q 95–170,12V140 engines
q Various temperature sensors
Examples)
Intake air temperature sensor in intake mani-
fold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Disconnect
Disconnect the connector by pulling lock (B) (on the
wiring harness side) of connector (2) outward.

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

2. Suction safety valve
1) Suction function
Function
q If the fan pump stops, the pressurized oil does
not flow into the motor.
q Since the motor continues to rotate with the force
of inertia, the pressure on the outlet side of the
motor increases.
q When the pressurized oil stops flowing in from
inlet port (P), suction safety valve (1) sucks in the
pressurized oil on the outlet side and supplies it
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
Engine and Cooling
Cooling fan pump
(2) When engine is stopped
q When the engine stops, the pump speed be-
comes 0 rpm.
q The pressurized oil from the pump is not sup-
plied to port (P).
q As the pressurized oil is not supplied to (MA)
side of the motor, the motor speed decreases
gradually to stop.
q If the motor shaft is rotated by the force of inertia
while the oil flow in port (P) is reducing, the pres-
surized oil in port (T) on the outlet side is sent by
suction safety valve (1) to (MA) side to prevent
cavitation.
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

3. Operation of reversible valve
1) When ON/OFF solenoid is de-energized
q When ON/OFF solenoid (1) is "de-energized",
the pressurized oil from the pump is shut off by
valve (2).
q Port (C) opens for the hydraulic tank circuit.
q Spool (3) is pushed to the right by spring (4).
q Port (MA) opens and pressurized oil flows in to
rotate the motor in normal direction (clockwise).
GD555-5,GD655-5,GD675-5
Engine and Cooling
Cooling fan pump
2) When ON/OFF solenoid is energized
q When ON/OFF solenoid (1) is "energized", valve
(2) is switched.
q The pressurized oil from the pump flows to spool
chamber (D) through port (C).
q The pressurized oil flowed in chamber (D) com-
presses spring (4).
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).
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)
q The oil sent from the ECMV flows through the oil
passage of shaft (1), is pressure-fed to the back
of piston (2), and pushes piston (2) to the right.
q Piston (2) compresses plates (3) and discs (4)
and the rotation of discs (4) is stopped by the
frictional force.
q As the internal teeth of discs (4) are meshed with
clutch gear (5), shaft (1) and clutch gear (5)
transfer the power in a body.
q The oil is drained from oil drain hole (6), but the
drain amount is less than the amount of oil sup-
plied, so there is no influence on the actuation of
the clutch.
10-36
When clutch is "disengaged" (released)
q When the oil sent from the ECMV is shut off, the
pressure of the oil exerted on the back of piston
(2) goes down.
q Piston (2) is pushed back to the left by reactive
force of wave spring (7).
q The friction force between plates (3) and discs
(4) is eliminated and shaft (1) and clutch gear (5)
are released.
q When the clutch is released, the oil on the back
of piston is drained by the centrifugal force
through oil drain hole (6) to prevent the clutch
from being partially engaged.
a Oil drain hole (6) is provided only with the 2nd,
3rd, and 4th clutches.
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

During filling (range B in chart)
q When current is applied to proportional solenoid
(1) with no oil in the clutch, the hydraulic force
balanced with the solenoid 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. When the clutch is filled with oil, pressure
detecting valve (4) actuates to turn "ON" fill
switch (5).
GD555-5,GD655-5,GD675-5
Power train system
ECMV
Pressure regulation (range C in chart)
q When current is passed to proportional solenoid
(1), the solenoid generates thrust in proportion to
the current. This thrust of the solenoid is bal-
anced with the sum of the thrust generated by
the oil pressure in clutch port and the reactive
force of pressure control valve spring (2), and
the pressure is settled.
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-
ing speed of the steering wheel.
q The steering pump delivery is reduced when the
steering wheel is turned at low speed, and the
former is increased when the latter is turned at
high speed.
q If the steering wheel is turned slowly during
high-speed travel, the steering pump delivery is
reduced and fine compensation of the steering is
possible, thus high steering performance is ob-
tained during high-speed travel.
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
3. Slack adjuster (right)
4. Main pump
5. Brake accumulator (right)
6. Brake accumulator (left)
7. Hydraulic tank
8. Priority valve
9. Wheel brake (rear)
11. Parking brake cylinder
12. Slack adjuster (left)
13. Stop lamp oil pressure switch
14. Accumulator charge valve
15. Hydraulic oil line filter
16. Parking brake, bank control valve

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

Operation
When the brake pedal is depressed
q Pistons (4) before the brake pedal is depressed
are returned as much as the distance corre-
sponding to stoke (S) (full stroke).
q When the brake pedal is depressed, the oil flow
from the brake valve is divided from slack adjust-
er port (P) to the left and right cylinders (2).
q Left and right pistons (4) moves to the left or right
as much as the distance corresponding to stroke
(S).
q The oil flow from port (C) to brake piston (7)
moves brake piston (7) as much as the distance
corresponding to stroke (S).
q As slack adjuster pistons (4) alone move, no
braking force is generated between the brake
piston and the disc; instead the clearance be-
tween them is reduced to zero.
GD555-5,GD655-5,GD675-5
Brake system
Slack adjuster
q When the pressure of the oil fed when the brake
pedal is depressed exceeds the set pressure of
check valve (3), check valve (3) opens to pres-
surize port (C), which acts on brake piston (7) as
a braking force.
q A time lag that is generated when braking stays
constant by the action of the slack adjuster.
When the brake pedal is released
q When the brake pedal is released, pistons (4)
are returned as much as the amount of oil corre-
sponding to stroke (S) by return spring (8) of the
brake and the brake is released.
q Return stroke (T) of brake pistons (7) is decided
by the oil volume for stroke (S) of the slack ad-
juster and the time lag when braking is kept con-
stant, regardless of wear of the brake disc.
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)
q If the pressure in port (P) (pump pressure)
rises above the set pressure, it compresses
spring (1) and moves ball (2) to the left.
q The pressure of the oil from the pump is
reduced across orifice (a), and the resulting
pressure difference compresses spring (3) and
moves valve (4) to the left largely.
q Port (P) being connected to port (T) drains the
pump pressure and, thereby, regulates the
maximum pressure in the charge circuit in
order to protect the circuit.
10-99-5
10-104
Shuttle valve (S1)
q When the pressure in port (ACC2) is higher
than that in port (ACC1), shuttle valve (1)
moves to the left to disconnect port (ACC2)
from oil passage (B).
q The open area between port (ACC1) and oil
passage (B) is increased and the oil is supplied
to the accumulator on port (ACC1) side.
q When the pressure in port (ACC1) is higher
than that in port (ACC2), the oil is supplied to
the accumulator on port (ACC2) side.
The oil from the pump is supplied first to the
low-pressure side of the 2 systems.
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
B1: To bank control cylinder
B2: To bank control cylinder
PB: To parking brake
T: To hydraulic tank
G2: Accumulator pressure pickup port
1. Bank control solenoid valve
2. Parking brake solenoid valve
3. Filter
4. Check valve
10-102
Outline
q The parking brake and bank control valve con-
tains a parking brake solenoid valve and a bank
control solenoid valve.
q If the parking brake solenoid is energized, the oil
is transmitted to the parking brake to release the
parking brake.
q If the bank control solenoid is energized, the oil
is transmitted to the bank control lock pin cylin-
der to move the lock pin in the pulling out direc-
tion.
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
q The cords of carcass (1) are arranged at right
angles to the center line of tread (T) (radially).
q Tread (T) is stabilized and protected by several
strong belts (2).
q Side wall (W) and tread (T) are independent from
each other.
Ground contact characteristics
q Even if the tire is deformed by a load, it avoids
wasteful behavior for ground contact surface,
and uniform ground contact surface is secured
stably.
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.
Structure
q The cords of carcass (1) are arranged bias
against the center line of tread (T).
q Side wall (W) and tread (T) are integral.
Ground contact characteristics
q If the tire is deformed by a load, the ground con-
tact surface is also deformed, leading to wasteful
behavior. As a result, the ground contact surface
becomes unstable.
Deformation characteristics
q Side wall (W) which receives loads and tread (T)
move together as one unit.

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
through the main pump to the priority valve.
2. The main pump serving as a hydraulic source for
the steering system and the work equipment
generates required pressure and oil flow
according to the demand ( LS pressure) from
relevant components.
Pump pressure = LS pressure + Control pres-
sure of 2.35 MPa {24 kg/cm2}
When the control levers are in NEUTRAL, the
pressure is set as follows : Steering LS pressure
of 0.8 – 1.1 MPa {8 –11 kg/cm2} + 2.35 MPa {24
kg/cm2} +Pipe pressure loss = 3.24 – 3.63 MPa
{33 – 37 kg/cm2}
10-110
3. Pressure loss due to the resistance to flow along
the way varies with temperature and, when there
is not enough control pressure at low tempera-
tures, required flow may not be ensured. To
prevent this, oil pressure (PP) in the vicinity of
each component is introduced to the main pump
and the main pump delivery is controlled so that
the differential pressure between (PP) and (LS)
is 2.35 MPa {24 kg/cm2}.
4. Using the PQ control in which the pressure and
delivery of the main pump are controlled to keep
the value PQ constant, the engine assuredly
provides a high torque at low rpms under
increased load or during combined operations.
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.
GD555-5,GD655-5,GD675-5

Steering circuit
1. The priority valve is designed to give flow priority
to the steering system that is closely related to
safety over the work equipment.
2. The steering valve of closed center hydraulic
system allows flow of hydraulic oil only when
necessary and does not allow it when the
steering wheel is not operated for energy saving
operation.
When the steering wheel is operated, pressure
(LS pressure) is transmitted to the servo valve of
the main pump through the LS regulating valve.
The main pump ensures required flow and
develops the Pb pressure (= LS + 25 +Pipe pres-
sure loss ). At the same time, the LS pressure is
transmitted to the priority valve and causes the
spool of the priority valve to stay at a position
where the required flow for the steering cylinder
circuit is ensured regardless of whether a flow
request from the work equipment is present,
3. The steering valve of Q-Amp type features
excellent controllability during high speed travel-
ling and ensures steering performance even if
the engine stops or the main pump fails.
4. Unlike the work equipment circuit pressure, the
maximum pressure of the steering circuit is
determined by the relief valve that is built in the
priority valve.
Brake circuit
1. The oil pressure from the brake pump is boosted
to a required value by the charge valve and
stored in the brake accumulator that is installed
in each of the dual brake circuits.
2. If the brake is applied and the pressure of the
brake circuit falls below the set pressure of 9.36
MPa {95 kg/cm2}, the charge valve is activated
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
Hydraulic system
Hydraulic system
4. As the pressure of the brake accumulator is
decreased, the parking brake release pressure
is decreased, which causes the parking brake to
be automatically applied by the force of spring. If
the machine is stopped for a certain period of
time, the parking brake will be automatically
applied, making it impossible to release the
brake until the engine is started.
5. The bank control lock pin is inserted or removed
to change the work equipment posture (to set the
blade to bank-cutting or shoulder reach posture).
The pressure of the brake accumulator is used
as a hydraulic source for these operations.
6. The brake pump is also hydraulic source for the
cooling fan motor.
LS pressure regulating valve
1. Since the main pump keeps delivering a
minimum flow to maintain quick response in the
quick steering operation and a quick response of
the work equipment, the control valve has an
unload valve.
2. During steering operations, the LS pressure of
the steering circuit increases and the main pump
delivery increases. This causes the Pb pressure
of the steering circuit and the priority valve func-
tions to deliver the remaining flow that has not
been taken up for steering to the control valve. If
the unload valve is open at this point in time, the
remaining flow is returned to the hydraulic tank
to result in loss of energy. When the work equip-
ment is not use, a signal pressure is transmitted
to the unload valve and the contral valve is put in
an loaded condition .As a result, the flow of oil to
the hydraulic tank is shut, and the remaining flow
is returned to the steering circuit, preventing loss
of energy.
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),
and shoe (4) slides on plane (A).
q Rocker cam (3) pivots on ball retainer (9), and
accordingly angle (a) between center line (X) of
rocker cam (3) and the axis of cylinder block (6)
changes.
q Angle (a) is called the swash plate angle.
q As center line (X) of rocker cam (3) matches the
axis of cylinder block (6) (swash plate angle = 0),
the difference between volumes (E) and (F) in-
side cylinder block (6) equals 0.
q The hydraulic oil is not sucked or discharged.
(Actually, however, the swash plate angle is not
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
A2: To leaning cylinder head
A3: To drawbar shift cylinder head
A4: To articulate cylinder
A5: To power tilt cylinder bottom
A6: To circle motor
A7: To blade shift cylinder bottom
A8: To L.H. blade lift cylinder bottom
A9: To optional actuator
B1: To R.H. blade lift cylinder head
B2: To leaning cylinder bottom
B3: To drawbar shift cylinder bottom
10-136
B4: To articulate cylinder
B5: To power tilt cylinder head
B6: To circle motor
B7: To blade shift cylinder head
B8: To L.H. blade lift cylinder head
B9: To optional actuator
LS: To LS pressure reducing valve LS (V) port
P1: From pump 1
P2: From pump 2
PP: To pump
T1, T2: To tank
TS: To tank (seal drain)
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
A3: To leaning cylinder head
A4: To drawbar shift cylinder head
A5: To articulate cylinder
A6: To power tilt cylinder bottom
A7: To circle motor
A8: To blade shift cylinder bottom
A9: To L.H. blade lift cylinder bottom
A10: To optional actuator
B1: To optional actuator
B2: To R.H. blade lift cylinder head
B3: To leaning cylinder bottom
B4: To drawbar shift cylinder bottom
B5: To articulate cylinder
B7: To circle motor
B8: To blade shift cylinder head
B9: To L.H. blade lift cylinder head
B10: To optional actuator
LS: To LS pressure reducing valve LS (V) port
P1: From pump 1
P2: From pump 2
PP: To pump
T1, T2: To tank
TS: To tank (seal drain)

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

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

Basic principle

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

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

LS relief valve
Function
q Even when LS pressure introduction and throttle
functions work, if other actuator relieves during
combined operation, the speed of the actuator is
slower than that in single operation.
q LS relief is adopted to prevent significant drop of
the actuator speed due to the relief of other ac-
tuator, that affects operation.
q Compact pilot relief valve mounted on LS circuit
controls the maximum pressure.
q Unload valve mounted on control valve works as
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
Hydraulic system
Functions and operation by valve
Operation
q If LS circuit pressure (PLS) increases and reach-
es the set pressure of LS relief valve (1), (PLS)
is kept at a constant level.
q Pump circuit (PP) pressure is set by [Spring
force + (PLS)] of unload valve (2).
q Pump circuit (PP) relief flow runs into tank circuit
(T) through unload valve (2). (Corresponding to
the minimum swash plate angle flow)
q Relief valve (3) functions as backing up LS relief
valve and as surge pressure absorbing valve.
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
q LS differential pressure (dPLS) for the control
valve is set higher than that for the steering
valve.
q With this hydraulic circuit, if steering operation is
performed, the pump delivery reaches the maxi-
mum, and the excessive flow is drained through
the unload valve of the control valve. This
causes a large energy loss.
q The LS pressure reducing valve reduces steer-
ing LS pressure to the same level as the LS dif-
ferential pressure of the control valve in order to
reduce the energy loss.
Operation
q Pump port pressure (PCF) and LS pressure
(PLS) (ST) are introduced from the steering
valve.
q Using pump port pressure (PCF) as a source
pressure, LS pressure (PLS) (V) is produced by
reducing the pressure corresponding the force of
spring (1) from LS pressure (PLS) (ST) and, is
introduced to the control valve.
q Check valve (2) prevents oil from flowing into the
steering valve through port (PP) when the work
equipment is operated.

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

1. Blade
2. Adjuster
3. Blade rail guide
4. Drawbar shift cylinder
5. Blade side shift cylinder
6. Power tilt cylinder
GD555-5,GD655-5,GD675-5
Work equipment
Blade
Function
q The side edge installed to the blade is structured
in such that it can be used twice if it is reversed
horizontally and vertically.
q The blade rail guide functions as a bushing for
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°.
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
2. Torque converter oil temperature gauge
3. Shift indicator
4. Fuel gauge
5. Engine speed indicator
6. Articulation indicator
7. Speedometer
8. Meter display indicator
9. Character display
10. Parking brake pilot lamp
11. Brake oil pressure caution lamp
12. Engine coolant temperature caution lamp
13. Engine oil pressure caution lamp
14. Engine oil level caution lamp (*1)
15. Engine pre-heating pilot lamp
16. Battery charge circuit caution lamp
17. Torque converter oil temperature caution lamp
18. Differential oil temperature caution lamp (*2)
19. Hydraulic oil temperature caution lamp
20. Emergency steering pilot lamp (*1)
21. RPM set pilot lamp
22. Water separator monitor
23. Maintenance caution lamp
24. Fan reverse rotation pilot lamp
25. Differential lock pilot lamp (*2)
26. Inching clutch overheat caution lamp
27. Economy operation pilot lamp
28. Turn signal pilot lamp (left)
29. Headlamp high beam pilot lamp
30. Front working lamp pilot lamp (*1)
31. Working lamp pilot lamp
32. Turn signal pilot lamp (right)
33. Centralized warning lamp
34. Blade float pilot lamp
35. Blade accumulator pilot lamp (*2)
36. Lift arm lock pin pilot lamp
37. P-mode pilot 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

perature
Testing exhaust gas color D
Adjusting valve clearance E
Testing compression
F
pressure
Testing blowby pressure
Testing engine oil pres-
H Pressure gauge: 60 MPa {600
sure
Testing fuel pressure K 2
Testing power train oil
K 790-261-1204 Digital hydraulic tester
pressure
Emergency escape
method in case of trans-
mission valve failure
1
Testing differential lock-up
oil pressure
M 2
Machine with differential
lock-up
3 Size:10 x 1.25 mm
Testing steering oil pres-
N
sure
Testing steering cylinder
oil leakage amount
799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
1 799-201-9001 Handy smoke checker 1
Available on the Bosch index: 0 – 9
2 Smoke meter 1
market
1 795-799-1131 Gear 1
Available on the
2 Clearance gauge 1 Intake: 0.33 mm, Exhaust: 0.71 mm
market
1 795-502-1590 Puller 1
2 795-799-6700 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
3 795-790-4410 Adapter 1 107E-1 engine
4 6754-11-3130 Gasket 1 107E-1 engine
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}
1
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
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
1
1 In common with H
2 799-401-2320 Hydraulic tester 1
794-423-1190 Plug 3
L
07002-22034 O-ring 3
799-101- 002 Hydraulic tester 1
790-261-1204 Digital hydraulic tester 1 In common with H
799-401-2320 Hydraulic tester 1
799-101-5220 Nipple 1
07002-11023 O-ring 1
799-101- 002 Hydraulic tester 1
1 In common with H1
790-261-1204 Digital hydraulic tester 1
799-203-2410 Adapter 1
2 Size:10 x 1.25 mm
07002-11023 O-ring 1
Available on the
P Measuring cylinder 1
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-

Testing/Adjusting item
bol
Troubleshooting for
engine controller, sen-
sors and actuators
Part No. Part name
799-601-4130 T-adapter
799-601-4130 T-adapter
799-601-4240 Socket
799-601-4250 Socket
799-601-4330 Socket
799-601- 9020 T-adapter
– 799-601-9030 T-adapter
799-60 -9040 T-adapter
799-601-9430 Socket
795-799-5530 Socket
795-799-5540 Socket
799 -601-4211 T-adapter
799-601-4220 T-adapter
Q'ty
Remarks
– For NE sensor
– For oil pressure sensor
– For ambient pressure sensor
– For boost pressure sensor
– For G sensor
– For injector
– For CAN
– For EGR valve position sensor
– For supply pump
For engine coolant temperature sen-
–
sor/fuel temperature sensor
– For boost temperature sensor
– Controller (50 poles)
– 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)

2. Testing low idle speed
1) Start the engine and hold the gear shift lever
in the P position.
2) Measure the engine speed with the acceler-
ator pedal released.
3. Testing high idle speed
1) Start the engine and hold the gear shift lever
in the P position.
2) Measure the engine speed with the acceler-
ator pedal depressed to the stroke end.
4. Testing torque converter stall speed
1) Start the engine and hold the gear shift lever
in the P position.
2) Switch the machine monitor function to the
display of "Torque converter stall" to prepare
for the torque converter stalled operation.
a The operating method, see "Special func-
tion of machine monitor (EMMS)".
a The engine speed is displayed on the up-
per row and torque converter oil tempera-
ture on the lower row.
5. Work after finishing testing
GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Testing engine speed
3) While firmly depressing the brake pedal, set
the gear shift lever to the F8 position.
4) Slowly depress the accelerator pedal to run
the engine at high speed with the torque
converter stalled.
k Keep the brake pedal firmly de-
pressed.
5) When the torque converter oil temperature
(lower row) reaches 90°C, return the accel-
erator pedal to the low idle position immedi-
ately and return also the gear shift lever to
the 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) While holding the gear shift lever in the P
position, run the engine at medium speed.
When the torque converter oil temperature
decreases to approximately 80°C, return
the engine to low idle.
7) Repeat the procedure 3) to 6) to make the oil
temperature of the torque converter and
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
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).
30-11
Engine and cooling system
Testing intake air pressure (boost pressure)
Testing intake air pressure (boost pressure)
a Testing tools for intake air pressure (boost pres-
sure)
Sym-
Part No. Part name
bol
1 799-201-2202 Boost gauge kit
B
2 790-301-1530 Elbow (R1/8xR1/8, 90°)
k Stop the machine on the level ground, set the
gear shift lever to the P position, and set
chocks to the tires.
k When installing and removing the testing in-
strument, take care not to touch a hot part of
the engine.
a Measure the intake air pressure (boost pres-
sure) 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. Open the right engine side cover and remove
intake air pressure pickup port plug (1) from the
intake connector.
2. Install the elbow B2 and nipple [1] of boost
gauge kit B1 and connect gauge [2].
30-12
30-12
3. Start the engine and run it at middle or higher
speed and discharge the oil from the hose.
a Insert the gauge connection into the hose
halfway and open the self-seal in the hose
connector. Repeating this action will drain
the oil.
a If Pm kit (A) is available, you may use the
air-bleeding coupling (790-261-1130) in that
kit.
a If oil is left in the hose, the gauge does not
work. Be sure to drain the oil.
4. Hold the gear shift lever in the P position and the
fuel control lever in the low idle position.
5. Switch the machine monitor function to the
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
(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
4. Procedure when conducting periodic testing
a Testing tools for exhaust temperature
Symbol Part No. Part name
C 799-101-1502 Digital thermometer
k Stop the machine on the level ground, set the
gear shift lever to the P position, and set
chocks to the tires.
k Install or remove the testing instrument after
the exhaust manifold temperature has low-
ered.
a Measure the exhaust temperature under the fol-
lowing condition.
q Coolant temperature: within operating range
q Torque converter oil temperature:
within operating range
q Hydraulic oil temperature: 45 – 55°C
1. Open the left engine side cover and remove the
heat insulation cover from the turbocharger.
2. Remove exhaust temperature pickup port plug
(1) from the exhaust manifold.
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
30-14
for Pm clinic, etc.
a In order to prevent the torque converter over-
heat, stabilize the exhaust temperature by a
full stall (torque converter stall + oil pressure
relief) operation, then run the engine with
only the torque converter stalled to perform
test.
1) Start the engine and hold the gear shift lever
in the P position and the accelerator pedal in
the low idle position.
2) Bring the right and left blade lift cylinders to
the RAISE storke end by the right and left
blade lift control levers.
3) Switch the machine monitor function to the
display of "Torque converter stall" to prepare
for the torque converter stalled operation.
a For the operating method, see "Special
function of machine monitor (EMMS)".
a The engine speed is displayed on the up-
per row and torque converter oil tempera-
ture on the lower row.
GD555-5,GD655-5,GD675-5
(01)
 Engine and cooling system
Testing exhaust gas temperature

4) While firmly depressing the brake pedal, set
the gear shift lever to the F8 position.
5) Slowly depress the accelerator pedal and run
the engine at high speed with the torque
converter stalled. At the same time, operate
the right and left blade lift control levers to the
lifting side to relieve oil pressure (bring the
machine to full stall condition).
k Keep the brake pedal firmly de-
pressed.
a Continue this operation until the exhaust
temperature reaches the standard value,
approx. 670°C.
5. Procedure when measuring the maximum
value in troubleshooting
Measure the maximum value of the exhaust
temperature when actually conducting work.
a The highest temperature is automatically re-
corded if the PEAK mode of the digital ther-
mometer is used.
a As the exhaust temperature differs greatly
depending on the ambient air temperature
(intake air temperature of the engine), correct
the value using the following formula if an ab-
normal value is recorded.
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
procedure.
a When the rocker arm for the exhaust valve
(EX side) of No. 1 cylinder is not moved by
hand, adjust valves with Q mark in the valve
layout drawing.
q When the rocker arm of the exhaust valve
(EX side) of No. 1 cylinder is moved by the
amount of valve clearance by hand, adjust
valves with q mark in the valve layout draw-
ing.
7. In the same manner as in procedure 5, rotate the
crankshaft in normal direction one turn by using
tool E1 and align wide slit (b) with top face (a) of
the protrusion.
8. Adjust the clearance of the remaining valves
according to procedure 6.
a When having adjusted valves with Q mark in
the layout drawing in procedure 4, adjust
valves with q mark. (When valves with q
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

10. Install a gasket F4 to the end of the adapter F3
and then insert the adapter into the injector
mounting bore.
11. Fix adapter F3 by using injector holder (8).
a Tighten the holder mounting bolts alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
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.
tools and return the machine to the original
condition.
a Install the injector and high pressure fuel
tube according to the following procedure.
1) Align the projection (a) on the injector with
the notch (b) in the holder, and install the
injector in the cylinder head.
a Install the injector with the above-men-
tioned mating part faced toward the fuel
inlet connector inserting side.

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
gear shift lever to the P position, and set
chocks to the tires.
k Very high pressure is generated in the
high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it pres-
ents a danger that could result in fire.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
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.
a If no fuel leakage is detected, check is com-
pleted.

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)

3) Connect the test hose [2] from the tester kit
W1 to the supply pump.
a Arrange the test hose so that it does not
slacken and put its end in a container.
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
cylinder W4.
a If the return rate from the supply pump is
in the following range, it is proper.
At low idle 400 cc
5) After completing the measurement, remove
the testing tools and return the machine to
the original condition.
GD555-5,GD655-5,GD675-5
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage
3. Testing the leak rate from the pressure
limiter
1) Disconnect the return hose (4) from the pres-
sure limiter section.
a Install the seal washer to the connector
bolt.
2) Install the disconnected connector bolt (5)
and the cap nut [1] from the tester kit W1 to
the return hose end in order to stop the
outflow of fuel.
3) At the common rail side, install the connector
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.
30-39
Engine and cooling system
Checking fuel delivery, return rate and leakage
4) Start the engine, and over a low-idling dura-
tion of 1 minute, measure the leak rate using
the measuring cylinder W4.
a If the leakage from the pressure limiter is
in the following range, it is proper.
At low idle
0 cc
(no leakage)
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.
a Install the seal washer to the connector
bolt.
30-40
2) At the cylinder head side, install the
connector W3 and connect the test hose [2]
from the tester kit W1, and put the end of the
hose in a container.
3) Install the disconnected connector bolt (7)
and the cap nut [1] from the tester kit W1 to
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
k If the engine cannot be started, you
may measure the fuel return rate
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}
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-
tioner compressor belt tension
[machines with air conditioner] 30-42
k Stop the machine on the level ground, set the
gear shift lever to the P position, and set
chocks to the fires.
Testing
1. Open the right engine side cover.
2. Measure deflection (a) when pressing the
midpoint of the compressor pulley and crank
pulley belt by a thumb.
q Belt pressing force: 98 N {10 kg}
q Deflection (a): 17 - 19 mm (when the belt is
retightened)
15 - 16 mm (when the belt is new)
30-42
Adjusting 30-42
1. Loosen locknut (1).
2. Turn adjusting nut (2) and displace compressor
(3) with the bracket as one to adjust belt tension.
a Be careful of overtension of the belt.
3. Tighten locknut (1) and fix compressor (3).
30-42 a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt with
V-groove.
a When the V-belt has so elongated that no al-
lowance for adjustment is left or it has a cut
or crack, replace it with a new one.
a When the V-belt is replaced, perform testing
and adjustment again in a few days.
4. After completing adjustment, return the machine
to original condition.
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)

Testing 30-47
1. Testing powertrain main relief pressure (Main)
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.
2) Connect the hydraulic tester K1 to the oil
pressure testing nipple (1) on the main relief
and torque converter relief valves.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2} .
3) Start the engine, keep the gear shift lever in
the P position, and raise the torque converter
oil temperature to the operating range.
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
their original position.
GD555-5,GD655-5,GD675-5
(01)
Power train
Testing power train oil pressure
2. Testing torque converter inlet pressure (In)
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.
2) Connect the hydraulic tester K1 to the oil
pressure testing nipple (2) on the main relief
and torque converter relief valves.
a Use an oil pressure gauge of 2.5 MPa {25
kg/cm2}.
3) Start the engine and keep the gear shift lever
in the P position.
4) Test the torque converter inlet pressure with
the engine at full speed.
5) After finishing measurement, remove the
testing tools and return the removed parts to
their original position.
30-47
Power train
Testing power train oil pressure
3. Testing torque converter outlet pressure
(Out)
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 (3) from the transmission case.
2) Install the hydraulic tester's nipple K3 and
connect the hydraulic tester K2.
a Use an oil pressure gauge of 1 MPa {10
kg/cm2}.
3) Start the engine, keep the gear shift lever in
the P position, and raise the torque converter
oil temperature to the operating range.
4) Test the torque converter outlet pressure
with the engine at full speed.
5) After finishing measurement, remove the
testing tools and return the removed parts to
their original position.
30-48
4. Testing torque converter lockup clutch pres-
sure (L/U)
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 (4) from the lockup 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 in
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-
sure.
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)

1. Adjusting input shaft speed sensor
1) Remove input shaft speed sensor (1), and
after checking that there is no adhesion of
iron powder or flaws on the tip of the sensor,
temporarily assemble it in its original posi-
tion.
2 Threads of sensor: Liquid gasket
(LG-5)
2) Tighten sensor (1) until its tip lightly contacts
the tooth tip of gear (2) of the input shaft.
3) Loosen sensor (1) 1/2 to one turn from the
position and besides, adjust so that the angle
formed by the lead wire of sensor (1) is within
the angle shown in the drawing below.
a Gap (a) 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}
GD555-5,GD655-5,GD675-5
(01)
Power train
Adjusting transmission speed sensor
2. Adjusting intermediate shaft speed sensor
1) Remove intermediate shaft speed sensor (4),
and after checking that there is no adhesion
of iron powder or flaws on the tip of the
sensor, temporarily assemble it in its original
position.
2 Threads of sensor: Liquid gasket
(LG-5)
2) Tighten sensor (4) until its tip lightly contacts
the tooth tip of gear (5) of the intermediate
shaft.
3) Loosen sensor (4) 1/2 to one turn from the
position and besides, adjust so that the angle
formed by the lead wire of sensor (4) is within
the angle shown in the figure below.
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 (4), tighten nut (6).
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
30-57
Power train
Adjusting transmission speed sensor
3. Adjusting output shaft speed sensor
1) Remove input shaft speed sensor (7), and
after checking that there is no adhesion of
iron powder or flaws on the tip of the sensor,
temporarily assemble it in its original posi-
tion.
2 Threads of sensor: Liquid gasket
(LG-5)
2) Tighten sensor (7) until its tip lightly contacts
the tooth tip of gear (8) of the input shaft.
3) Loosen sensor (7) 1/2 to one turn from the
position and besides, adjust so that the angle
formed by the lead wire of sensor (7) is within
the angle shown in the figure below.
a Gap (C) of 0.75 to 1.5 mm is created be-
tween the sensor tip and gear tooth tip.
4) While fixing sensor (7), tighten nut (9).
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
30-58
4. Check of sensor input signal
Check that signals from each speed sensor are
normally inputted with "Real time monitoring
function" of the machine monitor.
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
q Monitoring code (all TRANSMISSION 1):
Input shaft: 31200-T/M SPEED:IN
Intermediate shaft: 31300-T/M SPEED:MID1
Output shaft: 31400-T/M SPEED:OUT
k The speed other than that of the input
shaft cannot be checked unless actual
traveling of the machine or idle running of
the rear wheels is performed.
a For the method for idle running of the rear
wheels, see the section of "Testing power-
train oil pressure".
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)

Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]
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/cm2}.
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.
5) After finishing measurement, remove the
testing tools and return the removed parts to
their original position.
GD555-5,GD655-5,GD675-5
(01)
Power train
Adjusting 30-69
Adjusting differential lock-up relief valve
a Neither the outlet pressure of the differential
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.
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).
4. After completing adjustment, check that the oil
pressure is normal in the above-mentioned
testing procedure.
30-69
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
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.
2) Remove the oil pressure pickup port plug (1)
from the charge valve.
30-74
4) Start the engine at low speed and build up
pressure inside the accumulator.
a When the machine monitor's brake pres-
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)

6) Measure the cut-off pressure with the engine
at full speed.
1] Stop operating the brake pedal when the
pressure starts to rise above the cut-in
point.
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.
2. Testing wheel brake operation pressure and
pressure reduction
a The same procedure is used to test the
brakes for all four wheels.
1) Remove the brake piping cover from the
tandem case and remove the air bleeder (2).
k As high pressure remains in the accu-
mulator, operation of the brake pedal
must not be carried out when install-
ing or removing testing tools.
GD555-5,GD655-5,GD675-5
(01)
Brake system
Testing and adjusting brake oil pressure
2) Install the brake test kit Q2.
3) Bleed the air in the wheel brake circuit. For
details, see "Bleeding air from brake circuit".
a Air bleeding is performed using the air
bleeder from the brake test kit Q2.
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-
sponding to full depression of the brake
pedal.
5) Inspect the degree of reduction in the wheel
brake's operation pressure.
a Before performing the test, check that the
wheel brake operation pressure is nor-
mal.
1] Operate the engine at low speed for
several minutes, build up pressure inside
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.
30-75
Brake system
Testing and adjusting brake oil pressure
3. Testing parking brake operating pressure
1) Disconnect the parking brake valve's outlet
hose (3).
k As high pressure remains in the accu-
mulator, operation of the gear shift le-
ver to any position other than P must
not be carried out when installing or
removing the testing tools.
2) Install adapter Q3 and connect the discon-
nected hose again.
3) Install the nipple [1] of the hydraulic tester Q1
and connect it to the oil pressure gauge [2].
a Use an oil pressure gauge of 40 MPa
{400 kg/cm2}.
30-76
4) Operate the engine at low speed for several
minutes, build up pressure inside the accu-
mulator, and then stop the engine.
5) Turn on the starter switch and test the opera-
tion pressure when the gear shift lever is
moved to any position other than P.
6) After finishing measurement, remove the
measuring tools and return the removed
parts to their origimal position.
k Bleed air from the parking brake cir-
cuit after the testing tools have been
removed.
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
front brake circuit and rear brake circuit.
1) Remove the upper cover of the left battery
case and connect an air bleeding hose to air
bleeder (1) of the slack adjuster.
2) Run the engine at low speed.
3) Depress the brake pedal and hold it as it is.
4) Loosen air bleeder (2) approximately a half
turn and drain oil mixed with air.
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
k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
a Tests front and rear and right and left brakes in
the same procedure.
1. Remove the tire of the brake to be tested.
2. Loosen cap (1) of the wear gauge.
a Do not loosen the nut on the tandem case
side because it is for fixing the wear gauge.
30-80
3. Run the engine at low speed for a few minutes to
accumulate pressure in the accumulator and
then, stop the engine.
4. Depress the brake pedal with the engine
stopped and hold it as it is for a while.
5. Push shaft (2) of the wear gauge into the tandem
case in a state of Section 4, and determine a
wear amount by measuring its protrusion
amount (a).
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.
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
k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
1. Testing pad thickness
1) Start the engine, accumulate pressure in the
accumulator, and stop the engine.
2) Turn the starting switch ON and set the gear
shift lever to the N position.
3) Test front and rear pad (1) thickness (a)(b).
q When thickness (a)(b) is 3 mm or more:
The pads can be used as they are.
q When thickness (a)(b) is less than 3 mm:
The pads cannot be used. Replace.
2. Testing pad clearance
1) Start the engine, accumulate pressure in the
accumulator, and stop the engine.
2) Turn the starting switch ON and set the gear
shift lever to the N position.
3) Measure clearance (c) and (d) between front
and rear pads (1) and disc (2).
4) Calculate the total value of clearance.
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
30-82
3. Adjusting pad clearance
1) Start the engine, accumulate pressure in the
accumulator, and stop the engine.
2) Turn the starting switch ON and set the gear
shift lever to the N position.
3) Remove plug (3) and loosen lock nut (4).
4) Set the brake caliper free once in the
following procedure.
1] Loosen double nut (5) and loosen bolt (6)
approximately five times.
2] Loosen lock nut (7) and loosen bolt (8)
approximately three times.
a Pull the lock nut to the mount bracket
side.
5) Screw in adjustment bolt (9) until front and
rear pads (1) hit disc (2).
6) Screw in bolt (8) until it hits urethane spring
(10) and further screw it in a half turn.
7) Tighten lock nut (7) to the mount bracket
side.
3 Lock nut:
242 – 302 Nm {24.7 – 30.8 kgm}
(Target: 272 Nm {27.7 kgm})
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 charging tool R nitrogen cylinder (3).
1) Turn back handle [1] counterclockwise until it
stops.
2) Turn back handle [2] counterclockwise until it
stops.
3) Check that each connection of charging tool
R is fully tightened.

30-86 GD555-5,GD655-5,GD675-5
(01)
 Brake system
Filling gas into brake accumulator

4. Filling nitrogen gas q When the pressure is tested, filled gas slight-
1) When the valve of the nitrogen cylinder is ly decreases and the pressure drops. Refill
opened a little and nitrogen gas is discharged gas equivalent to the lost quantity..
at very low pressure, gas starts to be emitted
from handle [2]. Screw in handle [2] clock-
wise to stop the emission of gas.
a Perform the valve operation of the nitro-
gen cylinder little by little and slowly.
a Discharge start pressure
Approximately 0.2 – 0.3 MPa (2 – 3
kg/cm2)
2) Slowly turn handle [1] clockwise so as to
push valve (2) of the accumulator.
3) Gradually open the valve of the nitrogen
cylinder and gently fill nitrogen gas into the
accumulator.
a Close the valve of the nitrogen cylinder
halfway through filling from time to time
and check the indicated value when pres-
sure gauge [4] of the charging tool is sta-
bilized.
4) When nitrogen gas is filled into the accumu-
lator to the specified pressure, securely close
the valve of the nitrogen cylinder.
q Filling pressure:

3.4 ± 0.1 MPa {35 ± 1 kg/cm2} (at 20 ±

5 °C)
q Filling capacity: 3.75 l (Reference)
a The relationship between the filling pres-
sure of nitrogen gas and gas temperature
(C outside air temperature) is as follows.
Px = 35 x (273 + t)/(273 + 20)
(Px: Filling pressure [kg/cm2], t: Gas
temperature [°C])
a If nitrogen gas is filled on the high side,
gradually turn handle [2] counterclock-
wise to discharge gas.
5) Turn handle [1] fully counterclockwise and
close valve (2). Then, turn handle [2] coun-
terclockwise to discharge nitrogen gas in
charging tool R.

5. Removing charging tool R

1) Remove charging toolR from the accumu-
lator and nitrogen cylinder.
2) After checking that there is no gas leakage by
applying water or soapy water to valve (2),
install the cap of valve (2) and cover (1).

6. Testing after gas filling

q Test if the filling pressure is kept for approxi-
mately one week after gas filling using charg-
ing tool R.
q After that, test the pressure once a month or
once a half year depending on use condi-
tions.

GD555-5,GD655-5,GD675-5 30-87
(01)
Hydraulic system
Testing and adjusting work equipment oil pressure

Hydraulic system 30-8

Testing and adjusting work equipment oil pressure 30-8
3) Install nipple [1] of hydraulic tester S and
a Testing and adjusting tools for work equipment connect it to oil pressure gauge [2].
oil pressure a Use elbow (790-261-1231), etc. so that
Symbol Part No. Part name the quick coupler does not interfere with
799-101- 002 Hydraulic tester the frame.
S
790-261-1204 Digital hydraulic tester a Use an oil pressure gauge of 40 MPa
k Park the machine on a 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 work equipment oil pressure
under the following condition.
q Hydraulic oil temperature: 45 – 55°C

Testing 30-8
1. Preparation work
a The measuring point of work equipment oil
pressure is same as that of steering oil pres-
sure.
1) Remove transmission cover (1).

2. Measuring unload pressure

1) Start the engine.
2) Measure the oil pressure when all control
levers are set to the neutral position at full
speed.
a The oil pressure gauge indicates the
pressure when the unload valve of control
valve is activated.

2) Remove the work equipment pump pressure

pickup port plug (2).

30-88 GD555-5,GD655-5,GD675-5
(01)

3. Testing work equipment circuit relief pres-
sure (cylinder)
1) Start the engine and move the cylinder to be
measured to the stroke end.
2) Measure the oil pressure when the cylinder is
relieved at full speed.
a The oil pressure gauge indicates the
pressure when the main relief valve of the
control valve is activated.
4. Testing work equipment circuit relief pres-
sure (motor)
1) Start the engine and have the blade securely
cut into the ground.
2) Measure the oil pressure when the circle
rotation motor is relieved at high idle.
a The oil pressure gauge indicates the
pressure when the main relief valve of the
control valve is activated.
5. Work after finishing testing
After finishing measurement, remove the
measuring tools and return the removed parts to
their original position.
GD555-5,GD655-5,GD675-5
(04)
Hydraulic system
Testing and adjusting work equipment oil pressure
Adjusting 30-89
1. Adjusting unload pressure
a Unload pressure (unload valve of the control
valve) cannot be adjusted.
2. Adjusting work equipment circuit relief pres-
sure
a If the work equipment circuit relief pressure is
improper, adjust main relief valve (4) of the
control valve in the following procedure.
1) While fixing adjustment screw (5), loosen
lock nut (6).
2) Adjust the pressure by turnin adjustment
screw (5).
a If the adjustment screw is
q Turned clockwise, the pressure is in-
creased
q Turned conunterclockwise, the pres-
sure is decreased.
a Pressure adjustment amount per one turn
of adjustment screw:
10.2 MPa {104 kg/cm2}
3) While fixing adjustment screw (3), tighten
lock nut (4).
3 Lock nut: 58.5 – 78.5 Nm {6 – 8
kgm}
30-89
Hydraulic system
Testing and adjusting work equipment oil pressure

4) After finishing adjustment, recheck the oil

pressure in the above-mentioned testing
procedure.

30-90 GD555-5,GD655-5,GD675-5
(01)
 Hydraulic system
Testing and adjusting pump LS differential pressure

Testing and adjusting pump LS differential pressure 30-91

As the differential pressure is approximately
a Testing and adjusting tools for pump LS differen- 2.5 MPa {25 kg/cm2} at the maximum,
tial pressure measure while replacing the same gauge.
Symbol Part No. Part name
799-101- 002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Differential pressure
T 2 799-401-2701
gauge
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 pump LS differential pres-
sure under the following condition.
q Hydraulic oil temperature: 45 – 55°C

Testing 30-91
a To obtain the LS differential pressure, measure
the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and cal-
culate the difference.
3. Start the engine and measure the pump
discharge pressure and LS pressure (actuator
load pressure) simultaneously at full speed
under the following condition.
q Work equipment: When all are in neutral and

1. Open the right transmission cover and remove when in operation (Blade rotation is continu-
oil pressure pickup port plugs (1) and (2). ous and measuring is easy)
q Plug (1): Pump discharge pressure pickup
a When the work equipment is in operation,
port plug measure the oil pressure during operation
q Plug (2): LS pressure pickup port plug
while operating the lever through a full
stroke.
a Calculation of LS differential pressure (when
using an oil pressure gauge)
LS differential pressure = Pump discharge
pressure - LS pressure
a If the LS differential pressure is as follows, it
is normal.

Work equipment LS differential pressure

When all are in neu- Unload pressure

tral (See the standard value table.)
When work equip-
Specified LS differential pressure
ment is in operation
(See the standard value table.)
(half stroke)
2. Install nipple T3 and connect it to oil pressure
gauge [1] or differential pressure gauge T2 of
hydraulic tester T1.
a When using differential pressure gauge
Connect pump discharge pressure to the
high-pressure side (back side) and LS pres-
sure to the low-pressure side (lower side).
As the differential pressure gauge needs DC
12V power supply, connect it to one battery.
a When using oil pressure gauge
Use an oil pressure gauge of 1 MPa {40 MPa
{400 kg/cm2} in units of {10 kg/cm2}

GD555-5,GD655-5,GD675-5 30-91
(01)
Hydraulic system
Testing and adjusting pump LS differential pressure

4. After finishing measuring, remove the testing Adjusting 30-92

tools and return the removed parts to their orig- a If the LS differential pressure is improper, adjust
inal position. the LS valve (3) in the following procedure.
a When adjusting the LS valve, remove the upper
cover on the right side of the transmission.

1. While fixing plug (4), loosen lock nut (5).

2. Turn plug (4) for adjustment.

a If the plug is
q Turned clockwise, the differential pres-
sure is increased.
q Turned counterclockwise, the differential
pressure is decreased.
a Pressure adjustment amount per one turn of
plug (in LS differential pressure)
1.3 MPa {13.3 kg/cm2}
a Adjust while checking the LS differential
pressure in the above-mentioned testing.

3. While fixing plug (4), tighten lock nut (5).

3 Lock nut: 49 – 63.7 Nm {5 – 6.5 kgm}

4. After finishing adjustment, recheck that the LS

differential pressure is normal in the
above-mentioned testing procedure.

30-92 GD555-5,GD655-5,GD675-5
(01)
 Hydraulic system
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut]

Testing lift arm lock cylinder 3. Install adapter U2 and connect the disconnected
circuit oil pressure [machine with hoses again.
bank cut] 30-93
4. Install nipple [1] of hydraulic tester U1 and
a Testing tools for lift arm lock cylinder circuit oil connect it to oil pressure gauge [2].
pressure a Use an oil pressure gauge of 40 MPa {400
Sym- kg/cm2}.
Part No. Part name
bol
799-101- 002 Hydraulic tester
1
U 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size 02)

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 the lift arm lock cylinder circuit oil pressure
under the following condition.
q Hydraulic oil temperature: 45 – 55°C

1. Release the remaining pressure inside the brake

circuit. For details, see Testing and adjusting,
"Releasing remaining pressure from brake 5. Start the engine and measure the oil pressure
circuit".
k As pressurized oil in the brake accumula-
when the lift arm lock switch is operated at full
speed.
tor acts on the lift arm lock cylinder even a If the cylinder circuit pressure is as shown in
if the starting switch is in OFF position, do the table below, it is normal.
not prepare for the testing without releas- Lift arm
ing remaining pressure. lock pin Cylinder circuit pressure
pilot lamp
2. Disconnect hoses (1) and (2) from the lift arm Both are same as the parking
lock cylinder. When OFF brake operating pressure.
a As the lift arm lock cylinder operates by the (See the standard value table.)
pressure difference between the head side Bottom side: Same as the
parking brake operating pres-
and bottom side, measure both simultane-
sure
ously. When ON
Head side: The oil pressure
decreases compared to that of
the bottom side.

6. After finishing measurement, remove the testing

tools and return the removed parts to their orig-
inal position.

GD555-5,GD655-5,GD675-5 30-93
(01)
Hydraulic system
Testing work equipment cylinder oil leakage amount

Testing work equipment cylinder oil leakage amount 30-94

2. Testing drawbav side shift cylinder oil
a Testing tools for work-equipment cylinder oil leakage amount
leakage amount 1) Start the engine, move the drawbar side shift
Symbol Part No. Part name control lever to the right, and then extend the
Available on the drawbar side shift cylinder (2) to the end of its
V Measuring cylinder
market stroke.
k Park the machine on a level ground, set the 2) Disconnect the hose (3) on the cylinder's
gear shift lever to the P position, and secure head side and block it by using a plug.
the wheels with chocks. k Take care not to disconnect the hose
a Test oil leakage inside the work equipment cylin- on the cylinder bottom side.
der under the following conditions. a Use the following part to block the hose
q Hydraulic oil temperature: 45 – 55°C side.
07376-70315 (Plug #03)
1. Testing blade lift cylinder oil leakage amount
1) Start the engine, set the left and right blade
lift cylinder levers to the position for lowering,
and place the blade down on level ground.
2) Disconnect the drawbar connection section
and the rod end for the cylinder to be
inspected, and extend the cylinder to the end
of its stroke.
3) Disconnect hose (1) on the head side for the
cylinder to be inspected and block it 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. 3) Run the engine at full speed and relieve the
07376-70315 (Plug #03) circuit by performing drawbar right shift.
k Take care not to perform drawbar left
shift.
4) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
5) After finishing measurement, return the
removed parts to their original position.

4) Run the engine at full speed and relieve the

circuit by lowering the blade.
k Take care not to raise the blade.
5) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
6) After finishing measurement, return the
removed parts to their original position.

30-94 GD555-5,GD655-5,GD675-5
(01)

3. Testing blage side shift cylinder oil leakage
amount
1) Start the engine, move the blade side shift
control lever to the left , and then extend the
blade side shift cylinder (4) to the end of its
stroke.
2) Remove the left cylinder cover, disconnect
the hose (5) on the cylinder's head side, and
block it 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.
07376-70315 (Plug #03)
3) Run the engine at full speed and relieve the
circuit by performing blade left shift.
k Take care not to perform blade right
shift.
4) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
5) After finishing measurement, return the
removed parts to their original position.
GD555-5,GD655-5,GD675-5
(01)
Hydraulic system
Testing work equipment cylinder oil leakage amount
4. Testing power tilt cylinder leakage amount
(machines with power tilt blade)
1) Start the engine, move the power tilt control
lever to the large cutting angle position, and
then extend the power tilt cylinder (6) to the
end of its stroke.
2) Disconnect the hose (7) on the cylinder's
head side and block it 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.
07376-70315 (Plug #03)
3) Run the engine at full speed and relieve the
circuit by performing a power tilt large cutting
angle operation.
k Take care not to perform a power-tilt
small cutting angle operation.
4) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
5) After finishing measurement, return the
removed parts to their original position.
30-95
Hydraulic system
Testing work equipment cylinder oil leakage amount
5. Testing articulate cylinder leakage amount
1) Start the engine, operate the articulate
control lever, and then extend the articulate
cylinder (8) for test to the end of its stroke.
2) Disconnect the hose (9) on the head side for
the cylinder to be inspected and block it 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.
07376-70315 (Plug #03)
3) Run the engine at full speed and relieve the
circuit by extending the cylinder.
k Take care not to retract the cylinder.
4) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
5) After finishing measurement, return the
removed parts to their original position.
30-96
6. Testing leaning cylinder leakage amount
1) Start the engine, operate the leaning control
lever to the right leaning position, and then
extend the leaning cylinder (10) to the end of
its stroke.
2) Disconnect the hose (11) on the cylinder's
head side and block it 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.
07376-70315 (Plug #03)
3) Run the engine at full speed and relieve the
circuit by extending the cylinder.
k Take care not to perform left leaning.
4) Start testing the oil leakage 30 seconds after
relieving is started, and measure for 1
minute.
5) After finishing measurement, return the
removed parts to their original position.
GD555-5,GD655-5,GD675-5
(01)
 Hydraulic system
Bleeding air from work equipment circuit

Bleeding air from work equipment circuit 30-97

k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.

Bleeding air from hydraulic cylinder

a If the cylinder was removed and installed or its
piping was disconnected and connected, 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 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.

GD555-5,GD655-5,GD675-5 30-97
(01)
Work equipment
Clearance adjustment of drawbar ball joint

Work equipment 30-98

Clearance adjustment of drawbar
ball joint 30-98
k Part the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.
a When draw bar ball joint related parts are re-
placed or the draw bar does not move smoothly,
adjust clearance of the ball joint in the following
procedure.

1. Temporarily assemble ball joint (1) and holder

(2) to frame (3) with nut (4) without a shim
installed.
a Tighten four nuts (4) to the following torque.
3 Mounting nut: 58.8 – 73.6 Nm {6 – 7.5
kgm}

2. Measure clearance (a) of the tightened section

of nut (4) at four locations and calculate the
average value.

3. Determine the number of shims to be installed

from the average value of clearance (a).
q Shim thickness (mm): Average value of
clearance (a) + two shims
q Type of shim: 0.29 mm

4. Remove holder (2) and joint (1) from frame (3)

once.

5. Install selected shims, apply grease to ball joint

(1) and holder (2) and install them on frame (3).
3 Mounting nut:
588.4 – 1029.7 Nm {60 – 105 kgm}

6. Check that ball joint (1) moves smoothly.

a There must be no unusual noise caused by
looseness.

30-98 GD555-5,GD655-5,GD675-5
(01)
 Work equipment
Testing and adjusting circle guide clearance

Testing and adjusting circle guide clearance 30-9

k When the following condition is caused even
if an adjustment is made, replace the circle
guide.
q When clearance R between the circle and circle
guide is lost.
q When clearance between the tooth tip (or tooth
root) of the circle gear and tooth root (or tooth tip)
of the pinion gear of the circle rotator becomes
zero.

Testing 30-9
1. Testing vertical clearance
q Measure clearance P between the top face of
the circle and under surface of the draw bar
in the drawing with the blade suspended.
Standard clearance P: 1.5 ± 0.5 mm

2. Testing longitudinal clearance

q Measure clearance QF, QC, QR between the
circle and circle guide in the drawing with the
blade suspended and a force applied to the
rear.
Standard clearance QF (front): 0 mm
QC (center): 0.7 mm
QC (rear): 1.5 mm
Or QF = QR =1 mm
a GD555-5 has no B-B sectional view.

GD555-5,GD655-5,GD675-5 30-99
(01)
Work equipment
Testing and adjusting circle guide clearance

Adjusting 30-10 4) Standard clearance between the tooth tip of

1. Adjusting vertical clearance the circle gear and tooth root of the pinion
1) Raise the blade off the ground, remove bolts gear of the circle rotator is 1.5 to 3.0 mm.
(1), (5) and (9), remove circle guides (2), (6) 5) Return bolt (7) a quarter turn from the QC=0
and (10), and adjust with shims. condition and tighten lock nut (8). Then,
a Shim thickness:1 mm, 0.5 mm return circle guide (6) until it hits bolt (7) and
a Adjust the circle guide one by one. tighten bolt (5).
3 Bolt (5): 490.3 – 608 Nm {50 – 62
2. Adjusting longitudinal clearance kgm}
1) Lower the blade to the ground lightly, loosen 6) Check that the blade rotates even at right and
bolt (1) and lock nut (4), turn back bolt (3), left 90° high bank.
and spread out circle guide (2) to achieve
QF=0.
a Spread out right and left circle guides (2)
evenly.
2) Adjust clearance D between the end face of
the lower flange of the circle rotator and
sliding surface of the inner circumference of
the circle.
Standard clearance D: 20 – 22 mm

3) Tighten lock nut (4) and tighten bolt (1) from

the QF=0 condition.
3 Bolt (1): 490.3 – 608 Nm {50 – 62
kgm}

3. Adjusting transverse clearance

1) Loosen bolt (9) and lock nut (12), twist back
bolt (11), and spread out circle guide (10) to
achieve QR=0.
a Spread out right and left circle guides (10)
evenly.
2) Loosen bolt (5) and lock nut (8), turn back
bolt (7), and spread out circle guide (6) to
achieve QC=0.
a Spread out right and left circle guides (6)
evenly.
3) Return bolt (11) a half turn from the QR=0
condition and tighten lock nut (12). Then,
return circle guide (10) until it hits bolt (11)
and tighten bolt (9).
3 Bolt (9): 490.3 – 608 Nm {50 – 62
kgm}

30-100 GD555-5,GD655-5,GD675-5
(01)
 Work equipment
Testing and adjusting slip clutch type circle rotator

Testing and adjusting slip clutch

type circle rotator 30-101
k Park the machine on a level ground, place the
gear shift lever in the P position, and put
chocks under the wheels.

Testing 30-101
1. Remove mounting bolt (1) and cover (2).

2. Check that the internal tooth of worm wheel (3)

can be seen from the hole of P section.
a Check the clutch slip condition with rotation
of the worm wheel.
4. Set the engine speed to full speed and slowly
operate the circle rotation lever to check whether
the clutch slips.
q Check with rotation of worm wheel (3).
q When worm wheel (3) rotates but the blade
does not rotate, the clutch slips.
q When worm wheel (3) does not rotate, the
motor circuit is relieved.

Adjusting 30-101
1. When the clutch does not slip
1) Remove bolt (4) and holder (5) and add one
shim (6) of 0.2 mm.
2) Tighten holder (5) and bolt (4).
3. Push the blade against the ground so that the 3 Bolt (4):

circle does not rotate, or fix the blade edge. 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
q Method of lifting up front wheels
1] Lower the blade to the ground and extend
the blade lift cylinder until front wheels are
lifted of the ground.
2] Apply the parking brake.

GD555-5,GD655-5,GD675-5 30-101
(01)
Work equipment
Testing and adjusting slip clutch type circle rotator
3) Check whether the clutch slips in the testing
procedure.
4) Repeat section 1) - 3) until the clutch slips
and match the clutch to the slip limit.
5) When the clutch starts to slip, pull out one
shim (6) of 0.2 mm.
a When the shim adjustment is completed,
the clutch does not slip.
2. When the clutch slips
1) Remove bolt (4) and holder (5) and pull out
one shim (6) of 0.2 mm.
2) Tighten holder (5) and bolt (4).
3 Bolt (4):
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
3) Check whether the clutch slips in the "testing"
procedure.
4) Repeat section 1) - 3) until the clutch stops
slipping and match the clutch to the slip limit.
5) Pull out one shim (6) of 0.2 mm from the slip
limit.
a When the shim adjustment is completed,
the clutch does not slip.
30-102
3. Installation of cover
1) Install cover (2) and tighten bolt (1).
3 Bolt (1):
65.7 ± 6.8 Nm {6.7 ± 0.7 kgm}
Running-in work of clutch
q When the clutch disc is replaced with a new one,
perform running-in work of the clutch in the fol-
lowing procedure.
a When assembling a disc, apply GO#90 oil to
both sides of the disc.
1) Achieve the slip limit with adjustment proce-
dure 1 and 2.
2) Let the clutch slip by adding one shim of 0.2
mm.
3) Slip the clutch for 3.5 - 4.0 seconds.
q Engine speed: Full speed
q When the clutch slips for 3.5 to 4.0 sec-
onds, it rotates one turn.
4) Repeat section 3 every 3 minutes 20 to 25
times.
k When the clutch housing temperature
exceeds 50°C, interrupt the work until
it decreases to the normal tempera-
ture.
k When the clutch stops slipping half-
way, add one shim of 0.2 mm.
5) Wait until the clutch is cooled to the normal
temperature.
6) Match the clutch to the slip limit again (adjust-
ment procedure 1 and 2).
7) Set to shim thickness by pulling out one shim
of 0.2 mm so that the clutch does not slip.
a The above completes running-in.
GD555-5,GD655-5,GD675-5
(01)
 Work equipment
Filling gas into blade accumulator [machine with blade accumulator]

Filling gas into blade accumulator

[machine with blade accumulator]30-103
a When gas in the blade accumulator is released
or the pressure of gas lowers, fill nitrogen gas in
the following procedure.
a The procedure is same as that for the brake ac-
cumulator. For details, see the section of "Filling
gas into brake accumulator".
a The pressure and capacity are different between
the brake accumulator and blade accumulator.
For the blade accumulator, fill gas under pres-
sure at the following numerical values.

<Filling pressure and capacity>

2
q Filling pressure: 2.0 ± 0.1 MPa {20 ± 1 kg/cm }
(at 20 ± 5 °C)
q Filling capacity: 1 l (Reference)
a The relationship between the filling pressure of
nitrogen gas and gas temperature (C outside air
temperature) is as follows.
Px = 20 x (273 + t)/(273 + 20)
(Px: Filling pressure [kg/cm2], t: Gas tempera-
ture [°C])

GD555-5,GD655-5,GD675-5 30-103
(01)
Electrical system
Procedure for testing diodes
Electrical system
Procedure for testing diodes
2. When using analog multimeter
a The conductive direction of the single diode is in-
dicated on the surface of the diode as shown in
the diagram below.
1. When using digital multimeter
1) Set the multimeter in the diode range and
check the indicated value.
a When an ordinary multimeter is used, the
voltage of the internal battery is indicated.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (-) to the
cathode (N) of diode, and check the indicated
value.
3) Judge the condition of the diode by the indi-
cated value.
q The indicated value does not change: No
continuity (defective).
q The indicated value changes. Continuity
(normal) (See a mark.)
a In the case of a silicon diode, a value in
the range from 460 to 600 is indicated.
30-104
30-104
30-104
1) Set the multimeter in the resistance range.
2) Perform the following operation and check
the movement of the pointer.
1] Set red (+) test lead to diode anode (P)
side and black (-) test lead to cathode (N)
side.
2] Set red (+) test lead to diode cathode (N)
side and black (-) test lead to anode (P)
side.
3) Judge the condition of the diode by the move-
ment of the pointer.
q In the connection of the above 1] the
pointer does not move but in the connec-
tion of 2] it moves. Normal (However, the
magnitude of movement (resistance val-
ue) differs depending on the type of a
multimeter or selection of the measure-
ment range.)
q In either connection of above 1] or 2] the
pointer moves. Defective (internal short
circuit)
q In either connection of above 1] or 2] the
pointer does not move. Defective (Inter-
nal open circuit)
GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

Special functions of machine monitor (EMMS) 30-105

Display a Language shown in drawing in this manual and

1. Character display (16 digits, two rows)
Operation section
2. Machine monitor mode selector switch 1
U: Enter the input or selection, or perform the
funcition
t: Cancel, release, or enter the selection from
YES/NO
3. Machine monitor mode selector switch 2
>: Right-Next-Proceed
<: Left-Back-Return
a EMMS: Equipment Management Monitoring
display language on machine monitor
The display language on the machine monitor at
the time of shipment from the factory is set to
English (default), so characters in the drawings
are also displayed in English. However, the
display language can be selected from the
following seven languages if the language selec-
tion function is used. (The language can be
selected only in the operator mode.)
1) English, 2) Japanese, 3) German, 4) French,
5) Spanish, 6) Swedish and 7) Italian
System

GD555-5,GD655-5,GD675-5 30-105
(01)
Electrical system
Special functions of machine monitor (EMMS)

Machine monitor mode and flow of function (List of functions)

Operator mode Service mode

Service meter and odometer display function o Display function of electrical system failure history
1 11
(Standard operator mode screen) t [ELECTRIC FAULT]
< >OI<
+ Display function of mechanical system failure his-
UOIt [ID] 12 tory
[MACHINE FAULT]
>OI<
Operation information display Real-time monitoring function
2 13
(ON-OFF of display in service mode) [REAL-TIME MONITORING]
>OI < i >OI<
t Cylinder cutout test mode
3 Reverse travel odometer display function 14
[CYLINDER CUT-OUT]
>OI< >OI<
Maintenance monitor function and filter/oil No Injection Cranking Function
4 15
replacement time display function [NO INJECTION]
>OI< >OI<
Adjusting function
5 Telephone number input function 16
[TUNING]
>OI< >OI<
Maintenance monitor function
6 Language selecting function 17
[MAINTENANCE MONITOR]
>OI< >OI<
Speedometer or Gear speed display selection Operation information display function
7 18
function (*1) [OPERATION INFO]
>OI< >OI<
Option selecting function
8 Monitor brightness adjusting function 19
[OPTIONAL SELECTION]
>OI<
Forced low idle operation function
O [Automatic] 20
[ENG LOW IDLE]
>OI<
Torque converter stall function
9 Action code display function 21
[T/C STALL]
>O >OI<
Initializing function (exclusive for factory)
10 Failure code display function 22
[INITIALIZE]

Operator mode
a No.2 to 8 are displayed endlessly according to the switch operation.
a When a failure occurs, the display automatically shanges to No.9 regardless of the display of No.1 to 8.
a If the switch operation is not performed for 30 seconds or longer regardless of the current display, the dis-
play automatically:
q changes to No. 1: When no failure is occuring,
q changes to No. 9: When a failure occures.
a If the display is changed from No. 10 to No.1 by the switch operation, and if the switch operation is not
performed for 10 seconds or longer, the display automatically shanges to No. 9.

Service mode
a The No.11 to No.22 are displayed endlessly according to the switch operation.
a ID, once input and entered, is valid until the starting switch is turned OFF whichever mode the mode is
switched to.
*1: This function is displayed only when the optional non-SI unit system is selected at the time of shipment
from the factory.

30-106 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

Machine monitor mode and flow of function (indication on the caracter display)

GD555-5,GD655-5,GD675-5 30-107
(01)
Electrical system
Special functions of machine monitor (EMMS)
Operator mode function (outline)
a Only outline of the operator mode is described in
this section.
For detailed contents of each function and mode
and operating method, see "Operation and
Maintenance Manual".
1. Service meter and odometer display function
When the starting switch is turned to ON posi-
tion, the service meter is displayed on the upper
row and the odometer on the lower row after
self-check is finished.
a For details of the display method, see "Oper-
ation and Maintenance Manual".
a Press the U button to move to the second
layer.
2. Operation information display function
30-108
The fuel consumption related information can be
displayed on the machine monitor by the switch
operation.
1) Pressing the U button once displays the
amount of fuel consumed on the upper row
and average fuel consumption on the lower
row.
Pressing the t button once returns the
screen to the standard operator mode
screen.
2) In the 1) screen, pressing the > button once
displays the accumulated amount of fuel
consumed on the upper row and travel
distance on the lower row.
Pressing the < button once returns the
screen to the 1) screen, and pressing the t
button returns the screen to the standard
operator mode screen.
GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

3) In the 2) screen, pressing the > button once 3. Reverse travel odometer display function
displays the accumulated amount of fuel
consumed on the upper row and elapsed
time on the lower row.
Pressing the < button once returns the
screen to the 2) screen, and pressing the t
button once returns the screen to the stan-
dard operator mode screen.

The reverse travel odometer can be displayed

on the machine monitor by the switch operation.
a For details of the operating method and dis-
play method, see "Operation and Mainte-
nance Manual".
q > button: Proceed to the "Maintenance mon-
itor function" screen
q < button: Return to the "Operation informa-
4) In the 1), 2) and 3) screen, pressing the U
button once displays the reset screen, tion display function" screen
q t button: Return to the standard operator
pressing the U button on the reset screen
erases the data, and pressing the t button mode screen or alarm screen
does not reset but returns the screen to the
previous screen.

GD555-5,GD655-5,GD675-5 30-109
(01)
Electrical system
Special functions of machine monitor (EMMS)
4. Maintenance monitor function and filter/oil
replacement time display function
1) Filter/oil replacement time display function
(automatic display)
2) Maintenance monitor function (Selecting
When the filter/oil replacement time nears,
the machine monitor displays its information
to remind the operator to perform replace-
ment.
a The upper row displays the ID number
and the filter/oil to be replaced. The dis-
play “999h” shows the remaining time
until the next replacement. If the replace-
ment time is passed, ”-” is displayed.
The display range is from -999 to 9999
and the time is counted down and
stopped at -999. (The hours returns to
default by the reset operation.) Count-
down is made only when the engine is
running.
The display “9999” shows the number of
times replacement has been performed.
When countup is made and the number
reaches 9999, it is stopped at 9999.
a After initial display following the key ON
operation, the maintenance reminder is
displayed together with the maintenance
caution lamp for 30 seconds. (When 30
seconds elapses and the screen returns
to the standard operator mode screen
once, it is not displayed until the key is
turned to ON position again.) However,
the maintenace remainder is displayed
only when no warning is being raised.
a When a warning is being raised, the dis-
play switches to the specified screen.
When a warning is raised, it is also possi-
ble to move to the failure code display
screen by using the > button.
30-110
a When the warning is canceled within 30
seconds after self-check, the screen
changes to the maintenance reminder.
However, the display time of mainte-
nance reminder is limited to 30 seconds
after self-check.
When there are two or more maintenance
reminder items to be displayed, the
display shall be cyclic every three
seconds. When there are 10 or more
items, all are displayed once and then,
the display returns to the standard oper-
ator mode screen. The lighting period of
the maintenance caution lamp is equal to
that of maintenance reminder.
a For details of the display, see "Operation
and Maintenance Manual".
function)
In the machine monitor, when the filter/oil
replacement work is finished, the replace-
ment interval time can be reset by switch
operation.
a For details of the operating method and
display method, see "Operation and
Maintenance Manual".
a The replacement interval time can be set
in the service mode.
q > button: Proceed to the "Telephone
number input function" screen
q < button: Return to the "Reverse travel
odometer display function" screen
q t button: Return to the normal standard
operator mode screen or warning screen
q U button: Proceed to the "Maintenance
monitor item selection and display"
screen
GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

5. Telephone number input function 7. Speedometer or gear speed display seleting

function

The telephone number being set in the machine

monitor can be input, changed and canceled by
switch operation.
a The telephone number is displayed together
with "CALL" when action code "E03" is dis-
played.
a For details of the operating method and dis-
play method, see "Operation and Mainte-
nance Manual".
The machine monitor indicator is switched
between the speedometer display and gear
speed display by switch operation.
a This menu is displayed only when the non-SI
unit system is selected as option.
8. Monitor brighteness adjusting function

6. Language selecting function

The brighteness of monitor panel LCD1 and

LCD2 can be adjusted.
a For details of the operating method and dis-
A display language on the machine monitor can play method, see "Operation and Mainte-
be selected by switch operation. nance Manual".
a The language in the service mode, which is
not covered by the display selecting function,
is always displayed in English.
a For details of the operating method and dis-
play method, see "Operation and Mainte-
nance Manual".

GD555-5,GD655-5,GD675-5 30-111
(01)
Electrical system
Special functions of machine monitor (EMMS)

9. Action code display function

When an abnormality occurs in the machine, the

machine monitor automatically displays an
action code depending on the severity of the
abnormality to urge an operator to take an
appropriate action.
a The above diagram shows an example in
which action code "E03" and "CALL + tele-
phone number" are displayed alternately.
a When action codes "E01" and "E02" are dis-
played, "CALL + telephone number" is not
displayed.

30-112 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

a Action code and response an operator is urged to take

CALL + telephone Response an operator is urged to take (contents described in Operation and Main-
Action code
number tenance Manual)
q When a problem location is displayed and the maintenance caution lamp lights
up, perform maintenance on the displayed problem item when work is finished or
E01 Not displayed an operator changes.
q When "MAINTENANCE" is displayed together with "E01", check the failure code
and contact Komatsu distributor for repairs.
q When an overrun-related information is displayed, run the machine, cutting down
engine speed and machine speed.
q When an overheat-related information is displayed, stop the machine and run the
E02 Not displayed
engine at medium speed with no load.
q When the action code is displayed even after the action is taken, check the failure
code and contact Komatsu distributor for repairs.
q When this code is displayed, stop the machine immediately, check the failure
E03 Displayed
code and contact Komatsu distributor for repairs.

GD555-5,GD655-5,GD675-5 30-113
(01)
Electrical system
Special functions of machine monitor (EMMS)

10. Failure code display function q Section "A": Failure code

(4-digit location code + 2-digit symptom
code)
q Section "B": Controller code
(MON : Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
q Section "C": The system in which failure oc-
curred
a For details of the displayed failure code, see
the list of failure codes in "Troubleshooting
when a failure code is displayed (code dis-
play)".
a Note that the displayed information is partial-
ly different between the failure code display
function and failure history display function
When > button is pressed once with the action
(service mode).
code displayed on the machine monitor, the
failure code being generated is displayed.
q > button: A failure code is displayed.
a Failure codes detected in the past are
grouped into the electrical system failure and
mechanical system failure and are recorded
as a failure history. (For details, see the ser-
vice mode.)
a When multiple failures occur, press the > but-
ton further, and other failure codes are dis-
played.
a After pressing the > button to display all fail-
ure codes being generated, pressing the >
button further returns the screen to the ser-
vice meter and odometer display screen
(standard operator mode screen).
Pressing the > button again displays the
failure codes from the beginning.
a If no switch operation is performed for 30
seconds on this display screen, the screen
automatically changes to the action code dis-
play screen.
a In the failure code display function, the fol-
lowing information is displayed.

30-114 GD555-5,GD655-5,GD675-5
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Service mode function
Switching operation to service mode
a When using the service mode, perform the
following special operation to switch the
screen display.
1) Check of screen display
Check that the machine monitor is in the
operator mode, and that either "Service
meter and odometer" or "Action code" or
"Failure code" is displayed on the screen.
2) Display of ID input initial screen
Press the following two buttons simultane-
ously for five seconds or longer to display the
ID input initial screen.
q t button and < buttons
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
3) Input and entry of ID
Operate each button and input ID.
a ID : 6491
q > button: The number at the cursor pro-
ceeds
q < button: The number at the cursor re-
turns
q U button: The number at the cursor is en-
tered and the cursor moves to the right.
q t button: Return to the initial screen (see
the note)
Note: When the cursor is at the left end, the
screen returns to the operator mode screen.
Note: When the cursor is at a position other
than the left end, the cursor returns to the left
end.
a When no switch operation is performed
for 60 seconds or longer on the ID input
screen, the screen automatically returns
to the operator mode screen.
4) Display of service menu initial screen
Entering all four digits of ID displays the initial
screen of the service mode menu.
a Once input and entered, ID is valid until
the starting switch is turned to OFF posi-
tion.
30-115
Electrical system
Special functions of machine monitor (EMMS)

5) Selection of service mode menu 6) Finish of mode or function

When the > button or < button is pressed on The mode or function can be finished with
the menu screen, each menu of the service either of the following methods, with which-
mode is displayed in the following order ever function or at whichever layer the oper-
endlessly. ation is performed.
a The menu and information are displayed (1) When continuing the operation in other
in section "*". mode or function:
q > button: Proceed to the next menu Press the t button and return to the
q < button: Return to the previous menu mode screen or menu screen to be
(1) ELECTRIC FAULT: Electrical system used next.
failure history display function a Note that the t button on the
(2) MACHINE FAULT: Mechanical "YES/NO" screen serves as an
system failure history display function “Enter” key.
(3) REAL-TIMEM ONITOR: a If returning to the operator mode by
Real-time monitoring function mistake, operate again from the
(4) CYLINDER CUT-OUT: Cylinder above-mentioned procedure 1). (In
cutout test mode this case, ID input is not necessary.)
(5) NO INJECTION: No injection cranking (2) When finishing the operation completely
function Turn the starting switch to OFF position
without performing any other operations.
(6) TUNING: Adjusting function
(7) MAINTENANCE MONITOR
Maintenance monitor function
(8) OPERATION INFO: Operation infor-
mation display function
(9) OPTION SELECTION: Option selec-
tion function
(10) ENG LOW IDLE:
Forced low idle operation function
(11)T/C STALL :
Torque converter stall function
(12) INITIALIZE :
Initializing function (exclusive for
factory)

30-116 GD555-5,GD655-5,GD675-5
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11. Electrical system failure history display func-
tion [ELECTRIC FAULT]
The machine monitor records information of fail-
ures which occurred in the electrical system in
the past or information of an failure which is
occurring now as a failure record and displays
records when the following operation is
performed.
1) Selecting menu
Select "Electrical system failure history
display function" on the "Service Menu"
screen.
a The total number of the failure history re-
corded now is displayed on tht section
"**".
2) Display of failure history information
After selecting the menu, press the U button
to display the failure history information
recorded.
q U button: Perform the function
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
3) Failure history information to be displayed
The electrical system failure history display
function displays the following information.
q Section "1": Record number
q Section "A": Failure code
(4-digit location code + 2-digit symptom
code)
q Section "2" Number of occurrence (Num-
ber of occurrence of the same code in the
past)
q Section "3": Elapsed time 1 (Elapsed time
on the service meter from the point of time
when the failure occurred first)
q Section "4": Elapsed time 2 (Elapsed time
on the service meter from the point of time
when the failure occurred last)
a The failure code which is occurring now
flashes.
a For details of the displayed failure code,
see the list of failure codes in "Trouble-
shooting when a failure code is displayed
(code display)".
a Note that the displayed information is par-
tially different between the electrical sys-
tem failure history display function and
failure code display function (operator
mode).
a If no failure is logged, “-” is displayed on
all display sections.
30-117
Electrical system
Special functions of machine monitor (EMMS)

4) Switching of failure history display a The information of a failure which is

Pressing the > button or < button while the occurring now (flashing) cannot be
failure history information is displayed cleared.
switches information to other failure history
information recorded.
q > button: Proceed to the information of
the next record number
q < button: Return to the information of the
previous record number
a When the display of the failure history in-
formation is switched in succession, the
“all clear menu screen” is displayed last.

5) Clearing individual failure history information

1] Pressing the U button while the failure
history information to be cleared is
displayed displays the “individual clear
screen”.
q U button: Displays the clear menu
2] Operate the button according to the
screen instruction.
q < button: Select YES
q > button: Select NO
q t button: Enter the selection
a The information of a failure which is
occurring now (flashing) cannot be
cleared.
12. Mechanical system failure history display
function [MACHINE FAULT]
The machine monitor records information of fail-
ures which occurred in the mechanical system in
the past or information of an failure which is
occurring now as a failure record and displays
records when the following operation is
performed.
1) Selecting menu
Select "Mechanical system failure history
display function" on the menu screen in the
service mode.
a The total number of the failure history re-
corded now is displayed on the section
"**".

6) Clearing all failure history information

1] Pressing the > button or < button while
the failure history information is displayed
displays the “all clear menu screen”.
a When the display of the failure history
information is switched in succession,
the “all clear menu screen” is dis-
played last.
2] Pressing the U button once displays the
“all clear menu screen”.
q U button: Perform the "clear all oper-
ation"
3] Operate the button according to the
screen instruction.
q < button: Select YES
q > button: Select NO
q t button: Enter the selection

30-118 GD555-5,GD655-5,GD675-5
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 Electrical system
Special functions of machine monitor (EMMS)

2) Display of failure history information

After selecting the menu, press the U button
to display the failure history information
recorded.
q U button: Perform the function

3) Failure history information to be displayed

The mechanical system failure history
display function displays the following infor-
mation..
q Section "1": Record number
q Section "A": Failure code
(4-digit location code + 2-digit symptom
code)
q Section "2": Number of occurrence (Num-
ber of occurrence of the same code in the
past)
q Section "3": Occurrence time 1 (Service
meter time at the point of time when a fail-
ure occurred first)
q Section "4": Occurrence time 2 (Service
meter time at the point of time when a fail-
ure occurred last)
a The failure code of a failure which is oc-
curring now flashes.
a For details of the displayed failure code,
see the list of failure codes in "Trouble-
shooting when a failure code is displayed
(code display)".
a Note that the displayed information is par-
tially different between the mechanical
system failure history display function and
failure code display function (operator
mode).

GD555-5,GD655-5,GD675-5 30-119
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Electrical system
Special functions of machine monitor (EMMS)

a If no failure is logged, “-” is displayed on

all display sections.

4) Switching of failure history display

Pressing the > button or < button while the
failure history information is displayed
switches information to other failure history
information recorded.
q > button: Proceed to the information of
the next record number
q < button: Return to the information of the
previous record number
q t button: Return to the "Mechanical sys-
tem failure history display function"
screen
5) Clearing failure history information (inhibited)
a The mechanical system failure history in-
formation cannot be cleared.

13. Real-time monitoring function

[REAL-TIME MONITOR]
The machine monitor can monitor the condition
of the machine in real time by receiving signals
from various switches, sensors, and actuators
installed to many parts of the machine.
The real-time monitoring function can perform
the following two types of displays.
q single item display (by selecting a controller)
q 2-item simultaneous display (by inputting the
codes)

1) Selecting menu
Select "Real-time monitoring function" on the
menu screen of the service mode.

30-120 GD555-5,GD655-5,GD675-5
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 Electrical system
Special functions of machine monitor (EMMS)

2) Displaying sub menu 4) Setting single item monitoring

After selecting the menu, press the U button 1] Select a controller system to be moni-
to display the initial screen of the sub menu. tored on the sub menu screen.
q U button: Perform the function

2] After selecting the sub menu, press the

U button to display the initial screen of
3) Selecting sub menu the monitoring information.
When the > button or < button is pressed on q U button: Perform the sub menu func-
the menu screen, the sub menu is displayed tion
in the following order endlessly.
a The sub menu is displayed in the section
"*".
q > button: Proceed to the next menu
q < button: Return to the previous menu
(1) MONITOR PANEL: Machine monitor
system
(2) TRANSMISSION1: Transmission
controller system 1
(3) TRANSMISSION2: Transmission
controller system 2
(4) ENGINE: Engine controller system
(5) 2 ITEMS : 2-item display
q U button: Proceed to each item display 3] Press the > button or < button to select
screen the item to be monitored.
q t button: Return to the "Real-time moni- q > button: Proceed to the next item
toring function" screen q < button: Return to the previous item
q t button: Return to the "Sub menu"
selection screen
a Monitoring items are scroll displayed
according to the order of internal set-
ting.
a When the button continues to be
pressed, items are scrolled at high
speed.
a Pressing the U button stops update of
the displayed data. (Data freeze)
Data freeze is canceled by pressing
the U button and pressing other
button.
The U button flashes during data
freeze.

GD555-5,GD655-5,GD675-5 30-121
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Electrical system
Special functions of machine monitor (EMMS)
5) Displayed information by single item moni-
toring
On the single item monitoring screen, the
following information is displayed.
q Section "A": Item display
q Section "1": Monitoring code (5 digits)
q Section "2": Monitoring data (including
units)
a The monitoring data screen;
q displays the numerical value and unit
in the case of the numerical value, and
q displays characters in the case other
than the numerical value.
a For details, see the list of monitoring
codes.
6) Setting of 2-item simultaneous monitoring
1] Select "2 ITEMS" on the sub menu
screen.
30-122
2] After selecting the sub menu, press the
U button to display the monitoring code
input screen.
q U button: Perform the sub menu func-
tion
3] Operate each button and directly input
monitoring codes of two items to be moni-
tored.
q > button: The number at the cursor
proceeds
q < button: The number at the cursor re-
turns
q U button: The number at the cursor is
entered
q t button: Return to the code input
screen
a When the monitoring code on the left
is entered, the cursor moves to the
monitoring code on the right.
4] When both monitoring codes are entered,
the screen switches to the 2-item display
screen.
GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

5] Displayed information by 2-item simulta-

neous monitoring
On the 2-item simultaneous monitoring
screen, the following information is
displayed.
q Section "1": Monitoring code 1
q Section "A": Monitoring data 1 (includ-
ing units)
q Section "2": Monitoring code 2
q Section "B": Monitoring data 2 (includ-
ing units)
a The monitoring data screen;
q displays the numerical value and unit
in the case of the numerical value, and
q displays characters in the case other
than the numerical value.
a For details, see the list of monitoring
codes.

6] Holding and canceling monitoring data

When the U button is pressed during
monitoring, the monitoring data is held
and the U mark flashes.
Pressing the U button again returns the
state to an active state.
q t button: Return to the "2 ITEMS"
screen

GD555-5,GD655-5,GD675-5 30-123
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Electrical system
Special functions of machine monitor (EMMS)

List of monitoring codes

MONITOR PANEL [Machine monitor system]
Monitoring
No. Real-time monitor item Display item Data display range Unit
code
1 Part number PART NUMBER 20227 -
SERIAL NUM-
2 Serial number 20402 -
BER
XXXXRYYY [3 - 10 digits of the part
3 Monitor software part number VERSION 20200 -
number is displayed]
4 Application version VERSION(APP) 20221 8 digits -
5 Data version VERSION(DATA) 20222 8 digits -
6 Engine speed ENG SPEED 01001 0 – 3000 rpm
7 Fuel level FUEL SENSOR 04201 0 – 150 z
8 Fuel level FUEL SENSOR 04200 0.00 – 5.00 V
9 Engine coolant temperature COOLANT TEMP 04103 -40 – 210 °C
10 Battery charge ALTERNATOR R 04302 0.0 – 30.0 V
11 Input signal D_IN_0-7 D-IN--0------7 40921 01010101 -
12 Input signal D_IN_8-10 D-I- 8-10 40922 01000000 -
13 Output signal D_OUT_0-1 D-OUT-01 40925 01000000 -
Accumulator pressure switch (F 1: ON (there is pressure) 0: OFF(4.2
14 ACC OIL PRE F 35500 -
side) MPa or less)
Accumulator pressure switch (R 1: ON (there is pressure) 0: OFF(4.2
15 ACC OIL PRE R 35501 -
side) MPa or less)
16 Differential oil temp. DIFF TEMP 31907 1: ON (120° or higher) 0: OFF -

30-124 GD555-5,GD655-5,GD675-5
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 Electrical system
Special functions of machine monitor (EMMS)

TRANSMISSION 1 [transmission controller system 1]

Monitoring
No. Real-time monitor item Item display Data display range Unit
code
1 Part number PART NUMBER 20414 -
2 Serial number: SERIAL NUMBER 20413 -
Transmission controller software XXXXRYYY [3 - 10 digits of the part
3 VERSION 20201 -
part number number is displayed]
4 Application version VERSION (APP) 20223 8 digits -
5 Data version VERSION (DATA) 20224 8 digits -
6 Alternator R ALTERNATOR R 04301 1: ON (activation) 0: OFF -
7 Articulated angle sensor (voltage) ARTICULATE 43902 0.00 – 5.10 V
8 Differential control relay output DIFF RELAY 31903 1: ON (activation) 0: OFF -
9 Differential lockup switch DIFF LOCK SW 31904 1: ON (activation) 0: OFF -
10 Differential oil temperature DIFF TEMP 31909 0 – 150 °C
Differential oil temperature (input
11 DIFF TEMP 31910 0 – 5.00 V
voltage value)
12 ECMV output command value (1st) ECMV 1 DIR 31602 0 – 1000 mA
13 ECMV output detected value (1st) ECMV 1 31612 0 – 4000 mA
14 ECMV output command value (2nd) ECMV 2 DIR 31603 0 – 1000 mA
15 ECMV output detected value (2nd) ECMV 2 31613 0 – 4000 mA
16 ECMV output command value (3rd) ECMV 3 DIR 31604 0 – 1000 mA
17 ECMV output detected value (3rd) ECMV 3 31614 0 – 4000 mA
18 ECMV output command value (4th) ECMV 4 DIR 31605 0 – 1000 mA
19 ECMV output detected value (4th) ECMV 4 31615 0 – 4000 mA
ECMV output command value
20 ECMV H DIR 31600 0 – 1000 mA
(HIG)
21 ECMV output detected value (HIG) ECMV H 31610 0 – 4000 mA
ECMV output command value
22 ECMV L DIR 31601 0 – 1000 mA
(LOW)
23 ECMV output detected value (LOW) ECMV L 31661 0 – 4000 mA
24 ECMV output command value (L/U) ECMV L/U DIR 31609 0 – 1000 mA
25 ECMV output detected value (L/U) ECMV L/U 31642 0 – 4000 mA
ECMV output command value
26 ECMV REV DIR 31606 0 – 1000 mA
(REV)
27 ECMV output detected value (REV) ECMV REV 31616 0 – 4000 mA
28 Engine mode output ENG MODE SEL 41601 Display the reception data as it is -
29 Inching clutch load 1 INCHING LOAD1 44100 0 – 32767 -
30 Inching clutch load 2 INCHING LOAD2 44101 0 – 32767 -
31 Inching clutch load 3 INCHING LOAD3 44102 0 – 32767 -
32 Inching pedal potentiometer INCHING PEDAL 44105 0.00 – 5.10 V
33 KEY SW C terminal KEY SW C 32300 1: ON 0: OFF -
34 Shift indicator SFT INDICATOR 91102 N, F1 – F8, – R4, E, P -
Transmission shift lever
35 SFT PNFR_NP 91101 1: ON 0: OFF -
(PNFR_NP)
Transmission shift lever
36 SFT 12345678 91104 1: ON 0: OFF -
(12345678)
Transmission shift lever Display F1 – F8, R1 – R4, N, P, E
37 SHIFT LEVER 91103 -
position (value recognized by lever)
38 Gear shift mode switch SHIFT MODE SW 41700 1: ON 0: OFF -
T/C oil temperature (temperature
39 T/C OIL TEMP 30100 0 – 160 °C
converted value)
T/C oil temperature (input voltage
40 T/C OIL TEMP 30101 0.00 – 5.00 V
value)
T/C oil temperature (temperature
41 T/M OIL TEMP 32500 0 – 150 °C
converted value)
T/C oil temperature (input voltage
42 T/M OIL TEMP 32501 0.00 – 5.00 V
value)
43 T/M input shaft speed T/M SPEED : IN 31200 0 – 65535 rpm
T/M SPEED :
44 T/M intermediate shaft (1) speed 31300 0 – 65535 rpm
MID1
45 T/M output shaft speed T/M SPEED : OUT 31400 0 – 65535 rpm
46 Output of throttle upper limit THROTTLE LIMIT 44200 0 – 100 %
0 – 16 (data from T/M controller is
47 Gear shift mode state TM SHIFT MODE 38700 -
displayed as it is)
48 Cooling fan speed FAN SPEED 10009 0 – 3000 rpm

GD555-5,GD655-5,GD675-5 30-125
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Electrical system
Special functions of machine monitor (EMMS)

49 Fan output command value FAN EPC DIR 41400 0 – 1000 mA

50 Fan output detected value FAN EPC 41401 0 – 1000 mA
51 Hydraulic oil temperature HYD OIL TEMP 04410 0 – 150 °C
Hydraulic oil temperature (input
52 HYD OIL TEMP 04402 0 – 5.00 V
voltage value)
53 Input signal D_IN_0-7 D-IN--0-----7 40905 01010101 -
54 Input signal D_IN_8-15 D-IN--8-----15 40906 01010101 -
55 Input signal D_IN_16-23 D-IN-16-----23 40907 01010101 -
56 Input signal D_IN_24-31 D-IN-24-----24 40908 01010101 -
57 Input signal D_IN_32-39 D-IN-32-----39 40942 01010101 -
58 Output signal D_OUT_0-7 D-OUT-0----7 40949 01010101 -
59 Output signal D_OUT_8-15 D-OUT-8----15 40950 01010101 -
60 Output signal D_OUT_16-23 D-OUT-16---23 40951 01010101 -

TRANSMISSION 2 [transmission controller system 2]

Monitoring
No. Real-time monitor item Item display Data display range Unit
code
1 Fill SW FILL R1234LH 31520 1: ON 0: OFF -
2 Fill time (1) FILL TIME 1 41802 0.00 – 2.55 S
3 Fill time (2) FILL TIME 2 41803 0.00 – 2.55 S
4 Fill time (3) FILL TIME 3 41804 0.00 – 2.55 S
5 Fill time (4) FILL TIME 4 41805 0.00 – 2.55 S
6 Fill time (H) FILL TIME H 41801 0.00 – 2.55 S
7 Fill time (L) FILL TIME L 41800 0.00 – 2.55 S
8 Fill time (R) FILL TIME R 41806 0.00 – 2.55 S
9 Initial learning flag TRIF R1235LH 38918 1: ON 0: OFF -
10 1st clutch trigger correction amount TRIGGER MOD 1 38902 00000000 – FFFFFFFF -
2nd clutch trigger correction
11 TRIGGER MOD 2 38903 00000000 – FFFFFFFF -
amount
12 3rd clutch trigger correction amount TRIGGER MOD 3 38904 00000000 – FFFFFFFF -
13 4th clutch trigger correction amount TRIGGER MOD 4 38905 00000000 – FFFFFFFF -
High clutch trigger correction
14 TRIGGER MOD H 38901 00000000 – FFFFFFFF -
amount
Low clutch trigger correction
15 TRIGGER MOD L 38900 00000000 – FFFFFFFF -
amount
Rev clutch trigger correction
16 TRIGGER MOD R 38906 00000000 – FFFFFFFF -
amount

30-126 GD555-5,GD655-5,GD675-5
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 Electrical system
Special functions of machine monitor (EMMS)

ENGINE [Engine controller system]

Monitoring Monitoring item Display item Data display range Unit
No.
code (*1) (*2) (*3) (*4)
Condition
1 20400 Hardware serial number ECM S/N Arabic numeral
display
2 03200 Battery power supply POWER SUPPLY 0.0–480.0 V
3 01002 Engine speed ENG SPEED 0–4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP -40–210 °C
5 04105 Coolant temperature sensor voltage COOLANT TEMP 0.00–5.00 V
6 36400 Common rail pressure RAIL PRESS 0–400 Mpa
7 36402 Common rail pressure sensor voltage RAIL PRESS 0.00–5.00 V
8 37400 Ambient pressure AMBIENT PRESS -99.9–999.9 kPa
9 37402 Ambient pressure sensor voltage AMBIENT PRESS 0.00–5.00 V
10 18500 Charge air temperature CHG TEMP -50–200 °C
Charge air temperature sensor volt-
11 18501 CHG TEMP 0.00–5.00 V
age
12 36500 Boost Pressure CHG PRESS-A -99.9–999.9 kPa
13 36502 Charge pressure sensor voltage CHG PRESS-A 0.00–5.00 V
14 18700 Engine output torque OUTPUT TORQUE -24000–24000 Nm
15 36700 Converted torque TORQUE RATIO 0–100 %
16 31706 Final throttle position FINAL THROTTLE 0–100 %
17 37300 Instantaneous fuel consumption FUEL RATE 0.0–999.9 l/h
Final injection quantity command INJECT COM-
18 18600 0–1000 mg
(weight) MAND
19 36300 Final injection timing command TFIN INJECT TIMING -180.0–180.0 CA
20 31701 Throttle position THROTTLE POS 0–100 %
21 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00–5.00 V
Condition
22 18300 Idle validation signal 1 IVS 1 ON/OFF
display
Condition
23 18301 Idle validation signal 2 IVS 2 ON/OFF
display
24 18900 ECM internal temperature ECM IN TEMP -40–210 °C
Final common rail pressure command PRESS COM-
25 36200 0–400 Mpa
PFIN MAND
Condition
26 17500 Engine power mode POWER MODE 0–4
display
Condition
27 18800 WIF sensor condition WATER IN FUEL ON/OFF
display
The transmitted value is
Selected machine model name (top 8 displayed as it is. Condition
28 00400 MACHINE ID (H)
digits) (top 8 digits of 16 charac- display
ters)
The transmitted value is
Selected machine model name (bot- displayed as it is. Condition
29 00401 MACHINE ID (L)
tom 8 digits) (top 8 digits of 16 charac- display
ters)
The transmitted value is
Condition
30 20216 Build version BUILD VER displayed as it is (8 char-
display
acters).
The transmitted value is
Condition
31 20217 Calibration Data version CAL VER displayed as it is (8 char-
display
acters).
*1: Even if no sensor is installed due to the difference in the machine model or in the optional device
installed, all the items are displayed.
*2: The display is shortened due to restriction of the number of character display segments.
*3: The value out of the display range is displayable as "-----".
*4: Values with a unit are all displayed in the SI unit.

GD555-5,GD655-5,GD675-5 30-127
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Electrical system
Special functions of machine monitor (EMMS)
14. CYLINDER CUT-OUT TEST MODE
[CYLINDER CUT-OUT]
The machine monitor is equipped with an engine
cylinder cutout test mode which turns a given
cylinder (injector) into a no-injection state as a
troubleshooting method of the engine.
1) Starting engine
a Leave the engine running during the test
because this function determines a failed
cylinder by a change in engine speed
when cylinder is cut out.
2) Selecting menu
1] Select "CYLINDER CUT-OUT" on the
menu screen of the service mode.
2] After selecting the menu, press the U
button to display the cylinder selection
screen.
q U button: Perform the function
a The cylinder Number and engine
speed are simultaneously displayed.
30-128
3) Selecting cylinder to be cut out
Operate each button and select a cylinder to
be cut out.
q > button: The selection cursor moves to
the right.
q < button: The selection cursor moves to
the left.
q U button: Enter the cylinder selection
q t button: Return to the menu screen
a When the cylinder to be cut out is entered
by the U button, communication is per-
formed between the machine monitor and
engine controller, during which the cylin-
der number flashes. When the cylinder
number changes to lighting up and an
area below the cylinder number becomes
black after communication is completed,
this shows a state in which a cylinder is
cut out.
a One or more cylinders can be cut out.
4) Canceling cylinder cut out
a Cancel in the same procedure as selec-
tion.
GD555-5,GD655-5,GD675-5
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15. NO INJECTION CRANKING FUNCTION [NO
INJECTION]
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication. To prevent this, the
machine monitor has a function to crank the
engine without injecting fuel to lubricate the
engine before starting it.
Select the no-injection cranking while the engine
is stopped.
1) Selecting menu
Display the NO INJECTION screen on the
menu screen in the service mode.
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
2) Pressing the U button selects no injection
cranking.
a Turn the starting switch to the START po-
sition when this screen is displayed in or-
der to perform no-injection cranking.
a If this screen is not displayed even when
the U button is pressed, a communica-
tion error could occur.
a Setting the no-injection cranking during
engine running displays the engine stop
instruction screen.
a Stop the engine and set the no-injection
cranking again.
30-129
Electrical system
Special functions of machine monitor (EMMS)

16. Adjusting function [TUNING] 1] Learning data reset screen

The machine monitor is equipped with the func- q U button: Proceed to the "Learning
tion to adjust various parts when disassembly data reset" selection screen
and assembly are completed or the controller is q t button: Return to the "T/M trigger
replaced. learning data reset" selection screen
In the adjusting function, the following items can
be selected.
q Transmission-related adjustment (two items)
q Inching pedal-related adjustment
q Articulated angle sensor-related adjustment
q Maximum speed-related adjustment

1) Selecting menu
Select TUNING on the menu screen of the
service mode.

2] Learning data reset performing screen

2) Displaying sub menu
After selecting the menu, press the U button
to display the initial screen of the sub menu.
q U button: Perform the function
q t button: Return to TUNING selection
screen
Selects YES/NO by using < or >
button.
Selecting YES and pressing the t
button requests the transmission
controller to clear learning data, and
returns the screen to the "Learning
data reset" screen.
Selecting NO and pressing the t
button requests the transmission
controller to stop the learning data
clearing, and returns the screen to the
"Learning data reset" screen.

30-130 GD555-5,GD655-5,GD675-5
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3) Selecting sub menu
When the > button or < button is pressed on
the sub menu screen, the sub menu is
displayed in the following order endlessly.
a The sub menu is displayed in the section
"*".
q > button: Proceed to the next menu
q < button: Return to the previous menu
1] 01: TM TRIGGER
(T/M trigger learning data reset)
2] 02: ECMVTUNING(T/MECMV correc-
tion)
3] 03: INCHINGPEDAL
(Inching pedal adjustment)
4] 04: ARTICULATE
(Zero adjustment of articulation indicator)
5] 05: F8LIMIT (Maximum speed adjust-
ment)
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
<Adjustment procedure with an actual
machine>
For the actual adjustment procedure of
each adjustment item, see the following
and onward.
1] Procedure for transmission ECMV
tuning
2] Procedure for inching pedal adjust-
ment
3] Procedure for zero adjustment of
articulation indicator
4] Procedure for maximum speed adjust-
ment
Adjustment procedure for transmission ECMV
tuning 30-131
This function modifies difference of operating feel
due to individual difference of the transmission
ECMV to a certain level through the transmission
controller.
Perform adjusting work after conducting the follow-
ing work related to the powertrain.
Perform adjusting work by operating the machine
monitor and machine in the procedure explained in
the later pages.
q When transmission was overhauled of replaced
q When transmission valve was replaced
q When transmission controller was replaced
a Items within parentheses show real-time moni-
toring items or adjusting menu to be used for ad-
justing work.
q Adjusting transmission oil temperature
(Monitoring item: 32500 - T/MOILTEMP)
q Adjusting individual difference of valve (02:
AUTO of ECMV TUNING)
a The "01: TMTRIGGER" menu and "MANUAL"
menu of "02: ECMVTUNING" are not used for
service because they are factory-exclusive func-
tion.
30-131
Electrical system
Special functions of machine monitor (EMMS)
Adjusting transmission oil temperature 30-132
a The transmission ECMV tuning work must be
performed at the specified oil temperature. Ad-
just the transmission oil temperature in the fol-
lowing procedure while checking that the
machine does not indicate an abnormality.
1] Turn the starting switch to ON position
and have the machine monitor display
T/M OIL TEMP of the real-time monitoring
function.
2] If the transmission oil temperature is not
75 ± 5°C, start the engine to raise the
oil temperature.
a To raise the transmission oil tempera-
ture, "Torque converter stall function"
may be used.
k When using "Torque converter stall
function", be careful not to over-
heat the torque converter.
3] Return the gear shift lever to the N posi-
tion and leave it for three minutes. If the
transmission oil temperature is confirmed
to be within the specified temperature
under this condition, proceed to the
adjusting work.
a If the oil temperature is not stabilized
within the specified temperature, ad-
just so that the oil temperature is at 50
– 80°C while the tuning is made.
30-132
Resetting transmission initial learning and im-
plementing learning 30-132
a Before performing this adjustment item, be sure
to perform "Transmission ECMV current adjust-
ment".
a Before performing learning work, check that the
transmission oil temperature is 60°C or higher,
referring to "Adjustment of transmission oil tem-
perature". (Learning is not performed below 60
°C.)
k Perform learning work in a place where there
is a sufficient travel area, paying attention to
the safety of surroundings.
1) Select the TUNING on the service menu
selection screen.
2) After selecting the service menu, press the
U button to display the adjustment menu
selection screen.
q Press and hold the U switch for five sec-
onds or longer.
q U button: Perform tuning
3) Check that the transmission trigger adjust-
ment item (01:TM TRIGGER) is displayed on
the adjustment menu selection screen.
GD555-5,GD655-5,GD675-5
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4) After selecting the adjustment menu, press
the U button to display the initial learning
data reset screen.
q U button: Perform tuning
a The current initialization (learing data
clearing) status is displayed on the lower
row.
q Initialization already preformed: INITIAL
STATUS
q Initialization not yet preformed: TUNED
a When TUNED is displayed, proceed fur-
ther to the next procedure to clear the
learning data.
a When interrupting the reset operation,
press the t switch to return to the previ-
ous screen.
q t button: Return to the previous screen
5) After selecting the initialization menu screen,
press the U button to display the initialization
operation screen.
q U switch: Perform initialization
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
6) After selecting the initialization operation
screen, operate each switch of <, > and t to
perform initialization.
q <: Select YES (movement of cursor)
q >: Select NO (movement of cursor)
q t: Enter you selection (YES or NO)
a After performing initialization, check that
the message that initialization has been
performed is displayed on the lower row
of the screen.
q Initialization already preformed: INITIAL
STATUS
7) Return to the service menu selection screen
and select the real-time monitoring function
(REAL-TIMEMONITOR).
a To return to the service menu selection
screen, press the t switch several times.
30-133
Electrical system
Special functions of machine monitor (EMMS)

8) After selecting the service menu, press the

U button to display the system to be moni-
tored and function selection screen.
q U button: Perform monitoring
9) Press the > switch or < switch on the moni-
tored system and function selection screen,
and select the two item simultaneous moni-
toring (2 ITEMS).
q >: Proceed to the next monitored system
and function.

q <: Return to the previous monitored sys-

tem and function.

12) Set the AISS LOW switch to LOW.

13) Start the engine, hold the gear shift lever in
the N position at low idle for 10 seconds, and
operate the gear shift lever as follows.
a Gear shift lever operation: N o R1 o N
14) Check the trigger learning display of the R
clutch on the monitoring display.
a When the display is "1", proceed to the
next procedure.
a When the display is "0", repeat procedure
13) until the display shows "1".
a For clutch display with * mark, either "0"
or "1" is acceptable.
10) After selecting the two item simultaneous
monitoring, press the U switch to display the
monitoring code input screen.
q U: Perform selection of the monitored
system and function

11) Operate each switch of >, <, U and t on the

monitoring code input screen and directly
input the monitoring codes of two items to be
monitored.
q >: The number at the cursor increases
q <: The number at the cursor decreases
q U: The number at the cursor is entered
q t: The cursor moves to the left end or re-
turn to the monitored system and function
15) After setting the gear shift lever to F1 and
selection screen
traveling for 10 seconds, fully depress the
accelerator pedal to travel, and operate the
q Monitoring code: 32500 and 38922
gear shift lever through F1 o F2 o F3 o F4
a The upper row (32500) indicates the
to upshift.
transmission oil temperature while the
16) After releasing the accelerator pedal and
lower row (38922) the learning status of
traveling for 40 seconds, operate the gear
clutch trigger (0: Learning not completed,
shift lever through F4 o F3 to downshift.
1: Learning completed).

30-134 GD555-5,GD655-5,GD675-5
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17) Check the trigger learning display of the FL
clutch and FH clutch on the monitoring
display.
a When the display is "1", learning work is
completed.
a When the display is "0", repeat procedure
15) to 16) until the display shows "1".
a For clutch display with * mark, either "0"
or "1" is acceptable.
18) Finally check the trigger learning display on
the lower row on the monitoring display.
a When the display is as shown below, ini-
tial learning is successfully finished.
a For clutch display with * mark, either "0"
or "1" is acceptable.
19) Press the t switch several times to termi-
nate the service menu.
q t: Return to the previous screen
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
Adjusting individual difference of valve 30-135
a The adjusting work covers FL, R, 1st, 2nd, 3rd
and 4th, and when adjustment is started, correc-
tion for all clutches are automatically performed.
1) Set the machine to the following condition.
q Gear shift lever: P position
q Engine: Low idle
q Accelerator pedal: Released
q PRMset mode SW: OFF (neutral)
2) Operate the machine monitor to display the
adjustment menu screen.
q Adjustment menu: 02: AUTO of ECMV
TUNING
q > button: Proceed to the "Inching pedal
adjustment" screen
q < button: Return to the "T/M trigger learn-
ing data reset" screen
q U button: Proceed to the "Auto/Manual
selection" screen
q t button: Return to the "Adjusting func-
tion" selection screen
a To cancel the correction, press the t but-
ton.
3) Re-check the machine status and press the
U button to start the adjusting work.
(Change to the IP screen)
q U button: Perform adjustment
30-135
Electrical system
Special functions of machine monitor (EMMS)

a Adjustments for target clutches are made Code of abnormal termination and reason
four times in succession, respectively, Reason code
and the screen as shown in the table be- Out of correction condition 1
low is displayed. No fill 2
No. ECMV 1st time 2nd time 3rd time Exceeding correction
3
1 FL FL-1 FL-2 FL-3 value
2 FH FH-1 FH-2 FH-3
3 1st 1-1 1-2 1-3
4 2nd 2-1 2-2 2-3
5 3rd 3-1 3-2 3-3
6 4th 4-1 4-2 4-3
7 R R-1 R-2 R-3

a An acceptable result or unacceptable re-

sult is displayed for each adjusting work.
Take actions according to the indication.
q When "OK" is displayed:
The adjusting work is properly finished
and this screen may be terminated. (The
adjustment value is recorded in the
controller after a lapse of 10 seconds
from engine stop.)
q When "NG1" (out of correction condition)
is displayed:
Accurately adjust the transmission oil
temperature, check the set condition of
the machine again, and perform the
adjustment from procedure 1).
q When "NG2" (no fill) is displayed:
Perform troubleshooting for failure code
[15STMA] or [DDTTKA]. If the solution of
the problem is confirmed, perform the
adjustment from procedure 1) again.
q When "NG3" (exceeding correction val-
ue) is displayed:
Perform troubleshooting for failure code
[15STL1]. If it is confirmed to be normal,
the solution of the problem is confirmed,
perform the adjustment from procedure 1)
again.

30-136 GD555-5,GD655-5,GD675-5
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 Electrical system
Special functions of machine monitor (EMMS)

Procedure for inching pedal adjustment 30-137 q U button: When 0%, check the voltage
This adjustment enables the transmission controller value with the transmission controller. If it
to recognize the free position (state in which the is within the specified range, move to the
pedal is not depressed) and full stroke position adjustment screen at the time of 100%.
(state in which the pedal is fully depressed) of the q > button: Return to the current 100% rec-
inching pedal. ognition value confirmation screen
1) Before starting adjustment, check that the q t button: Return to the previous screen
gear shift lever is in the P position. q If the set range is inadequate, the display
2) Display the sub menu of the inching pedal changes to the message notifying the in-
adjustment. adequate condition
q > button: Proceed to the "Zero adjustment
of articulation indicator" selection screen
q < button: Return to the "ECMV correction"
selection screen
q U button: Move to the "Inching pedal ad-
justment" screen
q t button: Return to the "Adjusting func-
tion" selection screen

4) Set the inching pedal to the free position

(state in which the pedal is not depressed)
a The recognition value of the controller is
displayed in parentheses on the upper
row of the screen while the sensor output
value at that time is displayed on the low-
er row.
5) Check that the sensor output value on the
3) Press the U button on the sub menu scree to lower row of the screen is proper.
display the adjustment screen. q Sensor output value (when proper): 0.8 –
q U button: Perform adjustment 1.6 V
a If the sensor output value is not proper,
test the inching pedal for a defect.
6) While keeping the inching pedal in the free
position (state in which the pedal is not
depressed), press the U button to enter the
setting.
q U button: Enter the setting
7) Next, set the inching pedal to the full stroke
position (state in which the pedal is fully
depressed).
a The value recognized the controller is dis-
played in parentheses on the upper row
of the screen while the sensor output val-
ue at that time is displayed on the lower
row.

GD555-5,GD655-5,GD675-5 30-137
(01)
Electrical system
Special functions of machine monitor (EMMS)

Procedure for zero point adjustment of articula-

tion indicator 30-138
This adjustment enables the transmission controller
to recognize the zero point (straight travel posture of
the machine) of articulate angle.
1) Set the machine to the straight travel posture
and house the articulate lock pin at the lock
position.
2) Check that the installed condition of the artic-
ulate angle sensor is proper.
a Installed length (a) of rod (2) must be the
specified dimension (238 mm).

8) Check that the sensor output value on the

lower row of the screen is proper.
q Sensor output value (when proper): 3.2 -
4.0 V
9) While keeping the inching pedal in the full
stroke position (state in which the pedal is
depressed), press the U button to enter the
setting.
q U button: Enter the setting
q Move to the "Inching pedal adjustment"
screen if the value is within the set range.
a The above completes the adjustment. This
screen may be terminated. 3) Display the sub menu of the zero point
adjustment of the articulation indicator.
q > button: Proceed to the "Maximum
speed adjustment" screen
q < button: Return to the "Inching pedal ad-
justment" selection screen
q U button: Change to "Zero point adjust-
ment of the articulation indicator"
q t button: Return to the "Adjusting func-
tion" selection screen
a The voltage value, from which the judge-
ment that the current "articulated angle is
zero (straight)" is made, is displayed on
the lower row.

30-138 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

4) Press the U button on the sub menu scree to
display the adjustment screen.
q U button: Perform adjustment
a The voltage value recognized by the con-
troller is displayed on the upper row of the
screen while the sensor voltage value at
that time is displayed on the lower row.
a The above completes the adjustment.
This screen may be terminated.
q U button: Enter "Zero point adjust-
ment of the articulation indicator" and
return to the previous screen.
q > button: Move to the reset screen
q t button: Return to the adjusting func-
tion selection screen.

Procedure for adjusting hydraulic fan 30-139

This adjustment modifies the hydraulic fan speed at
the accelerator pedal full stroke position (state in
which the pedal is fully depresses).
Perform adjusting work after conducting the follow-
ing work related to the hydraulic fan.
q When hydraulic fan valve was replaced
q When transmission controller was replaced
Perform adjusting work in the following proce-
dure by operating the machine monitor and
machine.
a Items within parentheses show real-time moni-
toring items or adjustment menu to be used for
5) Check that the sensor voltage on the lower adjusting work.
row of the screen is proper. q Adjusting hydralic oil pressure
q Sensor voltage (when proper): 2.2 - 2.7 V
(Monitoring item: 04410 - HYD OIL TEMP)
a If the sensor output value is not proper, a The "01: FAN SPD 70%" menu is exclusive for
test the articulated angle sensor for a de- the factory. Do not use it for service.
fect.
6) After finishing confirmation of numerical
values, press the U button to enter the
setting.
q U button: Enter the setting
7) Resetting zero point adjustment of articula-
tion indicator
q U button: Return the value, from which
the judgement that the current "articulate
angle is zero (straight)" is made, to the
factory shipment value and return to the
"Zero point adjustment of the articulation
indicator" screen.
q < button: Return to the "Zero point adjust-
ment of the articulation indicator" screen
q t button: Return to the "Zero point adjust-
ment of the articulation indicator" sub
menu

GD555-5,GD655-5,GD675-5 30-139
(01)
Electrical system
Special functions of machine monitor (EMMS)
Adjusting hydraulic oil pressure
a The adjusting work of the hydraulic fan must be
performed at the specified oil temperature. Ad-
just the hydraulic oil temperature in the following
procedure while checking that the machine does
not indicate an abnormality.
1) Turn the starting switch to ON position and
have the machine monitor display HYD OIL
TEMP of the real-time monitoring function.
2) If the hydraulic oil temperature is not 50 ± 5
°C, start the engine and operate the work
equipment to raise the oil temperature.
3) Return the work equipment lever to the
neutral position and leave it for three
minutes. If the hydraulic oil temperature is
confirmed to be within the specified tempera-
ture under this condition, proceed to the
adjusting work.
30-140
30-140 Checking the hydraulic fan speed 30-140
a In this checking work, check the maximum hy-
draulic fan speed.
1) Set the machine to the following condition.
q Gear shift lever: P position
q Engine at high idle
2) Operate the machine monitor to display the
check screen.
q Check screen: 03: FAN SPD100%
q Rated hydraulic fan speed: 1500 ± 50
rpm
If the actually measured fan speed displayed
on the chck screen is different from the rated
speed, perform adjusting work.
a The current speed being output from the
sensor is displayed on the left of the lower
row of the screen while the rated speed,
which is the criteria for the adjustment, is
displayed on the right.
GD555-5,GD655-5,GD675-5
(01)

3) Operate the machine monitor to display the
adjustment screen.
q > button: Increase the target speed by
five rpm.
q < button: Decrease the target speed by
five rpm
q t button: The setting returns to the FAN
TUNING menu.
a The adjustable range of the target speed
is up to ±995 rpm. Adjustment cannot be
made beyond this range.
4) Operate the machine monitor to display the
check menu screen again.
q Check screen: 03: FAN SPD100%
q Rated hydraulic fan speed: 1500 ± 50
rpm
Make the adjustment of 3) until the speed
actually measured and displayed on the
check screen becomes the rated speed.
a The speed being output from the sensor
is displayed on the left of the lower row of
the screen while the rated speed, which is
the criteria for the adjustment, is dis-
played on the right.
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
17. Maintenance monitor function [MAINTE-
NANCE MONITOR]
Maintenance interval time of filters/oils that is
used standard for replacement time indication of
filters/oils can be set on the machine monitor.
The entire maintenance monitor (maintenace
reminder) function can be set to be stopped or
enabled.
1) Selecting menu
Select MAINTENANCE MONITOR on the
menu screen of the service mode.
2) Selecting kind of filter/oil for replacement
interval setting
1] After selecting the menu, press the U
button to display the initial screen of the
set items.
q U button: Perform setting
2] Press the > button or < button to select
item to be set.
q > button: The item proceeds
q > button: The item returns
a Set items are displayed in the order of
internal setting endlessly (See the list
of set items of filter and oil replace-
ment time).
a The setting function includes, "Default
value setting" and "All items timer stop
and enable setting". (See “Filter and
oil items and replacement interval”)
30-141
Electrical system
Special functions of machine monitor (EMMS)
3) Display contents of filter/oil replacement time
interval setting screen
When a replacement item is selected, the
following content is displayed.
q Section "1": Code (2 digits)
q Section "A": Filter/oil item for which re-
placement interval is to be set
q Section "2": Remaining time until the re-
placement time
q Section "3": Number of replacement up to
now
4) Change of interval time
1] After selecting the item, press the U
button to display the interval change
screen.
q U button: Select the interval changing
function
30-142
2] Press the U button further to display the
interval input screen.
q U button: Perform the interval chang
function
a Interval time currently set is displayed
on the lower row of the screen.
3] Operate each button to input interval
time.
q > button: The number at the cursor
proceeds
q < button: The number at the cursor re-
turns
q U button: The number at the cursor is
entered
q t button: Return to the item selection
screen
a Four digits must be input for interval
time. Input "0" where no numerical fig-
ure is necessary.
q When the input interval time is within
the settable range: Move to the entry
screen.
q When the input interval time is out of
the settable range: Return to the input
screen without interval time being
changed to the input value.
a The minimum value of interval time is
50 hours.
a If a wrong numerical value is inputted,
the cursor moves to the top digit by the
t button unless the cursor is at the top
digit. Thus, input can be done from the
beginning. At this time, values already
inputted remain as they are.
When the cursor is at the top digit, it
moves to the higher layer screen
when the t button is pressed.
4] When 4-digit interval time is entered, the
change confirmation screen is displayed.
Operate according to the screen display.
q < button: Select YES
q > button: Select NO
GD555-5,GD655-5,GD675-5
(01)

q t button: Enter the selector (YES or
NO)
5) Selecting timer stop by item/enable by item
1] On the screen of "Interval time change" in
section 8-1-4) when the < or > button is
pressed, the screen moves to the
"Selecting timer stop by item/enable by
item" screen.
a When "Timer by item" is in an opera-
tive status, "ON o OFF" is displayed.
a When "Timer by item" is in a stopped
status, "OFF o ON" is displayed.
a Default display is "ON".
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
2] Press the U button.
a When "Timer by item" is set to a stop,
"OFF" is displayed on the upper row.
a When "Timer by item" is set to activa-
tion, "ON" is displayed on the upper
row.
3] Press the < or > button to select "YES" or
"NO".
a The cursor flashes on the selected
item, and when the t button is
pressed, the change is entered if
"YES" is selected. If "NO" is selected,
no change is entered and the screen
returns to the "Maintenance interval
change item" screen.
a When the setting of the timer is
changed from "Stop" to "Enable", in-
terval time becomes the set value be-
fore it was disabled, and remaining
time of the timer is reset.
The number of resets (number of
replacement) becomes the value
before it was disabled.
30-143
Electrical system
Special functions of machine monitor (EMMS)

6) Function and operation of default value 7) Function and operation of all items timer stop
setting and enable setting
a When the default value setting is per- a In this function, the maintenance timer
formed, the interval time for the all items function of all items can be stopped or en-
are returned to default even if there is any abled.
item for which inerval time is changed re- 1] After selecting the set item, press the U
gardless of individual items being en- button to display the setting screen.
abled or disabled. q U button: Select the setting function
a Remaining time of the timer is “Default
value - elapsed time from previous
replacement”.
a Even if the default value setting is per-
formed, the number of resets remains the
one before the default vale setting is per-
formed.
a Setting of enable/disable of individual
items is set to be effective.
1] After selecting the set item, press the U
button to display the setting screen.
q U button: Select the setting function

2] When the U button is pressed further, the

change confirmation screen is displayed.
Switch the setting screen by the < button
and > button.
a When the setting screen is switched,
first, the screen displays the upper
row of the diagram below.
q < button: Switch to the OFF screen
q > button: Switch to the ON screen

2] When the U button is pressed further, the

change confirmation screen is displayed.
Operate according to the screen display.
q < button: Select YES
q > button: Select NO
q t button: Enter the selection (YES or
NO)

30-144 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

3] When the U button is pressed further, the

change confirmation screen is displayed.
Switch the setting screen by the < button
and > button.
q < button: Select YES
q > button: Select NO
q t button: Enter the selection (YES or
ON)

4] When all items stop is implemented

a The timer function of all items is
stopped and the screen returns to the
MAINTENANCE MONITOR screen.
a The individual setting is set to function
stop.
a When canceling, cancel the operation
and return to the MAINTENANCE
MONITOR screen.
5] When enabling of all items is imple-
mented
a Interval time for all items is set to the
set value before it was disabled re-
gardless of individual items being en-
abled or disabled.
a Reset the remaining time of the timer.
(The number of resets remains the
one before reset.)
a Return to the MAINTENANCE MONI-
TOR selection screen.
a The individual setting is set to enable.
a When canceling, cancel the operation
and return to the "Maintenance moni-
tor" screen.

GD555-5,GD655-5,GD675-5 30-145
(01)
Electrical system
Special functions of machine monitor (EMMS)

Filter and oil items and replacement interval

Replacement
No. Item code Display
time (h)
1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG FILT 500
3 Fuel pre-filter 41 PFULEL FILT 500
4 Fuel filter 03 FUEL FILT 1000
5 Transmission oil filter 13 TM FILT 1000
6 Transmission oil 12 TM OIL 1000
7 Final drive case oil 15 AXLE OIL 1000
8 Hydraulic filter 04 HYD FILT 1000
9 Hydraulic oil 10 HYD OIL 2000
10 Tandem case oil 37 TD CASE OIL 2000
11 Blade rotating gear case oil 36 CR CASE OIL 2000
12 Default value setting – INITIALIZE –
13 All items timer stop and enable setting – ALL ITEMS –

30-146 GD555-5,GD655-5,GD675-5
(01)

18. Operation information display function [OP-
ERATION INFO]
Press the > button of the maintenance monitor
function to displace the "Operation information
display function" screen.
> button: Proceed to the "Option selection func-
tion" screen
< button: Return to the "Maintenance monitor
selection function" screen
t button: Move to the standard operator mode.
U button: Proceed to the "Amount of fuel
consumed" (*1) screen
3) Amount of fuel consumed (*3)
1) Amount of fuel consumed (*1)
q The upper row displays the amount of fuel
consumed per 1 km from the last reset.
q The lower row displays the average fuel
consumption from the last reset.
> button: Proceed to the "Amount of fuel
consumed" (*2) screen
< button: Return to the "Amount of fuel
consumed" (*3) screen
U button: Proceed to the "Reset function"
screen
t button: Move to the "Operation information
display function" screen.
2) Amount of fuel consumed (*2)
q The upper row displays the accumulated
amount of fuel consumed from the last re-
set.
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
q The lower row displays the travel distance
from the last reset.
> button: Proceed to the "Amount of fuel
consumed" (*3) screen
< button: Return to the "Amount of fuel
consumed" (*1) screen
U button: Proceed to the "Reset function"
screen
t button: Move to the "Operation information
display function" screen.
q The upper row displays the accumulated
amount of fuel consumed from the last re-
set.
q The lower row displays the elapsed time
from the last reset.
a The amount of fuel consumed (*1) to (*3)
is calculated only when the engine is run-
ning.
> button: Proceed to the "Amount of fuel
consumed" (*1) screen
< button: Return to the "Amount of fuel
consumed" (*2) screen
U button: Proceed to the "Reset function"
screen
t button: Move to the "Operation information
display function" screen.
30-147
Electrical system
Special functions of machine monitor (EMMS)
4) Reset function
The data of respective amounts of fuel
consumed (*1), (*2) and (*3) is cleared by
using the U button and the screen returns to
the "Amount of fuel consumed" (*1) screen.
t button: Return to the previous screen
without clearing the data
Note) The data will be reset in the case of
"Initialization of monitor panel" and "Option
"OFF"" in addition to the above reset opera-
tion.
> button: Move to the "Gain correction"
screen
30-148
5) Gain correcting function
Procedure for setting gain correction
value
1] The screen displays the current set value,
and move the cursor over the code (+/-).
2] When the cursor is in the code position,
every time the > or < button is pressed
once, "+” and “-" is repeated.
3] Confirm the code by the U button.The
cursor moves to the top digit.
4] First the cursor is at the top digit, and
every time the > or < button is pressed
once, the figure increases/decreases,
changing the display of 0 - 9. (Top digits
are 0 - 2.)
5] When inputting the target numerical
value, press the U button to confirm.
6] The cursor moves to the bottom digit.
Input in the same procedure as 4) and 5).
7] Input the bottom digits and press the U
button. (When the figure is entered, the
screen returns to the previous screen.)
8] When the t button is pressed during
input of the numerical value, the numer-
ical value remains as it is and moves to
the code position.
When the t is pressed further, the screen
returns to the previous screen.
9] When the bottom digit is entered and if it
is not in the range of -50.0 – +50.0, the
numerical value remains as it is and
moves to the code position as when the t
button is pressed.
Action at monitor panel
q Default: 0.0%
q The accumulated amount of fuel con-
sumed (l) is corrected in the range of
"–50.0 – +50.0%" from this setting.
GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Special functions of machine monitor (EMMS)

19. Option selecting function [OPTIONAL SE-

LECTION]
The machine monitor is equipped with the func-
tion to set the tire size and speedometer display
unit matching the optional specifications.

1) Selecting menu
Select OPTIONAL SELECT on the menu
screen of the service mode.

3) Selection item
1] Tire size correction (01:TIRE SIZE)
This is a function to correct the diameter
that is recognized by the machine monitor
when the tire size is changed.
1] Selecting sub menu
Select TIRE SIZE on the sub menu
selection screen.

2) Selecting selection item

1] After selecting the menu, press the U
button for three seconds or longer to
display the initial screen of the set items.
q U button: Perform the function
2] Press the > button or < button to select
items to be set.
q > button: The item proceeds
q > button: The item returns
q t button: Return to the previous
screen
a Selection items are displayed in the
following order endlessly. a ADD (already set)/NO ADD (not yet
(1) TIRESIZE: Tire size correction set) is changed by using the U button.
(2) DIFF: Differential type (Switch the display by using the < and
(3) OPERATION: Display of operation > button.)
information (fuel related)
(4) BACKLIGHT: Backlight
(5) ARTICULATE: Articulation indicator
a If the option is not being selected, the
screen is displayed as shown in the
upper screen of the following picture.
If the option is already being selected,
the screen is displayed as shown in
the lower screen of the following pic-
ture.

GD555-5,GD655-5,GD675-5 30-149
(01)
Electrical system
Special functions of machine monitor (EMMS)

2] Displaying sub menu

After selecting the sub menu, press
the U button to display the screen for
performing sub menu.
q U button: Perform the function
a The current set value is displayed on
the lower row.

2] Differential type (02:DIFF)

Every time the U button is pressed,
installed (ADD)/not installed (NO ADD) is
switched. Select the one that applies.

3] Adjusting set value

1] Press the U button on the sub
menu function performing screen
to move to the input screen of the
set value.
q U button: Perform the function
2] Press the > button or < button to
select +/- of the set value, and
enter it by using the U button.
q > and < buttons: Select +/-
q U button: Enter +/-
3] Press the > button or < button
further to select the set value, and 3] Switching travel speed unit (03: SPEED
enter it by using the U button. (UNIT))
q > button: The number at the cursor in-
This is a function to switch the speed
creases displayed on the indicator (meter display)
q < button: The number at the cursor de-
between km/h and MPH.
creases
q U button: The number at the cursor is
entered
a Set and enter the numerical value digit
by digit from the left.
a The set value is in the range of ±20%
and can be set on a unit of 1%.
a If setting is carried out correctly, the
screen returns to the previous screen.
a When the t button is pressed during
input of the numerical value, the nu-
merical value remains as it is and
moves to the code position. When the
t is pressed further, the screen re-
turns to the previous screen. a MPH/km/h is changed by using the U
a When the bottom digit is entered and button.
if it is not in the range of –20 – +20, the a This menu is displayed only if the
numerical value remains as it is and non-SI unit system is selected as op-
moves to the code position as when tion at the time of factory shipment.
the t button is pressed.

30-150 GD555-5,GD655-5,GD675-5
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4] Operation information (fuel consumption
related) display (04:OPERATIONINFO)
This is a function to switch between
Yes/No of "Operation information display"
in the operator mode.
a ADD (display)/NOADD (no display) is
changed by using the U button.
(Switch the display with the > and <
buttons.
5] Backlight (05:BACK LIGHT))
This is a function to set the backlight to
ON/OFF when the night illumination is
OFF.
a Backlight ON/OFF is switched by us-
ing the U button when the night illumi-
nation is OFF. (There is no selection
entry screen and the selection is
changed every time the button is
pressed.) The display is switched by
using the > and < buttons.
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
6] Selecting articulation indicator
(06:ARTICULATE))
a Installed (ADD)/Not installed
(NO/ADD) is switched by using the U
button. When "Not installed" is select-
ed, the display of the gauge is fixed at
the center. (Switch the display by us-
ing the > and < buttons.
20. Forced low idle fixing function
[ENGINE LOW SIDE]
The machine monitor is equipped with a function
to forcibly fix the engine at low idle, when the
engine is restarted after completion of disas-
sembly and assembly of the hydraulic
compoent, to prevent damage to hydraulic
component caused by high-speed rotation of the
engine due to activation of automatic warm-up.
1) Selecting menu
Select "Forced low idle fixing function (ENG
LOW SIDE) on the menu screen of the
service mode.
30-151
Electrical system
Special functions of machine monitor (EMMS)
2) Setting function
After selecting the sub menu, press the U
button to perform the function.
q U button: Move to the "Forced low speed
low idle" screen
3) Canceling function
When the t button is pressed with the func-
tion enabled, the screen returns to the
previous screen and the function is canceled.
q t button: Cancel the function
a During the screen display, the engine
controller is requested to operate the en-
gine at “low speed low idle”.
Characters of "FIX LOW L-IDLE" flash.
When the screen is exited by using the t
button or by turning the starting switch to
OFF position, engine low speed low idle
is stopped.
30-152
21. Torque converter stall function [T/C STALL]
The machine monitor is equipped with a function
to always set the machine to the optimal condi-
tion and to automatically display the torque con-
verter oil temperature and engine speed when
the machine is tested with torque converter
stalled.
1) Selecting menu
Select "Torque converter stall function" on
the menu screen of the service mode.
2) Setting function
After selecting the sub menu, press the U
button to perform the function.
q U button: Move to the "T/C stall" screen
a This function is not enabled unless the
gear shift lever is in the P position.
a When the screen is as shown below, the
function is enabled. When the gear shift
lever is operated to the F8 position, the
transmission is always shifted to F8 gear
speed, and the torque converter is set to
the torque converter mode regardless of
the transmission mode selector switch
operation.
k Although the parking brake is applied
during activation of this function, the
machine can move. Securely depress
the brake pedal before operating the
gear shift lever.
a In this mode, engine speed and torque
converter oil temperature are simultane-
ously displayed.
GD555-5,GD655-5,GD675-5
(01)

a When the operation to activate the func-
tion done, the following screen is dis-
played if the function cannot be activated.
3) Canceling function
When the t button is pressed with the func-
tion enabled, the screen returns to the
previous screen and the function is
cancelled.
q t button: Cancel the function
a This function cannot be cancelled unless
the gear shift lever is in the P position.
a When the operation to cancel the function
is performed, the following screen is dis-
played if the function cannot be can-
celled.
(The screen returns to the previous
screen but the function continues.)
GD555-5,GD655-5,GD675-5
(01)
Electrical system
Special functions of machine monitor (EMMS)
k Method to cope with occurrence of an
abnormality during activation of
torque converter stall
1] When torque converter stall cannot be
properly canceled due to occurrence of
defective communication
Turn the starting switch to OFF position
with respect to the machine monitor.
Operate the gear shift lever to the P posi-
tion with respect to the transmission
controller.
2] When only the transmission controller
cancels torque converter stall
Turn the starting switch to OFF position
with respect to the machine panel.
There is no need to cope with the trans-
mission controller because cancellation
has already been made.
22. Initializing function [INITIALIZE]
a This function is exclusive for the factory. Do not
use it for service.
30-153
Electrical system
Handling high voltage circuit of engine controller

Handling high voltage circuit of

engine controller 30-154
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.

30-154 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
Handling high voltage circuit of engine controller

GD555-5,GD655-5,GD675-5 30-155
(01)
Electrical system
How to start KOMTRAX terminal operations

How to start KOMTRAX terminal operations 30-156

Procedure to start KOMTRAX 30-156
If installed before Countries 1. Register a machine on the KOMTRAX web screen. For instructions, see "Global
delivery except Japan KOMTRAX Web Reference Manual (For Key Person)".
2. After the machine is registered, proceed to make activation request by pressing
"Apply" button on the KOMTRAX web screen. For instructions, see "Global
KOMTRAX Web Reference Manual (For Key Person)".
3. After the machine is activated, press start button on the KOMTRAX web screen
to start communication. For instructions, see "Global KOMTRAX Web Reference
Manual (For Key Person)".
If installed after Countries 1. Follow the "installation procedure" and installed devices.
delivery except Japan 2. Follow the procedures explained in "Station opening check in machine side" and
perform on-board inspection.
3. Register a machine on the KOMTRAX web screen. For instructions, see "Global
KOMTRAX Web Reference Manual (For Key Person)". To check necessary
information in advance, see "Application for start of use".
4. After the machine is registered, proceed to make activation request by pressing
"Apply" button on the KOMTRAX web screen. For instructions, see "Global
KOMTRAX Web Reference Manual (For Key Person)".
5. After the machine is activated, press "Start" button on the KOMTRAX web screen
to start communication. For instructions, see "Global KOMTRAX Web Reference
Manual (For Key Person)".

For detailed procedures to start KOMTRAX operation, please contact the division in charge of KOMTRAX.

30-156 GD555-5,GD655-5,GD675-5
(01)
 Electrical system
How to start KOMTRAX terminal operations

Station opening check in machine side 30-157 3. When approximately 5 seconds elapsed after
q Standard specification the starting switch was set to ACC, make sure
a Complete steps 3. to 5. within 60 seconds. If 60 that the 7-segment indicator lamp changes to
seconds or above elapsed, begin with step 1. hyphen "–" on the KOMTRAX terminal.
again.
1. Turn OFF the starting switch and then, after
making sure 5 seconds have elapsed, proceed
to the next step.

2. Visually check that check connectors 1 and 2 are

connected.
q Check connector 1: CHK0
q Check connector 2: CHK1

4. Disconnect inspection connector 1, and wait for

approximately 5 seconds as it is.
a Ensure that the connector is disconnected.

5. Reconnect inspection connector 1, and wait for

approximately 5 seconds as it is.
a If the KOMTRAX terminal detects that the
connector was disconnected and connected,
the dot on the 7-segment indicator lamp
blinks a few times.

GD555-5,GD655-5,GD675-5 30-157
(03)
Electrical system
How to start KOMTRAX terminal operations

6. Make sure that the 7-segment indicator lamp is a As [Normal] is indicated, proceed to the next
indicated normally on the KOMTRAX terminal. step.
a If so, the 7-segment indicator lamp will indi- a If "–" remains displayed, execute steps 1. to
cate characters "d", "0", and "–" repeatedly 5. again.
for 30 seconds after step 5. was ended.
a Those characters, even if displayed normal-
ly, will change to a character other than hy-
phen "–" after 30 seconds or above elapsed.
The display may change to a character other
than "0" even within 30 seconds.

7. Turn the starting switch to START position for

approximately 5 seconds, and make sure that
the engine does not start.
a If the engine starts, re-execute the procedure
above from step 1.
a Do not return the starting switch to OFF posi-
tion.

8. Turn the starting switch from ACC position to

START position again, and make sure that the
engine starts.

9. Make sure that the KOMTRAX terminal's indi-

cator lamps are normally turned on.
a Move on to the next step if you can check that
the display is [Normal]. (It takes from 90 sec-
onds to 15 minutes before the display turns
normal.)
a If [GPS position data detection trouble] is in-
dicated, check if there is any abnormality on
the GPS antenna or cable. If there is any ab-
normality, repair it and start from procedure
1. again.
a If [Reception trouble] is indicated, check if
there is any abnormality on the appearance
of the communication antenna or cable. If
there is any abnormality, repair it then repeat
from procedure 1. again.
a If [GPS position data detection trouble and
reception trouble] is indicated, check if there
is any abnormality on the GPS antenna/cable
or communication antenna/ cable. If there is
any abnormality, repair it and start from pro-
cedure 1. again.

30-158 GD555-5,GD655-5,GD675-5
(01)

a If [Network trouble] is indicated, check the
display of [LED-C4] referring to "Lamp dis-
play of KOMTRAX terminal". If the CAN is not
recognized, check the CAN harness of the
KOMTRAX terminal, and then if there is any
abnormality, repair it and start from proce-
dure 1. again.
[A]: Normal
[B]: GPS position data detection trouble
[C]: Reception trouble
[D]: GPS position data detection trouble and
reception trouble
[E]: Network trouble
GD555-5,GD655-5,GD675-5
(01)
Electrical system
How to start KOMTRAX terminal operations
10. Turn the starting switch OFF.
11. Make sure that the 7-segment indicator lamp is
displayed normally after 5 seconds elapsed.
a When [Normal] appears, station opening
check is completed.
a If [Abnormal] appears, station opening check
does not end normally, so you should per-
form the procedure above from step 1. again.
a If station opening check ends normally, it
should not be rechecked.
30-159
Electrical system
How to start KOMTRAX terminal operations

Application for the start of use 30-160

a Application for the start of use should be made
only after the sign-up test is finished.
1. Notify the KOMTRAX operations administrator
of the following information about the machine
that completed the station opening check in the
machine side.
1) Information (model, part number, and serial
number) about the machine that completed
the station opening check in the machine
side
2) Part number and serial number of
KOMTRAX terminal
3) Value of service meter when the KOMTRAX
terminal was installed (in 0.1 hours)

2. The KOMTRAX operations administrator shall

use a KOMTRAX client PC to register the
machine.
a Refer to "Manual for KOMTRAX operations
administrator" for the procedure.
a For the procedure applied out of Japan, refer
to "Global KOMTRAX Web Reference Manu-
al (For Key Person)".
a Now the terminal is ready for use.

30-160 GD555-5,GD655-5,GD675-5
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 Electrical system
How to start KOMTRAX terminal operations

Station opening check in machine side 3. Approximately 5 seconds after the starting
a Chinese specification switch is turned to ON position, check that the
a Move the machine to an open outdoor place so 7-segment indicator lamp indicates "-" as shown
that it can receive the electric wave. below.
Complete steps 3. to 5. within 60 seconds. If 60
seconds or above elapsed, begin with step
1again.

1. Turn the starting switch to OFF position, and

then after making sure 5 seconds have elapsed,
proceed to the next step.

2. Visually check that check connector 1 is

connected.
q Check connector 1: CN-CHK1

4. Disconnect check connector 1 and wait for 5

seconds.
a Check that connector 1 is disconnected se-
curely.

5. Reconnect check connector 1 and wait for 5

seconds.
a If KOMTRAX senses that the connector is
disconnected or connected, the dot of the
7-segment indicator lamp blinks 2 – 3 times.

GD555-5,GD655-5,GD675-5 30-160-1
(03)
Electrical system
How to start KOMTRAX terminal operations

6. Make sure that the 7-segment indicator lamp is a If the indicator lamp displays normally, pro-
indicator normally on the KOMTRAX terminal. ceed to the next step.
a Even if "d", "0", and "-" are displayed normal- a If the indicator lamp displays abnormally, re-
ly, a character other than "-" is displayed after peat steps 1 to 5.
30 seconds.
The display may change and may indicate a
character other than "0".

7. Turn the starting switch to START position and

hold for approximately 5 seconds or more and
make sure that the engine does not start.
a If the engine starts, repeat the procedure
fr-om step 1.
a Do not turn the starting switch to OFF posi-
tion. If you did so, repeat the proced-ure from
step 1.

8. Turn the starting switch to ON position and then

turn it to START position again and make sure
that the engine starts.

9. Check that the 7-segment indicator lamp of the

KOMTRAX terminal displays normally.
a If the indicator lamp displays normally, pro-
ceed to the next step.
(It takes 90 seconds to 15 minutes before the
display becomes normal)
a If [GPS position data detection trouble] is dis-
played, check the GPS antenna and cable for
abnormality on the appearance. Repair ab-
normality, if there is any, and repeat the pro-
cedure from step 1. (It takes 90 seconds to 2
minutes before the display becomes normal)
a If [Reception trouble] is displayed, check the
communication antenna and cable for abnor-
mality on the appearance. Repair abnormali-
ty, if there is any, and repeat the procedure
from step 1.
(It takes 30 seconds to 2 minutes before the
display becomes normal)

30-160-2 GD555-5,GD655-5,GD675-5
(03)

a If [Network trouble and wiring harness trou-
ble] is indicated, the network type selection
input is not matched with the network ob-
tained data.
Check the machine wiring harness connec-
tions for a wrong connection. Repair abnor-
mality, if there is any, and repeat the
procedure from step 1.
[A]: Normal
[B]: GPS position data detection trouble
[C]: Reception trouble
[D]: Network trouble and wiring harness
trouble
GD555-5,GD655-5,GD675-5
(03)
Electrical system
How to start KOMTRAX terminal operations
10. Turn the starting switch to OFF position.
11. Check that the 7-segment indicator lamp displys
normally after 5 seconds.
a If the indicator lamp displays normally, the
sign-up test is completed.
a If the indicator lamp displays abnormally, the
sign-up test is not completed normally.
In this case, begin steps 1 again.
a If the sign-up test is completed normally, do
not perform it again.
30-160-3
Electrical system
How to start KOMTRAX terminal operations

Application for the start of use

a Application for the start of use should be made
only after the sign-up test is finished.
1. Notify the KOMTRAX operations administrator
of the following information of the machine which
has completed the sign-up test on machine side.
1) Information of machine which has completed
sign-up test on machine side (Model, Type.,
Serial No.)
2) Part No. and serial No. of KOMTRAX
terminal.
3) Reading of service meter when KOMTRAX
terminal was installed (0.1 h unit)

2. The KOMTRAX operations administrator regis-

ters the machine using the KOMTRAX client
personal computer.
a For the procedure, see "Manual for
KOMTRAX operations administrator".
a Now the terminal is ready for use.

30-160-4 GD555-5,GD655-5,GD675-5
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 Electrical system
Indicator lamps of KOMTRAX terminal

Indicator lamps of KOMTRAX terminal 30-161

q Standard specification

LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)

GD555-5,GD655-5,GD675-5 30-161
(03)
Electrical system
Indicator lamps of KOMTRAX terminal

In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.

Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication antenna
and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.

Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the en-
gine started.
Display
No. LED Name/Function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator
R signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF

State of engine control sig- ON Engine control signal: ON

2 LED-C2
nal OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF

States of S-NET connection Fast blink Starting switch C signal: ON

3 LED-C3
and starting switch C signal Slow blink (Not used)

OFF S-NET: Not connected, Starting switch C signal: OFF

ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)

6 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF

*1: Blink types and blink times

Fast blink: Blinks in approximately 1-second cycle
Slow blink: Blinks in approximately 4-second cycle

30-162 GD555-5,GD655-5,GD675-5
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 Electrical system
Indicator lamps of KOMTRAX terminal

2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.

Display
No. LED Name/Function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9 dis-
Number of unsent mails are indicated by “9”.) Light-on indicates that the
played
unsent mails, machine is in process of capturing the satellite.
7 7 segments
satellite capture The number indicates the number of unsent mails. (10 or more
state 0 to 9 fast
unsent mails are indicated by “9”.) Fast blink indicates that the
blink
satellite is not captured.
GPS positioning was completed. (The position can be confirmed.
ON
GPS positioning *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)

*2: Blink types and blink times

Fast blink: Blinks in approximately 1-second cycle
Slow blink: Blinks in approximately 4-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was turned
ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.

GD555-5,GD655-5,GD675-5 30-163
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Electrical system
Indicator lamps of KOMTRAX terminal

q Chinese specification

LED lamps for CPU
1. LED-1 (State of R or ACC signal)
2. LED-2 (Starting output state)
3. LED-3 (State of S-NET or C signal)
4. LED-4 (CAN state)
5. LED-5 (Download write state)
7-segment and dot displays for CPU
6. 7 segments (Station opening or operating state)
7. Dot (GPS positioning state or state of check con-
nector connection)

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 Electrical system
Indicator lamps of KOMTRAX terminal

In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.

Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication antenna
and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.

Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the en-
gine started.
LED Display
No. Name/Function Description
(color) (*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
LED-1
1 ACC signal and alternator
(green) Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
R signal
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF

LED-2 State of engine control sig- ON Engine control signal: ON

2
(red) nal OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF

LED-3 States of S-NET connection Fast blink Starting switch C signal: ON

3
(yellow) and starting switch C signal Slow blink (Not used)

OFF S-NET: Not connected, Starting switch C signal: OFF

ON CAN: Connected (without fuel sensor)

LED-4 Fast blink CAN: Connected (with fuel sensor)

4 State of CAN connection
(green) Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)

ON Download write mode: ON

LED-5
5 Download write state
(red)
OFF Download write mode: OFF (normal mode)

*1: Blink types and blink times

Fast blink: Blinks in approximately 1-second cycle (“ON for 0.5 sec and OFF for 0.5 sec” repeatedly)
Slow blink: Blinks in approximately 4-second cycle (“ON for 2 sec and OFF for 2 sec” repeatedly)

GD555-5,GD655-5,GD675-5 30-163-2
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Electrical system
Indicator lamps of KOMTRAX terminal

2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.

LED Display
No. Name/Function Description
(color) (*2)
Before execution of sign-up test
Station opening
[-] If sign-up test is not completed, [-] (bar) is kept displayed.
state
During sign-up test
Progress of * For display during the sign-up test, see Testing and Adjusting,
*
sign-up test "How to start KOMTRAX terminal operations".
After completion of sign-up test
[C] If server initialization communication is not completed
7 segments Configuration
6 ON Indicates machine is in communication range
(red) state
Fast blink Indicates machine is out communication range
Operating state
Number of mails waiting to be sent
Number of [0-9]
(9 or more mails are indicated by 9)
unsent mails, ON
Indicates machine is in communication range
in/out state of
Number of mails waiting to be sent
communication [0-9]
(9 or more mails are indicated by 9)
range Fast blink
Indicates machine is out communication range

GPS positioning is completed.

ON
(position is recognized. See *3)
GPS positioning state or
Dot
7 state of check connector GPS positioning is uncompleted
(red) OFF
connection (position is not recognized.See *3)
Blinks 2 to 3 times when sign-up test connector is
Fast blink
disconnected/connected

*2: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was turned
ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.

30-163-3 GD555-5,GD655-5,GD675-5
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 Electrical system
Indicator lamps of KOMTRAX terminal

GD555-5,GD655-5,GD675-5 30-163-4
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Electrical system
Preparation work for troubleshooting of electrical system

Preparation work for troubleshooting of electrical system 30-164

2. Engine controller
a When carrying out troubleshooting of an electric a The engine controller is installed on the en-
circuit related to the machine monitor, engine gine on the right side of the machine.
controller, and transmission controller, expose 1) Open the right side cover (2).
the related connectors in the following proce-
dure.

1. Machine monitor
1) Remove the four mounting bolts and pull out
machine monitor (1) to the operator seat
side.

2) Insert or connect troubleshooting T-adapters

in or to connectors EC1 and EC2 on engine
controller (3).
a Connectors EC1 and EC2 are fixed by
screws. When disconnecting them, loos-
en the screws.
a When returning the connectors, tighten
2) Insert or connect troubleshooting T-adapters the screws to the specified torque.
in or to connectors FP1 and FP2 on the
machine monitor.

3 Screw: 2.55 – 3.1 Nm {0.26 – 0.32

kgm}

30-164 GD555-5,GD655-5,GD675-5
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 Electrical system
Preparation work for troubleshooting of electrical system

3. Transmission controller 3) Insert or connect troubleshooting T-adapters

a The transmission controller is installed in left
box (4) of the operator’s seat.
1) Remove two cover (4) mounting bolts (5) and
cover (4).
in or to connectors TM39, TM40, and TM41
on transmission controller (8).
a The connectors are fixed by screws.
When disconnecting them, loosen the
screws.
a When returning the connectors, tighten
the screws to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}

2) Remove mounting plate (7) of KOMTRAX

terminal (6).
a Leave the connector of the KOMTRAX
terminal disconnected.

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Pm clinic
Pm Clinic

Pm clinic 30-16
Pm Clinic 30-16

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 Pm clinic
Pm Clinic

Testing points for Pm Clinic (1/3) 30-167

For the measurement procedures, see the following sections (pages).

*1. Engine speed: Testing engine speed (page 5 - 6)
*2. Blowby pressure: Testing blowby pressure (page 15 - 16)
*3. Engine oil pressure: Testing engine oil pressure (page 17)
*4. Boost pressure: Testing boost pressure (page 7 - 8)
*5. Exhaust gas temperature: Testing exhaust gas temperature (page 9 - 10)

GD555-5,GD655-5,GD675-5 30-167
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Pm clinic
Pm Clinic

Testing points for Pm Clinic (2/3) 30-168

For the measurement procedures, see the following

sections (pages).
*6. Power train oil pressure: Testing power train oil pressure (page 27 - 35)

30-168 GD555-5,GD655-5,GD675-5
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 Pm clinic
Pm Clinic

Testing points for Pm Clinic (3/3) 30-169

For the measurement procedures, see the following sections (pages).

*7. Steering oil pressure: Testing and adjusting steering oil pressure (page 47)
*8. Brake oil pressure: Testing and adjusting brake oil pressure (page 49 - 52)
*9. Work equipment oil pressure: Testing and adjusting work equipment oil pressure (page 61 - 62)
*10. LS differential pressure: Testing and adjusting pump LS differential pressure (page 64 - 65)

GD555-5,GD655-5,GD675-5 30-169
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Pm clinic
Pm Clinic

Testing sheets for Pm Clinic (1/3) 30-170

GD555 - 5
Machine serial number GD655 - 5 #
GD675 - 5
hour testing SAA6D107E - 1
Engine serial No.
#

Work order Date of inspection Service meter reading Inspector

Year Month Day hours
a After engine is started, torque converter oil temperature should not exceed 90°C when the torque con-
verter is stalled.
Standard Mea-

Good
Service limit

Bad
Item Test conditions Unit value for new sured
value
machine results
q Coolant temper-
ature: within op- Low idle 800 - 850 800 - 850
erating range
q Torque converter E-mode 1800 - 1900 1800 - 1900
oil temperature: High idle
60 - 80°C (P range)
Engine speed P-mode rpm 2175 - 2225 2175 - 2225
q Set in torque
converter stall
function
(when measuring Torque converter stall
1589 - 1789 -
torque converter speed
stall speed)
Blowby pres- kPa <Max. 0.98> <1.96>
q At rated horsepower
sure {mmH2O} {<Max. 100>} {<200>}

q Coolant temper-
Engine

ature: Within op- Min. 0.29 0.25

High idle
erating range {Min. 3.0} {25}
Engine oil q SAE 0W30EOS MPa
pressure 5W40EOS {kg/cm2}
10W30DH Min. 0.10 0.07
15W40DH Low idle
{Min. 1.0} {0.7}
30DH

Min. 140 113

q Aftercooler outlet GD555 - 5
Boost pres- kPa {Min. 1050} {850}
q At rated horse-
sure {mmHg} Min. 140 113
power GD655/675 - 5
{Min. 1150} {950}
Exhaust tem- Ambient temperature - -
q Whole speed
perature
range
(Turbo- °C
q Outside air tem- Exhaust temperature Max. 650 Max. 700
charger inlet
perature: 20°C
temperature)

30-170 GD555-5,GD655-5,GD675-5
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 Pm clinic
Pm Clinic

Standard value Mea-

Good
Service limit

Bad
Item Test conditions Unit for new sured
value
machine results
2.1 - 2.5 2.1 - 2.5
Power train main Low speed
{21.4 - 25.5} {21.4 - 25.5}
relief pressure
2.31 - 2.71 2.31 - 2.71
Full speed
q Torque converter oil {23.6 - 27.1} {23.6 - 27.1}
Torque converter temperature: 60 - 80°C 0.83 - 1.03 0.83 - 1.03
inlet pressure q During idle running with Full speed {8.5 - 10.5} {8.5 - 10.5}
gear shift lever in P pos-
Torque converter tion or each gear speed Full speed 0.55 - 0.75 0.55 - 0.75
outlet pressure {5.6 - 7.7} {5.6 - 7.7}
Torque converter
1.86 - 2.26 1.86 - 2.26
Power train oil pressure

lock-up clutch Full speed

{19 - 23.1} {19 - 23.1}
pressure
1.96 - 2.45 1.96 - 2.45
FL MPa {20 - 25} {20 - 25}
{kg/cm2} 2.06 - 2.45 2.06 - 2.45
R
{21 - 25} {21 - 25}
1.96 - 2.45 1.96 - 2.45
FH
{20 - 25} {20 - 25}
Transmission con- q Torque converter oil
1.96 - 2.45 1.96 - 2.45
trol valve set pres- temperature: 60 - 80°C 1st
{20 - 25} {20 - 25}
sure q Engine: Full speed
1.96 - 2.45 1.96 - 2.45
2nd
{20 - 25} {20 - 25}
1.96 - 2.45 1.96 - 2.45
3rd
{20 - 25} {20 - 25}
1.96 - 2.45 1.96 - 2.45
4th
{20 - 25} {20 - 25}

Standard value Mea-

Good
Service

Bad
Item Conditions Unit for new sured
limit value
machine results
q Hydraulic oil tem- Cut-in pressure 8.86 - 9.36
8.56 - 9.36
Brake accumula- {90.4 - 95.5}
{87.3 - 95.5}
perature: 45 - 55°C
tor charge pres-
q Engine at full Cut-out pres- 13.3 - 13.8 11.46 - 12.26
sure MPa
speed sure {kg/cm2} {135.7 - 140.8} {116.9 - 125.1}
Brake

q Hydraulic oil temperature: 45 - 55°

Wheel brake oper- 3.55 - 4.35 3.55 - 4.35
C
ating pressure {36.2 - 44.4} {36.2 - 44.4}
q Engine at full speed
q Hydraulic oil temperature: 45 - 55°
Wheel brake brak- C
m Max. 14 Max. 14
ing distance q Engine at full speed
q Braking distance from 35 km/h

GD555-5,GD655-5,GD675-5 30-171
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Pm clinic
Pm Clinic

Testing sheets for Pm Clinic (2/3) 30-172

Standard Mea-

Good
Service

Bad
Item Conditions Unit value for new sured
limit value
machine results
q Hydraulic oil temperature: 45 - 55°C
Steering oil pres- MPa 16.2 - 18.2 16.2 - 18.2
Steering

q Engine at full speed 2

sure {kg/cm } {165 - 186} {165 - 186}
q When steering is relieved
Steering wheel q Engine running at low idle
mm 0 - 25 -
play q Front wheels raised off the ground
Standard Mea-

Good
Service

Bad
Item Conditions Unit value for sured
limit value
new machine results
Hydraulic tank:
Work equipment oil pressure and LS differential pressure

surface tempera- q Engine stopped °C - -

ture
q Hydraulic oil temperature:
45 - 55°C Unload 3.3
-
q Engine at full speed pressure {34}
q Unload pressure: When
Work equipment
all work equipment in neu- Work
oil pressure
tral equip-
23.4
q Work equipment relief ment -
{250}
pressure: When leaning relief
cylinder relieved pressure MPa
{kg/cm2}

q Hydraulic oil temperature: 45 - 55°

LS differential C 2.25 - 2.45
-
pressure q Engine at full speed {2 - 25}
q During blade rotation operation

30-172 GD555-5,GD655-5,GD675-5
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 Pm clinic
Pm Clinic

Standard
Mea-

Good
value for Service

Bad
Item Conditions Unit sured
new limit value
results
machine
RAISE 2.3 - 3.1 4.0
Blade lifting speed
LOWER 2.3 - 3.1 4.0
Shift to
8.0 - 10.2 11.0
Blade side shift left
speed Shift to
8.0 - 10.2 11.0
right
Shift to
6.2 - 8.4 10.0
Drawbar side shift left
speed q Hydraulic oil temperature: 45 - Shift to
6.4 - 8.6 10.0
55°C right
q Engine at full speed Left rota-
7.5 - 10.1 12.0
Blade rotating q Blade lift: While cylinder travels tion
Work equipment speed

speed 350 mm, right/left operated in- Right

7.5 - 10.1 12.0
dependently rotation
q Blade side shift: Cylinder trav- Large
elling from end to end cutting 2.8 - 4.2 7.0
angle sec.
Power tilt speed q Blade rotation: Start of rotation
to 90°(degrees) Small
q Power tilt: Cylinder travelling cutting 3.0 - 4.6 7.0
from end to end angle
q Articulate: Cylinder travelling Left
5.9 - 8.1 14.0
from end to end swing
Articulate speed
Right
q Leaning: Cylinder travelling 5.9 - 8.1 14.0
swing
from end to end
Left lean-
1.5 - 2.1 6.0
ing
Leaning speed
Right
1.5 - 2.1 6.0
leaning
RAISE 1.5 - 1.9 3.0
Ripper speed
LOWER 1.2 - 1.6 3.0
Scarifier elevating RAISE 1.7 - 2.3 3.0
speed LOWER 1.7 - 2.3 3.0
a After setting the blade, stop the engine.
Standard
Mea-
Good
value for Service
Bad
Item Conditions Unit sured
new limit value
results
machine
Hydraulic drift

q Engine stopped
Blade hydraulic drift mm/10
q Cylinder at LOWER stroke end 10 20
(machine lifted) minutes
q Retraction of cylinder

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Pm clinic
Pm Clinic

Testing sheets for Pm Clinic (3/3) 30-174

a Replace with spare plug

Standard value

Good
Service Test

Bad
Item Conditions Unit for new
limit value results
machine
Visual inspection of There must be no excessive
FD

q Engine stopped -
final drive drain plug metal particles
Standard value

Good
Service Test

Bad
Item Conditions Unit for new
limit value results
machine
Front left
wheel
Front right
wheel 14.00-24-10PR:
Rear left 230 - 270 {2.3 - 2.7}
front side kPa 14.00-24-12PR:
Tire

Tire air pressure:

Rear left {kg/cm2} 255 - 295 {2.6 - 3.0}
rear side 17.5R25TG:
Rear right 230 - 270 {2.3 - 2.7}
front side
Rear right
rear side

Notes: Enter here phenomena and facts you noticed during today's check.

30-174 GD555-5,GD655-5,GD675-5
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GD555-5,GD655-5,GD675-5
SEN0521512-00 40-1

MOTOR GRADER
Shop Manual 40-1

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

40 Troubleshooting 40-1

GD555-5,GD655-5,GD675-5 40-1
(01)
Table of contents

Table of contents 40-2

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
Failure code [CA111] Engine controller internal error.......................................................... 40- 148
Failure code [CA115] Engine Ne, Bkup speed sensor error ................................................ 40- 149

40-2 GD555-5,GD655-5,GD675-5
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 Table of contents

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
Failure code [D160KB] Backup lamp relay: Ground fault .................................................... 40- 240
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault............................ 40- 242

GD555-5,GD655-5,GD675-5 40-3
(01)
Table of contents

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 error40-256
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 error40-285
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 match40-303
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
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

40-4 GD555-5,GD655-5,GD675-5
(01)
 Table of contents

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
E-29 Window washer does not operate............................................................................... 40- 454
E-30 KOMTRAX system does not operate correctly ........................................................... 40- 458

GD555-5,GD655-5,GD675-5 40-5
(01)
Table of contents

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

40-6 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Points to remember when troubleshooting

General information on troubleshooting 40-7

Points to remember when troubleshooting 40-7
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
ventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
standthe structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious
questions to form some idea of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassem-
bled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out trouble-
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble-
shooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
4) Check maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to reenact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspec-
tion in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the failure exactly.
a The basic procedures for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or informa-
tion.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.To prevent this, always investigate
why the problem occurred. Then, remove the
root cause.

3. Checks before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.

GD555-5,GD655-5,GD675-5 40-7
(01)
General information on troubleshooting
Sequence of events in troubleshooting

Sequence of events in troubleshooting 40-8

(Rev. 2007. 12)

40-8 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

Checks before troubleshooting 40-9

No. Item Criterion Remedy

1 Check for abnormal sounds and smells – Repair

2 Check for dirt around engine – Remove

3 Check for water leakage around engine – Repair

4 Check for oil leakage around engine – Repair

a Engine, lubricating oil and coolant

5 Check for leakage from fuel line – Repair

6 Check of radiator for clogging – Remove

7 Check of level and type of fuel – Refill oil

8 Check for foreign matter in fuel – Clean and drain

9 Check of fuel prefilter – Replace

10 Check of fuel filter – Replace

11 Check of level (in oil pan) and type of engine oil Between H – L Refill oil

12 Check of coolant level (in sub tank) Between H – L Refill coolant

No clogging
13 Check of air cleaner clogging indication on Clean or replace
monitor
1 Check for abnormal sounds and smells – Repair

2 Check for oil leakage – Repair

b Hydraulic and mechanical equipment

3 Check of hydraulic oil Between H – L Refill oil

4 Check of hydraulic oil strainer – Clean and drain

5 Check of hydraulic oil filter – Replace

6 Check of oil level in transmission case Between H – L Refill oil

7 Check of power train pump strainer – Clean and drain

8 Replacement of transmission oil filter – Replace

9 Check of final drive case oil level Between H – L Refill oil

10 Performing air bleeding operation – Air bleeding

GD555-5,GD655-5,GD675-5 40-9
(01)
General information on troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy

Retighten or
1 Check of battery cable terminals for looseness and corrosion –
replace
Retighten or
2 Check of alternator terminals for looseness and corrosion –
replace
Retighten or
3 Check of starting motor terminals for looseness and corrosion –
replace
Charge or
4 Check of battery voltage (with engine stopped) 20–30 V
replace

5 Check of battery electrolyte level Between H - L Add or replace

6 Check of wiring harness for discoloration, burnt areas and cover peeling – Repair or replace

Check for coming off of wiring harness clamp and sagging of wiring har-
7 – Repair
ness
c Electrical equipment

8 Check of grounding – Repair

9 Check for loose connector and damaged lock – Repair or replace

10 Check of connector pin for corrosion, bends and deformation – Repair or replace

Dry, clean or
11 Check for water and foreign matter in connector –
replace

12 Check of open circuit or or short circuit in wiring harness – Repair or replace

13 Check of fuse for blowout and corrosion – Replace

14 Slow-blow fuse – Replace

After several
minutes opera-
15 Check of alternator voltage (when engine speed is medium or higher) Replace
tion: 27.5 - 29.5
V
Check of battery relay operation sound (when starting switch is turned to
16 – Replace
ON or OFF position)
e: Interior parts d: Exterior parts

1 Check of tires – Repair

2 Check of handrails and steps – Repair

3 Check of rear view mirrors – Clean or repair

1 Check of gauges and monitors – Clean or replace

2 Check of seat belt – Repair

40-10 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

Testing procedure before troubleshooting 40-1

Walk-around check 40-1

Before starting the engine, look around and under the machine to check for any loose bolts or nuts, leakage
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.

k Accumulated combustibles around hot engine parts such as the engine muffler, turbocharger, etc.
and leaking fuel and oil may cause a machine fire. Check thoroughly and repair any abnormalities
without fail.

a1., b1. Check for abnormal sounds and smells
Check for abnormal sounds and smells.
Some causes of abnormal sounds and smells
can damage the machine if they are left as they
are. Therefore, stop the machine immediately
when you discover the cause.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around
the engine and any combustibles (dead leaves,
twigs, etc.) on hot engine parts such as the en-
gine muffler, turbocharger, etc.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the battery.
d1. Check of tires for abnormalities, wear, loose
bolts
Repair any abnormalities.

a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any wa-
ter leaks from the cooling system. If any of them
is abnormal, repair it.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and
tubes. If any of them is abnormal, repair it.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the radiator.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning
and testing of radiator fins, oil cooler fins, after-
cooler fins, and air conditioner condenser fins."
d2. Check of handrails and steps for abnormali-
ties and loose bolts
Repair any abnormalities and retighten any
loose bolts.
d3. Check and cleaning of rear view mirrors (if
equipped)
Check and repair any abnormalities and break-
age of the rear view mirrors.
Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind him
from the operator's seat.
e1. Check of gauges and monitors for abnormal-
ities
Check the gauges and monitors inside the oper-
ator cab. If any of them is abnormal, replace it.
Clean up the surfaces.

b2. Check of work equipment, cylinders, linkage e2. Check of seat belt and mounting hardware
and hoses for breakage, wear and clearance Check any damaged hooks, locks and hook fit-
Check the work equipment, cylinders, linkage tings. If any of them is abnormal, repair it.
and hoses for cracks and excessive wear, check
that each clearance is within the normal range,
and then repair any abnormalities.

GD555-5,GD655-5,GD675-5 40-11
(01)
General information on troubleshooting
Checks before troubleshooting
Testing according to testing procedure
a. Engine lubricating oil and coolant
a7. Check of level and type of fuel
k Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it over-
flow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (G) in
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level.
q If the filter of breather (1) is clogged, the pres-
sure in the tank decreases and fuel may not
be supplied. To prevent this, clean the filter.
40-12
40-12 a8. Check for foreign material in fuel
40-12 Open drain valve (1) to discharge the sediment and
water in the bottom together with the fuel into a
waste oil container.
a9. Check of fuel pre-filter (water separator)
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel prefilter cartridges use a
special filter with a high filtration efficiency.
When replacing, be sure to use a Komatsu gen-
uine cartridges.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel prefilter cartridge other than
Komatsu genuine one is used, foreign matter
may enter, which can cause a trouble in the in-
jection system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
GD555-5,GD655-5,GD675-5
(01)

1. Open the left engine side cover.
2. Remove connector (1) and clamp (2).
a Cover the terminals of the removed connec-
tor by using a vinyl bag or a tape to protect
them.
3. Place the fuel container under filter cartridge (3).
4. Disconnect hose (6) connected to drain plug (5).
5. Using the filter wrench, rotate filter cartridge (3)
to the left to remove.
6. Rotate cup (4) of the water separator installed to
the bottom of the removed cartridge to the left to
remove. If there is any damage, replace the cup.
7. Install removed cup (4) to the bottom of the new
fuel prefilter cartridge. At this time, be sure to
replace the seal ring with a new one.
3 Tightening torque of cup (4): 10 Nm
{1.0 kgm}
a When installing the seal ring, apply clean
fuel to its surface.
8. Ensure that drain plug (5) at the bottom of cup
(4) of the fuel prefilter is tightened securely.
3 Tightening torque:
0.2 - 0.45 Nm {0.02 - 0.046 kgm}
9. Clean the filter base.
10. Fill the new filter cartridge with clean fuel through
eight small holes (B) on it.
11. Thinly apply clean oil to the packing surface of
the filter cartridge.
12. Remove filter cartridge cap (A) and install the
filter cartridge to the filter base.
GD555-5,GD655-5,GD675-5
(01)
General information on troubleshooting
Checks before troubleshooting
13. When installing the filter cartridge, tighten it by
3/4 turns after its packing surface has been
securely placed on the sealing surface of the
filter base.
a If the filter cartridge is over tightened, fuel will
leak because of the breakage of the packing.
If the filter cartridge is not tightened suffi-
ciently, fuel will also leak through the clear-
ance of the packing. Therefore, observe the
tightening angle.
14. Connect removed connector (1), clamp (2), and
hose (6).
15. Then, proceed to "a10. Check of fuel filter".
a10. Check of fuel filter
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridges.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
40-13
General information on troubleshooting
Checks before troubleshooting

q Prepare the filter wrench.
1. Open the right engine side cover.
2. Place the fuel container under the filter cartridge.
3. Using the filter wrench, rotate filter cartridge (1)
to the left to remove.
4. Clean the filter base.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
2. Open the right engine side cover.
3. Remove oil level gauge (G) and wipe oil off with
a cloth.
4. Insert oil level gauge (G) fully and pull it out.

5. Apply oil to the packing surface of the filter 5. If the oil level is between stamps on oil level
cartridge. gauge (G), it is at the correct level.
6. Remove filter cartridge cap (A) and install the If the oil level is below the stamp, add oil through
filter cartridge to the filter base. oil filler port (F).
7. When installing the filter cartridge, tighten it by
3/4 turns after its packing surface has been
securely placed on the sealing surface of the
filter base.
a If the filter cartridge is over tightened, fuel will
leak because of the damage to the packing.
If the filter cartridge is not tightened suffi-
ciently, fuel will also leak through the clear-
ance of the packing. Therefore, observe the
tightening angle.

6. If the oil level is above H

1) Place a waste oil container directly below
drain plug (P) on the rear right side.
A 2) Open drain plug (P) to drain the oil.
3) Tighten drain plug (P).
3 Tightening torque of drain plug:
118 - 162 Nm {12 - 16.5 kgm}

9 J A0 7 6 3 9

a11. Check of level (in oil pan) and type of en-

gine oil
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
7. If the oil is at the correct level, tighten the oil filler
level.
cap securely and close the engine hood.

40-14 GD555-5,GD655-5,GD675-5
(01)

a12. Check of coolant level (in sub tank)
k The radiator cap does not need to be opened
for the usual check.. Check the coolant level
on the sub tank side while the engine is cold.
k Immediately after the engine is stopped, the
coolant is hot and pressure is accumulated
in the radiator. If the cap is opened under
these conditions, you may be scalded. When
the radiator cap needs to be removed, wait
until the temperature drops and rotate the
cap slowly to release the pressure. Remove it
fully, exercising care.
1. Check that the coolant level in sub tank (1) is
between FULL and LOW. If the coolant level is
insufficient, open the cover and add Super-
coolant (AF-NAC) through the coolant filler of
sub tank (1) up to between FULL and LOW.
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank has been empty, the coolant may
be leaking. Check and repair immediately if
there is any abnormality. If there are no abnor-
malities, check the coolant level in the radiator
and add Supercoolant (AF-NAC) if necessary.
Then, add Supercoolant (AF-NAC) to the sub
tank.
GD555-5,GD655-5,GD675-5
(01)
General information on troubleshooting
Checks before troubleshooting
a13. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as safety
glasses, cotton gloves, dust mask, etc. to
protect yourself from dirt that will fly out.
k It is dangerous to use excessive force to pull
out the outer element from the air cleaner
body. When working in an elevated or unsta-
ble location, take care that you do not fall due
to the momentum created when you pull out
the outer element.
k If the air cleaner is checked, cleaned, or ser-
viced while the engine is running, dirt will en-
ter the engine and damage the engine. Be
sure to stop the engine before working on the
air cleaner.
Testing
1. Open the right engine side cover.
2. If yellow indicator plate (2) in the transparent
portion of dust indicator (1) has reached red line
(3), clean the air cleaner element.
a Do not clean the element of dust indicator (1).
If the element is cleaned frequently before the
yellow indicator plate of dust indicator (1)
reaches the red line, the true performance of the
air cleaner will not be realized and the cleaning
effect will decrease.
40-15
General information on troubleshooting
Checks before troubleshooting
Cleaning and replacement of outer element
a Do not leave or store the element in direct sun-
light before or after cleaning it.
a Replace the outer element after cleaning it 6
times or after using it for 1 year. When replacing
the outer element, replace the inner element,
too.
a If the yellow indicator plate of the dust indicator
reaches the center of the scale (5 kPa) just after
the outer element is cleaned, replace both outer
and inner elements, even if the outer element
has not been cleaned 6 times.
1. Open the right engine side cover and remove
clip (3) and dust cup (4).
2. Take out outer element (5) and clean the inside
of the air cleaner body and dust cup (4).
a Never remove inner element (6). If it is re-
moved, dirt will enter and can lead to engine
troubles.
a When cleaning the dust cup, do not remove
vacuator valve (7).
40-16
3. Blow dry compressed air (Max. 0.20 MPa {2
kg/cm2}) along the inside pleats of the element.
Next, blow air along the outside pleats, and blow
again along the inside pleats.
4. After cleaning, light up the inside of the element
to check it. If the element has a small hole or a
thin area, replace it.
a When cleaning the element, do not hit it or
strike it against something.
a Do not use the element if its pleats, gasket or
seal is damaged.
a If the element is installed forcibly, it can dam-
age the clip or the air cleaner body. Install it
by pushing it in straight.
a Do not run the engine with the inner element
removed since doing so damages the en-
gine.
5. Set the cleaned outer element, install dust cup
(4), and fix them with clip (3).
k If the inner and outer elements were re-
placed, be sure to replace O-ring (8) with
a new one.
6. Press the button of dust indicator (1) to return the
yellow indicator plate.
7. Close the right engine side cover.
GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

b. Hydraulic and mechanical equipment 40-17

b3. Check of hydraulic oil level

k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and remove it.
1. Set the machine in the posture for checking the
oil level according to the following explanation. 5. If the oil level is above the gauge window, drain
q Set the front tires upright in the straight travel the excessive oil through drain plug, and then
direction. check the oil level again.
q Set the front frame and rear frame straight 6. If the oil is at the correct level, tighten the cap of
(articulate angle: 0 degrees) and install the oil filler port (F) securely and remove the hose.
articulate lock pin.
q Set the blade sideway shift mechanism to the b4. Check of hydraulic oil strainer
center of the machine, set the blade at a right k Immediately after the engine is stopped, its
angle to the machine, and then bring it in light parts and oil are still very hot and they may
contact with the ground. burn your hands on contact them. Therefore,
q If the machine is equipped with the blade ac- wait until they have cooled down before
cumulator, turn the blade accumulator switch starting the work.
ON and raise the blade to the maximum to k If the oil filler cap is removed quickly, the oil
discharge the oil from the accumulator. Then, may spurt out. Therefore rotate the oil filler
turn the accumulator switch OFF and lower cap slowly to release the internal pressure
the blade to the ground. and then remove it.
2. Start the engine and run at low idle. 1. Remove bolts (1) to remove cover (2).)
3. Check the oil level by using sight gauge (G). If
the oil level is in the window of gauge (G), it is
proper.
a Do not add oil to above the gauge window. If
too much is added, it may damage the hy-
draulic circuit and spurt out.
a If the oil level is higher than the gauge win-
dow, stop the engine. After the hydraulic oil
has cooled, drain excessive oil through the
drain plug.

2. Loosen oil filler (F) gradually to release all the air

in the hydraulic tank.

4. If the oil level is below the window of gauge (G),

remove bolts (1) (6 pieces) and cover (2), and
add oil through oil filler port (F).

GD555-5,GD655-5,GD675-5 40-17
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General information on troubleshooting
Checks before troubleshooting

b5. Check of hydraulic oil filter

3. After stopping the engine, depress the brake
pedal about 20 times to return the oil in the accu-
mulator to the tank. If the machine is equipped
with the blade accumulator, stop the engine with
the accumulator "ON" and operate the blade lift
lever to release the pressure.
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k If the oil filler cap is removed quickly, the oil

4. Place a waste oil container under drain plug (P).
5. Loosen drain plug (P) so that the oil will not spurt
over you, and drain the oil.
a Loosen drain plug (P) slowly so that the oil
will not spout out.
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and then remove it.
1. Remove bolts (1) to remove cover (2).
2. Remove bolts (3) to remove cover (4).

6. After draining the oil, remove bolts (3) (6 pieces)

and cover (4).
a When removing bolts (3), keep pressing cov-
er (4) down since it may be flown out by gas
spring (5).
7. Pull up the top of rod (6) and remove spring (5)
and strainer (7).
8. Remove dirt from strainer (7) and clean using
cleaning oil. If strainer (7) is broken, replace it
with a new one.
9. Insert and set strainer (7) in projected portion (8)
of the tank.
10. While pressing down spring (5) with the projec-
tion at the bottom of cover (4), install bolts (3).

11. Tighten drain plug (P).

40-18 GD555-5,GD655-5,GD675-5
(01)

3. Remove the element, clean the removed parts
and the inside of the filter case, and install the
new element.
4. Install cover (4) and bolts (3).
5. Install cover (2) and bolts (1).
GD555-5,GD655-5,GD675-5
(01)
General information on troubleshooting
Checks before troubleshooting
b6. Check oil level in transmission case
k Immediately after the engine is stopped, its
parts and oil are still very hot. Therefore, wait
until they have cooled down before starting
the work.
k Before starting inspection, set the gear shift
lever to the P (PARKING) position so that the
machine does not move, and ensure that all
other levers are in the neutral position.
q Oil remains in each part and the oil level can-
not be checked correctly for 12 hours after
the engine is stopped. Accordingly, wait for at
least 12 hours before checking the oil level.
1. Stop the engine.
2. Remove the cap of oil filler port (F).
3. Pull out oil level gauge (G), wipe the oil from it
with cloth, and the insert it fully in the oil filler pipe
and pull it out.
4. If the oil level is between stamps H and L of oil
level gauge (G), it is at the correct level.
q If the oil level is below L, add oil through oil
filler port (F).
5. If the oil level is above H, remove drain plug (1)
and loosen drain plug (2) gradually to drain the
excessive oil, and then check the oil level again.
40-19
General information on troubleshooting
Checks before troubleshooting

6. If the oil is at the correct level, insert oil level

gauge (G) in the oil filler pipe and install the oil
filler cap.
q Oil level gauge (G) has stamps for checking
(A) while the engine is stopped (ENG STOP)
on one side and (B) while the engine is idling
(ENG IDLING) on the other side. Use the
stamp checking (A) when the engine is
stopped (ENG STOP).

6. Remove dirt from strainer (7) and clean it by

using diesel fuel oil or cleaning oil. If the strainer
is broken, replace it with a new one.
7. After cleaning, install strainer (7), replace O-ring
(6) of cover (5) with a new one, install cover (5),
and tighten bolts (4).

8. Add oil through oil filler port (F) up to the speci-

fied level.
b7. Transmission 9. After adding oil, check the oil level, referring to
1. Place the oil container under the transmission "Check of oil level in transmission case".
case.
2. Remove drain plug (1).
q Loosen drain plug (2) slowly so that the oil
will not spout out.
3. After draining the oil, tighten drain plug (2) and
install drain plug (1).
3 Drain plug (1): 59 - 78.5 Nm {6 - 8 kgm}
3 Drain plug (2): 49 - 78.5 Nm {5 - 8 kgm}
3 Drain plug (3): 9.8 - 12.7 Nm {1.0 - 1.3
kgm}
4. Remove drain plug (3) to drain the oil.
5. Remove bolts (4) to remove cover (5) and
remove and clean strainer (7).

40-20 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

b8. Replacement of transmission oil filter and

cartridge
k Immediately after the engine is stopped, its
parts and oil are still very hot. Therefore, wait
until they have cooled down before starting
the work.
q Prepare the box-end combination wrench.
1. Place the oil container under the filter cartridge.
2. Using the box-end combination wrench, rotate
filter cartridge (1) to the left to remove.
3. Clean the filter base, apply clean engine oil to
the sealing surface of the new filter cartridge,
and install the filter cartridge.
3 Tightening torque: 49 - 59 Nm {5 - 6 4. If the oil level is above H, drain the excessive oil
kgm} through drain plug (P), and then check the oil
level again.
5. If the oil is at the correct level, insert oil level
gauge (G) in the oil filler pipe and install the oil
filler cap.

b9. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
1. Stop the engine and wait for at least five
minutes.
2. Remove the oil filler cap, pull out oil level gauge
(G) from the oil filler, wipe the oil from it with
b10. Execution of air bleeding operation
q For the procedure for bleeding air from the fuel
system, see Testing and adjusting, "Bleeding air
from fuel circuit".
q For the procedure for bleeding air from the hy-

cloth, and the insert it fully in the oil filler pipe and draulic equipment, see Testing and adjusting,
pull it out. "Bleeding air from work equipment circuit".
3. If the oil level is between stamps H and L of oil
level gauge (G), it is at the correct level.
q If the oil level is below L, add oil through oil
filler port (F).

GD555-5,GD655-5,GD675-5 40-21
(01)
General information on troubleshooting
Checks before troubleshooting
c. Electrical equipment 40-2
c1. Check of battery terminals for looseness and
corrosion
Check the terminals of battery (1) at the left rear of
the cab for looseness and corrosion.
c2. Check of alternator terminals for looseness
and corrosion
Open the engine hood and check alternator termi-
nals B and R for breakage, looseness and corro-
sion.
40-22
c3. Check of starting motor terminals for loose-
ness and corrosion
Open the engine hood and check starting motor ter-
minals B and C for breakage, looseness and corro-
sion.
c4. Testing of battery voltage (with engine
stopped)
Using the battery tester, test the battery voltage
while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with wa-
ter and contact your doctor.
a Do not add battery electrolyte to above the UP-
PER LEVEL mark. If too much is added, it can
damage the painted surface and corrode the
parts.
a As refined water (example: commercially avail-
able battery fluid) added to the battery may
freeze, add it before starting work for the day so
that it will not freeze.
q When checking the electrolyte level from the
side of the battery
1. Clean around the electrolyte level lines with a
cloth dampened with water and check that the
electrolyte level is between UPPER LEVEL
(U.L.) and LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since
static electricity may cause an explosion.
GD555-5,GD655-5,GD675-5
(01)

2. If the electrolyte level is below the center
between the U.L. and L.L. lines, remove cap (2)
and add refined water (example: commercially
available battery fluid) to the U.L. line immedi-
ately.
3. After adding the refined water, tighten cap (1)
securely.
a If you have added refined water above the
U.L. line, take some of it out by using a sy-
ringe or similar tool. Neutralize the liquid that
has been taken out with sodium bicarbonate
or other suitable liquid, and wash it out with a
large amount of water.
q When electrolyte level cannot be checked from
the side of the battery
1. Remove cap (1) on the top of the battery.
(described previously)
2. Look into electrolyte level opening (2) to check
the electrolyte level. If the electrolyte level is
below sleeve (3), be sure to add refined water
(example: commercially available battery fluid)
up to the sleeve bottom (U.L. line).
q (A) Correct level: Since the electrolyte level is
higher than the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level is below
the sleeve bottom, the shape of the electrode
plates will appear straight.
3. After adding the refined water, tighten cap (1).
GD555-5,GD655-5,GD675-5
(01)
General information on troubleshooting
Checks before troubleshooting
a If you have added refined water above the
U.L. line, take some of it out by using a sy-
ringe or similar tool. Neutralize the liquid that
has been taken out with sodium bicarbonate
or other suitable liquid, and wash it out with a
large amount of water.
c6. Check of wiring harness for discoloration,
burnt areas and cover peeling
q Check the wiring harness and cables for discol-
oration and burn.
a Discoloration and burnt areas indicate the possi-
bility of the short circuit or ground fault.
q Check the wiring harnesses and cables for dam-
age and peeling of the covers.
q If any fault are discovered, repair or replace the
wiring harness or cable.
c7. Check for removal of wiring harness clamps
and sagging of the wiring harness
q Check the wiring harnesses for sagging and play
caused by coming off of the clamp.
a In particular, carefully check around the hot and
movable parts.
q If any part is off the clamp, secure it with clamp
again.
40-23
General information on troubleshooting
Checks before troubleshooting

c8. Check of grounding

a Check the ground terminal for looseness and
rusting in particular.
1. Check the connection of ground strap (1) of
engine controller (EC).

5. Open cover (12).

2. Open covers (3) and (4).

3. Remove cover (5).

6. Check ground cables (13) – (15).

4. Check the ground cables (6) – (11).

40-24 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

7. Check the ground cable (16).

q Check the connector to see whether it is un-

8. Remove cover (17). locked and check its lock portion and housing for
cracks.
1. Remove covers (1) and (2).

9. Check ground cable (18).

2. Check lock screws (L) of controller (CNT) for

looseness.
a Use a 4-mm (width across flats) hexagonal
wrench.

c9. Check for loose connectors and damaged

locks
q Pull the male and female parts of the connector
by the hand to check the condition of their con-
nection.
q If the connecting condition is abnormal, connect
it securely.

GD555-5,GD655-5,GD675-5 40-25
(01)
General information on troubleshooting
Checks before troubleshooting

c10. Check of connector pin for corrosion, q Remove foreign matter in the connector by using
bends and deformation a cloth or other material, and blow compressed
q Disconnect the connector and check the pins for air against the inside of the connector.
corrosion, bending and retraction. Check that
the female pins have not expanded.
q If any pin is found to be abnormal, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times.)

c11. Check for water and foreign matter in the

connector
q Disconnect the connector and check whether
there is water, dirt, sand, etc. in it.

Caution
1. How to disconnect connector R1
Remove the connector straight slowly and check
it for breakage and coming off of the seal and
sticking of foreign matter.
a If the seal is defective, replace it.

a If there is sand or foreign matter in the connec-

tor, check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector by using a dri-
er.

2. How to install connector R1

1) Check that the seal is installed to the plug
correctly.
2) Check that the key is fitted to the receptacle
side (It must be in the correct direction).
3) Match the connector on the plug side straight
with the receptacle (since the seal is
projected), and fit the connector a little while
checking that the seal does not roll up.
4) Tighten the hexagonal head bolt at the center
of the connector by 2 - 3 turns.
5) Fit the connector on the plug side fully and
adjust it so that the clearance between it and
receptacle will be even when viewed from
each direction.
6) Tighten the lock bolt to the specified torque.
3 Hexagonal head bolt:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}

40-26 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

a Tightening too strongly can break the lock
bolt. So be careful.
c13. Check of fuse for breakage and corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF posi-
tion).
q The fuse holder is installed to the right front of
the operator seat.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace the fuse with a new one of the same ca-
pacity.

c12. Check of wiring harness for open and short

circuiting
q Check the connections (crimped parts) between
each connector pin and wiring harness.
q If there is any open circuit in wiring harness or
connector as illustrated in (A), repair or replace
them.

q Visually check whether any pins are touching

any adjacent pins due to peeling of the wire cov-
er, defective crimping of the pin, etc.

GD555-5,GD655-5,GD675-5 40-27
(01)
General information on troubleshooting
Checks before troubleshooting
c14. Slow-blow fuse
q The slow-blow fuse breaks the electrical circuit
to protect the electrical equipment and wiring
when an overcurrent flows through it.
q When the starting switch is turned to the ON po-
sition, if the power is not supplied, the slow-blow
fuse may be broken. Check the slow-blow fuse
and replace it if necessary.
(1) 60A: Secondary power supply slow-blow fuse
(2) 30A: Unswitched power supply slow-blow
(3) 120A: Heater relay (intake air heater) slow-blow
fuse
(4) 120A: Alternator slow-blow fuse
40-28
c15. Check of alternator voltage (when engine
speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) line of the tester to alter-
nator terminal (B) and connect the negative (-)
line to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is abnormal, repair or replace
the alternator.
c16. Check of battery relay operation sound
1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 in the E
mode.
q If the related circuits are free from abnormal-
ities, replace the battery relay.
GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Classification and procedures for troubleshooting

Classification and procedures for troubleshooting 40-29

Classification of troubleshooting 40-29
Mode Contents
Display of code Troubleshooting by failure code (Display of code)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine

Procedure for troubleshooting 40-29

If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting
No. according to the following procedure, and then go to the corresponding troubleshooting section.

1. Procedure for troubleshooting when action code is displayed on machine monitor:

If an action code is displayed on the machine monitor, display the failure code by using the abnormality
record display function (electrical system and mechanical system) of the machine monitor (EMMS).
a Since two or more troubles may have occurred simultaneously, press [>] button and record all the fail-
ure codes.
Perform the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
a Since the failure code "blinks" when a trouble is detected, that trouble may not have been repaired
even if the failure code "lights up" when the starting switch is turned to the ON position (Some codes
detect troubles when the starting switch is turned to the ON position, however).
a If any failure code is recorded, be sure to perform the operation to reproduce that code to see if the
trouble of that code has been or has not been repaired (For the reproduction method, see the trouble-
shooting in "Display of code").

2. Procedure for troubleshooting when failure code is recorded:

If an action code is not displayed on the machine monitor, display the failure code of the electrical system
and mechanical system by using the abnormality record display function of the machine monitor (EMMS).
If a failure code is recorded, perform troubleshooting for the corresponding "Display of code" according to
the failure code.
a Since the failure code "blinks" when a trouble is detected, that trouble may not have been repaired
even if the failure code "lights up" when the starting switch is turned to the ON position (Some codes
detect troubles when the starting switch is turned to the ON position, however).
a If any failure code is recorded, be sure to perform the operation to reproduce that code to see if the
trouble of that code has been or has not been repaired (For the reproduction method, see the trouble-
shooting in "Display of code").

3. Procedure for troubleshooting when action code is not displayed and failure code is not recorded:
If no failure code is found in the machine monitor (EMMS), a trouble that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list of "Failure and troubleshooting numbers", and then perform troubleshooting
corresponding to that problem in the "E-mode", "H-mode", or "S-mode".

GD555-5,GD655-5,GD675-5 40-29
(01)
General information on troubleshooting
Failure codes table

Failure codes table 40-30

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
TORQFLOW transmission: Double Mechanical
1500L0 TM – Q E03 40-99
engagement system
Electrical
15G0MW Transmission R clutch: Slip TM – Q E03 40-100
system
Electrical
15H0MW Transmission FH clutch: Slip TM – Q E03 40-101
system
Electrical
15J0MW Transmission FL clutch: Slip TM – Q E03 40-101
system
Electrical
15K0MW Transmission 1st clutch: Slip TM – Q E03 40-102
system
Electrical
15L0MW Transmission 2nd clutch: Slip TM – Q E03 40-103
system
Electrical
15M0MW Transmission 3rd clutch: Slip TM – Q E03 40-104
system
Electrical
15N0MW Transmission 4th clutch: Slip TM – Q E03 40-105
system
ECMV R clutch: Fill signal is ON Electrical
15SBL1 TM – – E01 40-106
when command signal is OFF system
Electrical
15SBMA ECMV R clutch: Malfunction TM – Q E03 40-108
system
ECMV FH clutch: Fill signal is ON Electrical
15SCL1 TM – – E01 40-110
when command signal is OFF system
Electrical
15SCMA ECMV FH clutch: Malfunction TM – Q E03 40-112
system
ECMV FL clutch: Fill signal is ON Electrical
15SDL1 TM – – E01 40-114
when command signal is OFF system
Electrical
15SDMA ECMV FL clutch: Malfunction TM – Q E03 40-116
system
ECMV 1st clutch: Fill signal is ON Electrical
15SEL1 TM – – E01 40-118
when command signal is OFF system
Electrical
15SEMA ECMV 1st clutch: Malfunction TM – Q E03 40-120
system
ECMV 2nd clutch: Fill signal is ON Electrical
15SFL1 TM – – E01 40-122
when command signal is OFF system
Electrical
15SFMA ECMV 2nd clutch: Malfunction TM – Q E03 40-124
system
ECMV 3rd clutch: Fill signal is ON Electrical
15SGL1 TM – – E01 40-126
when command signal is OFF system
Electrical
15SGMA ECMV 3rd clutch: Malfunction TM – Q E03 40-128
system
ECMV 4th clutch: Fill signal is ON Electrical
15SHL1 TM – – E01 40-130
when command signal is OFF system
Electrical
15SHMA ECMV 4th clutch: Malfunction TM – Q E03 40-132
system
Electrical
15SJMA ECMV lockup clutch: Malfunction TM – Q E03 40-134
system
Mechanical
15U0NT Inching clutch: Overheat TM – Q E02 40-134
system
Mechanical
2G42ZG Front accumulator: Pressure drop MON Q*2 Q E03 40-135
system
Mechanical
2G43ZG Rear accumulator: Pressure drop MON Q*2 Q E03 40-135
system
Mechanical
AA1ANX Air cleaner clogging MON Q*1 – E01 40-136
system

40-30 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Alternator: Engine start and stop Electrical
AB00L6 MON Q Q E03 40-138
signals are not matched system
Mechanical
AB00MA Alternator: Malfunction MON Q Q E03 40-140
system
Derating in speed due to engine oil Mechanical
B@BAZG ENG Q Q E03 40-142
pressure drop system
Mechanical
B@BCNS Engine coolant overheat ENG Q Q E02 40-142
system
Mechanical
B@CENS Torque converter oil overheat MON Q Q E02 40-143
system
Mechanical
B@CKNS Differential case: Overheat MON Q Q E02 40-144
system
Mechanical
B@HANS Hydraulic oil: Overheating MON Q Q E02 40-146
system
Electrical
CA111 Engine controller internal error ENG – Q E03 40-148
system
Electrical
CA115 Engine Ne, Bkup speed sensor error ENG – Q E03 40-149
system
Electrical
CA122 Charge pressure sensor high error ENG – Q E03 40-150
system
Electrical
CA123 Charge pressure sensor low error ENG – Q E03 40-152
system
Electrical
CA131 Throttle sensor high error ENG – Q E03 40-154
system
Electrical
CA132 Throttle sensor low error ENG – Q E03 40-156
system
Electrical
CA144 Coolant sensor high error ENG – – E01 40-158
system
Electrical
CA145 Coolant sensor low error ENG – – E01 40-160
system
Charge temperature sensor high Electrical
CA153 ENG – – E01 40-162
error system
Electrical
CA154 Charge temperature sensor low ENG – – E01 40-164
system
Speed derating error by high charge Electrical
CA155 ENG – Q E03 40-166
temperature system
Electrical
CA187 Sensor power supply 2 low error ENG – Q E03 40-168
system
Atmospheric pressure sensor high Electrical
CA221 ENG – – E01 40-170
error system
Atmospheric pressure sensor low Electrical
CA222 ENG – – E01 40-172
error system
Electrical
CA227 Sensor power supply 2 high error ENG – Q E03 40-174
system
Mechanical
CA234 Engine overspeed ENG – Q E02 40-174
system
Electrical
CA238 Ne speed sensor power supply error ENG – Q E03 40-175
system
Electrical
CA271 IMV/IMA: Short circuit ENG – Q E03 40-176
system
Electrical
CA272 IMV/IMA open circuit ENG – Q E03 40-178
system
Electrical
CA322 Inj #1 (L#1) open/short ENG – Q E03 40-180
system
Electrical
CA323 Inj #5(L#5) open/short ENG – Q E03 40-182
system
Electrical
CA324 Inj #3 (L#3) open/short ENG – Q E03 40-184
system
Electrical
CA325 Inj #6 (L#6) open/short ENG – Q E03 40-186
system

GD555-5,GD655-5,GD675-5 40-31
(01)
General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Electrical
CA331 Inj #2 (L#2) open/short ENG – Q E03 40-188
system
Electrical
CA332 Inj #4 (L#4) open/short ENG – Q E03 40-190
system
Data compatibility error in engine Electrical
CA342 ENG – Q E03 40-192
controller system
Electrical
CA351 Injector drive circuit error ENG – Q E03 40-193
system
Electrical
CA352 Sensor power supply 1 low error ENG – Q E03 40-194
system
Electrical
CA386 Sensor power supply 1 high error ENG – Q E03 40-195
system
Electrical
CA428 Water-in-fuel sensor high error ENG – – E01 40-196
system
Electrical
CA429 Water-in-fuel sensor low error ENG – – E01 40-198
system
Electrical
CA431 Idle validation switch error ENG – – E01 40-200
system
Electrical
CA432 Idle validation action error ENG – Q E03 40-204
system
Electrical
CA435 Engine oil pressure switch error ENG – – E01 40-207
system
Electrical
CA441 Power supply voltage low error ENG – Q E03 40-208
system
Electrical
CA442 Power supply voltage high error ENG – Q E03 40-210
system
Electrical
CA449 Common rail pressure high error 2 ENG – Q E03 40-211
system
Common rail pressure sensor high Electrical
CA451 ENG – Q E03 40-212
error system
Common rail pressure sensor low Electrical
CA452 ENG – Q E03 40-214
error system
Torque derating error by high charge Electrical
CA488 ENG – Q E03 40-216
temperature system
Electrical
CA553 Common rail pressure high error 1 ENG – Q E03 40-217
system
Electrical
CA559 Supply pump pressure low error 1 ENG – Q E03 40-218
system
Electrical
CA689 Engine Ne speed sensor error ENG – Q E03 40-219
system
Engine Bkup speed sensor phase Electrical
CA731 ENG – Q E03 40-221
error system
Electrical
CA757 All continuous data lost error ENG – Q E03 40-222
system
Electrical
CA778 Engine Bkup speed sensor error ENG – Q E03 40-223
system
Electrical
CA1633 KOMNET CAN communication error ENG – Q E03 40-226
system
Throttle sensor power supply high Electrical
CA2185 ENG – Q E03 40-228
error system
Throttle sensor power supply low Electrical
CA2186 ENG – Q E03 40-230
error system
Electrical
CA2249 Supply pump pressure low error 2 ENG – Q E03 40-232
system
Electrical
CA2311 Abnormality in IMV (IMA) solenoid ENG – Q E03 40-233
system
Electrical
CA2555 Intake heater relay open circuit ENG – – E01 40-234
system

40-32 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Electrical
CA2556 Intake heater relay short circuit ENG – – E01 40-236
system
Backup lamp relay: Open circuit, hot Electrical
D160KA TM – – E01 40-238
short ciruit in wiring harness system
Electrical
D160KB Backup lamp relay: Ground fault TM – – E01 40-240
system
Differential lock relay: Open circuit, Electrical
D19KKZ TM – – E01 40-242
ground fault system
C terminal signal: Signal does Electrical
D5ZHL6 MON – – E01 40-244
match to actual engine state system
CAN communication failure (monitor Electrical
DAFRKR TM – Q E03 40-246
panel) system
Transmission controller: Power sup- Electrical
DAQ0KK TM – Q E03 40-248
ply voltage drop (input) system
Transmission controller: Non-vola- Electrical
DAQ0KT TM – – E01 40-250
tile memory error system
Transmission controller load power
Electrical
DAQ2KK line: Power supply voltage drop TM – Q E03 40-252
system
(input)
Transmission controller model
DAQ9KQ selection: Model selection signal MON – Q E03 – 40-254
disagreement

Transmission controller CAN com- Electrical

DAQRKR MON – Q E03 40-256
munication: Communication error system

Transmission controller option set-

DAQRMA MON – Q E03 – 40-260
ting: Malfunction
Engine controller CAN communica- Electrical
DB2RKR MON – Q E03 40-261
tion: Communication error system
Fan reverse switch signal: Short cir- Electrical
DD1NLD TM – – E01 40-268
cuit system
RPM set switch power supply short Electrical
DD1PKB TM – Q E03 40-270
circuit system
Electrical
DD1QKB RPM set mode switch short circuit TM – Q E03 40-272
system
Transmission gearshift lever: Park- Electrical
DDB6L4 TM – Q E03 40-274
ing brake signal error system
Electrical
DDTHKA Fill switch for FH clutch: Open circuit TM – – E01 40-276
system
Electrical
DDTJKA Fill switch for FL clutch: Open circuit TM – – E01 40-276
system
Electrical
DDTKKA Fill switch for 1st clutch: Open circuit TM – – E01 40-277
system
Fill switch for 2nd clutch: Open cir- Electrical
DDTLKA TM – – E01 40-277
cuit system
Fill switch for 3rd clutch: Open cir- Electrical
DDTMKA TM – – E01 40-277
cuit system
Electrical
DDTNKA Fill switch for R clutch: Open circuit TM – – E01 40-278
system
Electrical
DDTPKA Fill switch for 4th clutch: Open circuit TM – – E01 40-279
system
Transmission gearshift lever: No Electrical
DF10KA TM – Q E03 40-281
gear speed signal is input system

GD555-5,GD655-5,GD675-5 40-33
(01)
General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Transmission gearshift lever: Gear Electrical
DF10L4 TM – Q E03 40-285
speed/travel direction signal error system
Transmission oil temperature sen- Electrical
DGF1KX TM – Q E03 40-288
sor: Input signal out of range system
Hydraulic oil temperature sensor: Electrical
DGH2KB TM – – E01 40-290
Ground fault system
Torque converter oil temperature Electrical
DGT1KX TM – – E01 40-292
sensor: Input signal out of range system
Differential oil temperature sensor: Electrical
DGT7KB TM – – E01 40-294
Ground fault system
Electrical
DJF1KA Fuel level sensor: Open circuit MON – – E01 40-296
system
Inching pedal angle sensor: Input Electrical
DK70KX TM – Q E03 40-298
signal out of range system
Articulation angle sensor: Input sig- Electrical
DKD0KA TM – – E01 40-300
nal out of range system
Transmission input shaft speed sen- Electrical
DLF1KA TM – Q E03 40-302
sor: Open circuit system
Transmission input shaft speed sen- Electrical
DLF1LC TM – Q E03 40-303
sor: Speed signal does not match. system
Transmission intermediate shaft Electrical
DLF2KA TM – Q E03 40-304
speed sensor: Open circuit system
Transmission intermediate shaft
Electrical
DLF2LC speed sensor: Speed signal does TM – Q E03 40-305
system
not match.
Electrical
DLM3KA Fan speed sensor: Open circuit TM – – E01 40-306
system
Electrical
DLM3LC Fan speed sensor: Short circuit TM – – E01 40-307
system
Transmission output shaft speed Electrical
DLT3KA TM – Q E03 40-308
sensor: Open circuit system
Electrical
DV00KB Bazzer: Short circuit MON – – E01 40-310
system
Parking brake solenoid valve: Open Electrical
DW4BKA TM – Q E03 40-312
circuit system
Parking brake solenoid valve: Short Electrical
DW4BKB TM – Q E03 40-314
circuit system
Electrical
DW7BKA Fan reverse solenoid: Open circuit TM – – E01 40-315
system
Electrical
DW7BKB Fan reverse solenoid: Short circuit TM – – E01 40-316
system
Fan reverse solenoid: Short circuit Electrical
DW7BKY TM – – E01 40-318
to power supply line system
Fan motor EPC solenoid: Open cir- Electrical
DX16KA TM – – E01 40-320
cuit system
Fan motor EPC solenoid: Short cir- Electrical
DX16KB TM – – E01 40-321
cuit system
Fan motor EPC solelnoid: Short cir- Electrical
DX16KY TM – – E01 40-322
cuit to power supply line system
Electrical
DXH1KA Lockup solenoid: Open circuit TM – Q E03 40-324
system
Electrical
DXH1KB Lockup solenoid: Short circuit TM – Q E03 40-325
system
Lockup ECMV solenoid: Short cir- Electrical
DXH1KY TM – Q E03 40-326
cuit to power supply line system

40-34 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
FH clutch ECMV solenoid: Open cir- Electrical
DXH2KA TM – Q E03 40-328
cuit system
FH clutch ECMV solenoid: Short cir- Electrical
DXH2KB TM – Q E03 40-329
cuit system
FH clutch ECMV solenoid Short cir- Electrical
DXH2KY TM – Q E03 40-330
cuit to power supply line system
FL clutch ECMV solenoid: Open cir- Electrical
DXH3KA TM – Q E03 40-332
cuit system
FL clutch ECMV solenoid: Short cir- Electrical
DXH3KB TM – Q E03 40-334
cuit system
FL clutch ECMV: Short circuit to Electrical
DXH3KY TM – Q E03 40-336
power supply line system
1st clutch ECMV solenoid: Open cir- Electrical
DXH4KA TM – Q E03 40-338
cuit system
1st clutch ECMV solenoid: Short cir- Electrical
DXH4KB TM – Q E03 40-340
cuit system
1st clutch ECMV solenoid: Short cir- Electrical
DXH4KY TM – Q E03 40-342
cuit to power supply line system
2nd clutch ECMV solenoid: Open Electrical
DXH5KA TM – Q E03 40-344
circuit system
2nd clutch ECMV solenoid: Short Electrical
DXH5KB TM – Q E03 40-346
circuit system
2nd clutch ECMV solenoid: Short Electrical
DXH5KY TM – Q E03 40-348
circuit to power supply line system
3rd clutch ECMV solenoid: Open cir- Electrical
DXH6KA TM – Q E03 40-350
cuit system
3rd clutch ECMV solenoid: Short cir- Electrical
DXH6KB TM – Q E03 40-352
cuit system
3rd clutch ECMV solenoid: Short cir- Electrical
DXH6KY TM – Q E03 40-354
cuit to power supply line system
R clutch ECMV solenoid: Open cir- Electrical
DXH7KA TM – Q E03 40-356
cuit system
R clutch ECMV solenoid: Short cir- Electrical
DXH7KB TM – Q E03 40-357
cuit system
R clutch ECMV solenoid: Short cir- Electrical
DXH7KY TM – Q E03 40-358
cuit to power supply line system
4th clutch ECMV solenoid: Open cir- Electrical
DXHHKA TM – Q E03 40-360
cuit system
4th clutch ECMV solenoid: Short cir- Electrical
DXHHKB TM – Q E03 40-362
cuit system
4th clutch ECMV solenoid: Short cir- Electrical
DXHHKY TM – Q E03 40-364
cuit to power supply line system

GD555-5,GD655-5,GD675-5 40-35
(01)
General information on troubleshooting
Failure codes table

*1: If the air cleaner is clogged, the maintenance caution lamp lights up.
*2: If the accumulator oil pressure drops, the brake oil pressure caution lamp lights up.
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
TM: Transmission controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary screen
when abnormality related to them occurs. They are simply recorded in the fault history of the service menu
(electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the failure history of service menu.

40-36 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure and troubleshooting numbers

Failure and troubleshooting numbers 40-37

Failure and troubleshooting numbers
Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Action code and failure code
The action code and failure code are displayed on the machine moni-
1
tor.
When abnormality record is checked, failure code is shown in
2 Take actions by following the failure code.
mechanical system abnormality record
When abnormality record is checked, failure code is shown in electri-
3
cal system abnormality record

Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Failure related to engine
4 Starting performance is poor S-1 40-512
5 Engine does not start E-1, S-2 40-366, 40-513
6 Engine does not pick up smoothly S-3 40-516
7 Engine stops during operations S-4, H-1 40-517, 40-466
8 Engine does not run smoothly S-5 40-518
9 Engine lacks output (or lacks power) S-6 40-519
10 Exhaust smoke is black (incomplete combustion) S-7 40-520
11 Oil consumption is excessive (or exhaust smoke is blue) S-8 40-521
12 Oil becomes contaminated quickly S-9 40-522
13 Fuel consumption is excessive S-10 40-523
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-524
15 Oil pressure drops S-12 40-525
16 Oil level rises (Entry of coolant/fuel) S-13 40-526
17 Coolant temperature becomes too high (overheating) S-14 40-527
18 Abnormal noise is made S-15 40-528
19 Vibration is excessive S-16 40-529
20 The preheater does not operate E-2 40-372
Failure related to power train
21 Machine does not start. H-2 40-467
22 Gear is not shifted. H-3 40-468
23 Machine travel speed is slow or power is insufficient. H-4 40-469
24 Torque converter lockup does not operate, or can not be released. H-5 40-474
25 Too much time lag at starting of travel or changing gear shift H-6 40-475
26 Oil temperature of torque converter is high. H-7 40-480
27 Differential lock-up function does not operate or can not be released. H-8, E-18 40-485, 40-408
Failure related to steering
28 Steering speed is slow or power is insufficient. H-9 40-486
29 Steering wheel does not move. H-10 40-487
Failure related to brake
30 Wheel brake does not operate or insufficient. H-11 40-488
31 Wheel brake cannot be released or drags. H-12 40-489
32 Parking brake does not operate or insufficient. H-13 40-490
Parking brake (including emergency release system) cannot be
33 H-14 40-491
released or drags.
Failure related to work equipment
34 Speed of all work equipment is slow or power is insufficient. H-15 40-492
35 No work equipment operates. H-16 40-493
36 Abnormal sound comes out from around hydraulic pump H-17 40-494
37 Blade lift speed is too slow or lacks power. H-18 40-495
38 Excessive hydraulic drift of blade lift cylinders H-19 40-496
39 Speed of shifting drawbar in sideways is slow or power is insufficient. H-20 40-497
40 Speed of shifting blade in sideways is slow or power is insufficient. H-21 40-498
41 Power tilt speed is slow or power is insufficient. H-22 40-499
42 Articulate speed is low or power is insufficient. H-23 40-500
43 Leaning speed is slow or power is insufficient. H-24 40-501
44 Excessive hydraulic drift of leaning cylinders. (leaning) H-25 40-502
45 Blade does not rotate. H-26 40-503

GD555-5,GD655-5,GD675-5 40-37
(01)
General information on troubleshooting
Failure and troubleshooting numbers

Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Lift arm lock pin does not lock, or lock cannot be released.
46 H-27, E-19 40-504, 40-412
[for lift arm specification]
Blade accumulator function does not operate or cannot be released.
47 H-28, E-20 40-505, 40-414
[for blade accumulator and float specification]
Blade float function does not operate or cannot be released.
48 H-29, E-1 40-506, 40-366
[for blade accumulator and float specification]
Failure related to machine monitor
49 When starting switch turned ON, machine monitor displays nothing E-3 40-377
When starting switch is turned to ON position, machine monitor does
50 E-4 40-380
not display normally.
When starting switch is turned to ON position, caution item blinks or
51 E-5 40-380
lights up, or machine monitor does not display normally.
52 Emergency stop item lights up while engine is running E-6 40-381
53 Speedometer and engine tachometer do not display normally. E-7 40-385
54 Engine coolant temperature gauge does not indicate normally E-8 40-386
55 Articulation gauge does not display normally. E-9 40-388
56 Torque converter oil temperature gauge does not display normally. E-10 40-390
57 Fuel level gauge does not indicate normally E-11 40-392
58 Character display does not display normally. E-12 40-394
59 Centralized warning lamp does not light up or go off. E-13 40-396
60 Alarm buzzer does not sound or stop sounding. E-14 40-398
61 Machine monitor mode selector switch does not function. E-15 40-400
62 Transmission mode does not change. E-16 40-404
63 Engine mode does not change. E-17 40-406
Differential lock function does not work or is not reset [for differential
64 E-18 40-408
lock-up specification].
65 Lift arm lock pin is not locked or reset [for lift arm specification]. E-19 40-412
Blade accumulator function does not work or is not reset [for blade
66 E-20 40-414
accumulator specification].
67 Horn does not sound or stop sounding. E-21 40-418
68 Backup alarm does not sound or stop sounding. E-22 40-420
69 Headlamp, clearance lamp, and tail lamp do not light up or go off. E-23 40-423
70 Front working lamp does not light up or go off. E-24 40-430
71 Turn signal lamp and hazard lamp do not blink. E-25 40-436
72 Stop lamp does not light up or go off. E-26 40-442
73 Backup lamp does not light up or go off. E-27 40-444
74 Windshield wiper does not operate. E-28 40-446
75 Window washer does not operate. E-29 40-454
76 KOMTRAX system does not operate normally. E-30 40-458

40-38 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Information in troubleshooting table

Information in troubleshooting table 40-39

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.

User code Failure code

Description of failure that is diaplayed on machine monitor
Display on Failure
Display on machine as abnormality record
machine moni-
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action taken by the controller or machine monitor to protect system or devices when
Action of controller
machine monitor or controller detects failure
Problem that appears on the machine as a result of the action taken by the machine mon-
Problem on machine
itor or controller (shown above)
Related information Information related to the detected failure or troubleshooting

Cause Procedure, measuring location, criteria and remarks

Probable causes
1 Defective xxxx
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3
(Contact with ground circuit)
Hot short
4
(Contact with 24 V circuit)
5 Short circuit in wiring harness
6 Defective controller
<Details of description>
q Procedure
q Measuring location
a "Between A and B" means the measurement of voltage, resistance or
others between terminals A and B.
q Criteria: voltage, resistance, etc.
q Remarks for judgment
<How to use the troubleshooting sheet>
q Perform troubleshoot in the following procedure in numerical order.
q If the test result does not meet the criteria, the probable cause described
on the left column is the actual cause of the failure.
q If the test result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
<Failures in wiring harness>
q Open circuit in wiring
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
A harness not connected to the power circuit (24 V) contacts the power
circuit.
q Short circuit
An independent wire in the harness abnormally contacts with other wire.
(Poor insulation at connector and others)
<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless other-
wise specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
male connectors.
q When "male" or "female" is indicated with a connector number, discon-
nect the connector, and connect T-adapter only to either male or femae
end.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.

GD555-5,GD655-5,GD675-5 40-39
(01)
General information on troubleshooting
Information in troubleshooting table

Circuit diagram related to - - - - - 40-40

This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

40-40 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

Troubleshooting method for open circuit in wiring harness of pressure

sensor system 40-41
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the differences among the resistances measured and its own polarities. So troubleshooting must be
performed carefully.

Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: RailPress sensor high error

Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Take several measurement in both
steps 1 and 2. Consider this dispersion when judging whether the wiring harness is disconnected
in step 3.

2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected.
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.

3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.

GD555-5,GD655-5,GD675-5 40-41
(01)
General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

List of pressure sensor measuring locations and reference values

Internal resistance of
Measuring location at sensor
Sensor sensor Remarks
pin
(reference value)
Charge pressure R2: Between (2) and (4) Approx. 100 z Sensor is common to engine mod-
sensor R1: Between (1) and (4) Approx. 200 z els 107 and 114
Sensor is common to engine mod-
R2: Between (3) and (1) Approx. 23 kz
Common rail els 107 and 114
pressure sensor If polarities are inverted, resis-
R1: Between (1)(+) and (2)(-) Approx. 10 Mz
tance is infinite.

*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)

Measurement record (For measuring locations, see circuit diagram related to each code.)
Sensor + Wiring harness
Sensor unit
(Measuring location at wir- Measured
Sensor (Measuring location on sen- Measured value
ing harness on engine value
sor pin side)
controller side)
R2': Between (37) and (47)
Charge pressure R2: Between (2) and (4)
(*)
sensor
R1: Between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail (*)
pressure sensor R1': Between (47)(+) and
R1: Between (1)(+) and – (2)(-)
(25)(-)

40-42 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Connector list and layout 40-43

GD555-5,655-5,675-5
Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
A. PRESS. SEN. 3 Ambient pressure sensor ZY-3
AC1 SWP 12 Intermediate connector U-6
AC3 SWP 14 Intermediate connector AM-4
AC4 SWP 6 Intermediate connector AM-4
AC5 SWP 22 Controller (inside cab) AK-8
AC6 SWP 14 Controller (inside cab) AK-8
B. PRESS. TEMP.
4 Boost pressure and boost temperature sensor AY-3
SEN.
B11 DT2 3 Articulation sensor T-4
B13 DT2 3 Blake lamp switch R-3
B15 KES1 2 Window washer door U-2
B16 YAZAKI 2 Front window washer T-2
B17 YAZAKI 2 Rear window washer T-2
B19 DT2 2 T-6
BZ DT2 2 Backup alarm J-7
C. RAIL PRESS. SEN. 3 Common rail pressure sensor AZ-4
C1 DT2 12 Intermediate connector V-5
C1 DT2 12 Intermediate connector AM-4
C10 KES 6 Rear wiper relay AM-5
C11 M 4 Left door wiper motor AL-4
C12 KES 6 Door wiper relay AM-5
C13 M 4 Right door wiper motor AJ-6
C14 KES 6 Front wiper relay AM-5
C15 X 6 Front wiper motor AK-6
C16 M 4 Rear window wiper motor AM-5
C17 SWP 6 Front wiper switch AM-6
C18 M 2 Rear fan AM-7
C2 DT2 12 Intermediate connector V-5
C2 DT2 12 Intermediate connector AM-4
C20 SWP 6 Revolving warning lamp switch AL-6
C21 SWP 6 Work lamp switch AL-6
C22 KES 6 Work lamp relay AM-5
C23 M 2 work lamp AJ-6
C24 M 2 work lamp AJ-6
C25 M 2 work lamp AJ-6
C26 M 2 work lamp AJ-6
C27 M 3 Right winker AJ-6
C28 M 3 Left winker AJ-6
C29 DT-T 2 Intermediate connector AJ-6
C3 KES 2 Room lamp AK-6
C30 DT-T 2 Rotary lamp AJ-7
C31 KES 6 Revolving warning lamp relay AM-5
C33 YAZAKI 6 Front wiper intermit relay AM-5

GD555-5,GD655-5,GD675-5 40-43
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
C34 YAZAKI 6 Rear wiper intermit relay AM-5
C35 YAZAKI 6 Right door wiper intermit relay AM-5
C36 YAZAKI 6 Left door wiper intermit relay AM-5
C37 SWP 6 Intermit wiper switch AM-6
C38 DT-T 2 Diode AJ-4
C39 X 2 Inter lock door solenoid AJ-4
C40 M 1 Right door switch AJ-6
C41 M 1 Left door switch AK-5
C42 KES 6 Inter lock door solenoid relay AJ-4
C5 YAZAKI 9 Radio AK-7
C6 M 2 Left speaker AL-7
C7 M 2 Left speaker AM-7
C8 SWP 6 Rear wiper switch AM-6
C9 SWP 6 Door wiper switch AM-6
CAN DT2 12 KOMNET service connector S-5
CAN 3 CAN AX-2
CAN1 DT-T 3 CAN terminating resistance AY-2
CHK0A X 1 Intermediate connector T-5
CHK0B X 1 Intermediate connector T-5
CHK1A X 1 Intermediate connector T-2
CHK1B X 1 Intermediate connector T-5
CON DT2 6 12 V converter AF-6
CT41 Terminal 1 Ground AM-4
E01 DT-T 2 Safety relay AW-6
E02 Terminal 1 Alternator AX-7
E07 Terminal 1 Grid heater AY-3
E19 Terminal 1 Safety relay AW-6
E20 Terminal 1 Safety relay AW-6
E21 Terminal 1 Starting motor AW-5
E29 Terminal 1 Alternator AX-7
E30 Terminal 1 Starting motor K-2, AW-5
E31 Terminal 1 Holder 2 AW-6
E32 Terminal 1 Holder 2 AW-6
E33 Terminal 1 Holder 2 AW-6
EC1 DRC 60 Engine controller AY-2
EC2 DRC 50 Engine controller AY-3
EC3 DRC 4 Engine controller AY-2
ENG.PRESS.SW. Terminal 1 Engine oil pressure switch (low pressure) AY-3
ENG.W.TEMP.SW. 2 Engine coolant temperature sensor AX-3
ER1 DT2 12 Intermediate connector I-6, AW-6
ER2 DTP 2 Intermediate connector I-6, AW-6
ER3 DT2 12 Intermediate connector I-6, AW-6
ET103A Terminal 1 Ground AY-3
ET103B Terminal 1 Ground AY-3

40-44 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
ET104 DT-T 2 Intermediate connector AW-6
ET39 DT2 2 Fuel level sensor J-7
ET40A Terminal 1 Breaker K-3
ET40B Terminal 1 Ground K-1
ET41A Terminal 1 Battery K-3
ET41B Terminal 1 Breaker K-3
ET42 Terminal 1 Battery K-3
ET43 Terminal 1 Battery K-3
ET44 Terminal 1 Battery K-3
ET45 Terminal 1 Battery relay B-7
ET46 Terminal 1 Battery relay B-7
ET47 Terminal 1 Fuse holder B-8
ET48 Terminal 1 Fuse holder B-8
ET49 Terminal 1 Battery relay B-7
ET54 Terminal 1 Heater relay AW-6
ET58 Terminal 1 Battery relay B-7
ET59 Terminal 1 Fuse holder B-8
ET60 Terminal 1 Fuse holder B-8
ET75 Terminal 1 Battery relay B-7
ET76 Terminal 1 Battery relay B-7
ET77 Terminal 1 Ground I-6
ET82 Terminal 1 Heater relay AW-6
ET88 DT 2 Chlorofluorocarbon compressor magnetic clutch AY-2
ET89 Terminal 1 Ground I-6
FB1 – 30 Fuse box AC-6
FB2 – 30 Fuse box AD-6
FL1 DT2 3 Right head lamp B-4
FL10 DT 2 Front work lamp L.H. G-5
FL11 DT2 2 Center work lamp R.H. D-5
FL12 DT2 2 Center work lamp L.H. D-5
FL13 DT2 2 Right accumulator solenoid valve E-5
FL14 DT 2 Left accumulator solenoid valve E-5
FL15 DT 2 Diode E-5
FL17 DT2 12 Intermediate connector Q-4
FL17 DT2 12 Intermediate connector G-6
FL18 DT2 6 Intermediate connector C-4
FL2 DT2 3 Left head lamp D-3
FL3 DT 3 Right turn signal B-4
FL4 DT 3 Left turn signal C-3
FL5 DT 2 Right clearance lamp B-4
FL6 DT 2 Left clearance lamp C-3
FL6 DT2 3 Inching pedal R-3
FL7 X 2 Right horn B-3
FL8 X 2 Left horn C-3

GD555-5,GD655-5,GD675-5 40-45
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
FL9 DT 2 Front work lamp R.H. F-5
FLG1 Terminal 1 Ground (frame front end) C-3
FLG2 Terminal 1 Ground (ROPS frame) F-6
FP1 AMP070 20 Monitor panel P-7
FP10 DT2 12 Intermediate connector Q-4
FP11 DT2 12 Intermediate connector Q-4
FP12 DT2 6 Differential lockup switch N-7
FP13 DT2 4 Intermediate connector Q-5
FP14 DT-T 3 Left float engine cancel switch X-7
FP15 DT-T 3 Right float engine cancel switch Q-3
FP2 AMP070 12 Monitor panel P-7
FP3 DT-2 12 Monitor panel P-7
FP4 M 2 Alarm buzzer Q-7
FP5 DT-2 6 Monitor mode switch 2 Q-7
FP6 DT-2 6 Monitor mode switch 1 Q-7
FP7 DT-2 6 Dimmer switch P-7
FP8 DT-2 3 Turn signal switch P-7
FP9 DT-2 2 Horn switch N-7
FT10 Terminal 1 Ground T-3
FT11 Terminal 1 Ground U-3
FT12 Terminal 1 Ground G-5
FT13 Terminal 1 Ground I-6
G SEN. 3 G sensor AX-2
H X 1 Intermediate connector AG-3
H3 DT-T 6 Additional heater switch –
H5 DT-T 3 Additional heater unit –
IMA 2 IMA fuel pump actuator AZ-3
ING. #1,2 4 Injector #1, 2 AX-3
ING. #3,4 4 Injector #3, 4 AY-3
ING. #5,6 4 Injector #5, 6 AY-4
L80 DRC 40 KOMTRAX controller U-6
NE SEN. 3 NE sensor AX-2
R1 DRC 70 Intermediate connector T-3
R1 DRC 70 Intermediate connector G-5
R10 DT 2 Lifter solenoid H-7
R11 DT 2 Park solenoid H-7
R15 DT2 2 Accumulator oil pressure switch J-2
R16 DT2 2 Accumulator oil pressure switch J-2
R17 DT-T 2 Hydraulic oil temperature sensor J-3
R18 DT 2 Diode B-8
R19 DT 2 Diode B-8
R20 DT2 2 Dust indicator K-3,AV-8
R21 DT2 6 Intermediate connector J-3
R28 DT 2 Diode AW-6

40-46 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
R29 DT 2 Diode AW-6
R31 DT-T 2 Diode AW-6
R5 #4 1 Intermediate connector G-5
R5 DTDH 1 Intermediate connector S-3
R6 #8 1 Intermediate connector G-5
R6 DTDH 1 Intermediate connector S-3
R7 DTP 2 Intermediate connector G-5,S-3
R8 DT 2 Differential oil temperature sensor I-6
R9 DT 2 Differential lockup solenoid I-6
RL1 DT2 12 Intermediate connector J-8
RL10 DT 2 License lamp –
RL2 DT 6 Right combination lamp J-8
RL3 DT 6 Left combination lamp J-7
RL4 DT 2 Rear work equipment lamp J-9
RL5 DT 2 Rear work equipment lamp K-8
RL9 DT 2 Intermediate connector J-8
RT6 DT2 2 Fan reverse rotation valve J-8
RT7 DT2 2 Fan motor EPC J-8
RT8 DT2 2 Fan speed sensor J-8
SCT1 YAZAKI 2 12 V power supply AE-8
SP11 KES 6 Dimmer relay AE-7
SP12 KES 6 Small lamp relay AE-7
SP13 KES 6 Head lamp relay AE-7
SP14 KES 6 Front work lamp relay AE-7
SP15 KES 6 Rear work lamp relay AE-7
SP16 KES 6 Stop lamp relay AE-7
SP17 KES 6 Safety relay AE-7
SP18 KES 6 Hazard lamp relay 1 AE-7
SP19 KES 6 Hazard lamp relay 2 AE-7
SP21 SWP 6 Accumulator switch AD-8
SP22 KES 6 Head lamp switch AE-8
SP23 SWP 6 Front work lamp switch AD-8
SP24 SWP 6 Rear work lamp switch AD-8
SP25 SWP 6 Hazard lamp switch AD-8
SP26 KES 4 Turn signal lamp relay AE-2
SP27 KES 6 Horn relay AE-7
SP28 DT2 2 Lifter lock switch AE-7
SP29 YAZAKI 2 24 V cigarette lighter AE-8
SP30 KES 6 Cut out relay 1 AE-7
SP31 KES 6 Accumulator relay AE-7
SP32 KES 6 Dust indicator relay AE-7
SP33 KES 6 S hold relay AE-7
SP34 DT 2 Diode AF-3
SP35 DT 2 Diode AF-3
SP36 DT 2 Diode AE-3

GD555-5,GD655-5,GD675-5 40-47
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
SP37 DT 2 Diode AE-3
SP38 KES 6 Float engine cancel relay AG-3
SP39 KES 6 Float lamp relay AG-3
SP40 KES 6 Preheater relay AF-3
ST10 Terminal 1 Starting switch ACC AE-8
ST6 Terminal 1 Starting switch B AE-8
ST7 Terminal 1 Starting switch BR AE-8
ST8 Terminal 1 Starting switch R1 AE-8
ST9 Terminal 1 Starting switch C AE-8
T20 DT2 12 Intermediate connector AS-6
T21 DT2 12 Intermediate connector AS-6
T22 DT2 12 Intermediate connector AS-5
T24 DT2 2 FL solenoid AQ-7
T25 DT2 2 FH solenoid AP-7
T26 DT2 2 R solenoid AP-7
T27 DT2 2 1st clutch solenoid AP-7
T28 DT2 2 2nd clutch solenoid AQ-7
T29 DT2 2 3rd clutch solenoid AQ-7
T30 DT2 2 4th clutch solenoid AQ-7
T31 DT2 2 L/U solenoid AQ-7
T32 DT2 2 Transmission input shaft speed sensor AT-1
T33 DT2 2 Transmission output shaft speed sensor AR-4
T34 DT2 2 Torque converter oil temperature sensor AS-4
T35 DT2 2 Transmission oil temperature sensor AQ-5
T36 DT2 2 FL clutch oil pressure AQ-7
T37 DT2 2 FH clutch oil pressure AP-7
T38 DT2 2 R clutch oil pressure AP-7
T39 DT2 2 1st clutch oil pressure AP-7
T40 DT2 2 2nd clutch oil pressure AP-7
T41 DT2 2 3rd clutch oil pressure AQ-7
T42 DT2 2 4th clutch oil pressure AQ-5
T47 DT2 2 Intermediate shaft speed sensor AQ-5
T9A DT2 6 Accelerator pedal R-4
T9B DT2 2 Accelerator pedal R-4
TEL DT-T 12 Intermediate connector V-6
TG1 Terminal 1 Ground AQ-7
TM30 SWP 6 Transmission mode switch AD-8
TM31 SWP 6 Hydraulic fan reverse rotation switch AE-8
TM35 DT2 3 Intermediate connector AG-3
TM36 DT-T 21 Shifter AG-3
TM37 SWP 6 RPM set/resume switch AD-7
TM38 KES 7 RPM set mode switch AD-8
TM39 DRC 24 Transmission controller U-6
TM40 DRC 40 Transmission controller U-5

40-48 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
TM41 DRC 40 Transmission controller U-5
TM42 KES 6 Backup lamp relay AE-7
TM43 KES 6 Differential lockup relay AE-7
TM45 SWP 6 Engine mode switch AE-8
W60 KES 6 Engine cut relay U-5
WIF1 DT-T 2 WIF AY-7
WIF2 DT-T 2 Intermediate connector AY-2
– 4 Compressor relay –
– 2 Pressure switch –
– 4 Blower OFF relay –
– 2 Blower motor –
– 3 Blower amplifier –
– 2 Evacuator sensor –
– 6 Motor actuator (air mix) –
Motor actuator (FRESH/RECIRC air change-
– 6 –
over)

GD555-5,GD655-5,GD675-5 40-49
(01)
General information on troubleshooting
Connector list and layout

Layout of connector (1/8)

40-50 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(2/8)

GD555-5,GD655-5,GD675-5 40-51
(01)
General information on troubleshooting
Connector list and layout

(3/8)

40-52 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(4/8)

GD555-5,GD655-5,GD675-5 40-53
(01)
General information on troubleshooting
Connector list and layout

(5/8)

40-54 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(6/8)

GD555-5,GD655-5,GD675-5 40-55
(01)
General information on troubleshooting
Connector list and layout

(7/8)

40-56 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(8/8)

GD555-5,GD655-5,GD675-5 40-57
(01)
General information on troubleshooting
Connection table for connector pin numbers

Connection table for connector pin numbers 40-58

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

40-58 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-59
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-60 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-61
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-62 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-63
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-64 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-65
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-66 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-67
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-68 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-69
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-70 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-71
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-72 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-73
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-74 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-75
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-76 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-77
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-78 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-79
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-80 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-81
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-82 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-83
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-84 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-85
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-86 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-87
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-88 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-89
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-90 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-91
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-92 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-93
(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T- branch box and T- branch adapter table 40-94

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
799-601-2790 Adapter for ECONO 12 ECONO12P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for M 7 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q

40-94 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7160 Adapter for S (Blue) 12 S12P q q q

799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 ― q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapterfor relay 5 REL-5P q
799-601-7370 Adapterfor relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 ― q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-60 -9040 Adapter for DT 4 DT4 q q q q
799-60 -9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 p q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q

GD555-5,GD655-5,GD675-5 40-95
(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

Socket for engine (HPI-T2)

795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 ― q
795-799-5470 Cable for engine (HPI-T2) 3 ― q
795-799-5480 Cable for engine (HPI-T2) 3 ― q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
Socket for engine (CRI-T3)
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 ― q
799-601-4280* Box for controller (PUMP) 121 ― q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 and DTM2 3, ― q
4
“*” Shows not T-adapter but socket.

40-96 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Locations of fuses

Locations of fuses 40-97

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box (A
switched power supply is the power which is supplied only while the starting switch is in the ON position
and the unswitched power supply is the power which is supplied while the starting switch is in the OFF and
ON positions).
a When performing troubleshooting related to the electrical system, check the fuse boxes to see if the power
is supplied properly.

Fuse box 1 (Fuse box FB1)

Power supply
Fuse No. Fuse capacity Destination of power
type
1 10A Monitor
Unswitched
power supply 2 15 A Key switch
slow-blow fuse 3 10 A Transmission controller unswitched power supply
(30A)
4 10A Hazard lamp
5 15 A Cab-mounted working lamp
6 10 A Turn signal lamp
7 15 A Solenoid
8 10A Cigarette lighter
Switched
power supply 9 15 A Rear working lamp
slow-blow fuse 10 15 A Front working lamp
(60A)
11 10A Transmission controller
12 15 A Headlamp
13 10 A Backup lamp and stop lamp
14 10A Horn
Switched
power supply
15 5A Engine controller
Starting switch
ACC

GD555-5,GD655-5,GD675-5 40-97
(01)
General information on troubleshooting
Locations of fuses

Fuse box 2 (Fuse box FB2)

Power supply
Fuse No. Fuse capacity Destination of power
type
1 20 A Air conditioner blower motor
Unswitched
power supply 2 10 A Cab unswitched power supply
slow-blow fuse 3 10A Room lamp
(30A)
4 30 A Engine controller unswitched power supply
5 10A Optional device (heater)
6 10 A Optional device (12 V inverter)
7 5A Radio
8 5A Air conditioner compressor (clutch)
Switched 9 10A Illumination
power supply
10
slow-blow fuse
(60A) 11 5A Air conditioner controller
12 15 A Cab-mounted working lamp
13 10 A Yellow revolving warning lamp
14 20 A Door glass wiper
15 20 A Front and rear wipers

Location of fuse box and fuse numbers

40-98 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [1500LO] TORQUEFLOW transmission: Double engagement

Troubleshooting by failurecode 40-9

Failure code [1500LO] TORQUEFLOW transmission: Double engage-
ment 40-9
Action code Failure code TORQFLOW transmission: Double engagement
Failure
(Transmission controller system)
E02 1500L0
Detail of failure q Fill signals for two clutches for unusual combination is input.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains gear speed in Neutral.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Machine stops when traveling and it does not start to travel when stopped.
machine
q Input (ON/OFF) from each clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234HL)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (every gear speed).

Cause Procedure, measuring location, criteria and remarks

1 Defective clutch ECMV system If different failure code is displayed, perform troubleshooting for it.

When no other failure code is displayed, controller may be defective. (Since it

2 Defective transmission controller
is an internal defect, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-99
(01)
Troubleshooting by failurecode
Failure code [15G0MW] Transmission R clutch: Slip

Failure code [15G0MW] Transmission R clutch: Slip 40-10

Action code Failure code Transmission R clutch: Slip
Failure
(Transmission controller system)
E03 15G0MW
q When outputting to R clutch ECMV solenoid, the value calculated from engine speed, transmission
Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, transmission
output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to R clutch ECMV solenoid can be checked with
Related infor- monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of R1 to R4).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective reverse clutch oil pres-
1 2. Check that clutch oil pressure is normal by referring to Testing and
sure or mechanical system
adjusting, "Testing power train oil pressure".

Defective reverse clutch ECMV Perform troubleshooting for failure codes [DXH7KA], [DXH7KB] and
2
solenoid system [DXH7KY].

40-100 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15H0MW] Transmission FH clutch: Slip

Failure code [15H0MW] Transmission FH clutch: Slip 40-101

Action code
Failure code Transmission FH clutch: Slip
Failure
(Transmission controller system)
E03 15H0MW
q When outputting to FH clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code:TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F2, F4, F6
and F8)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective FH clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

Defective FH clutch ECMV sole- Perform troubleshooting for failure codes [DXH2KA], [DXH2KB] and
2
noid system [DXH2KY].

Failure code [15J0MW] Transmission FL clutch: Slip 40-101

Action code Failure code Transmission FL clutch: Slip
Failure
(Transmission controller system)
E03 15J0MW
q When outputting to FL clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV H DIR, TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective FL clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

Defective FL clutch ECMV sole- Perform troubleshooting for failure codes [DXH3KA], [DXH3KB] and
2
noid system [DXH3KY].

GD555-5,GD655-5,GD675-5 40-101
(01)
Troubleshooting by failurecode
Failure code [15K0MW] Transmission 1st clutch: Slip

Failure code [15K0MW] Transmission 1st clutch: Slip 40-102

Action code Failure code Transmission 1st clutch: Slip
Failure
(Transmission controller system)
E03 15K0MW
q When outputting to 1st clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 1st clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code:TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 1st clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 1st clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXH4KA], [DXH4KB] and
[DXH4KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-102

40-102 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15L0MW] Transmission 2nd clutch: Slip

Failure code [15L0MW] Transmission 2nd clutch: Slip 40-103

Action code Failure code Transmission 2nd clutch: Slip
Failure
(Transmission controller system)
E03 15L0MW
q When outputting to 2nd clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 2nd clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code:TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F3, F4, and
R2).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 2nd clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 2nd clutch ECMV sole- Perform troubleshooting for failure codes [DXH5KA], [DXH5KB] and
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
[DXH5KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-103

GD555-5,GD655-5,GD675-5 40-103
(01)
Troubleshooting by failurecode
Failure code [15M0MW] Transmission 3rd speed clutch: Slip

Failure code [15M0MW] Transmission 3rd speed clutch: Slip 40-104

Action code Failure code Transmission 3rd clutch: Slip
Failure
(Transmission controller system)
E03 15M0MW
q When outputting to 3rd clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 3rd clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F5, F6 and
R3)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 3rd clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 3rd clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXH6KA], [DXH6KB] and
[DXH6KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-104

40-104 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15N0MW] Transmission 4th clutch: Slip

Failure code [15N0MW] Transmission 4th clutch: Slip 40-105

Action code Failure code Transmission 4th clutch: Slip
Failure
(Transmission controller system)
E03 15N0MW
q When outputting to 4th clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 4th clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F7, F8 and
R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 4th clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 4th clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXHHKA], [DXHHKB] and [DXH-
HKY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-105

GD555-5,GD655-5,GD675-5 40-105
(01)
Troubleshooting by failurecode
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF

Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command

signal is OFF 40-106
Action code Failure code ECMV R clutch: Fill signal is being sent when command signal is
Failure not being sent
E01 15SBL1 (Transmission controller system)

q Signal from fill switch remains turned ON after output to R clutch ECMV solenoid is turned OFF,
Detail of failure
and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Only reverse travel is available.
machine
q Command current value output to R clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
mation q Input (ON/OFF) from R clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective R clutch oil pressure
1 2. Then, check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective R clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SBL1] recurs, ground fault is present in wiring harness or
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T38 and connect T-adapter to male side.
Between T38 (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T38.
power train controller is defective.
(If failure code [15SBL1] does not appear anymore, R clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T38, and connect T-adapter to female
side of one of them.
Between TM40 (female) (27) or T38 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector T38.
a Maintain gear shift lever at N position.
Between TM40 (27) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (27) and ground R1 Voltage Max. 1 V

40-106 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to reverse clutch ECMV40-107

GD555-5,GD655-5,GD675-5 40-107
(01)
Troubleshooting by failurecode
Failure code [15SBMA] ECMV R clutch: Malfunction

Failure code [15SBMA] ECMV R clutch: Malfunction 40-108

Action code Failure code ECMV R clutch: Malfunction
Failure
(Transmission controller system)
E02 15SBMA
q Signal from fill switch remains turned OFF even after power is output to R clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to R clutch ECMV solenoid, clutch slip is detected from engine speed signal,
transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal
and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to R clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Only forward travel is available.
machine
q Command current value output to R clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
mation q Input (ON/OFF) from R clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective R clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T38 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T38 (male) (1) and ground Resistance Min. 1 Mz
Defective R clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T38 (male) (1) and ground R1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T38, and connect T-adapters to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (27) and T38 (female) (1) Resistance Max. 1 z

1. Turn starting switch to OFF position.

2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.

Between TM40 (27) and ground Voltage 7 – 11 V

4 Defective transmission controller
1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (27) and ground R1 Voltage Max. 1 V

40-108 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SBMA] ECMV R clutch: Malfunction

Circuit diagram related to reverse clutch ECMV40-109

GD555-5,GD655-5,GD675-5 40-109
(01)
Troubleshooting by failurecode
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF

Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command

signal is OFF 40-1 0
Action code Failure code ECMV FH clutch: Fill signal is being sent when command signal
Failure is not being sent
E01 15SCL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to FH clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F2, F4, F6, and F8 is available
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FH clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective FH clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SCL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T37 and connect T-adapter to male side.
Between T37 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch is turned OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T37.
ness or transmission controller is defective.
(If failure code [15SCL1] does not appear anymore, FH clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T37, and connect T-adapter to female
side of one of them.
Between TM40 (female) (7) or T37 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (7) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (7) and ground F2 Voltage Max. 1 V

40-110 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to FH clutch ECMV 40-1 1

GD555-5,GD655-5,GD675-5 40-111
(01)
Troubleshooting by failurecode
Failure code [15SCMA] ECMV FH clutch: Malfunction

Failure code [15SCMA] ECMV FH clutch: Malfunction 40-1 2

Action code Failure code ECMV FH clutch: Malfunction
Failure
(Transmission controller system)
E02 15SBMA
q Signal from fill switch remains turned OFF even after power is output to FH clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to FH clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to FH clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1, F3, F5, F7, R1, R2, R3, and R4 is available.
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
Related infor-
q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F2, F4, F6
and F8)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FH clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T37 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T37 (male) (1) and ground Resistance Min. 1 Mz
Defective FH clutch ECMV fill
2 1 and 2 are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T37 (male) (1) and ground F2 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T37, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (7) and T37 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (7) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (7) and ground F2 Voltage Max. 1 V

40-112 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SCMA] ECMV FH clutch: Malfunction

Circuit diagram related to FH clutch ECMV 40-1 3

GD555-5,GD655-5,GD675-5 40-113
(01)
Troubleshooting by failurecode
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF

Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command

signal is OFF 40-1 4
Action code Failure code ECMV FL clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SDL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after output power to FL clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F1, F3, F5, and F7 is available.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
mation q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FL clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective FL clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SDL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T36 and connect T-adapter to male side.
Between T36 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T36.
ness or transmission controller is defective.
(If failure code [15SDL1] does not appear any more, FL clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T36, and connect T-adapter to female
side of either connector.
Between TM40 (female) (17) or T36 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (17) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (17) and ground F1 Voltage Max. 1 V

40-114 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to FL clutch ECMV 40-1 5

GD555-5,GD655-5,GD675-5 40-115
(01)
Troubleshooting by failurecode
Failure code [15SDMA] ECMV FL clutch: Malfunction

Failure code [15SDMA] ECMV FL clutch: Malfunction 40-1 6

Action code Failure code ECMV FL clutch: Malfunction
Failure
E02 15SDMA (Transmission controller system)
q Signal from fill switch remains turned OFF even after power is output to FL clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to FL clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to FL clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F2, F4, F6, F8, R1, R2, R3, and R4 is available.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
Related infor-
q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F3, F5,
and F7)
Cause Procedure, measuring location, criteria and remarks
1. Check transmission oil filter for clogging, etc.
Defective FL clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T36 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Defective FL clutch ECMV fill Between T36 (male) (1) and ground Resistance Min. 1 Mz
2 1 to 2 are same as above.
switch (It does not turn ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T36 (male) (1) and ground F1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness
3 (wire breakage or defective con- 2. Disconnect connectors TM40 and T36, and connect T-adapter to each
tact) female side.
Between TM40 (female) (17) and T36 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
4. Start engine.
4 Defective transmission controller a Maintain gear shift lever at N position.
Between TM40 (17) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (17) and ground F1 Voltage Max. 1 V

40-116 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SDMA] ECMV FL clutch: Malfunction

Circuit diagram related to FL clutch ECMV 40-1 7

GD555-5,GD655-5,GD675-5 40-117
(01)
Troubleshooting by failurecode
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF

Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command
signal is OFF 40-1 8
Action code Failure code ECMV 1st clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SEL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after output power to 1st clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F1, F2, and R1 is available
machine
q Commanded current value output to 1st clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 1st clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 1st clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SEL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T39 and connect T-adapter to male side.
Between T39 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T39.
ness or transmission controller is defective.
(If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T39, and connect T-adapter to female
side of one of them.
Between TM40 (female) (13) or T39 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (13) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V

40-118 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 1st clutch ECMV 40-1 9

GD555-5,GD655-5,GD675-5 40-119
(01)
Troubleshooting by failurecode
Failure code [15SEMA] ECMV 1st clutch: Malfunction

Failure code [15SEMA] ECMV 1st clutch: Malfunction 40-120

Action code Failure code ECMV 1st clutch: Malfunction
Failure
(Transmission controller system)
E02 15SEMA
q Signal from fill switch remains turned OFF even after power is output to 1st clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 1st clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 1st clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F3 - F8 and R2 - R4 is available
machine
q Command current value output to 1st clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
Related infor-
q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 1st clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T39 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T39 (male) (1) and ground Resistance Min. 1 Mz
Defective 1st clutch ECMV fill
2 1 and 2 are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T39 (male) (1) and ground F1/R1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T39, and connect T-adapter to each
3 (disconnection or defective con- female side.
tact)
Between TM40 (female) (13) and T39 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (13) and ground Voltage 7 – 11 V
4 Defective transmission controller 1 and 2 are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V

40-120 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SEMA] ECMV 1st clutch: Malfunction

Circuit diagram related to 1st clutch ECMV 40-121

GD555-5,GD655-5,GD675-5 40-121
(01)
Troubleshooting by failurecode
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF

Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command
signal is OFF 40-12
Action code Failure code ECMV 2nd clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SFL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 2nd clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F3, F4 and R2 is available
machine
q Command current value output to 2nd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
mation q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 2nd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 2nd clutch ECMV fill
2
switch (internal short circuit)
Ground fault of wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SFL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T40 and connect T-adapter to male side.
Between T40 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T40.
ness or transmission controller is defective.
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T40, and connect T-adapter to female
side of one of them.
Between TM40 (female) (3) or T40 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (3) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (3) and ground F3 Voltage Max. 1 V

40-122 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 2nd clutch ECMV 40-123

GD555-5,GD655-5,GD675-5 40-123
(01)
Troubleshooting by failurecode
Failure code [15SFMA] ECMV 2nd clutch: Malfunction

Failure code [15SFMA] ECMV 2nd clutch: Malfunction 40-124

Action code Failure code ECMV 2nd clutch: Malfunction
Failure
(Transmission controller system)
E02 15SFMA
q Signal from fill switch remains turned OFF even after power is output to 2nd clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 2nd clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 2nd clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1, F2, F5 to F8, R1, R3, and R4 is available.
machine
q Command current value output to 2nd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
Related infor-
q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F3, F4, and
R2).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 2nd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T40 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T40 (male) (1) and ground Resistance Min. 1 Mz
Defective 2nd clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T40 (male) (1) and ground F3 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T40, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (3) and T40 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (3) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (3) and ground F3 Voltage Max. 1 V

40-124 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SFMA] ECMV 2nd clutch: Malfunction

Circuit diagram related to 2nd clutch ECMV 40-125

GD555-5,GD655-5,GD675-5 40-125
(01)
Troubleshooting by failurecode
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF

Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command
signal is OFF 40-126
Action code Failure code ECMV 3rd clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SGL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 3rd clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F5, F6, and R3 is available
machine
q Command current value output to 3rd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
mation q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 3rd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 3rd clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SGL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T41 and connect T-adapter to male side.
Between T41 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T41.
ness or transmission controller is defective.
(If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective)
a If cause 3 is not cause for faulure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T41, and connect T-adapter to female
side of one of them.
Between TM40 (female) (2) or T40 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (2) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (2) and ground F5 Voltage Max. 1 V

40-126 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 3rd clutch ECMV 40-127

GD555-5,GD655-5,GD675-5 40-127
(01)
Troubleshooting by failurecode
Failure code [15SGMA] ECMV 3rd clutch: Malfunction

Failure code [15SGMA] ECMV 3rd clutch: Malfunction 40-128

Action code Failure code ECMV 3rd clutch: Malfunction
Failure
(Transmission controller system)
E02 15SGMA
q Signal from fill switch remains turned OFF even after power is output to 3rd clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 3rd clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 3rd clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1 to F4, F7, F8, R1, R2, and R4 is available.
machine
q Command current value output to 3rd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
Related infor-
q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F5, F6 and
R3)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 3rd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T41 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T41 (male) (1) and ground Resistance Min. 1 Mz
Defective 3rd clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T41 (male) (1) and ground F5 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T41, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (2) and T41 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (2) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (2) and ground F5 Voltage Max. 1 V

40-128 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SGMA] ECMV 3rd clutch: Malfunction

Circuit diagram related to 3rd clutch ECMV 40-129

GD555-5,GD655-5,GD675-5 40-129
(01)
Troubleshooting by failurecode
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF

Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command
signal is OFF 40-130
Action code Failure code ECMV 4th clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SHL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 4th clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F7, F8, and R4 is available
machine
q Command current value output to 4th clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
mation q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 4th clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 4th clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SHL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T42 and connect T-adapter to male side.
Between T42 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T42.
ness or transmission controller is defective.
(If failure code [15SHL1] does not appear anymore, 4th clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T42, and connect T-adapter to female
side of one of them.
Between TM40 (female) (38) or T42 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (38) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (38) and ground F7 Voltage Max. 1 V

40-130 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 4th clutch ECMV 40-131

GD555-5,GD655-5,GD675-5 40-131
(01)
Troubleshooting by failurecode
Failure code [15SHMA] ECMV 4th clutch: Malfunction

Failure code [15SHMA] ECMV 4th clutch: Malfunction 40-132

Action code Failure code ECMV 4th clutch: Malfunction
Failure
(Transmission controller system)
E03 15SHMA
q Signal from fill switch remains turned OFF even after power is output to 4th clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 4th clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 4th clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1 to F6 and R1 to R3 is available
machine
q Command current value output to 4th clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
Related infor-
q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F7, F8 and
R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 4th clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T42 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T42 (male) (1) and ground Resistance Min. 1 Mz
Defective 4th clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T42 (male) (1) and ground F7 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T42, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (38) and T42 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (38) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (38) and ground F7 Voltage Max. 1 V

40-132 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SHMA] ECMV 4th clutch: Malfunction

Circuit diagram related to 4th clutch ECMV 40-13

GD555-5,GD655-5,GD675-5 40-133
(01)
Troubleshooting by failurecode
Failure code [15SJMA] ECMV lockup clutch: Malfunction

Failure code [15SJMA] ECMV lockup clutch: Malfunction 40-134

Action code Failure code ECMV lockup clutch: Malfunction
Failure
(Transmission controller system)
E03 15SJMA
q When power is output to lockup clutch ECMV solenoid, clutch slip is detected from engine speed
Detail of failure signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains output of power to lockup clutch ECMV solenoid turned OFF.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on q Automatic mode (torque conveter mode) is always turned on even when manual mode is selected
machine through transmission mode selector switch.
q Command current value output to lockup clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation
q Method of reproducing failure code:
Start engine and operate transmission mode selector switch (Manual mode)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective lockup switch oil pres-
1 2. Check that clutch pressure is normal by referring to Testing and adjusting,
sure and mechanical systems
"Testing power train oil pressure".

Defective lockup clutch ECMV Perform troubleshooting for failure codes [DXH1KA], [DXH1KB] and
2
solenoid system [DXH1KY].

Failure code [15UONT] Inching clutch: Overheating 40-134

Action code Failure code Inching clutch: Overheating
Failure
(Transmission controller system)
E02 15U0NT
Detail of failure q Clutch temperature estimated from inching clutch oil temperature sensor has exceeded 200°C
Action of con- q Blinks centralized warning lamp, sounds alarm buzzer for 2 seconds and disengages lockup clutch.
troller q If cause of failure disappears, system resets itself.
Problem on
q Lockup clutch is disengaged.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Since overheating of inching clutch can be experienced now or has been
Overload on inching clutch experienced in the past, investigate cause and damage condition resulted
1
(when system is normal) from such cases to correct above failure.(including improper inching opera-
tion)
Defective transmission oil temper-
2 Perform troubleshooting for failure code [DGF1KX].
ature sensor system

40-134 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [2G42ZG] Front accumulater: Oil pressure drop

Failure code [2G42ZG] Front accumulater: Oil pressure drop 40-135

Action code Failure code Front accumulator: Pressure drop
Failure
(Machine monitor system)
E03 2G42ZG
q While engine is running, front accumulator oil pressure switch detects drop of front accumulator
Detail of failure
pressure.
Action of con- q Blinks centralized warning lamp and turns on alarm buzzer.
troller q If cause of failure disappears, system resets itself.
Problem on
q Brake oil pressure caution lamp lights up while engine is running.
machine
q Input (ON/OFF) from front accumulator OIL pressure switch can be checked by using monitoring
Related infor-
function. (Code: MONITOR-40921-D-IN-4)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Since drop of front accumulator pressure can be experienced now or has been
Drop of front accumulator pres-
1 experienced in the past, investigate cause and damage condition resulted
sure (when system is normal)
from such cases to correct above failure.
Defective brake oil pressure cau- Perform troubleshooting for brake oil pressure caution lamp system being
2
tion lamp system listed in E-mode "E-6 Emergency stop lamp lights up while engine is running".

Failure code [2G43ZG] Rear accumulater: Pressure drop 40-135

Action code Failure code Rear accumulator: Pressure drop
Failure
(Machine monitor system)
E03 2G43ZG
q While engine is running, rear accumulator oil pressure switch detects drop of rear accumulator
Detail of failure
pressure.
Action of con- q Blinks centralized warning lamp and turns on alarm buzzer.
troller q If cause of failure disappears, system resets itself.
Problem on
q Brake oil pressure caution lamp lights up while engine is operating.
machine
q Input (ON/OFF) from front accumulator OIL pressure switch can be checked by using monitoring
Related infor-
function. (Code: MONITOR-40921-D-IN-5)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Since drop of rear accumulator pressure can be experienced now or has been
Drop of rear accumulator pressure
1 experienced in the past, investigate cause and damage condition resulted
(when system is normal)
from such cases to correct above failure.
Defective brake oil pressure cau- Perform troubleshooting for brake oil pressure caution lamp system being
2
tion lamp system listed in E-mode "E-6 Emergency stop lamp lights up while engine is running".

GD555-5,GD655-5,GD675-5 40-135
(01)
Troubleshooting by failurecode
Failure code [AA1ANX] Air cleaner: Clogging

Failure code [AA1ANX] Air cleaner: Clogging 40-136

Action code Failure code Air cleaner: Clogging
Failure
(Machine monitor system)
E01 AA1ANX
Detail of failure q When engine is started, air cleaner clogging sensor circuit is closed.
Action of con- q Air cleaner clogging caution lamp lights up.
troller q If cause of failure disappears, system resets itself.
q Engine does not start easily, does not pick up smoothly, lacks output power and exhaust smoke is
Problem on
black.
machine
q If machine is operated as it is, engine may be damaged.
q Input (ON/OFF) from air cleaner clogging sensor can be checked by using monitoring function.
(Code: MONITOR PANEL-40921-D-IN-2)
Related infor-
q Since inside of dust indicator is composed of electronic circuit, judgment can not be done by resis-
mation
tance.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Air cleaner clogging Air cleaner may be clogged. Check it for clogging and then clean or replace if
1
(When system is normal) clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector SP32, and connect T-adapter to male side.
Resis-
Between SP32 (male) (1) and (2) 200 - 400 z
tance
Defective dust indicator relay
2 1. Turn starting switch to OFF position.
(internal failure)
2. Replace dust indicator relay (SP32) with another relay of the same model
(5-pin).
3. Start engine.
If engine starts up normally, original relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and SP32, and connect a T-adapter to female
side of them.
Resis-
Between FP1 (female) (9) and SP32 (female) (5) Max. 1 z
tance
Resis-
Between R20 (female) (1) and SP32 (female) (2) Max. 1 z
Open circuit in wiring harness tance
3 (Wire breakage or defective con- Resis-
Between R20 (female) (2) and ground Max. 1 z
tact of connector) tance
1. Turn starting switch to OFF position.
2. Disconnect connector SP32 and connect T-adapter to female side.
3. Turn starting switch ON.
Between SP32 (female) (1) and ground Voltage 20–30 V
Between SP32 (female) (3) and ground Voltage 20–30 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors FP1 and SP32, and connect T-adapter to female
4 side of either of them.
(Contact with ground circuit)
Between FP1 (female) (9) and ground or between Resis-
Min. 1 Mz
SP32 (female) (5) and ground tance
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R20.
3. Start engine.
Defective dust indicator (internal
5 Air cleaner:
failure) Voltage 20 – 30 V
When normal
Between R20 (1) and (2)
Air cleaner:
Voltage Max. 10 V
When clogged

40-136 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AA1ANX] Air cleaner: Clogging

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found by above checks, machine monitor is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
6 Defective machine monitor 3. Start engine.
Air cleaner:
Voltage Max. 1 V
When normal
Between FP1 (9) and (3)
Air cleaner:
Voltage 20 – 30 V
When clogged

Circuit diagram related to air cleaner clogging 40-137

GD555-5,GD655-5,GD675-5 40-137
(01)
Troubleshooting by failurecode
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.

Failure code [AB00L6] Alternator; Engine start and stop signals are not
matched. 40-138
Action code Failure code Alternator: Signal does not match engine running or stopped
Failure condition
E03 AB00L6 (Machine monitor system)

Detail of failure q When engine is stopped, alternator terminal R input voltage is 12 V or above.
q Turns on caution lamp for defective charge circuit.
Action of con-
q Turns on centralized warning lamp and alarm buzzer.
troller
q If cause of failure disappears, system resets itself.
Problem on q Engine does not start.
machine q Service meter reading advances only with starting switch turned to ON position.
q Input voltage from alternator can be checked by using monitoring function. (Code: MONITOR
Related infor-
04302 ALTERNATOR R).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator
(Internal failure)
Hot short in wiring harness
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
3 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect terminal E02.
3. Turn starting switch to ON position.
Between alternator terminal R (alternator side) and
Voltage Max. 1 V
ground
1. Turn starting switch to OFF position.
2. Disconnect terminal E02.
Between terminal E02 (on wiring harness) and
Voltage Max. 1 V
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP2.
3. Turn starting switch to ON position.
Between FP2 (9) and ground Voltage Max. 1 V

40-138 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.

Circuit diagram related to alternator 40-139

GD555-5,GD655-5,GD675-5 40-139
(01)
Troubleshooting by failurecode
Failure code [AB00MA] Alternator: Malfunction

Failure code [AB00MA] Alternator: Malfunction 40-140

Action code Failure code Alternator: Defective mechanical system
Failure
(Machine monitor system)
E03 AB00MA
Detail of failure q When engine is running, alternator terminal R input voltage becomes 5 V or below.
q Turns on charge circuit failure caution lamp.
Action of con-
q Turns on centralized warning lamp and alarm buzzer.
troller
q If cause of failure disappears, system resets itself (12 V or above is secured).
Problem on
q Deterioration of battery or insufficient charging
machine
q Input voltage from alternator can be checked by using monitoring function. (Code: MONITOR
Related infor-
04302 ALTERNATOR R).
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Deteriorated battery Battery may be deteriorated. Check it directly.
1. Turn starting switch to ON position and perform troubleshooting.
2. Start engine and perform troubleshooting.
Defective alternator
2 Engine at medium
(Internal failure) Between alternator ter- speed or higher Voltage 27.5 – 29.5 V
minal E02 and ground
Engine stopped Voltage Max. 1 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect terminal E02 and connector FP2.
3 (Wire breakage or defective con- 3. Connect T-adapter to female side of FP2.
tact of connector)
Between terminal E02 and FP2 (female) (9) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect terminal R34 and connector FP2.
Ground fault in wiring harness
4 3. Connect T-adapter to female side of FP2.
(Contact with ground circuit)
Between terminal E02 or FP2 (female) (9) and
Resistance Max. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP2.
3. Start engine.
5 Defective machine monitor Engine at medium
Between FP2 (9) and Voltage 27.5 – 29.5 V
speed or higher
ground
Engine stopped Voltage Max. 1 V

40-140 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AB00MA] Alternator: Malfunction

Circuit diagram related to alternator 40-141

GD555-5,GD655-5,GD675-5 40-141
(01)
Troubleshooting by failurecode
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop

Failure code: [B@BAZG] Derating in speed due to engine oil pressure

drop 40-142
Action code Failure code Engine is derated due to engine oil pressure drop.
Failure
(Engine controller system)
E03 B@BAZG
q Engine controller detects abnormal drop of engine oil pressure when voltage from engine oil pres-
Detail of failure
sure switch drops to ground level while engine is running.
Action of con- q Turns on engine oil pressure caution lamp on machine monitor.
troller q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Signal of engine oil pressure switch is input to engine controller and then this code is transmitted
to machine monitor through CAN communication.
Related infor-
q For troubleshooting of engine oil pressure switch while engine is not running, see failure code
mation
[CA435].
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Drop of engine oil pressure Engine oil pressure may be low. Check pressure and remove cause of prob-
1
(when system is normal) lem.
Defective engine oil pressure sen- If no failure is found by check on cause 1, engine oil pressure sensor system
2
sor system may be defective. Perform troubleshooting for failure codes [CA435].

Failure code: [B@BCNS] Engine coolant overheat 40-142

Action code Failure code Engine coolant overheating
Failure
(Engine controller system)
E02 B@BCNS
Detail of failure q While engine is running, engine coolant temperature exceeds operating range.
Action of con- q Turns on engine coolant temperature caution lamp on machine monitor.
troller q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 04105 COOLANT TEMP).
mation
q Temperature sensed by engine coolant sensor can be checked by using monitoring function
(Code: ENGINE 04104 COOLANT TEMP).
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Engine coolant overheat
1 Engine coolant may be overheating. If it is overheated, remove cause.
(when system is normal)
Defective engine coolant tempera- If no cause is found by check on cause 1, engine coolant sensor system may
2
ture sensor system be defective. Perform troubleshooting for failure codes [CA144] and [CA145].

40-142 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@CENS] Torque converter oil overheat

Failure code: [B@CENS] Torque converter oil overheat 40-143

Action code Failure code Torque converter oil overheating
Failure
(Machine monitor system)
E02 B@CENS
q While engine is running, voltage of torque converter oil temperature sensor drops and transmission
Detail of failure
controller detects overheating (approximately 120°C or above) of torque converter oil.
q Lights up torque converter oil temperature caution lamp on machine monitor.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated at it is, torque converter may seize up.
machine
q Signal of torque converter oil temperature sensor is input to transmission controller and then data
is transmitted to machine monitor through CAN communication system.
Related infor- q Input voltage and temperature from torque converter oil temperature sensor can be checked by
mation using of monitoring function.
(Code: TRANSMISSION1-30101-T/C OIL TEMP (V), 30100-T/C OIL TEMP (°C))
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of torque converter
1 Torque converter oil may be overheated. If it is overheated, remove cause.
oil (When system is normal)
Defective torque converter oil tem-
2 Perform troubleshooting for failure code [DGT1KX].
perature sensor system

GD555-5,GD655-5,GD675-5 40-143
(01)
Troubleshooting by failurecode
Failure code: [B@CKNS] Differential case: Overheat

Failure code: [B@CKNS] Differential case: Overheat 40-14

Action code Failure code Differential case oil overheat
Failure
(Machine monitor system)
E02 B@CKNS
Detail of failure q Differential oil temperature caution appears (differential oil temperature above 120 °C)
q Turns on centralized warning lamp and alarm buzzer.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Lights up differential oil temperature caution lamp.
Problem on
q Differential may seize up if used as is.
machine
q Input voltage and temperature from differential oil temperature sensor can be checked by using of
Related infor- monitoring function.
mation (Code: TRANSMISSION1-31910-DIFF TEMP(V), 31909-DIFF TEMP(°C))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Since differential case oil overheating can be experienced now or has been
Differential case oil overheating
1 experienced in the past, investigate cause and damages for such cases in
(when system is normal)
order to correct above failure.
1. Turn starting switch to OFF position.
2. Disconnect connector R8 and connect T-adapter to male side.
Between R8 (male) (1) 25°C Resistance 38 – 49 kz
Defective differential oil tempera- and (2)
2 ture sensor (internal open circuit a Temperature charac-
teristics of oil temper- 100°C Resistance 3.7 – 4.0 kz
or short circuit)
ature sensor
Between each of R8
(male) (1), (2) and All range Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (14) and ground
3
ing harness a Resistance is the same as that shown in Oil tem-
Resistance 3.7 – 49 kz
perature sensor temperature characteristics of
cause 1 (25 – 100°C).
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and R8, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (3) and R8 (female) (1) Resistance Max. 1 z
Between R8 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R8 and TM39, and connect T-adapter to female
5 side of one of them.
(Contact with ground circuit)
Between R8 (female) (1) or TM39 (female) (14) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short or short circuit in wiring 2. Disconnect connector R8 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Between R8 (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, transmission controller is defective.
7 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

40-144 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@CKNS] Differential case: Overheat

Circuit diagram related to differential oil temper-

ature sensor 40-145

GD555-5,GD655-5,GD675-5 40-145
(01)
Troubleshooting by failurecode
Failure code: [B@HANS] Hydraulic oil: Overheating

Failure code: [B@HANS] Hydraulic oil: Overheating 40-146

Action code Failure code Hydraulic oil overheat
Failure
(Machine monitor system)
E02 B@HANS
q While engine is running, voltage of hydraulic oil temperature sensor drops and transmission con-
Detail of failure
troller detects overheating (approximately 100°C or above) of hydraulic oil temperature.
q Lights up hydraulic oil temperature caution lamp on machine monitor.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal of hydraulic oil temperature sensor is input to transmission controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related infor- q Input voltage value and temperature from hydraulic oil temperature sensor can be checked by us-
mation ing monitoring function.
(Code: TRANSMISSION1-04402-HYD OIL TEMP(V), 04410-HYD OIL TEMP(°C))
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Hydraulic oil overheat Check hydraulic oil for overheating. If it is overheated, remove cause to
1
(when system is normal) restore system.
1. Turn starting switch to OFF position.
2. Disconnect connector R17 and connect T-adapter to male side.
Between R17 (male) (1) 25°C Resistance 38 – 49 kz
Defective hydraulic oil tempera- and (2)
2 ture sensor (Internal open circuit a Temperature charac-
teristics of oil temper- 100°C Resistance 3.7 – 4.0 kz
or short circuit)
ature sensor
Between each of R17
(male) (1), (2) and All range Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open or short circuit in wiring har- Between TM39 (female) (20) and (21)
3
ness a Resistance is the same as that shown in Oil tem-
Resistance 3.7 – 49 kz
perature sensor temperature characteristics of
cause 1 (25 – 100°C).
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and R17, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (20) and R17 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and R17 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R17 and TM39, and connect T-adapter to female
5 side of one of them.
(Contact with ground circuit)
Between R17 (female) (1) or TM39 (female) (20)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short or short circuit in wiring 2. Disconnect connector R17 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Between R17 (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, transmission controller is defective.
7 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

40-146 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@HANS] Hydraulic oil: Overheating

Circuit diagram related to hydraulic oil tempera-

ture sensor 40-147

GD555-5,GD655-5,GD675-5 40-147
(01)
Troubleshooting by failurecode
Failure code [CA111] Engine controller internal error

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

Action code Failure code Engine controller internal failure
Failure
(Engine controller system)
E03 CA111
Detail of failure q Memory or power supply circuit in engine controller is defective.
Action of con-
q None in particular
troller
Problem on q Engine may stop suddenly or may not be able to start.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

1 Failure in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

40-148 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA115] Engine Ne, Bkup speed sensor error

Failure code [CA115] Engine Ne, Bkup speed sensor error 40-149
Action code Failure code Engine Ne and Bkup speed sensor failure
Failure
(Engine controller system)
E03 CA115
Detail of failure q Both signals from engine Ne speed sensor and engine Bkup speed sensor are abnormal.
Action of con-
q None in particular
troller
q Engine stops.
Problem on
q Engine does not start.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective connection of sensor Connections of harness connectors to Ne speed sensor and Bkup speed sen-
1
connector sor may be inverted. Check harness connector connections.
Defective Ne speed sensor sys-
2 Perform troubleshooting for Items 1 to 10 of failure code [CA689].
tem
Defective Bkup speed sensor sys-
3 Perform troubleshooting for failure code [CA778].
tem
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-149
(01)
Troubleshooting by failurecode
Failure code [CA122] Charge pressure sensor high error

Failure code [CA122] Charge pressure sensor high error 40-150

Action code Failure code Charged air pressure sensor voltage is high.
Failure
(Engine controller system)
E03 CA122
Detail of failure q High voltage is detected in pressure signal circuit of charge (boost) pressure/temperature sensor.
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from charge (boost) pressure sensor can be checked by using monitoring function
(Code: ENGINE 36502 CHG PRESS-A).
q Boost pressure from charge pressure sensor can be checked by using monitoring function (Code:
Related infor-
ENGINE 36500 CHG PRESS-A).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected, "Low error" code, namely [CA123] ,is displayed, even in nor-
mal condition.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective sensor power supply 2
2 If failure code [CA227] is also indicated, perform troubleshooting for it first.
line
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT.
3. Turn starting switch to ON position.
Defective charge pressure/tem- If failure code changes from [CA122] to [CA123] ,charge pressure sensor is
3
perature sensor defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of
sensor.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (37) and (44) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to
Hot short in wiring harness connector ECM.
5 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
(Contact with 24 V circuit)
disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-150 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA122] Charge pressure sensor high error

Circuit diagram related to charge pressure sensor 40-151

GD555-5,GD655-5,GD675-5 40-151
(01)
Troubleshooting by failurecode
Failure code [CA123] Charge pressure sensor low error

Failure code [CA123] Charge pressure sensor low error 40-152

Action code Failure code Charged air pressure sensor voltage is low.
Failure
(Engine controller system)
E03 CA123
Detail of failure q Low voltage is detected in pressure signal circuit of charge (boost) pressure/temperature sensor.
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from charge (boost) pressure sensor can be checked by using monitoring function
(Code: ENGINE 36502 CHG PRESS-A).
q Boost pressure from charge (boost) pressure sensor can be checked by using monitoring function
Related infor- (Code: ENGINE 36500 CHG PRESS-A).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q Since T-adapter for sensor connector is "socket", open circuit in the wiring harness or voltage at
sensor connector cannot be checked for.
q If sensor connector is disconnected, this code is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective power supply system of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
charge (boost) pressure sensor for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM.
Between ECM (female) (37) and (47) Resistance Min. 100 kz
Between ECM (female) (44) and (47) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
If no failure is found by the above checks, wiring harness may be discon-
5 Open circuit in wiring harness
nected. (*)
a If causes 1 to 5 are not cause for failure and check result in cause 6 indi-
cates failure, sensor is defective.
Defective boost pressure/temper-
1. Turn starting switch to OFF position.
ature sensor
6 2. Insert T-adapter to connector ECM.
(Improper input voltage to engine
controller) 3. Turn starting switch to ON position.
Sensor out- Min. 0.3 -
Between ECM (44) and (47) Voltage
put 4.7 V
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" in "Related in-
formation to troubleshooting".

40-152 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA123] Charge pressure sensor low error

Circuit diagram related to charge pressure sensor 40-153

GD555-5,GD655-5,GD675-5 40-153
(01)
Troubleshooting by failurecode
Failure code [CA131] Throttle sensor high error

Failure code [CA131] Throttle sensor high error 40-154

Action code Failure code Throttle sensor voltage is high
Failure
(Engine controller system)
E03 CA131
Detail of failure q High voltage is detected in throttle sensor signal circuit.

Action of con- q Runs engine at 0% throttle when accelerator pedal is released , and at 50% throttle when acceler-
troller ator pedal is depressed.

Problem on q The engine power does not reach full throttle power.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from throttle sensor can be checked by using monitoring function (Code: ENGINE
31707 THROTTLE POS).
Related infor-
q Information on throttle position detected by throttle sensor can be checked by using monitoring
mation
function (Code: ENGINE 31701 THROTTLE POS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective throttle sensor power
2 If failure code [CA2185] is also indicated, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between EC2 (female) (9) and (22), or between
Resistance Min. 1 Mz
T9A (female) (1) and (2)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector T9A and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(contact with 24V circuit)
Between T9A (female) (2) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON postion.
Defective accelerator pedal (throt-
5 Depress decelerator
tle sensor) Voltage 3.7 – 4.0 V
Between T9A (2) and pedal.
(3) Release decelerator
Voltage 0.5 – 0.8 V
pedal.
If no failure is found by above checks, engine controller is defective. (Since
failure is in it, troubleshooting cannot be performed.)
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
3. Turn starting switch to ON position.
4. Operate accelerator pedal and troubleshoot.
6 Defective engine controller
Between EC2 (22) and
Power supply Voltage 4.75 – 5.25 V
(23)
Depress accelerator
Voltage 3.7 – 4.0 V
Between EC2 (9) and pedal.
(23) Release accelerator
Voltage 0.5 – 0.8 V
pedal.

40-154 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA131] Throttle sensor high error

Circuit diagram related to throttle sensor 40-15

GD555-5,GD655-5,GD675-5 40-155
(01)
Troubleshooting by failurecode
Failure code [CA132] Throttle sensor low error

Failure code [CA132] Throttle sensor low error 40-156

Action code Failure code Throttle sensor voltage is low.
Failure
(Engine controller system)
E03 CA132
Detail of failure q Low voltage is detected in throttle sensor signal circuit.

Action of con- q Runs engine at 0% throttle when accelerator pedal is released, and at 50% throttle when acceler-
troller ator pedal is depressed.

Problem on q The engine power does not reach full throttle power.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from throttle sensor can be checked by using monitoring function (Code: ENGINE
31707 THROTTLE POS).
Related infor-
q Information on accelerator pedal position detected by throttle sensor can be checked by using mon-
mation
itoring function (Code: ENGINE31701 THROTTLE POS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.

If failure code [CA2186] is also indicated, perform troubleshooting for it first.

1. Turn starting switch and disconnect switch to OFF position.

2. Disconnect connector T9A and T9B, and connect T-adapters to female
Defective throttle sensor power sides.
2
supply system 3. Turn starting switch to ON position.

Between T9A (female) (1) and (3) Voltage 4.75 – 5.25 V

Between T9B (female) (1) and (2) Voltage 4.75 – 5.25 V

1. Turn starting switch and disconnect switch to OFF position.

2. Disconnect connectors EC2, T9A, T9B, TM39 and TM41, and connect
T-adapter to each female side.
a If cause 2 is not cause for failure, this check
is not required.
Resistance Max. 1 Mz
Between EC2 (female) (22) and T9A (female)
(1)
Open circuit in wiring harness a If cause 2 is not cause for failure, this check
3 (Wire breakage or defective con- is not required.
tact of connector) Resistance Max. 1 z
Between EC2 (female) (23) and T9A (female)
(3)
Between EC2 (female) (9) and T9A (female) (2) Resistance Max. 1 z
Between TM39 (female) (4) and T9B (female)
Resistance Max. 1 z
(2)
Between TM41 (female) (34) and T9B (female)
Resistance Max. 1 z
(1)
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side
4 Short circuit in wiring harness of one of them.
Between EC2 (female) (9) and (23), or between
Resistance Min. 1 Mz
T9A (female) (2) and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side
5 of one of them.
(Contact with ground circuit)
Between EC2 (female) (9) or T9A (female) (2)
Resistance Min. 1 Mz
and ground

40-156 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA132] Throttle sensor low error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
Defective accelerator pedal (throt-
6 Depress accelerator
tle sensor) Voltage 3.7 – 4.0 V
Between T9A (2) and pedal.
(3) Release accelerator
Voltage 0.5 – 0.8 V
pedal.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
3. Turn starting switch to ON position.
7 Defective engine controller 4. Operate accelerator pedal and troubleshoot.
Between EC2 (22) and
Power supply Voltage 4.75 – 5.25 V
(23)
Depress accelerator
Voltage 3.7 – 4.0 V
Between EC2 (9) and pedal.
(23) Release accelerator
Voltage 0.5 – 0.8 V
pedal.

Circuit diagram related to throttle sensor 40-157

GD555-5,GD655-5,GD675-5 40-157
(01)
Troubleshooting by failurecode
Failure code [CA144] Coolant sensor high error

Failure code [CA144] Coolant sensor high error 40-158

Action code Failure code Coolant temperature sensor voltage is high
Failure
(Engine controller system)
E01 CA144
Detail of failure q Signal circuit of coolant temperature sensor detects high voltage.
Action of con-
q Fixes coolant temperature value and continues operation.
troller

Problem on q Engine does not start easily at low temperature.

machine q Overheat prevention function does not work.

q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
(Code: ENGINE 04105 COOLANT TEMP).
q Temperature detected by engine coolant sensor can be checked by using monitoring function
Related infor- (Code: ENGINE 04104 COOLANT TEMP).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Since T-adapter for sensor connector is "socket", T-adapter cannot be connected to wiring har-
ness.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side
of connector.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor
as normal.
Defective coolant temperature
2 0°C Resistance 30 – 37 kz
sensor
Between COOLANT
25°C Resistance 9.3 – 10.7 kz
TEMP (male) (A) and (B)
a Coolant temperature- 50°C Resistance 3.2 – 3.8 kz
Resistance character-
80°C Resistance 1.0 – 1.3 kz
istics
95°C Resistance 700 – 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem-
3 perature: Min. 0°C)
ness Resis-
a Use "Coolant temperature-Resistance charac- 700 z - 37 kz
tance
teristics" table shown above as resistance crite-
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-158 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA144] Coolant sensor high error

Circuit diagram related to coolant temperature sensor 40-159

GD555-5,GD655-5,GD675-5 40-159
(01)
Troubleshooting by failurecode
Failure code [CA145] Coolant sensor low error

Failure code [CA145] Coolant sensor low error 40-160

Action code Failure code Coolant temperature sensor voltage is low.
Failure
(Engine controller system)
E01 CA145
Detail of failure q Signal circuit of coolant temperature sensor detected low voltage.
Action of con-
q Fixes coolant temperature value and continues operation.
troller

Problem on q Engine does not start easily at low temperature.

machine q Overheat prevention function does not work.

q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
(Code: ENGINE 04105 COOLANT TEMP).
q Temperature detected by engine coolant sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 04104 COOLANT TEMP).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for High Error is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side
of connector.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor
as normal.
0°C Resistance 30 – 37 kz
Defective coolant temperature Between COOLANT
2 25°C Resistance 9.3 – 10.7 kz
sensor TEMP (male) (A) and (B)
a Coolant temperature 50°C Resistance 3.2 – 3.8 kz
-Resistance charac-
80°C Resistance 1.0 – 1.3 kz
teristics
95°C Resistance 700 – 800 z
Whole cool-
Between TWTR (male)
ant temper- Resistance Min. 100 kz
(B) – ground
ature range
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Between ECM (female) (15) and (38) (Coolant tem-
3 Short circuit in wiring harness perature: Min. 0°C)
Resis-
a Use "Coolant temperature-Resistance charac- 700 z – 37 kz
tance
teristics" table shown above as resistance crite-
ria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and COOLANT TEMP, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-160 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA145] Coolant sensor low error

Circuit diagram related to coolant temperature sensor 40-161

GD555-5,GD655-5,GD675-5 40-161
(01)
Troubleshooting by failurecode
Failure code [CA153] Charge temperature sensor high error

Failure code [CA153] Charge temperature sensor high error 40-162

Action code Failure code Charged air temperature sensor voltage is high.
Failure
(Engine controller system)
E01 CA153
q High voltage is detected in temperature signal circuit of charge (boost) pressure/temperature sen-
Detail of failure
sor.
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem on
q Engine protection function based on charge air temperature does not work.
machine
q Input voltage from charge temperature sensor can be checked by using monitoring function (Code:
ENGINE 18501 CHG TEMP).
q Temperature detected by charge temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 18500 CHG TEMP).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q Since T-adapter for sensor connector is "socket", T-adapter cannot be connected.
q This failure code is displayed if temperature sensor connector is disconnected.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.

-40°C Resistance 41 kz – 48 kz
-20°C Resistance 14 kz – 16 kz
Defective charge temperature Between BOOST
2
sensor PRESS & IMT (male) (3) 0°C Resistance 5.4 kz – 6.1 kz
and (4)
30°C Resistance 1.6 kz – 1.8 kz
a Charge temperature
-Resistance charac- 60°C Resistance 560 – 600 z
teristic
90°C Resistance 230 – 250 z
130°C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or short circuit in wir- Between ECM (female) (23) and (47)
3
ing harness a Use "Charge temperature-Resistance charac- 80 z -
Resistance
teristics" table shown above as resistance crite- 48 kz
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-162 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA153] Charge temperature sensor high error

Circuit diagram related to charge temperature sensor 40-163

GD555-5,GD655-5,GD675-5 40-163
(01)
Troubleshooting by failurecode
Failure code [CA154] Charge temperature sensor low error

Failure code [CA154] Charge temperature sensor low error 40-164

Action code Failure code Charged air temperature sensor voltage is low.
Failure
(Engine controller system)
E01 CA154
q Low voltage is detected in temperature signal circuit of charge (boost) pressure/temperature sen-
Detail of failure
sor.
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem on
q Engine protection function based on charge air temperature does not work
machine
q Input voltage from charge temperature sensor can be checked by using monitoring function (Code:
ENGINE 18501 CHG TEMP).
q Temperature detected charge temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 18500 CHG TEMP).
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for "High Error" is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.

-40°C Resistance 41 kz – 48 kz
-20°C Resistance 14 kz – 16 kz
Defective charge temperature Between BOOST
2
sensor PRESS & IMT (male) (3) 0°C Resistance 5.4 kz – 6.1 kz
and (4)
30°C Resistance 1.6 kz – 1.8 kz
a Charge temperature
-Resistance charac- 60°C Resistance 560 – 600 z
teristic
90°C Resistance 230 – 250 z
130°C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
3 Short circuit in wiring harness Between ECM (female) (23) and (47)
a Use "Charge temperature-Resistance charac- 80 z –
Resistance
teristics" table shown above as resistance crite- 48 kz
ria.
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4
(Contact with ground circuit) T-adapter to female side of ECM.
Between ECM (female) (23) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-164 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA154] Charge temperature sensor low error

Circuit diagram related to charge temperature sensor 40-165

GD555-5,GD655-5,GD675-5 40-165
(01)
Troubleshooting by failurecode
Failure code [CA155] Speed derating error by high charge temperature

Failure code [CA155] Speed derating error by high charge temperature 40-16
Action code Failure code Charged air temperature is high and power drops
Failure
(Engine controller system)
E03 CA155
q Charge air temperature sensed by charge (boost) pressure/temperature sensor indicates that tem-
Detail of failure
perature exceeded upper limit of control temperature.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine stops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Charge air temperature sensed by charge (boost) pressure/temperature sensor can be checked
Related infor-
by using monitoring function (Code: ENGINE 18500 CHG TEMP)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

The deterioration of aftercooler cooling performance is suspected. Directly
check the following points:
Drop of cooling performance of
1 q Looseness and damage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Unusual rise of turbocharger outlet Outlet temperature of turbocharger may be unusually high. Check related
2
temperature parts directly.
If no failure is not found by above checks, charge temperature sensor system
3 Defective engine controller may be defective. Perform troubleshooting for failure codes [CA153] and
[CA154].

40-166 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA155] Speed derating error by high charge temperature

GD555-5,GD655-5,GD675-5 40-167
(01)
Troubleshooting by failurecode
Failure code [CA187] Sensor power supply 2 low error

Failure code [CA187] Sensor power supply 2 low error 40-168

Action code Failure code Sensor power supply 2 voltage is low.
Failure
(Engine controller system)
E03 CA187
Detail of failure q Low voltage is detected in sensor power supply 2 circuit.
Action of con- q Runs engine with charge (boost) pressure and charge (boost) temperature set to fixed values.
troller q Limits engine output and allows engine to run.
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
1 Defective wiring harness connector of "Check before troubleshooting" of "Related information to troubleshooting",
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because connector is discon-
2 Defective sensor or wiring harness nected. Ignore failure codes other than [CA187].
Sensor or harness Connector
Boost pressure/temperature sensor BOOST PRESS & IMT
Common rail pressure sensor FUEL RAIL PRESS
Bkup speed sensor CAM SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness discon-
nected.
Between ECM (male) (37) and (47) Voltage 4.75 – 5.25 V

40-168 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA187] Sensor power supply 2 low error

Circuit diagram related to sensor power supply 2 40-169

GD555-5,GD655-5,GD675-5 40-169
(01)
Troubleshooting by failurecode
Failure code [CA221] Atmospheric pressure sensor high error

Failure code [CA221] Atmospheric pressure sensor high error 40-170

Action code Failure code Ambient air pressure sensor voltage is high.
Failure
(Engine controller system)
E01 CA221
Detail of failure q High voltage is detected in signal circuit of ambient air pressure sensor.
Action of con-
q Fixes ambient air pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient air pressure sensor can be checked by using monitoring function
(Code: ENGINE 37402 AMBIENT PRESS).
Related infor-
q Ambient air pressure sensed by ambient air pressure sensor can be checked by using monitoring
mation
function (Code: ENGINE 37400 AMBIENT PRESS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective sensor power supply 1 If failure code [CA352] or [CA386] is displayed simultaneously, troubleshoot it
2
system
Defective ambient air pressure
3 3. Turn starting switch to ON position.
sensor
4 Short circuit in wiring harness
Hot short in wiring harness
5
(Contact with 24 V circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
first.
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
If failure code changes from [CA221] to [CA222] ,sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
T-adapter to female side of one of them.
Between ECM (female) (33) and (3), or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or
insert T-adapter in connector ECM.
4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE
disconnected).
Between ECM (3) and (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-170 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA221] Atmospheric pressure sensor high error

Circuit diagram related to ambient pressure sensor 40-171

GD555-5,GD655-5,GD675-5 40-171
(01)
Troubleshooting by failurecode
Failure code [CA222] Atmospheric pressure sensor low error

Failure code [CA222] Atmospheric pressure sensor low error 40-172

Action code Failure code Ambient air pressure sensor voltage is low.
Failure
(Engine controller system)
E01 CA222
Detail of failure q Low voltage is detected in signal circuit of ambient air pressure sensor.
Action of con-
q Fixes ambient air pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient air pressure sensor can be checked by using monitoring function
(Code: ENGINE 37402 AMBIENT PRESS).
Related infor-
q Ambient air pressure sensed by ambient air pressure sensor can be checked by using monitoring
mation
function (Code: ENGINE 37400 AMBIENT PRESS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Defective power supply system of 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
2
ambient air pressure sensor female side.
3. Turn starting switch to ON position.
Between AMB. AIR PRESSURE
Power input Voltage 4.75 – 5.25 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect
T-adapter to each female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resis-
Max. 10 z
Short circuit in wiring harness Between ECM (female) (33) and AMB. AIR tance
3 (wire breakage or defective con- PRESSURE (female) (1)
tact of connector) a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resis-
Max. 10 z
Between ECM (female) (38) and AMB. AIR tance
PRESSURE (female) (2)
Between ECM (female) (3) and AMB. AIR PRES- Resis-
Max. 10 z
SURE (female) (3) (sensor output) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
Ground fault in wiring harness T-adapter to female side of one of them.
4
(contact with ground circuit)
Between ECM (female) (3) and ground, or between Resis-
Min. 100 kz
AMB. AIR PRESSURE (female) (3) and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
5 Short circuit in wiring harness T-adapter to female side of one of them.
Between ECM (female) (3) and (38), or between Resis-
Min. 100 kz
AMB. AIR PRESSURE (female) (2) and (3) tance
a If cause items 1 to 5 are not cause for failure and check result of cause 6 is
abnormal, sensor is defective.
Defective ambient air pressure 1. Turn starting switch to OFF position.
6 sensor (improper input voltage to 2. Insert T-adapter to connector ECM.
engine controller) 3. Turn starting switch to ON position.
Sensor out-
Between ECM (3) and (38) Voltage 0.5 – 4.5 V
put

40-172 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA222] Atmospheric pressure sensor low error

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor 40-173

GD555-5,GD655-5,GD675-5 40-173
(01)
Troubleshooting by failurecode
Failure code [CA227] Sensor power supply 2 high error

Failure code [CA227] Sensor power supply 2 high error 40-174

Action code Failure code Sensor power supply 2 voltage is high.
Failure
(Engine controller system)
E03 CA227
Detail of failure q High voltage is detected in sensor power supply 2 circuit.

Action of con- q Fixes charge air pressure and charge air temperature values and continues operation.
troller q Restrains engine output and allows engine to run.

q Engine output drops.

Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA187].

Failure code [CA234] Engine overspeed 40-174

Action code Failure code Engine overspeed
Failure
(Engine controller system)
E02 CA234
Detail of failure q Engine speed exceeds controlled upper speed limit.
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem on q Engine speed fluctuates.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Engine speed can be checked by using monitoring function.
Related infor-
(Code: 01002 Engine speed)
mation
q Method of reproducing failure code: Run engine at high idle.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly

2 Improper use of machine Machine may be used improperly. Instruct operator proper way to use.

If causes 1 and 2 are not detected, engine controller may be defective. (Since
3 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-174 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA238] Ne speed sensor power supply error

Failure code [CA238] Ne speed sensor power supply error 40-175

Action code Failure code Ne speed sensor power supply voltage is low.
Failure
(Engine controller system)
E03 CA238
Detail of failure q Low voltage is detected in power supply circuit of engine Ne speed sensor.
Action of con-
q Controls engine with signal from engine Bkup speed sensor.
troller
q Running engine stops (when Bkup speed sensor is also failed).
q Stopped engine cannot be started (when Bkup speed sensor is also failed).
Problem on
q Starting performance is poor.
machine
q Engine hunts.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor CRANK SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller
nected.

Between ECM (male) (16) and (48) Voltage 4.75 – 5.25 V

Circuit diagram related to engine Ne speed sensor 40-175

GD555-5,GD655-5,GD675-5 40-175
(01)
Troubleshooting by failurecode
Failure code [CA271] IMV/IMA: Short circuit

Failure code [CA271] IMV/IMA: Short circuit 40-176

Action code Failure code IMV/IMA short circuit
Failure
(Engine controller system)
E03 CA271
Detail of failure q Short circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine speed does not increase from low idle.
Problem on q Engine output drops.
machine q Common rail fuel pressure rises above commanded value.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
2 Defective supply pump actuator
Short circuit or ground fault in wir-
3
ing harness
4 Short circuit in wiring harness
Ground fault in wiring harness
5 T-adapter to female side of either connector.
(contact with ground circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272] ,supply pump actuator is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Between ECM (female) (2) and (32) Resistance 1-5z
Between ECM (female) (2) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapter to female side of either connector.
Between ECM (female) (2) and (32), or between
Resistance Min. 100 kz
CP3 PUMP REGULATOR (female) (1) and (2)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
Between ECM (female) (2) and ground or between
Resistance Min. 100 kz
CP3 PUMP REGULATOR (female) (1) and ground
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-176 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA271] IMV/IMA: Short circuit

Circuit diagram related to IMV/IMA 40-17

GD555-5,GD655-5,GD675-5 40-177
(01)
Troubleshooting by failurecode
Failure code [CA272] IMV/IMA open circuit

Failure code [CA272] IMV/IMA open circuit 40-178

Action code Failure code IMV/IMA open circuit
Failure
(Engine controller system)
E03 CA272
Detail of failure q Open circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine runs but it does not stabilize.
Problem on
q Common rail fuel pressure rises above commanded value.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
2 Defective supply pump actuator
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
Hot short in wiring harness
5 4. Turn starting switch to ON position and perform troubleshooting after one
(Contact with 24 V circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
Between CP3 PUMP REGULATOR (male) (1) and
Resistance Max. 5 z
(2)
1. Turn starting switch to OFF position.
Between ECM (female) (2) and (32) Resistance Max. 5 z
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapters to each female side.
Between ECM (female) (2) and CP3 PUMP REGU-
Resistance Max. 10 z
LATOR (1)
Between ECM (female) (32) and CP3 PUMP REG-
Resistance Max. 10 z
ULATOR (2)
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
3. Insert T-adapter in connector ECM, or connect T-adapter to female side of
CP3 PUMP REGULATOR.
minute or longer (with connector CP3 PUMP REGULATOR disconnected).
a Average voltage is displayed because of PWM.
Between ECM (2) and (32), or between CP3 PUMP
Voltage Max. 3 V
REGULATOR (female) (1) and (2)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-178 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA272] IMV/IMA open circuit

Circuit diagram related to IMV/IMA 40-179

GD555-5,GD655-5,GD675-5 40-179
(01)
Troubleshooting by failurecode
Failure code [CA322] Injector #1 (L#1) open/short

Failure code [CA322] Injector #1 (L#1) open/short 40-180

Action code Failure code Injector #1 (L#1) has open or short circuit
Failure
(Engine controller system)
E03 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 1 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 1 injector
Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (45) and (53) Resistance Max. 2 z
Between ECM (female) (45) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (45) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (3)
Between ECM (female) (53) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (4)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (45) or INJECTOR CYL
1&2 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective injectors in other cylin-
7
ders or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (45) and each pin other No continuity (no sound
than (45) is heard)
Between ECM (female) (53) and each pin other No continuity (no sound
than (53) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them, too.
If causes 1 to 7 are not causes for failure, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-180 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA322] Injector #1 (L#1) open/short

Circuit diagram related to injector #1 40-181

GD555-5,GD655-5,GD675-5 40-181
(01)
Troubleshooting by failurecode
Failure code [CA323] Injector #5 (L#5) open/short

Failure code [CA323] Injector #5 (L#5) open/short 40-182

Action code Failure code Injector #5 (L#5) has open or short circuit
Failure
(Engine controller system)
E03 CA323
Detail of failure q Open or short circuit is detected in drive circuit of No. 5 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approximately 65 V is supplied to injector (+)
mation
side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective No. 5 injector
Between INJECTOR CYL 5&6 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (46) and (60) Resistance Max. 2 z
Between ECM (female) (46) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (46) and INJECTOR
tact of connector) Resistance Max. 2 z
CYL 5&6 (female) (3)
Between ECM (female) (60) and INJECTOR
Resistance Max. 2 z
CYL 5&6 (female) (4)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (46) or INJECTOR CYL
5&6 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective injectors in other cylin-
7
ders or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (46) and each pin other No continuity (no sound is
than (46) heard)
Between ECM (female) (60) and each pin other No continuity (no sound is
than (60) heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-182 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA323] Injector #5 (L#5) open/short

Circuit diagram related to injector #5 40-183

GD555-5,GD655-5,GD675-5 40-183
(01)
Troubleshooting by failurecode
Failure code [CA324] Injector #3 (L#3) open/short

Failure code [CA324] Injector #3 (L#3) open/short 40-184

Action code Failure code Injector #3 (L#3) has open or short circuit.
Failure
(Engine controller system)
E03 CA324
Detail of failure q Open or short circuit is detected in drive circuit of No. 3 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 3 injector
Between INJECTOR CYL 3&4 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (55) and (52) Resistance Max. 2 z
Between ECM (female) (55) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (55) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (3)
Between ECM (female) (52) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (4)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (55) or INJECTOR CYL
3&4 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (55) and each pin other No continuity (no sound
than (55) is heard)
Between ECM (female) (52) and each pin other No continuity (no sound
than (52) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-184 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA324] Injector #3 (L#3) open/short

Circuit diagram related to injector #3 40-185

GD555-5,GD655-5,GD675-5 40-185
(01)
Troubleshooting by failurecode
Failure code [CA325] Injector #6 (L#6) open/short

Failure code [CA325] Injector #6 (L#6) open/short 40-186

Action code Failure code Injector #6 (L#6) has open or short circuit.
Failure
(Engine controller system)
E03 CA325
Detail of failure q Open or short circuit is detected in drive circuit of No. 6 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of apporx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective injector No. 6
Between INJECTOR CYL 5&6 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (1) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (57) and (59) Resistance Max. 2 z
Between ECM (female) (57) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
4 (Wire breakage or defective con- T-adapter to female side of one of them.
Between ECM (female) (57) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
5&6 (female) (1)
Between ECM (female) (59) and INJECTOR CYL
Resistance Max. 2 z
5&6 (female) (2)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (57) or INJECTOR CYL
Resistance Min. 100 kz
5&6 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
6 Short circuit in wiring harness a Check by using multimeter in continuity mode.
Between ECM (female) (57) and each pin other No continuity (no sound
than (57) is heard)
Between ECM (female) (59) and each pin other No continuity (no sound
than (59) is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them as well.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-186 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA325] Injector #6 (L#6) open/short

Circuit diagram related to injector #6 40-187

GD555-5,GD655-5,GD675-5 40-187
(01)
Troubleshooting by failurecode
Failure code [CA331] Injector #2 (L#2) open/short

Failure code [CA331] Injector #2 (L#2) open/short 40-18

Action code Failure code Injector #1 (L#1) has open or short circuit.
Failure
(Engine controller system)
E03 CA331
Detail of failure q Open or short circuit is detected in drive circuit of No. 2 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 2 injector
Between INJECTOR CYL 1&2 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (54) and (51) Resistance Max. 2 z
Between ECM (female) (54) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (54) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (2)
Between ECM (female) (51) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (1)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (54) or INJECTOR CYL
1&2 (female) (2) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (54) and each pin other No continuity (no sound
than (54) is heard)
Between ECM (female) (51) and each pin other No continuity (no sound
than (51) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-188 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA331] Injector #2 (L#2) open/short

Circuit diagram related to injector #2 40-189

GD555-5,GD655-5,GD675-5 40-189
(01)
Troubleshooting by failurecode
Failure code [CA332] Injector #4 (L#4) open/short

Failure code [CA332] Injector #4 (L#4) open/short 40-190

Action code Failure code Injector #4 (L#4) has open or short circuit.
Failure
(Engine controller system)
E03 CA332
Detail of failure q Open or short circuit is detected in drive circuit of No. 4 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 4 injector
Between INJECTOR CYL 3&4 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (56) and (58) Resistance Max. 2 z
Between ECM (female) (56) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (56) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (2)
Between ECM (female) (58) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (1)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (56) or INJECTOR CYL
3&4 (female) (2) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (56) and each pin other No continuity (No sound
than (56) is heard)
Between ECM (female) (58) and each pin other No continuity (No sound
than (58) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-190 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA332] Injector #4 (L#4) open/short

Circuit diagram related to injector #4 40-191

GD555-5,GD655-5,GD675-5 40-191
(01)
Troubleshooting by failurecode
Failure code [CA342] Data compatibility error in engine controller

Failure code [CA342] Data compatibility error in engine controller 40-192

Action code Failure code Data inconsistency in engine controller
Failure
(Engine controller system)
E03 CA342
Detail of failure q Data inconsistency occurres in engine controller.
Action of con-
q None in particular
troller
Problem on q Engine continues to run normaly, but it may stop or it may not restart if it stops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

40-192 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA351] Injector drive circuit error

Failure code [CA351] Injector drive circuit error 40-193

Action code Failure code Injector drive circuit error
Failure
(Engine controller system)
E03 CA351
Detail of failure q Error occurs in power circuit to drive injectors.
Action of con-
q Limits engine output and allows engine to run.
troller
q Exhaust gas becomes black.
q Combustion becomes irregular.
Problem on
q Engine output drops.
machine
q Engine cannot be started.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

GD555-5,GD655-5,GD675-5 40-193
(01)
Troubleshooting by failurecode
Failure code [CA352] Sensor power supply 1 low error

Failure code [CA352] Sensor power supply 1 low error 40-194

Action code Failure code Sensor power supply 1 voltage is low.
Failure
(Engine controller system)
E03 CA352
Detail of failure q Low voltage is detected in sensor power supply 1 circuit.
Action of con-
q Takes ambient air pressure to be fixed value and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when connector is disconnected, separated
sensor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because connector is un-
plugged. Ignore all failure codes except for [CA352].
Sensor or harness Connector
Ambient pressure sensor AMB. AIR PRESSURE
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller
nected.

Between ECM (male) (33) and (38) Voltage 4.75 – 5.25 V

Circuit diagram related to sensor power 1 circuit 40-194

40-194 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA386] Sensor power supply 1 high error

Failure code [CA386] Sensor power supply 1 high error 40-195

Action code Failure code Sensor power supply 1 voltage is high.
Failure
(Engine controller system)
E03 CA386
Detail of failure q High voltage is detected in sensor power supply 1 circuit.
Action of con-
q Takes ambient air pressure to be fixed value and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA352]

GD555-5,GD655-5,GD675-5 40-195
(01)
Troubleshooting by failurecode
Failure code [CA428] Water-in-fuel sensor high error

Failure code [CA428] Water-in-fuel sensor high error 40-196

Action code Failure code Voltage of water-in-fuel sensor is high.
Failure
(Engine controller system)
E01 CA428
Detail of failure q High voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor does not work correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800 WATER IN FUEL)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" to "Related information to troubleshooting",
tor
Defective water-in-fuel sensor
2 a If water is in water separator, drain it.
installed to fuel prefilter
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector WIF1 and connect T-adapter to female side.
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Between ECM (female) (14) and (47)
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to each
female side.
Between ECM (female) (14) and WIF1 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and WIF1 (female) (2) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard)
If no failure is found by above checks, engine controller is defective. (Since
tihis is internal failure, troubleshooting cannot be performed.)

40-196 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA428] Water-in-fuel sensor high error

Circuit diagram related to water-in-fuel sensor 40-197

GD555-5,GD655-5,GD675-5 40-197
(01)
Troubleshooting by failurecode
Failure code [CA429] Water-in-fuel sensor low error

Failure code [CA429] Water-in-fuel sensor low error 40-198

Action code Failure code Voltage of water-in-fuel sensor is low.
Failure
(Engine controller system)
E01 CA429
Detail of failure q Low voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor does not woek correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800 WATER IN FUEL)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective water-in-fuel sensor
2
installed to fuel prefilter
Short circuit or ground fault in wir-
3 Between ECM (female) (14) and (47)
ing harness
4 Short circuit in wiring harness
Ground fault in wiring harness
5
(Contact with ground circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector WIF1 and connect T-adapter to female side.
a If water is in water separator, drain it.
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
Between WIF1 (female) (1) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
Between ECM (female) (14) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of one of them.
Between ECM (female) (14) or WIF1 (female) (1)
Resistance Min. 100 kz
and ground
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-198 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA429] Water-in-fuel sensor low error

Circuit diagram related to water-in-fuel sensor 40-19

GD555-5,GD655-5,GD675-5 40-199
(01)
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

Failure code [CA431] Idle validation switch error 40-20

Action code Failure code Idle validation switch error
Failure
(Engine controller system)
E01 CA431
Detail of failure q Signals 1 and 2 (IVS1 and IVS2) from idle validation switch are unusual.
Action of con-
q Runs engine at the throttle opening decided based on signal from throttle sensor.
troller
Problem on
machine
q Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function
(Code: ENGINE 18300 IVS 1)
Related infor-
q Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function
mation
(Code: ENGINE 18301 IVS 2)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 ment" of "Checks before troubleshooting" in "General information on trouble-
tor
2 Defective power supply system
Defective accelerator pedal
3 is not abnormal, accelerator pedal is defective.
(internal failure)
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
See the descriptions of wiring harness and connectors in "c: Electrical equip-
shooting" , and check them directly.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9B.
3. Turn starting switch to ON position.
a If abnormal, go to cause 4.
Between T9B (1) and (2) Voltage 4.75 – 5.25 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
a If abnormal, check wiring harness for causes 4 and 5. When wiring harness
See IVS1 in the figure 1
Between T9A (5) and (4)
on the next page.
See IVS2 in the figure 1
Between T9A (6) and (4)
on the next page.
1. Turn starting switch and disconnect switch to OFF position.
2. Disconnect connectors T9A, T9B, EC2, TM39 and TM41, and connect
T-adapters to female side of them.
Resis-
Between EC2 (female) (32) and T9A (female) (4) Max. 1 z
tance
Resis-
Between EC2 (female) (11) and T9A (female) (5) Max. 1 z
tance
Between EC2 (female) (1) and T9A (female) (6) Resis- Max. 1 z
tance
Between TM41 (female) (34) and T9B (female) (1) Resis- Max. 1 z
tance
Between TM39 (female) (4) and T9B (female) (2) Resis- Max. 1 z
tance
1. Turn starting switch and disconnect switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of connector EC2.
Between EC2 (female) (1) and each pin other than Resis-
Min. 1 Mz
(1) tance
Between EC2 (female) (11) and each pin other than Resis-
Min. 1 Mz
(11) tance

40-200 GD555-5,GD655-5,GD675-5
(01)

Cause
Defective transmission controller
6
(internal failure)
Defective engine controller
7 3. Turn starting switch to ON position.
(internal failure)
Circuit diagram related to idle validation
GD555-5,GD655-5,GD675-5
(01)
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error
Procedure, measuring location, criteria and remarks
1. Turn starting switch and disconnect switch to OFF position.
2. Insert T-adapter into connectors TM39 and TM41.
3. Turn disconnect switch to ON position.
4. Turn starting switch to ON position.
Between TM41 (34) and TM39 (4) Voltage 4.75 – 5.25 V
If no abnormality is found in the above, engine controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
See IVS1 in the figure 1 on the next
Between EC2 (11) and (32)
page.
See IVS2 in the figure 1 on the next
Between EC2 (1) and (32)
page.
40-201
40-201
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

Pedal stroke: Accelerator pedal stroke

Output voltage: Output voltage (Pin 2 of connector
T9A, pin 9 of EC2)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Area where both signals of IVS1 and
IVS2 are OFF

Fig. 1

40-202 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

GD555-5,GD655-5,GD675-5 40-203
(01)
Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Failure code [CA432] Idle validation action error 40-204

Action code Failure code Idle validation action error
Failure
(Engine controller system)
E03 CA432
Detail of failure q Idle validation switch signal and throttle sensor signal are inconsistent.
1. In the case where controller judges that signal from idle validation switch shows "release" of accel-
erator pedal and signal from throttle sensor shows "depression" of accelerator pedal: Runs engine
at 0 % throttle when accelerator pedal is released, and at 50 % throttle when accelerator pedal is
Action of con-
depressed.
troller
2. In the case where controller judges that signal from idle validation switch shows "depression" of
accelerator pedal and signal from throttle sensor shows "release" of accelerator pedal: Runs
engine at 0 % throttle (Fixes throttle position for low idle operation).
Problem on q Engine speed does not rise from low idling.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function
(Code: ENGINE 18300 IVS 1)
q Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function
(Code: ENGINE 18301 IVS 2)
Related infor-
q Input voltage from the throttle sensor can be checked by using monitoring function (Code: ENGINE
mation
31707 THROTTLE POS)
q Accelerator pedal position sensed by the throttle sensor can be checked by using monitoring func-
tion (Code: ENGINE 31701 THROTTLE POS)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

As for idle validation switch, perform troubleshooting for failure code [CA431].
1
(For throttle sensor, perform troubleshooting for causes 2 and after.)
2 Defective power supply system
Defective accelerator pedal
3 a If abnormal, check wiring harness for causes 4 and 5. When wiring harness
(internal failure)
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
a If abnormal, go to cause 4.
4.75 – 5.25
Between T9A (1) and (3) Voltage
V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
is not abnormal, accelerator pedal is defective.
See output voltage in the figure 1 on
Between T9A (2) and (3)
the next page.
1. Turn starting switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of them.
Between EC2 (female) (22) and T9A (female) (1) Resistance Max. 1 z
Between EC2 (female) (9) and T9A (female) (2) Resistance Max. 1 z
Between EC2 (female) (23) and T9A (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of connector EC2.
Between EC2 (female) (9) and each pin other than
Resistance Min. 1 Mz
(9)

40-204 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found in the above, engine controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
Defective engine controller
6 2. Insert T-adapter into connector EC2.
(internal failure)
3. Turn starting switch to ON position.
See output voltage in the figure 1 on
Between EC2 (9) and (23)
the next page.

Circuit diagram related to idle validation 40-205

GD555-5,GD655-5,GD675-5 40-205
(01)
Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Pedal stroke: Accelerator pedal stroke

Output voltage: Output voltage (Pin 2 of connector
T9A, pin 9 of EC2)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Area where both signals of IVS1 and
IVS2 are OFF

Fig. 1

40-206 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA435] Engine oil pressure switch error

Failure code [CA435] Engine oil pressure switch error 40-207

Action code Failure code Engine oil pressure switch error
Failure
(Engine controller system)
E01 CA435
Detail of failure q Abnormality is detected in signal circuit of engine oil pressure switch.
Action of con-
q None in particular
troller
Problem on q Engine protection function based on engine oil pressure does not work.
machine q Engine oil pressure monitor does not work correctly.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Engine oil pressure switch is closed (turned ON) when oil pressure is low (when engine is stopped),
and is open (turned OFF) when high (when engine is running).
Related infor-
q As for generation of this failure code, engine controller checks engine oil pressure switch only when
mation
engine is not running. It checks whether the switch is closed (ON) or not, in other words, the signal
potential is ground level or not.
q When engine is running, failure of engine oil pressure switch is shown by failure code [B@BAZG].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
Defective engine oil pressure 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to
2 male side.
switch
Between OIL PRESSURE SWITCH (male) (1) and
Resistance Max. 10 z
ground
1. Turn starting switch to OFF position.
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Between ECM (female) (17) and ground Resistance Max. 10 z
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch 40-207

GD555-5,GD655-5,GD675-5 40-207
(01)
Troubleshooting by failurecode
Failure code [CA441] Power supply voltage low error

Failure code [CA441] Power supply voltage low error 40-208

Action code Failure code Power supply voltage is low.
Failure
(Engine controller system)
E03 CA441
Detail of failure q Low voltage is detected in controller power supply circuit.
Action of con-
q None in particular
troller
q Engine stops.
Problem on
q Starting performance is poor.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Loose or corroded battery cable
1 Battery cable terminal may be loose or corroded. Check it directly.
terminal
1) Turn starting switch to OFF position.
Loose terminal or partial wire
2 Check terminals of alternator, battery relay, ground (ET103) etc. for loose-
breakage at terminal
ness.
See descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
3 ment" of "Check before troubleshooting" of "Related information to trouble-
tor
shooting", and check them.
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position, and at engine
4 Low battery voltage cranking.
Between battery terminals (+) and (-). Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ET104.
5 Defective alternator 3. Start engine (run engine at middle or faster speed).
Between ET104 (1) and ground Voltage 27 – 29.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference: Use following criteria to check that power supply system is nor-
mal.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapter between male and female sides of EC3.
6 Defective engine controller
3. Connect ground cable.
4. Measure voltage with starting switch at OFF position, and when engine is
cranked.
Between EC3 (3) and (1) Voltage 20 – 30 V
Between EC3 (4) and (2) Voltage 20 – 30 V

40-208 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA441] Power supply voltage low error

Circuit diagram related to power supply voltage 40-209

GD555-5,GD655-5,GD675-5 40-209
(01)
Troubleshooting by failurecode
Failure code [CA442] Power supply voltage high error

Failure code [CA442] Power supply voltage high error 40-210

Action code Failure code Power supply voltage is high.
Failure
(Engine controller system)
E03 CA442
Detail of failure q High voltage (36 V or higher) is detected in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine may stop.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA441].

40-210 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA449] Common rail pressure high error 2

Failure code [CA449] Common rail pressure high error 2 40-21

Action code Failure code Common rail pressure is high.
Failure
(Engine controller system)
E03 CA449
Detail of failure q High pressure error (2) is detected in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine sound becomes large when engine is running with no load or light load.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 RAIL PRESS)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Air in low pressure circuit
3 Defective fuel return circuit parts
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
5 Defective pressure limiter
6 Defective supply pump
Air may be in low pressure circuit. Check it directly according to following pro-
cedure.
1. Remove pressure pickup port plug (outlet side) in fuel main filter head.
2. Operate feed pump near fuel pre-filter.
3. Check leakage of fuel and air from pressure pickup port.
a For check of fuel return circuit pressure, see Testing and adjusting, Check-
ing fuel pressure.
Max. 0.02 MPa
Fuel return circuit pres-
At low idle or cranking
sure {Max. 0.19 kg/cm2}
a For check of leakage from pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
Leakage from pressure
At low idle 0 cc (No leakage)
limiter
If no failure is found by above checks, supply pump may be defective.

GD555-5,GD655-5,GD675-5 40-211
(01)
Troubleshooting by failurecode
Failure code [CA451] Common rail pressure sensor high error

Failure code [CA451] Common rail pressure sensor high error 40-212
Action code Failure code Common rail pressure sensor voltage is high
Failure
(Engine controller system)
E03 CA451
Detail of failure q High voltage is detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine speed or output lowers.
Problem on
q Engine does not start
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Signal voltage of common rail pressure sensor can be checked by using monitoring function.
(Code: 36401 RAIL PRESS)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position.
mation q This code is displayed if common rail pressure sensor connector is disconnected.
q Since T-adapter for sensor connector is "socket", open circuit in the wiring harness or voltage at
sensor connector cannot be checked.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective common rail pressure
2
sensor power supply line
3 Short circuit in wiring harness
Hot short in wiring harness
4
(Contact with 24 V circuit)
5 Open circuit in wiring harness
Defective common rail pressure
sensor
6 2. Insert T-adapter to connector ECM.
(Improper input voltage to engine
controller)
7 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
If failure code [CA227] or [CA187] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3. Connect T-adapter to female side of ECM.
Between ECM (female) (25) and (37) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to
connector ECM.
3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
disconnected).
a Pin (25) of ECM is connected to 5V line via resistor inside engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
If no abnormality is found by above checks, wiring harness may be discon-
nected. (*)
a If no abnormality is found by checks on causes 1 to 5 and check result for
cause 6 is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
Sensor out-
Between ECM (25) and (47) Voltage 0.2 – 4.6 V
put
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation to troubleshooting".

40-212 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA451] Common rail pressure sensor high error

Circuit diagram related to common rail pressure sensor 40-213

GD555-5,GD655-5,GD675-5 40-213
(01)
Troubleshooting by failurecode
Failure code [CA452] Common rail pressure sensor low error

Failure code [CA452] Common rail pressure sensor low error 40-214
Action code Failure code Common rail pressure sensor voltage is low.
Failure
(Engine controller system)
E03 CA452
Detail of failure q Low voltage is detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine speed or output lowers.
Problem on
q Engine does not start.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Signal voltage of common rail pressure sensor can be checked by using monitoring function.
(Code: 36401 RAIL PRESS)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If sensor connector is disconnected, this failure code is not displayed but failure code [CA451] for
High Error is displayed even if there is no high voltage problem.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective common rail pressure If failure code [CA187] (ground fault in sensor power supply line) or [CA227] is
2
sensor power supply line indicated, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault in sensor power supply line)
is not displayed.
Defective common rail pressure 1. Turn starting switch to OFF position.
3 2. Disconnect connector FUEL RAIL PRESS.
sensor
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451] , sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Between ECM (female) (25) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
5 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (25) and (47) Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-214 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA452] Common rail pressure sensor low error

Circuit diagram related to common rail pressure sensor 40-215

GD555-5,GD655-5,GD675-5 40-215
(01)
Troubleshooting by failurecode
Failure code [CA488] Torque derating error by high charge temperature

Failure code [CA488] Torque derating error by high charge temperature40-216

Action code Failure code Charged air temperature is abnormality high and engine is der-
Failure ated.
E03 CA488 (Engine controller system)

Detail of failure q Temperature signal of boost pressure and temperature sensor exceeds upper limit of temperature.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Boost temperature can be checked by using monitoring function.
Related infor-
(Code: 18500 CHG TEMP)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may lower. Directly check following points:
Lowered cooling performance of
1 q Insufficient cooling air
aftercooler
q Clogging of aftercooler fins

Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
Defective boost temperature sen-
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sor

40-216 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA553] Common rail pressure high error 1

Failure code [CA553] Common rail pressure high error 1 40-217

Action code Failure code Common rail pressure is high.
Failure
(Engine controller system)
E03 CA553
Detail of failure q High pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
q Engine sound becomes large when engine is running with no load or light load.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 RAIL PRESS)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Cable connection to ground terminal may be incorrect. Check following termi-

nals directly.
Defective connection at ground q Ground terminal of machine ((–) terminal of battery)
2
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
Damaged O-ring of supply pump
3 O-ring of supply pump actuator may be broken. Check it directly.
actuator
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system

GD555-5,GD655-5,GD675-5 40-217
(01)
Troubleshooting by failurecode
Failure code [CA559] Supply pump pressure low error 1

Failure code [CA559] Supply pump pressure low error 1 40-218

Action code Failure code Common rail pressure is low.
Failure
(Engine controller system)
E03 CA559
Detail of failure q Low pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
q Engine does not start at all or does not start easily.
Problem on q Exhaust gas becomes black.
machine q Engine output drops.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly.
Fuel may be leaking to outside. Check it directly (check visually while running
2 Fuel leakage to outside
engine at low idle).
a For checking method, see “Note 1”. To check pressure of low-pressure fuel
line, see Testing and adjusting, “Testing fuel pressure”.
Negative pressure at fuel
At high idle Max. -50.7 MPa
supply pump inlet (outlet
(if engine can be started) {Max. -380 mmHg}
side of fuel pre-filter)
3 Defect in low pressure circuit parts
During cranking 0.3 – 1.1 MPa
Fuel pressure in low-pres- (if engine cannot be
sure circuit started) {3.1 – 11.3 kg/cm2}
(Inlet pressure of fuel main 0.5 – 1.3 MPa
At low idle
filter)
(if engine can be started) {5.1 – 13.3 kg/cm2}
a For check of leakage through pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
4 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
a For check of return rate from injector, see Testing and adjusting, “Checking
fuel return rate and leakage”.
Defective injector During cranking
5 (including high-pressure pipe in (if engine cannot be Max. 90 cc/min
cylinder head) Return rate from injector started)
At low idle
Max. 180 cc/min
(if engine can be started)
a For check of return rate from supply pump, see Testing and adjusting,
“Checking fuel return rate and leakage”.
During cranking
6 Defective supply pump (if engine cannot be Max. 140 cc/min
Return rate from supply
started)
pump
At low idle
Max. 1,000 cc/min
(if engine can be started)
Defective common rail pressure
7 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
Note 1: Check the low-pressure line parts for the following.
1) Remaining fuel level
2) Clogging of fuel tank breather
3) Fuel leakage through and clogging of low-pressure pipe
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace the fuel filter if problem is not removed by clearing clogging.

40-218 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA689] Engine Ne speed sensor error

Failure code [CA689] Engine Ne speed sensor error 40-219

Action code Failure code Engine Ne speed sensor error
Failure
(Engine controller system)
E03 CA689
Detail of failure q Signal from engine Ne speed sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Bkup speed sensor.
troller
q Engine hunts.
Problem on q Starting performance is poor.
machine q Engine output drops.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related infor-
q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
mation
multimeter.
q Speed sensor senses holes of speed sensing wheel that is installed on inside of crankshaft vibra-
tion damper and rotated by crankshaft.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
3 (looseness) of engine Ne speed
sensor
Defective power supply input to
4
Ne speed sensor
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
6 Short circuit in wiring harness
Ground fault in wiring harness
7
(Contact with ground circuit)
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
Engine Ne speed sensor may be broken or may have improper installation
(looseness). Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CRANK SENSOR and connect T-adapter to female
side.
3. Turn starting switch to ON position.
Between CRANK SENSOR (female) Power
Voltage 4.75 – 5.25 V
(1) and (2) input
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (16) and CRANK tance
SENSOR (female) (1)
a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and CRANK tance
SENSOR (female) (2)
Between ECM (female) (27) and CRANK SEN- Resis-
Max. 10 z
SOR (female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (16) and (27) or CRANK Resis-
Min. 100 kz
SENSOR (female) (1) and (3) tance
Between ECM (female) (27) and (48) or CRANK Resis-
Min. 100 kz
SENSOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (27) or CRANK SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance

GD555-5,GD655-5,GD675-5 40-219
(01)
Troubleshooting by failurecode
Failure code [CA689] Engine Ne speed sensor error

1. Turn starting switch to OFF position.

2. Disconnect connector CRANK SENSOR.
Hot short circuit in wiring harness
8 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between CRANK SENSOR (female) (3) and
Voltage Max. 1 V
ground
Cause Procedure, measuring location, criteria and remarks
Damaged or loose speed sensing
9 Inspect speed sensing ring directly.
ring
If no failure is found by above checks, Ne speed sensor is defective. (Since
10 Defective Ne speed sensor
this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
11 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor 40-2 0

40-220 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA731] Engine Bkup speed sensor phase error

Failure code [CA731] Engine Bkup speed sensor phase error 40-2 1
Action code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E03 CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on q Idle speed is unstable.
machine q Exhaust gas becomes black.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Breakage of engine Ne speed
1 Engine Ne speed sensor may be broken. Check it directly.
sensor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Defective installation or breakage
3 of speed sensing wheel on crank-
shaft side
Defective installation or breakage
4 of speed sensing ring on camshaft
side
Defective timing of crankshaft and
5 Timing of crankshaft and camshaft may be defective. Check it directly.
camshaft
Defective connection at ground
6
terminal
Speed sensing wheel on crankshaft side may be installed defectively or bro-
ken. Check it according to following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
a Do not align with mark of No. 1 cylinder compression top dead center.
(Approx. 80 ° before compression top dead center)
2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed
sensor top (M2), installation is correct.
Speed sensing ring on camshaft side may be installed defectively or broken.
Check it according to following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
a Do not align with mark of No. 1 cylinder compression top dead center.
(Approx. 80 ° before compression top dead center)
2. Remove Bkup speed sensor.
3. If you can see double-slot part (with one crest) on speed sensing ring (B)
through sensor mounting hole (H), speed sensing ring is installed correctly.
Cable connection to ground terminal may be incorrect. Check following termi-
nals directly.
q Ground terminal of machine ((-) terminal of battery)
q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor

GD555-5,GD655-5,GD675-5 40-221
(01)
Troubleshooting by failurecode
Failure code [CA757] All continuous data lost error

Failure code [CA757] All continuous data lost error 40-2 2

Action code Failure code All continuous data lost error
Failure
(Engine controller system)
E03 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
q None in particular
troller
q Engine may stop and may not restart.
Problem on
q Monitoring function of machine monitor (engine controller system) may not work normally.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

40-222 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

Failure code [CA778] Engine Bkup speed sensor error 40-2 3

Action code Failure code Engine Bkup speed sensor error
Failure
(Engine controller system)
E03 CA778
Detail of failure q Abnormal engine Bkup speed (cam) sensor signal is detected.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Starting performance is poor.
Problem on
q Engine output lowers.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related infor- be determined to be normal by measuring its resistance with multimeter.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
q Speed sensor detects rotating slot on speed sensing ring installed on camshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective sensor power supply 2
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
line
Damage or incorrect (loose) instal-
Check engine Bkup speed (cam) sensor directly as it may be damaged or
3 lation of engine Bkup speed (cam)
incorrectly (loosely) installed.
sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Defective power supply input to side.
4
engine Bkup speed sensor 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (1) Power sup-
Voltage 4.75 – 5.25 V
and (2) ply
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
each female side.
Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR Resis-
5 (Wire breakage or defective con- Max. 10 z
(female) (1) tance
tact of connector) Between ECM (female) (47) and CAM SENSOR Resis-
Max. 10 z
(female) (2) tance
Between ECM (female) (26) and CAM SENSOR Resis-
Max. 10 z
(female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
female side of either connector.
6 Short circuit in wiring harness Between ECM (female) (26) and (37) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (1) and (3) tance
Between ECM (female) (26) and (47) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
Ground fault in wiring harness female side of either connector.
7
(Contact with ground circuit)
Between ECM (female) (26) or CAM SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance

GD555-5,GD655-5,GD675-5 40-223
(01)
Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

1. Turn starting switch to OFF position.

2. Disconnect connector CAM SENSOR, and connect T-adapter to female
Hot short circuit in wiring harness side.
8
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
Remove engine Bkup speed (cam) sensor, and check ring directly through
hole (H).
9 Loose speed sensing ring
a If speed sensing ring (B) is loosely installed, follow instructions given in the
"Reference" column.

Cause Procedure, measuring location, criteria and remarks

Defective engine Bkup speed
10
(cam) sensor
11 Defective engine controller
If no failure is found by above checks, engine Bkup speed (cam) sensor is
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor 40-2 4

40-224 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

Reference for troubleshooting for CA778 (107 5. Check mounting bolt (4) of camshaft ring (5) for
series engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4): 10 ± 2 Nm
Remove the front cover and check the camshaft ring (DP): Dowel pin
for looseness.
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-2 5
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
(DP): Dowel pin

Installation 40-2 5
a See the figures in "Removal" for installation.
1. Install front cover (2).
3 Front cover: Liquid gasket LG-7
2. Install the front seal according to the following
procedure. For details, see "Removal and instal-
lation of front seal" in Disassembly and
assembly.
1) Install front seal (3).
2) Install dowel pin (DP), and install the damper
assembly.
3. Remove front cover (2). 3) Install the fan and fan belt.
4. Remove front seal (3). 4) Install the cooling system assembly.
(RING): Ring

GD555-5,GD655-5,GD675-5 40-225
(01)
Troubleshooting by failurecode
Failure code [CA1633] KOMNET (CAN communication) error

Failure code [CA1633] KOMNET (CAN communication) error 40-2 6

Action code Failure code KOMNET (CAN communication) error
Failure
(Engine controller system)
E03 CA1633
q Engine controller detects communication error in KOMNET communication circuit between engine
Detail of failure
controller and transmission controller or machine monitor.

Action of con- q Controls engine in default mode, and holds state at the time of abnormally.
troller q If cause of failure disappears, system resets itself.

q Information may not be transmitted normally through CAN (KOMNET) communication lines and
Problem on
consequently machine may not operate normally. (Symptom depends on failed section.)
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [DB2RKR].

40-226 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA1633] KOMNET (CAN communication) error

GD555-5,GD655-5,GD675-5 40-227
(01)
Troubleshooting by failurecode
Failure code [CA2185] Throttle sensor power supply high error

Failure code [CA2185] Throttle sensor power supply high error 40-2 8
Action code Failure code Throttle sensor power supply volaget is high
Failure
(Engine controller system)
E03 CA2185
Detail of failure q High voltage (5.25 V or higher) is detected in throttle sensor power supply circuit.

Action of con- q Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle
troller when pedal is depressed, and allows engine to run.

Problem on q Engine does not run at full throttle.

machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and turn starting switch to ON position.
Defective throttle sensor (acceler-
2 If this failure code is not displayed, throttle sensor is defective.
ator pedal)
a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2, EC3 and T9A, and connect T-adapters to
female sides of EC2 and EC3.
3 Short circuit in wiring harness Between EC2 (female) (22) and each pin other than Resis-
Min. 1 Mz
EC2 (22) tance
Resis-
Between EC2 (female) (22) and EC3 (female) (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and connect T-adapter to female side.
Hot short circuit in wiring harness
4 3. Turn starting switch to ON position.
(Contact with 24 V)
Between T9A (female) (1) and ground Voltage 4.75 – 5.25 V

1. Turn starting switch to OFF position.

2. Disconnect connector EC2 and connect T-adapter to female side.
5 Defective engine controller 3. Turn starting switch to ON position.

Between EC2 (female) (22) and (23) Voltage 4.75 – 5.25 V

40-228 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2185] Throttle sensor power supply high error

Circuit diagram related to throttle sensor 40-2 9

GD555-5,GD655-5,GD675-5 40-229
(01)
Troubleshooting by failurecode
Failure code [CA2186] Throttle sensor power supply low error

Failure code [CA2186] Throttle sensor power supply low error 40-230
Action code Failure code Throttle sensor power supply voltage is low
Failure
(Engine controller system)
E03 CA2186
Detail of failure q Low voltage is detected in throttle sensor power supply circuit.

Action of con- q Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle
troller when accelerator pedal is depressed, and allows engine to run.

Problem on q Engine does not run at full throttle.

machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting"
tor
, and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and turn starting switch to ON position.
Defective throttle sensor (acceler-
2 If this failure code is not displayed, throttle sensor is defective.
ator pedal)
a Other failure codes are displayed too. This is because that connector is dis-
connected. Ignore failure codes other than [CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between EC2 (female) (22) or T9A (female) (1) and Resis-
Min. 1 Mz
ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
4 Short circuit in wiring harness side of EC2.
Between EC2 (female) (22) and each pin other than Resis-
Min. 1 Mz
EC2 (22) tance
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.

Between EC2 (female) (22) and (23) Voltage 4.75 – 5.25 V

40-230 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2186] Throttle sensor power supply low error

Circuit diagram related to throttle sensor 40-231

GD555-5,GD655-5,GD675-5 40-231
(01)
Troubleshooting by failurecode
Failure code [CA2249] Supply pump pressure low error 2

Failure code [CA2249] Supply pump pressure low error 2 40-232

Action code Failure code Common rail pressure is abnormality low.
Failure
(Engine controller system)
E03 CA2249
Detail of failure q Low pressure error (2) is detected in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Starting performance is poor.
Problem on q Exhaust gas becomes black.
machine q Engine output lowers.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA559] .

40-232 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2311] Abnormality in IMV (IMA) solenoid

Failure code [CA2311] Abnormality in IMV (IMA) solenoid 40-23

Action code Failure code IMV solenoid error
Failure
(Engine controller system)
E03 CA2311
Detail of failure q Resistance of supply pump actuator circuit is abnormally high or low.
Action of con-
q None in particular
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [CA271] and [CA272].

GD555-5,GD655-5,GD675-5 40-233
(01)
Troubleshooting by failurecode
Failure code [CA2555] Intake heater relay open circuit

Failure code [CA2555] Intake heater relay open circuit 40-234

Action code Failure code Preheat relay has open circuit
Failure
(Engine controller system)
E01 CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Boost temperature detected by charge air temperature sensor (boost temperature sensor) can be
checked by using monitoring function (code: ENGINE 18500 CHG TEMP).
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor-
is below -4 °C)
mation
q Troubleshooting of this failure code covers circuit from engine controller to primary (coil) circuit of
preheat relay SP40.
q For troubleshooting of secondary circuit of heater relay and preheat relay SP40, see E-mode E-2.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect relay SP40, and connect T-adapter to male side.

Between SP40 (male) (1) and (2) Resistance 200 - 400 z

2 Defective preheat relay SP40
Open circuit or short circuit in wir- 2. Disconnect connector EC2 and connect T-adapter to female side.
3
ing harness
4 Open circuit in wiring harness
5 Short circuit in wiring harness
6 Defective engine controller
1. Turn starting switch to OFF position.
2. Replace relay SP40 with another one.
3. Turn starting switch to ON postion.
If this failure code disappears, original preheat relay SP40 is defective.
1. Turn starting switch to OFF position.
Between EC2 (female) (40) and ground
Resistance 200 - 400 z
a Relay SP40 coil resistance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of them.
Between EC2 (female) (40) and SP40 (female) (1) Resistance Max. 1 z
Between SP40 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of EC2.
a Check by using multimeter in continuity mode.
Between EC2 (female) (40) and each pin other than No continuity
(40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-234 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2555] Intake heater relay open circuit

Circuit diagram related to preheat relay 40-235

GD555-5,GD655-5,GD675-5 40-235
(01)
Troubleshooting by failurecode
Failure code [CA2556] Intake heater relay short circuit

Failure code [CA2556] Intake heater relay short circuit 40-236

Action code Failure code Preheat relay has short circuit
Failure
(Engine controller system)
E01 CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Boost temperature detected by charge air temperature sensor (boost temperature sensor) can be
checked by using monitoring function (code: ENGINE 18500 CHG TEMP).
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor-
is below -4 °C)
mation
q Troubleshooting of this failure code covers circuit from engine controller to primary (coil) circuit of
preheat relay SP40.
q For troubleshooting of secondary circuit of heater relay and preheat relay SP40, see E-mode E-2.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect relay SP40, and connect T-adapter to male side.

Between SP40 (male) (1) and (2) Resistance 200 - 400 z

2 Defective preheat relay SP40
3 Ground fault in wiring harness
4 Short circuit in wiring harness
5 Defective engine controller
1. Turn starting switch to OFF position.
2. Replace relay SP40 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheat relay SP40 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of one of them.
Between EC2 (female) (40) or SP40 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of EC2.
a Check by using multimeter in continuity mode.
Between EC2 (female) (40) and each pin other than No continuity
(40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-236 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2556] Intake heater relay short circuit

Circuit diagram related to preheat relay 40-237

GD555-5,GD655-5,GD675-5 40-237
(01)
Troubleshooting by failurecode
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness

Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit
in wiring harness 40-238
Action code Failure code Backup lamp relay: Open circuit, hot short circuit in wiring har-
Failure ness
E01 D160KA (Transmission controller system)
q Transmission controller cannot activate backup lamp relay due to open circuit in backup lamp relay
primary circuit (coil side).
Detail of failure
q Backup lamp relay remains activated due to hot short circuit in backup lamp relay primary circuit
(coil side) regardless of output of transmission controller to backup lamp relay.
Action of con-
q Stops output to backup lamp relay.
troller
q Backup lamp does not light up (open circuit).
q Backup buzzer does not sound (open circuit).
Problem on q Backup lamp does not go off (hot short circuit).
machine q Backup buzzer does not stop (hot short circuit).
q Output state (ON/OFF) to backup lamp relay can be checked with monitoring function (Code:
TRANSMISSON1-40951-D-OUT-19)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate gear shift le-
mation ver.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to male side.

Between TM42 (male) (1) and (2) Resistance 200 - 400 z

Defective backup lamp relay 1. Turn starting switch to OFF position.

1
(TM42) (internal failure)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Hot short circuit in wiring harness
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
2. Replace backup lamp relay (TM42) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Set gear shift lever to R (reverse) position.
If condition becomes normal, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (18) and ground
Resistance 200 - 400 z
(resistance of backup lamp relay coil)
a If no abnormality is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM42, and connect T-adapters to female
side of them.
3. Turn starting switch to ON position.
Between TM42 (female) (1) and TM41 (female) (18) Resistance Max. 1 z
Between TM42 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
Between TM42 (female) (2) and ground Voltage Max. 1 V

40-238 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness

Cause Procedure, measuring location, criteria and remarks

If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4 Defective transmission controller 4. Operate gear shift lever and troubleshoot.
Gear shift lever:
Voltage 20–30 V
Between TM41 (female) R (Reverse)
(18) and (31) Gear shift lever:
Voltage Max. 1 V
Other than the above

Circuit diagram related to backup lamp relay 40-239

GD555-5,GD655-5,GD675-5 40-239
(01)
Troubleshooting by failurecode
Failure code [D160KB] Backup lamp relay: Ground fault

Failure code [D160KB] Backup lamp relay: Ground fault 40-240

Action code Failure code Backup lamp relay: Ground fault
Failure
(Transmission controller system)
E01 D160KB
q Transmission controller cannot activate backup lamp relay due to ground fault in backup lamp relay
Detail of failure
primary circuit (coil side).
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller OFF position.
Problem on q Backup lamp does not light up.
machine q Backup buzzer does not sound.
q Method of reproducing failure code: Turn starting switch to ON position and operate gear shift le-
Related infor- ver.
mation q Output state (ON/OFF) to backup lamp relay can be checked with monitoring function (Code:
TRANSMISSON1-40951-D-OUT-19)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to male side.

Between TM42 (male) (1) and (2) Resistance 200 - 400 z

Defective backup lamp relay 1. Turn starting switch to OFF position.

1
(TM42) (internal failure)
Ground fault in wiring harness
2
(Contact with ground circuit)
3 Defective transmission controller
2. Replace backup lamp relay (TM42) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Set gear shift lever to R (reverse) position.
If condition becomes normal, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM42, and connect T-adapter to female
side of either of them.
Between TM42 (female) (1) and ground, or
Resistance Min. 1 Mz
between TM41 (female) (18) and ground
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate gear shift lever and troubleshoot.
Gear shift lever:
Voltage 20–30 V
Between TM41 (female) R (Reverse)
(18) and (31) Gear shift lever:
Voltage Max. 1 V
Other than the above

40-240 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D160KB] Backup lamp relay: Ground fault

Circuit diagram related to backup lamp relay 40-241

GD555-5,GD655-5,GD675-5 40-241
(01)
Troubleshooting by failurecode
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault

Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault40-242
For machine equipped with differential lock

Action code Failure code Differential lock relay: Open circuit or ground fault
Failure
(Transmission controller system)
E01 D19KKZ
Detail of failure q Differential lock relay primary circuit (coil side) has open circuit or ground fault.
q Stops output to differential lock-up relay.
Action of con- q When cause of failure is open circuit, system resets itself if cause of failure disappears.
troller q When cause of failure is ground fault, system does not reset itself even if cause of failure disap-
pears until starting switch is turned to OFF position.
Problem on
q Differential lock does not work correctly.
machine
q Output state (ON/OFF) to differential lock relay can be checked with monitoring function.
Related infor- (Code: TRANSMISSION1-31903-DIFF RELAY)
mation q Method of reproducing failure code: Turn starting switch to ON position and turn on differential lock
switch.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM43 and connect T-adapter to male side.

Between TM43 (male) (1) and (2) Resistance 200 - 400 z

Defective differetial lock relay 1. Turn starting switch to OFF position.

1
(TM43) (internal defect)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
2. Replace differential lock relay (TM43) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Turn on differential lock switch.
If condition becomes normal, original differential lock-up relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (8) and ground
Resistance 200 - 400 z
(resistance of differential lock relay coil)
a If no abnormality is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM43, and connect T-adapters to
female side of them.
3. Turn starting switch to ON position.

Between TM43 (female) (1) and TM41 (female) (8) Resistance Max. 1 z

Between TM43 (female) (2) and ground Resistance Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring harness
3 side of either of them.
(Contact with ground circuit)
4 Short circuit in wiring harness
2. Disconnect connectors TM41 and TM43, and connect T-adapter to female
Between TM43 (female) (1) and ground, or
Resistance Min. 1 Mz
between TM41 (female) (8) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM43, and connect T-adapter to female
side of TM43.
3. Turn starting switch to ON position.
Between TM43 (female) (1) and (2) Resistance Min. 1 Mz

40-242 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault

Cause Procedure, measuring location, criteria and remarks

6 Defective transmission controller
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate differential lock switch and troubleshoot.
Differential lock switch:
Voltage 20 – 30 V
Between TM41 (female) OFF
(8) and (31) Differential lock switch:
Voltage Max. 1 V
ON

Circuit diagram related to differential lock relay 40-243

GD555-5,GD655-5,GD675-5 40-243
(01)
Troubleshooting by failurecode
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state

Failure code [D5ZHL6] C terminal signal: Signal does not match to actual
engine state 40-24
Action code Failure code C terminal signal: Signal does not match to actual engine state,
Failure running or stop.
E01 D5ZHL6 (Machine monitor system)
q Wire breakage or ground fault in C terminal circuit (engine speed is more than 500 rpm & alternator
R terminal has some voltage & No record that C terminal is 24 V)
Detail of failure
(Although engine is started, machine monitor can not recognize that starting switch has been set
to START position.)
Action of8* con- q None in particular.
troller q If cause of failure disappears, system resets itself.
Problem on
machine
q Since engine started, C terminal signal of starting switch between starting switch and starting motor
is regarded as normal.
q Normal startup of engine indicates that voltage of C terminal of starting switch is applied to starting
Related infor-
motor. Therefore, defective starting switch or ground fault of wiring is not probable as the cause.
mation
q Input state (ON/OFF) to machine monitor from C terminal of starting switch can be checked with
monitoring function (Code: 40921, D-IN-0).
q Method of reproducing failure code: Turn starting switch to START position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Turn starting switch sequentially to OFF, ON and START positions, and
troubleshoot.
Defective starting switch (internal Starting switch:
1 Voltage 20–30 V
failure) START
Between ST8 and
ground Starting switch:
OFF, ON Voltage Max. 1 V

1. Turn starting switch to OFF position.

Open circuit in wiring harness 2. Disconnect connectors TEL and FP1, and connect T-adapter to male and
2 (Wire breakage or defective con- female side.
tact of connector)
Between TEL (male) (8) and FP1 (female) (7) Resistance Max. 1 z
If no abnormality is found by above checks, machine monitor is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch sequentially to OFF, ON and START positions, and
3 Defective machine monitor troubleshoot.
Starting switch:
START Voltage 20–30 V
Between FP1 (female)
(7) and (3) Starting switch:
OFF, ON Voltage Max. 1 V

40-244 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state

Circuit diagram related to C terminal signal 40-245

GD555-5,GD655-5,GD675-5 40-245
(01)
Troubleshooting by failurecode
Failure code [DAFRKR] CAN communication failure (monitor panel)

Failure code [DAFRKR] CAN communication failure (monitor panel) 40-246

Action code Failure code CAN communication is disabled (with machien nonitor)
Failure
(Transmission controller system)
E03 DAFRKR
q Because CAN communication is disabled, transmission controller is not capable of getting infor-
Detail of failure
mation from machine monitor.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Uses CAN information obtained from machine monitor just before failure occurs.
troller
q If cause of failure disappears, system resets itself.
Problem on
q Machine monitor does not display correct information.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN com-
munication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it
Related infor-
can be observed only through KOMTRAX system.
mation
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective power supply to machine
1 Perform troubleshooting for E mode, "E-3".
monitor
2 Defective CAN communication Perform troubleshooting for cause 2 and after of failure code [DAQRKR].

40-246 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAFRKR] CAN communication failure (monitor panel)

GD555-5,GD655-5,GD675-5 40-247
(01)
Troubleshooting by failurecode
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)

Failure code [DAQ0KK] Transmission controller: Power supply voltage

low error (input) 40-248
Action code Failure code Transmission controller: Power supply voltage drops (input)
Failure
(Transmission controller system)
E03 DAQ0KK
Detail of failure q While engine running, the voltage of controller power supply circuit becomes 18 V or below.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps gear shift to NEUTRAL position.
troller q If cause of failure disappears, system resets itself (however, gear shift is kept NEUTRAL until gear
shift lever is set to NEUTRAL position).
Problem on
q Machine stops.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuses (holder If slow-blow fuse is broken, circuit probably has ground fault. In this case,
1
1, 30A)
2 Defective fuse (FB1, No.3)
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
perform troubleshooting for cause 3 first.
If fuse has blown out, the circuit probably has ground fault. In this case, per-
form troubleshooting for cause item 3 first.
q Ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
a Looseness or rust on ground terminal ET89
Between TM41 (female) (21) and ground, and
Resistance Max. 1 z
between (31) - (33) and ground
1. Turn starting switch to OFF position.
2. Set disconnect swithc to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
4. Set disconnect switch to ON.

Between TM41 (female) (1) and (21) Voltage 20–30 V

Between TM41 (female) (11) and (32) Voltage 20–30 V

a If slow-blow fuse or fuse is not blown, this check is not required.

1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Set disconnect switch to OFF.
4
(Contact with ground circuit) 3. Disconnect connector TM41 and connect T-adapter to female side.

Between TM41 (female) (1) and ground Resistance Min. 1 Mz

5 Defective alternator
6 Defective transmission controller
Perform troubleshooting for failure code [AB00MA].
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between TM41 (1) and (21), and between TM41 (1)
Voltage 20–30 V
and (31)
Between TM41 (11) and (32), and between TM41
Voltage 20–30 V
(11) and (33)

40-248 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)

Circuit diagram related to transmission controller power supply 40-249

GD555-5,GD655-5,GD675-5 40-249
(01)
Troubleshooting by failurecode
Failure code [DAQOKT] Transmission controller: Non-volatile memory error

Failure code [DAQOKT] Transmission controller: Non-volatile memory

error 40-250
Action code Failure code Transmission controller: Non-volatile memory error
Failure
(Transmission controller system)
E01 DAQ0KT
Detail of failure q Information in the ROM (non-volatile memory) of transmission controller is abnormal.
q Sets memory data on ROM (non-volatile memory) to default values.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
q Transmission shifting feel may become bad.
Problem on
q Feel of inching may degrade.
machine
q Travel speed in R8 travel may deviate from the set value.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Since this is internal failure, troubleshooting cannot be performed.
1 Defective transmission controller (When recognizable problem does not appear on machine, you may use con-
troller after performing initial setting and adjustment for it.)

40-250 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQOKT] Transmission controller: Non-volatile memory error

GD555-5,GD655-5,GD675-5 40-251
(01)
Troubleshooting by failurecode
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)

Failure code [DAQ2KK] Transmission controller load power line: Power

supply voltage drop (input) 40-252
Action code Failure code Transmission controller: Actuator solenoid power supply voltage
Failure drop (input)
E03 DAQ2KK (Transmission controller system)
q When starting switch is turned to ON position (with engine stopped or running), voltage of solenoid
Detail of failure
power supply circuit is 18 V or lower though power supply circuit voltage of controller is normal.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains gear speed in Neutral position.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Machine stops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (holder 1, If slow-blow fuse is broken, circuit probably has ground fault. In this case, per-
1
60 A)
2 Defective fuses (FB1, No.11)
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
form troubleshooting for cause 3 first.
If fuse blows, circuit may have ground fault. In this case, perform trouble-
shooting for cause 3 first.
q Ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
a Looseness or rust on ground terminal ET89
Between ground and TM41 (female) (21), (31) to
Resistance Max. 1 z
(33)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
4. Set disconnect switch to ON.
5. Turn starting switch ON.

Between TM41 (female) (2) and (31) Voltage 20 – 30 V

Between TM41 (female) (12) and (33), between

Voltage 20 – 30 V
(22) and (33)

Ground fault in wiring harness
4
(Contact with ground circuit)
a If slow-blow fuse or fuse is not blown out, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.

Between TM41 (female) (2) and ground Resistance Min. 1 Mz

5 Defective alternator Perform troubleshooting for failure code [AB00MA].

40-252 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)

Cause Procedure, measuring location, criteria and remarks

6 Defective transmission controller
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.

Between TM41 (2) and (21), between (2) and (31) Voltage 20 – 30 V

Between TM41 (12) and (32) Voltage 20 – 30 V

Between TM41 (22) and (33) Voltage 20 – 30 V

Circuit diagram related to transmission controller power supply 40-253

GD555-5,GD655-5,GD675-5 40-253
(01)
Troubleshooting by failurecode
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement

Failure code [DAQ9KQ] Transmission controller model selection: Model

selection signal disagreement 40-254
Action code Failure code Transmission controller model selection: Model selection signal
Failure disagreement
E03 DAQ9KQ (Machine monitor system)
q Model setting ID on controller is not correct.
q Model information obtained from machine monitor disagrees with model information stored on con-
Detail of failure
troller.
q Information of model stored on controller is one for which model setting is disabled.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Even if failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective transmission controller Since this is internal failure, troubleshooting cannot be performed.

3 Defective machine monitor Since this is internal failure, trouble shooting cannot be performed.

40-254 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement

GD555-5,GD655-5,GD675-5 40-255
(01)
Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Failure code [DAQRKR] Transmission controller CAN communication:

Communication error 40-256
Action code Failure code Transmission controller cannot communicate through CAN
Failure
(Machine monitor system)
E03 DAQRKR
Detail of failure q In CAN communication, machine monitor cannot recognize transmission controller.
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on q Machine monitor may not operate normally or may not display correct information.
machine q Machine monitor uses values obtained through CAN just before failure occurs.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q If failure code [DB2RKR] is also displayed, engine controller may be defective. In such case, per-
Related infor- form troubleshooting for [DB2RKR] first.
mation q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective power supply to trans-
1 Perform troubleshooting for failure codes [DAQ0KK] and [DAQ2KK] first.
mission controller
Defective CAN terminating resistor
2 (Internal open or short circuit in
wiring)
Open circuit or short circuit in wir-
3 to see if there is short circuit between wiring harnesses or in controller.
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connectors CAN1 and FP2, and connect T-adapter to male
side.
Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
Between FP2 (male) (6) and (3) Resistance 120 ± 12 z
qCAN communication line
a Machine monitor also has 120 z CAN terminating resistor. Since 120 z re-
sistors are connected in parallel, if paralled resistance measured at con-
nector of controller other than machine monitor is 60 z, wiring harness is
not open.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors of EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of connector disconnected.
a If connectors are short-circuited (resistance between terminals is 1 z or
below), disconnect all of EC2, TM40, L80, CAN1 and FP2, and check again
Approx.
Between EC2 (female) (46) and (47) Resistance
60 z
Approx.
Between TM40 (female) (32) and (22) Resistance
60 z
Approx.
Between L80 (female) (8) and (7) Resistance
60 z
Approx.
Between CAN1 (female) (A) and (B) Resistance
120 z
Approx.
Between FP2 (female) (3) and (1) Resistance
120 z

40-256 GD555-5,GD655-5,GD675-5
(01)

Failure code [DAQRKR] Transmission controller CAN communication: Communication error
Cause
Isolating open-circuited wiring har- Between TM40 (female) (22) and FP2 (female) (3) Resistance
ness
4 Between TM40 (female) (32) and EC2 (female) (46) Resistance
(Wire breakage or defective con-
tact of connector)
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
Ground fault of wiring harness
6
(contact with ground circuit)
GD555-5,GD655-5,GD675-5
(01)
Troubleshooting by failurecode
Procedure, measuring location, criteria and remarks
a If check result of cause 3 is normal, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of each connector.
Between TM40 (female) (32) and FP2 (female) (6),
Resistance Max. 1 z
between (32) and (1)
Max. 1 z
Max. 1 z
Between TM40 (female) (22) and EC2 (female) (47) Resistance Max. 1 z
Between TM40 (female) (32) and L80 (female) (8) Resistance Max. 1 z
Between TM40 (female) (22) and L80 (female) (7) Resistance Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A) Resistance Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect swithc to OFF.
2. Insert T-adapter into connectors TM41, L80, FP1 and EC2.
3. Turn starting switch to ON position, and set disconnect switch to ON.
Between TM41 (14) and (31), or between (24) and
Voltage 20 – 30 V
(31)
Between L80 (26) and (37), or between (36) and
Voltage 20 – 30 V
(37)
Between FP1 (1) and (3), or between (2) and (3) Voltage 20 – 30 V
Between EC2 (39) and ground Voltage 20 – 30 V
q CAN communication line
a If check result of cause 3 is normal (there is no open circuit), measure at
only 1 place.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM40, L80, FP2 and EC2, and connect T-adapter
to female side of one of them.
Between ground and either one of TM40 (female)
(32), L80 (female) (8), FP2 (female) (1), (6) and Resistance Min. 1 Mz
EC2 (female) (46)
Between ground and either one of TM40 (female)
(22), L80 (female) (7), FP2 (female) (3), (6) and Resistance Min. 1 Mz
EC2 (female) (47)
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41, L80 and FP1, and connect T-adapter to
female side of one of them.
3. Disconnect connector EC2 and connect T-adapter to female side.
Between ground and either one of TM41 (female)
(14), (24), L80 (female) (26), (36) and FP1 (female) Resistance Min. 1 Mz
(1), (2)
Between EC2 (female) (39) and ground Resistance Min. 1 Mz
40-257
Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

a If check result of cause 3 is normal (there is no open circuit), measure at
only 1 place in each of the above.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connector to either of TM40, L80, FP2 and EC2.
3. Set disconnect switch to ON.
Short circuit or hot short circuit 4. Turn starting switch ON.
7 a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communi-
(Contact with 24 V circuit)
cation is continued, they are judged to be normal if they are 1 - 4 V.
Between ground and either one of TM40 (32), L80
Voltage 1–4V
(8), FP2 (1), (6) and EC2 (46)
Between ground and either one of TM40 (22), L80
Voltage 1–4V
(7), FP2 (3) and EC2 (47)
If cause is not found by above checks and another failure code related to CAN
communication such as [DB2RKR] is not displayed, identify which controller
is defective according to following procedure.
q Step 1
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect KOMTRAX controller (connector L80).
3. Turn starting switch to ON position, and set disconnect switch to ON.
Defective KOMTRAX
YES
controller
Defective engine controller, trans-
Has this failure code disappeared? Defective transmission
8 mission controller or KOMTRAX
NO controller or engine con-
controller
troller
q Step 2
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect engine controller (connector EC2).
3. Turn starting switch to ON position, and set disconnect switch to ON.
Defective transmission
NO
controller
Is failure code [DB2RKR] displayed?
Defective engine control-
YES
ler
If no abnormality is found by above diagnoses, machine monitor is defective.
9 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

40-258 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Circuit diagram related to CAN communication circuit 40-259

GD555-5,GD655-5,GD675-5 40-259
(01)
Troubleshooting by failurecode
Failure code [DAQRMA] Transmission controller option setting: Malfunction

Failure code [DAQRMA] Transmission controller option setting:

Malfunction 40-260
Action code Failure code Transmission controller option setting: Malfunction
Failure
(Machine monitor system)
E03 DAQRMA
q Option setting ID on controller is not correct..
Detail of failure q Differential setting information obtained from machine monitor disagrees with differential setting in-
formation stored on controller.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Even if failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective transmission controller Since this is an internal defect, it cannot be diagnosed.

40-260 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Failure code [DB2RKR] Engine controller CAN communication: Commu-

nication error 40-261
Action code Failure code Transmission controller cannot communicate through CAN
Failure
(Transmission controller system)
E03 DB2RKR
Detail of failure 1)Transmission controller cannot recognize engine controller in CAN communication.
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on q Machine monitor may not function normally or may not display correct information.
machine q Machine monitor uses values obtained through CAN just before failure occurs.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB2RKR] is displayed on machine monitor, CAN communication between transmission controller
Related infor- and machine monitor is normal.
mation That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since signal of CAN communication line in operation is pulse voltage, it cannot be measured with
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective fuse for engine controller
1 If fuse blows, short circuit is probably occurred in controller.
or fuse (4) of FB2
Defective engine controller
2
(Internal short circuit)
Improper power supply to engine
3
controller
Defective fuse for ACC of engine
4
controller or fuse (15) of FB1
Defective CAN terminating resistor
5 (Internal open circuit or short cir-
cuit)
a If fuse does not blow, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC3 and connect T-adapter to male side.
a Measured value: approx. 9 – 20 kz
a If measured resistance is 10 z or below, engine controller is defective (in-
ternal short circuit).
Between EC3 (male) (3) and (1) Resistance Min. 10 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC3 and connect T-adapter to female side.
3. If fuse blows, replace it.
4. Set disconnect switch to ON.
a If result is abnormal, perform troubleshooting for failure code [DB2RKR]
(Detail of failure 2).
Between EC3 (female) (3) and (1), or between (3)
Voltage 20 – 30 V
and ground
Between EC3 (female) (4) and (2), or between (4)
Voltage 20 – 30 V
and ground
If fuse blows, circuit may have ground fault. In this case, perform trouble-
shooting for cause 9 first.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors CAN1 and FP2, and connect T-adapter to male
side.
Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
Between FP2 (male) (6) and (3) Resistance 120 ± 12 z

GD555-5,GD655-5,GD675-5 40-261
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error
Cause
Open circuit or short circuit in wir-
6 to see if there is short circuit between wiring harnesses or in controller.
ing harness
Isolating open-circuited wiring har- Between TM40 (female) (22) and FP2 (female) (3) Resistance
ness
7 Between TM40 (female) (32) and EC2 (female) (46) Resistance
(Wire breakage or defective con-
tact of connector)
Open circuit in wiring harness
8 (Wire breakage or defective con-
tact of connector)
Ground fault of wiring har-
9 3. Disconnect connector EC2 and connect T-adapter to female side.
ness(Contact with ground circuit)
10 Defective engine controller
40-262
Procedure, measuring location, criteria and remarks
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too.
Since 120 z resistor is connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is com-
bined resistance, wiring harness is not open cricuited.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors of EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of connector disconnected.
a If connectors are short-circuited (resistance between terminals is1 z or be-
low), disconnect all of EC2, TM40, L80, CAN1 and FP2, and check again
Approx.
Between EC2 (female) (46) and (47) Resistance
60 z
Approx.
Between TM40 (female) (32) and (22) Resistance
60 z
Approx.
Between L80 (female) (8) and (7) Resistance
60 z
Approx.
Between CAN1 (female) (A) and (B) Resistance
120 z
Approx.
Between FP2 (female) (3) and (1) Resistance
120 z
a If check result of cause 6 is normal, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC2, TM40, L80, CAN1 and FP2, and connect
T-adapter to female side of each connector.
Between TM40 (female) (32) and FP2 (female) (6),
Resistance Max. 1 z
between (32) and (1)
Max. 1 z
Max. 1 z
Between TM40 (female) (22) and EC2 (female) (47) Resistance Max. 1 z
Between TM40 (female) (32) and L80 (female) (8) Resistance Max. 1 z
Between TM40 (female) (22) and L80 (female) (7) Resistance Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A) Resistance Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connectors TM41, L80, FP1 and EC2.
3. Set disconnect switch to ON, and turn starting switch to ON position.
Between TM41 (14) and (31), or between (24) and
Voltage 20 – 30 V
(31)
Between L80 (26) and (37), or between (36) and
Voltage 20 – 30 V
(37)
Between FP1 (1) and (3), or between (2) and (3) Voltage 20 – 30 V
Between EC2 (39) and ground Voltage 20 – 30 V
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41, L80 and FP1, and connect T-adapter to
female side of one of them.
Between ground and either one of TM41 (female)
(14), (24), L80 (female) (26), (36) and FP1 (female) Resistance Min. 1 Mz
(1), (2)
Between EC2 (female) (39) and ground Resistance Min. 1 Mz
If no abnormality is found by above diagnosis, engine controller is defective.
(Since this is internal failure, troubleshooting cannot be performed.)
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found by above diagnoses, transmission controller is
11 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to CAN communication circuit 40-263

GD555-5,GD655-5,GD675-5 40-263
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error
Detail of failure 2) Defective power supply circuit to engine controller
Cause
Loose or corroded battery termi-
1
nals or ground terminal
Defective wiring harness connec-
2 of "Check before troubleshooting" of "Related information of troubleshooting",
tor
3 Defective battery voltage
Defective relay for engine control-
4
ler power supply
5 Defective diode (SP36, SP37)
Open circuit in wiring harness
6 (Wire breakage or defective con-
tact of connector)
40-264
Procedure, measuring location, criteria and remarks
Check battery terminals and ground (ET103) terminal directly for loose and
corrosion.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Start engine and perform diagnosis.
Between (+) and (-) terminals of battery (2 pieces) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Exchange relays (SP30) for engine controller power supply with another
relay.
3. Turn starting switch to ON position.
If this failure code goes off, original relay SP30 is defective.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Remove diodes SP36 and SP37 and connect T-adapter to male side.
a Check the continuity in diode range.
Between SP36 (male) (2) (+) and (1) (-) Continuity
Between SP36 (male) (1) (+) and (2) (-) No continuity
Between SP37 (male) (2) (+) and (1) (-) Continuity
Between SP37 (male) (1) (+) and (2) (-) No continuity
q Ground circuit
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC2, EC3 and SP30, and connect T-adapter to
each female side of them.
Between EC3 (female) (1) and ground
Resistance Max. 1 z
a Rusted or loose ground terminal (ET103)
Between EC3 (female) (2) and ground
Resistance Max. 1 z
a Rusted or loose ground terminal (ET103)
Between EC2 (female) (33) and SP36 (6) Resistance Max. 1 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapters into SP37, SP30, and EC3.
3. Set disconnect switch to ON, and turn starting switch to ON position.
a Check to where 24 V is supplied to identify open place.
Between SP37 (2) and ground Voltage 20 – 30 V
Between SP37 (1) and ground Voltage 20 – 30 V
Between SP30 (5) and (6) Voltage 20 – 30 V
Between SP30 (1) and (6) Voltage 20 – 30 V
Between SP30 (3) and (6) Voltage 20 – 30 V
Between EC3 (3) and (2) Voltage 20 – 30 V
Between EC3 (4) and (1) Voltage 20 – 30 V
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors SP30, SP37 and EC3, and connect T-adapter to
each female side of them.
Between SP37 (female) (1) and ground Resistance Min. 1 Mz
Ground fault in wiring harness
7 Between EC3 (female) (3) and ground Resistance Min. 1 Mz
(Contact with ground circuit)
Between EC3 (female) (4) and ground Resistance Min. 1 Mz
Between ground and SP30 (1), (3) Resistance Min. 1 Mz
Between ground and SP30 (2), (4) Resistance Min. 1 Mz
If no abnormality is found by above diagnosis, engine controller is defective.
8 Defective engine controller
(Since this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-265
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Circuit diagram related to engine controller power supply 40-26

40-266 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

GD555-5,GD655-5,GD675-5 40-267
(01)
Troubleshooting by failurecode
Failure code [DD1NLD] Fan reverse switch signal: Short circuit

Failure code [DD1NLD] Fan reverse switch signal: Short circuit 40-268
Action code Failure code Fan reverse switch circuit has short circuit
Failure
(Transmission controller system)
E01 DD1NLD
q Since fan manual reverse switch system has hot short circuit, fan reverse switch stay in ON posi-
Detail of failure
tion. (When it stays over 30 second, state is judged as failure.)
Action of con-
q None in particular.
troller
Problem on
q Fan keeps rotating reverse.
machine
q Input from fan manual reverse switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-40905-D-IN-6)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM31 and connect T-adapter to male side.
Defective fan reverse switch (inter-
1 Fan reverse switch: ON Resistance Max. 1 z
nal short circuit) Between TM31 (male)
(5) and (6)
Fan reverse switch: OFF Resistance Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in wiring harness 2. Disconnect connector TM31 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TM31 (female) (6) and ground Voltage Max. 1 V
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3 Defective transmission controller 3. Turn starting switch to ON position.

Fan reverse switch: ON Voltage 20 – 30 V

Between TM39 (12) and
(4)
Fan reverse switch: OFF Voltage Max. 1 V

40-268 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1NLD] Fan reverse switch signal: Short circuit

Circuit diagram related to fan reverse switch 40-269

GD555-5,GD655-5,GD675-5 40-269
(01)
Troubleshooting by failurecode
Failure code [DD1PKB] RPM set switch power supply short circuit

Failure code [DD1PKB] RPM set switch power supply short circuit 40-270
Action code Failure code RPM set switch power supply short circuit
Failure
(Transmission controller system)
E03 DD1PKB
q "SET" and "RESUME" functions of RPM set switch become active simultaneously.
Detail of failure
q When operating RPM set switch, both “SET” and “RESUME” functions are kept active.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Sets RPM set mode to "OFF".
Problem on
q RPM set mode is kept “OFF” and RPM set function is disabled.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors TM38 and TM41, and connect T-adapter to female
side of TM41.
Wiring harness between TM41 (female) (2) and
1 Short circuit in wiring harness Resistance Min. 1 Mz
(20)
Between TM41 (female) (2) and (30) Resistance Min. 1 Mz
Between TM41 (female) (20) and (30) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM38.
3. Insert T-adapter into connector TM41.
Hot short circuit in wiring harness
2 4. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TM41 (female) (20) and (21) Voltage Max. 1 V
Between TM41 (female) (30) and (31) Voltage Max. 1 V
If no abnormality is found in cause 1 and 2, transmission controller may be
3 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-270 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1PKB] RPM set switch power supply short circuit

Circuit diagram related to RPM set switch and RPM set mode switch 40-271

GD555-5,GD655-5,GD675-5 40-271
(01)
Troubleshooting by failurecode
Failure code [DD1QKB] RPM set mode switch short circuit

Failure code [DD1QKB] RPM set mode switch short circuit 40-272
Action code Failure code RPM set mode switch short circuit
Failure
(Power train controller system)
E03 DD1QKB
q "AUTO" and "MANUAL" functions of RPM set mode switch are turned on simultaneously.
Detail of failure
q When operating set mode switch, both “AUTO” and “MANUAL” functions are kept ON.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Sets RPM set function to "OFF" mode.
Problem on
q RPM set mode is kept “OFF” and RPM set function is disabled.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1 Short circuit in wiring harness
Hot short circuit in wiring harness
2
(Contact with 24 V circuit)
3 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors TM37 and TM39, and connect T-adapter to female
side of TM37.
Between TM37 (female) (4) and (5) Resistance Min. 1 Mz
Between TM37 (female) (4) and (6) Resistance Min. 1 Mz
Between TM37 (female) (5) and (6) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM37 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between TM37 (female) (4) and (2) Voltage Max. 1 V
Between TM37 (female) (6) and (2) Voltage Max. 1 V
If no abnormality is found in cause 1 and 2, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-272 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1QKB] RPM set mode switch short circuit

Circuit diagram related to RPM switch and RPM mode switch 40-273

GD555-5,GD655-5,GD675-5 40-273
(01)
Troubleshooting by failurecode
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error

Failure code [DDB6L4] Transmission gearshift lever: Parking brake

signal error 40-274
Action code Failure code Impossible parking brake signal from gearshift lever
Failure
(Transmission controller system)
E03 DDB6L4
Detail of failure q Both of “P” signal and “NOT P” signal are ON or OFF at the same time.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Resets system if combination of “P” signal and possible signal is input from gearshift lever.
q When gearshift lever is in NEUTRAL or PARK position and travel speed is 1.0 km/h or below, park-
Problem on
ing brake is applied automatically.
machine
q When gearshift lever is in a position other than NEUTRAL and PARK, parking brake is not applied.
q Input (ON/OFF and gear position) from gearshift lever can be checked by using monitoring func-
Related infor- tion.
mation (Code: TRANSMISSION1-91101-SFT PNFR_NP)
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

Defective fuse No.11 in fuse box
1 If fuse is blown, circuit may have ground fault. (See cause 3.)
FB1
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 Resistance Min. 1 Mz
(Contact with ground circuit)
4 Short circuit in wiring harness
Hot short circuit in wiring harness
5 4. Set disconnect switch to ON.
(Contact with 24 V circuit)
Defective gear shift lever (internal
6 See failure code [DF10KA] to perform troubleshooting.
failure)
1. Turn starting switch to OFF position.
2. Disconnect connectors TM36 and TM41, and connect T-adapters to
female side of them.
Between No.11 in fuse box FB1 and TM36 (female)
Resistance Max. 1 z
(1)
Between TM36 (female) (2) and ground Resistance Max. 1 z
Between TM36 (female) (5) and TM41 (female)
Resistance Max. 1 z
(40)
Between TM36 (female) (6) and TM41 (female)
Resistance Max. 1 z
(39)
1. Turn starting switch to OFF position.
2. Disconnect connectors TM36 and TM41, and connect T-adapters to
female side of them.
Between No.11 in fuse box FB1 and ground or
between TM36 (female) (1) and ground
Between TM36 (female) (5) and ground or between
Resistance Min. 1 Mz
TM41 (female) (40) and ground
Between TM36 (female) (6) and ground or between
Resistance Min. 1 Mz
TM41 (female) (39) and ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM36.
Between TM36 (female) (5) and each pin other than
Resistance Min. 1 Mz
(5)
Between TM36 (female) (6) and each pin other than
Resistance Min. 1 Mz
(6)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM36 and connect T-adapter to female side (leave
gearshift lever disconnected).
5. Turn starting switch to ON position.
Between TM36 (female) (5) and (2) Voltage Max. 1 V
Between TM36 (female) (6) and (2) Voltage Max. 1 V

40-274 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error

Cause Procedure, measuring location, criteria and remarks

If cause is not found by the above checks, transmission controller is defective.
7 Defective transmission controller
q Reference: See failure code [DF10KA] before performing voltage check.

Circuit diagram related to transmission gearshift lever 40-275

GD555-5,GD655-5,GD675-5 40-275
(01)
Troubleshooting by failurecode
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit

Failure code [DDTHKA] Fill switch for FH clutch: Open circuit 40-276
Action code Failure code Fill switch for FH clutch has open circuit
Failure
(Transmission controller system)
E01 DDTHKA
q When outputting current to FH clutch ECMV solenoid, clutch is engaged but signal from FH clutch
Detail of failure
fill switch does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F2, F4, F6, or F8).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SCMA].

Failure code [DDTJKA] Fill switch for FL clutch: Open circuit 40-276
Action code Failure code Fill switch for FL clutch has open circuit
Failure
(Transmission controller system)
E01 DDTJKA
q When outputting current to FL clutch ECMV solenoid, clutch is engaged but signal from FL clutch
Detail of failure
fill switch does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F1, F3, F5, or F7).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SDMA].

40-276 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit

Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit 40-27
Action code Failure code Fill switch for 1st clutch has open circuit
Failure
(Transmission controller system)
E01 DDTKKA
q When outputting current to 1st clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F1, F2, or R1).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SEMA].

Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit 40-27
Action code Failure code Fill switch for 2nd clutch has open circuit
Failure
(Transmission controller system)
E01 DDTLKA
q When outputting current to 2nd clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F3, F4, or R2).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SFMA].

GD555-5,GD655-5,GD675-5 40-277
(01)
Troubleshooting by failurecode
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit

Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit 40-278
Action code Failure code Fill switch for 3rd clutch has open circuit
Failure
(Transmission controller system)
E01 DDTMKA
q When outputting current to 3rd clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F5, F6, or R3).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SGMA].

40-278 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDTNKA] Fill switch for R clutch: Open circuit

Failure code [DDTNKA] Fill switch for R clutch: Open circuit 40-279
Action code Failure code Fill switch for R clutch has open circuit
Failure
(Transmission controller system)
E01 DDTNKA
q When outputting current to R clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from R clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of R1 through R4).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SBMA].

GD555-5,GD655-5,GD675-5 40-279
(01)
Troubleshooting by failurecode
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit

Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit 40-280
Action code Failure code Fill switch for 4th clutch has open circuit
Failure
(Transmission controller system)
E01 DDTPKA
q When outputting current to 4th clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked with monitoring function.
Related infor- (Code: TRANSMISSION2-31520-FILL R1234LH)
mation q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, or
R4)

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SHMA].

40-280 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Failure code [DF10KA] Transmission gearshift lever: No gear speed

signal is input 40-281
Action code Failure code Transmission gearshift lever: No gear speed signal is input
Failure
(Transmission controller system)
E03 DF10KA
q Impossible combination of signal voltages is input to transmission controller with gearshift lever at
intermediate position between two gear speed positions.
Detail of failure q Signal is not input from gearshift lever due to ground fault or open circuit.
(Although voltage appears at “NOT P” signal terminal of controller, no voltage appears at any of
gear speed signal terminals.)
q Blinks centralized warning lamp and sounds alarm buzzer.
q Keeps gear speed at NEUTRAL when travel speed is decreased below 1.0 km/h for 0.5 second by
applying brake, etc.
Action of con-
q Holds possible combination of gear speed and travel direction signals input most recently.
troller
q If cause of failure disappears, system resets itself.
q Note that system does not reset itself until starting switch is turned to OFF position if failure code
[DF10L4] is also detected.
Problem on
q Shifting gears is not possible.
machine
q Input (ON/OFF) from gearshift lever can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-91101-SFT PNFR_NP, TRANSMISSION1-91104-SFT 12345678)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

q Gearshift lever is pressed by force other than control effort.
1 Wrong operation
q Gearshift lever is stopped midway between two gear speed positions.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapters to
female side of them.
Between TM36 (female) (3) and TM40 (25) Resistance Max. 1 z
Between TM36 (female) (4) and TM40 (15) Resistance Max. 1 z
Between TM36 (female) (7) and TM40 (35) Resistance Max. 1 z
Open circuit in wiring harness Between TM36 (female) (8) and TM40 (5) Resistance Max. 1 z
2 (Wire breakage or defective con-
tact of connector) Between TM36 (female) (9) and TM40 (36) Resistance Max. 1 z
Between TM36 (female) (10) and TM40 (26) Resistance Max. 1 z
Between TM36 (female) (11) and TM40 (16) Resistance Max. 1 z
Between TM36 (female) (12) and TM40 (6) Resistance Max. 1 z
Between TM36 (female) (13) and TM41 (9) Resistance Max. 1 z
Between TM36 (female) (14) and TM41 (19) Resistance Max. 1 z
Between TM36 (female) (15) and TM41 (29) Resistance Max. 1 z

GD555-5,GD655-5,GD675-5 40-281
(01)
Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
3
(Contact with ground circuit)
Defective gearshift lever (internal
4
failure)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM40 and TM41.
Between TM40 (female) (5) and ground Resistance Min. 1 Mz
Between TM40 (female) (6) and ground Resistance Min. 1 Mz
Between TM40 (female) (15) and ground Resistance Min. 1 Mz
Between TM40 (female) (16) and ground Resistance Min. 1 Mz
Between TM40 (female) (25) and ground Resistance Min. 1 Mz
Between TM40 (female) (26) and ground Resistance Min. 1 Mz
Between TM40 (female) (35) and ground Resistance Min. 1 Mz
Between TM40 (female) (36) and ground Resistance Min. 1 Mz
Between TM41 (female) (9) and ground Resistance Min. 1 Mz
Between TM41 (female) (19) and ground Resistance Min. 1 Mz
Between TM41 (female) (29) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM36.
3. Turn starting switch to ON position.
4. Operate gearshift lever and troubleshoot.
Between TM36 each pin Lever position marked Voltage 20 – 30 V
and ground with q
a See the output table Lever position marked
of gearshift lever. Voltage Max. 1 V
withQ
If cause is not found by the above checks, transmission controller is defective.
q Reference: To measure input voltage at each pin of transmission controller
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate gearshift lever and troubleshoot.
Between TM41 each pin Lever position marked Voltage 20 – 30 V
and ground with q
a See output table of Lever position marked
Voltage Max. 1 V
gearshift lever. with Q

40-282 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Circuit diagram related to transmission gearshift lever 40-283

GD555-5,GD655-5,GD675-5 40-283
(01)
Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Output table of gearshift lever

Gearshift lever signal
F R Not P p N 1st 2nd 3rd 4th 5th 6th 7th 8th
F8 q Q q Q Q Q Q Q Q Q Q Q q
F7 q Q q Q Q Q Q Q Q Q Q q Q
F6 q Q q Q Q Q Q Q Q Q q Q Q
q Q q Q Q Q Q Q Q q Q Q Q
Gearshift lever position

F5
F4 q Q q Q Q Q Q Q q Q Q Q Q
F3 q Q q Q Q Q Q q Q Q Q Q Q
F2 q Q q Q Q Q q Q Q Q Q Q Q
F1 q Q q Q Q q Q Q Q Q Q Q Q
N Q Q q Q q Q Q Q Q Q Q Q Q
p Q Q Q q q Q Q Q Q Q Q Q Q
R1 Q q q Q Q q Q Q Q Q Q Q Q
R2 Q q q Q Q Q q Q Q Q Q Q Q
R3 Q q q Q Q Q Q q Q Q Q Q Q
R4 Q q q Q Q Q Q Q q Q Q Q Q
TM36
(gear
(3) (4) (5) (6) (7) (5) (9) (10) (11) (12) (13) (14) (15)
shift
lever)
Pin No.

TM40
(Cotroll (25) (15) – – (35) – (36) (26) (16) (6) – – –
er)
TM41
(Cotroll – – (40) (39) – – – – – – (9) (19) (29)
er)
Note: q voltage: 20 - 30 V, Q voltage: Max. 1 V

40-284 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel

direction signal error 40-285
Action code Failure code Transmission gearshift lever: Gear speed and travel direction sig-
Failure nal is incorrect
E03 DF10L4 (Transmission controller system)
q Impossible combination of signal voltage for travel direction (any of F, N or R) and signal for gear
Detail of failure
speed (any of 1st to 8th gear) is input to transmission controller from gearshift lever.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Keeps gear speed at NEUTRAL when travel speed is decreased below 1.0 km/h for 0.5 second by
Action of con- applying brake, etc.
troller q Holds possible combination of gear speed and travel direction signals input most recently.
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q Shifting gears is not possible.
machine
q Input (ON/OFF) from gearshift lever can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-91101-SFT PNFR_NP, TRANSMISSION1-91104-SFT 12345678)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM36.
Between TM36 (female) (3) and each pin other than
Resistance Min. 1 Mz
(3)
Between TM36 (female) (4) and each pin other than
Resistance Min. 1 Mz
(4)
Between TM36 (female) (7) and each pin other than
Resistance Min. 1 Mz
(7)
Between TM36 (female) (8) and each pin other than
Resistance Min. 1 Mz
(8)
1 Short circuit in wiring harness Between TM36 (female) (9) and each pin other than
Resistance Min. 1 Mz
(9)
Between TM36 (female) (10) and each pin other
Resistance Min. 1 Mz
than (10)
Between TM36 (female) (11) and each pin other
Resistance Min. 1 Mz
than (11)
Between TM36 (female) (12) and each pin other
Resistance Min. 1 Mz
than (12)
Between TM36 (female) (13) and each pin other
Resistance Min. 1 Mz
than (13)
Between TM36 (female) (14) and each pin other
Resistance Min. 1 Mz
than (14)
Between TM36 (female) (15) and each pin other
Resistance Min. 1 Mz
than (15)

GD555-5,GD655-5,GD675-5 40-285
(01)
Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM36 and connect T-adapter to female side (leave
gearshift lever disconnected).
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Hot short circuit in wiring harness Between TM36 (female) (3) and (2) Voltage Max. 1 V
2
(Contact with 24 V circuit)
Between TM36 (female) (4) and (2) Voltage Max. 1 V
Between TM36 (female) (7) and (2) Voltage Max. 1 V
Between TM36 (female) (8) and (2) Voltage Max. 1 V
Between TM36 (female) (9) and (2) Voltage Max. 1 V
Between TM36 (female) (10) and (2) Voltage Max. 1 V
Between TM36 (female) (11) and (2) Voltage Max. 1 V
Between TM36 (female) (12) and (2) Voltage Max. 1 V
Hot short circuit in wiring harness
2 Between TM36 (female) (13) and (2) Voltage Max. 1 V
(Contact with 24 V circuit)
Between TM36 (female) (14) and (2) Voltage Max. 1 V
Between TM36 (female) (15) and (2) Voltage Max. 1 V
Defective gear shift lever (internal
3 See the failure code [DF10KA] and troubleshoot.
failure)
If cause is not found by the above checks, transmission controller is defective.
4 Defective transmission controller q Reference: See failure code [DF10KA] before performing the voltage
check.

40-286 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Circuit diagram related to transmission gearshift lever 40-287

GD555-5,GD655-5,GD675-5 40-287
(01)
Troubleshooting by failurecode
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range

Failure code [DGF1KX] Transmission oil temperature sensor: Input

signal out of range 40-28
Action code Failure code Transmission oil temperature sensor: Input signal is out of range
Failure
(Transmission controller system)
E03 DGF1KX
Detail of failure q Transmission oil temperature sensor signal is out of normal range (0.9 to 4.5 V).
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q If failure disappears, system resets itself.
Problem on
q Gearshift shock is large.
machine
q Input voltage value and temperature from transmission oil temperature sensor can be checked by
Related infor- using monitoring function.
mation (Code: TRANSMISSION1-32501-T/M OIL TEMP(V), 32500-T/M OIL TEMP(°C))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T35 and connect T-adapter to male side.
Between T35 (male) (1) 25°C Resistance 38 – 49 kz
Defective transmission oil temper- and (2)
1 ature sensor (Internal open circuit a Thermal characteris-
or short circuit) tics of oil temperature 100°C Resistance 3.7 – 4.0 kz
sensor
Between ground and T35
All range Resistance Min. 1 Mz
(male) (1), (2)
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (3) and (21)
2
ing harness a Resistance is the same as thermal characteris-
Resistance 3.7 – 49 kz
tics of oil temperature sensor in cause 1 (25°C
- 100°C) in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and T35, and connect T-adapters to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (3) and T35 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and T35 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors T35 and TM39, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and T35 (female) (1) or TM39
Resistance Min. 1 Mz
(female) (3)
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connector T35 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between T35 (female) (1) and (2) Voltage Approx. 5 V
If no abnormality is found in above diagnoses, transmission controller is
6 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

40-288 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range

Circuit diagram related to transmission oil temperature sensor 40-289

GD555-5,GD655-5,GD675-5 40-289
(01)
Troubleshooting by failurecode
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault

Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault 40-290
Action code Failure code Hydraulic oil temperature sensor: Ground fault
Failure
(Transmission controller system)
E01 DGH2KB
q Hydraulic oil temperature of 150°C or above (0.97 V or below) is detected (ground fault is detect-
Detail of failure
ed in hydraulic oil temperature signal circuit).
Action of con- q Fixes hydraulic oil temperature used for hydraulic fan control to 90°C.
troller q If cause of failure disappears, system resets itself.
Problem on
q Hydraulic fan speed increases.
machine
q Input voltage and temperature from hydraulic oil temperature sensor can be checked by using
Related infor- monitoring function.
mation (Monitoring code: TRANSMISSION1 - 04410 HST OIL TEMP (°C))
(Monitoring code: TRANSMISSION1 - 04402 - HST OIL TEMP (V))

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector R17 and connect T-adapter to male side.
Between R17 (male) (1) 25°C Resistance 38 – 49 kz
and (2)
Defective hydraulic oil tempera-
1 a Thermal characteris-
ture sensor (Internal defect) 100°C Resistance 3.7 – 4.0 kz
tics of oil temperature
sensor
Between ground and
– (Anytime) Resistance Min. 1 Mz
R17 (male) (1), (2)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R17, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between ground and TM39 (female) (10) or R17
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
3 Defective transmission controller Hydraulic oil tempera-
Voltage 4.4 – 4.6 V
Between TM39 (20) and ture: 25°C
(21) Hydraulic oil tempera-
Voltage 2.1 – 2.3 V
ture: 100°C

40-290 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault

Circuit diagram related to hydraulic oil temperature sensor 40-291

GD555-5,GD655-5,GD675-5 40-291
(01)
Troubleshooting by failurecode
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range

Failure code [DGT1KX] Torque converter oil temperature sensor: Input

signal out of range 40-292
Action code Failure code Torque converter oil temperature sensor: Input signal is out of
Failure range
E01 DGT1KX (Transmission controller system)

Detail of failure q Torque converter oil temperature sensor signal is out of normal range (0.9 to 4.5 V).
Action of con- q Transmits torque converter oil temperature as abnormal value to machine monitor.
troller q If failure disappears, system resets itself.
Problem on q Torque converter overheat cannot be detected.
machine q Large shock is generated when torque converter is locked up.
q Input voltage value and temperature from torque converter oil temperature sensor can be checked
Related infor- by using of monitoring function.
mation (Code: TRANSMISSION1-30100-T/C OIL TEMP(°C), 30101-T/C OIL TEMP(V))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T34 and connect T-adapter to male side.
Defective torque converter oil tem- Between T34 (male) (1) 25°C Resistance 38 – 49 kz
1 perature sensor (Internal open cir- and (2)
cuit or short circuit) 100°C Resistance 3.7 – 4.0 kz
Between ground and T34
All range Resistance Min. 1 Mz
(male) (1), (2)
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (9) and (21)
2
ing harness a Resistance is the same as thermal characteris-
Resistance 3.7 – 49 kz
tics of oil temperature sensor in cause 1 (25°C
- 100°C) in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and T34, and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (9) and T34 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and T34 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors T34 and TM39, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and T34 (female) (1) or TM39
Resistance Min. 1 Mz
(female) (3)
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connector T34 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between T34 (female) (1) and (2) Voltage Approx. 5 V
If no abnormality is found in above diagnoses, transmission controller is
6 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

40-292 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range

Circuit diagram related to torque converter oil temperature sensor 40-293

GD555-5,GD655-5,GD675-5 40-293
(01)
Troubleshooting by failurecode
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault

Failure code [DGT7KB] Differential oil temperature sensor: Ground fault40-294

Action code Failure code Differential oil temperature sensor: Ground fault
Failure
(Transmission controller system)
E01 DGT7KB
q Differential oil temperature of 150°Cor above (0.97 V or below) is detected (ground fault is detect-
Detail of failure
ed in differential oil temperature signal circuit).
Action of con- q Does not detect overheat of differential oil.
troller q Outputs power to differential lock control relay.
Problem on
q Differential lock is turned off regardless of switch position.
machine
q Input voltage value and temperature from differential oil temperature sensor can be checked by us-
Related infor- ing of monitoring function.
mation (Monitoring code: TRANSMISSION1 - 31909 - DIFF TEMP (°C))
(Monitoring code: TRANSMISSION1 - 31910 - DIFF TEMP (V))

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector R8 and connect T-adapter to male side.
Between R8 (male) (1) 25°C Resistance 38 – 49 kz
and (2)
Defective differential oil tempera- a Thermal characteris-
1
ture sensor (Internal defect) tics of oil temperature 100°C Resistance 3.7 – 4.0 kz
sensor
Between each of R8
(male) (1) and (2) and – (Anytime) Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R8, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between ground and TM39 (female) (14) or R8
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
3 Defective transmission controller Differential oil tempera-
Voltage 4.4 – 4.6 V
Between TM39 (14) and ture: 25°C
ground Differential oil tempera-
Voltage 2.1 – 2.3 V
ture: 100°C

40-294 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault

Circuit diagram related to differential oil temperature sensor 40-295

GD555-5,GD655-5,GD675-5 40-295
(01)
Troubleshooting by failurecode
Failure code [DJF1KA] Fuel level sensor: Open circuit

Failure code [DJF1KA] Fuel level sensor: Open circuit 40-296

Action code Failure code Fuel level sensor: Open circuit
Failure
(Machine monitor system)
E01 DJF1KA
Detail of failure q Open circuit is detected in fuel level sensor circuit.
Action of con-
q None in particular.
troller
Problem on
q Fuel level gauge does not indicate correct level.
machine
q Resistance and voltage values from fuel level sensor can be checked by using monitoring function.
Related infor- (Code: MONITOR PANEL-04201-FUEL SENSOR (z), MONITOR PANEL-04200-FUEL SENSOR
mation (V))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector ET39, and connect T-adapter to male side.
FULL Resistance Max. 7 z
Defective fuel level sensor Between ET39 (male) (1) 3/4 Resistance (10 z)
1
(Internal open circuit) and (2)
1/2 Resistance 32 z
a Fuel level sensor
characteristics table 1/4 Resistance (50 z)
EMPTY Resistance Min. 85 z
1. Turn starting switch to OFF position.
Open circuit or short circuit in wir- 2. Disconnect connector FP2 and connect T-adapter to female side.
2 Between FP2 (female) (10) and ground
ing harness
a Resistance is the same as fuel level sensor Resistance 10 – 80 z
characteristics in cause 1 in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors FP2, and ET39 and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between FP2 (female) (10) and ET39 (female) (1) Resistance Max. 1 z
Between ET39 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector ET39, and connect T-adapter to female side.
Hot short circuit or short circuit in
4 3. Turn starting switch to ON position.
wiring harness
Approx. 3 -
Between ET39 (female) (1) and (2) Voltage
5V
If no abnormality is found by above diagnoses, machine monitor is defective.
5 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

40-296 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DJF1KA] Fuel level sensor: Open circuit

Circuit diagram related to fuel level sensor 40-297

GD555-5,GD655-5,GD675-5 40-297
(01)
Troubleshooting by failurecode
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range

Failure code [DK70KX] Inching pedal angle sensor: Input signal out of
range 40-298
Action code Failure code Inching pedal angle sensor: Input signal is out of range
Failure
(Transmission controller system)
E03 DK70KX
Detail of failure q Inching pedal angle sensor signal is out of normal range (0.4 - 4.5 V).
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Performs neutral processing to disable inching function.
troller
q If cause of failure disappears with gearshift lever in N position, system resets itself.
Problem on
q Inching function does not work.
machine
q Input voltage values from inching angle sensor can be checked by use of monitoring function.
Related infor-
(Code: TRANSMISSION1-44105-INCHING PEDAL)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate inching pedal).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector FL6 and connect T-adapter to male side.
Defective inching angle sensor
1 (Internal open circuit or short cir- Between FL6 (male) (A) and (C) Resistance 4.0 – 6.0 kz
cuit) Between FL6 (male) (B) and (A) Resistance 0.25 –5.0 kz *
Between FL6 (male) (B) and (C) Resistance 0.25 –5.0 kz *
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39, TM41, and FL6, and connect T-adapter to
Open circuit in wiring harness each female side.
2 (Wire breakage or defective con- Between TM39 (female) (21) and FL6 (female) (C) Resistance Max. 1 z
tact of connector)
Between TM39 (female) (7) and FL6 (female) (B) Resistance Max. 1 z
Between TM41 (female) (34) and FL6 (female) (A) Resistance Max. 1 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39, TM41, and FL6, and connect T-adapter to
Ground fault in wiring harness female side of one of them.
3 Between ground and TM41 (female) (34) or FL6
(Contact with ground circuit) Resistance Min. 1 Mz
(female) (A)
Between ground and TM39 (female) (7) or FL6
Resistance Min. 1 Mz
(female) (B)
1. Turn starting switch to OFF position.
2. Disconnect connector FL6 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(Contact with 24 V circuit) Between FL6 (female) (A) and (C) Voltage Approx. 5 V
Between FL6 (female) (B) and (C) Voltage Max. 2.5 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapters into connector TM39 and TM41.
3. Set disconnect switch to ON.
5 Defective transmission controller 4. Turn starting switch to ON position.
Between TM41 (34) and TM39 (21) Voltage 4.6 – 5.4 V
Between TM39 (7) and (21) Voltage 0.4 – 4.5 V

*: As inching pedal is pressed, resistance changes.

40-298 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range

Circuit diagram related to inching pedal angle sensor 40-29

GD555-5,GD655-5,GD675-5 40-299
(01)
Troubleshooting by failurecode
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range

Failure code [DKD0KX] Articulation angle sensor: Input signal out of

range 40-30
Action code Failure code Articulation angle sensor: Input signal is out of range
Failure
(Transmission controller system)
E01 DKD0KX
Detail of failure q Articulation angle sensor signal is out of normal range.
Action of con-
q If cause of failure disappears, system resets itself.
troller
Problem on
q Articulation angle sensor does not indicate correct articulation angle.
machine
q Input voltage from articulation angle sensor can be checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-43902-ARTICULATE)
mation q Method of reproducing failure code: Start engine and perform articulate operation.
q See E-mode troubleshooting, “E-9 Articulation angle indicator does not indicate correctly”.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to male side.
3. Perform troubleshooting with starting switch at OFF position, and then
connect connector B11.
Defective articulation angle sen- 4. Start engine, change articulation angle, and then return to step 1.
1 sor (internal open circuit or short Approx.
Straight Resistance
circuit) Between B11 (male) (A) 2.5 kz
and (B) Fully to left (25°) Approx. 1 –
Resistance
Fully to right (25°) 3.8 kz
Approx.
Between B11 (male) (A) and (C) Resistance
5 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM39 and B11, and connect T-adapter to each
Open circuit in wiring harness female side.
2 (Wire breakage or defective con- Between TM39 (female) (8) and B11 (female) (B) Resistance Max. 1 z
tact of connector)
Between TM39 (female) (21) and B11 (female) (A) Resistance Max. 1 z
Between TM39 (female) (22) and B11 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM39 and B11, and connect T-adapter to female
Ground fault in wiring harness side of one of them.
3 Between ground and TM39 (female) (8) or B11
(Contact with ground circuit) Resistance Min. 1 Mz
(female) (B)
Between ground and TM39 (female) (22) or B11
Resistance Min. 1 Mz
(female) (C)
1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(Contact with 24 V circuit) Between FL06 (female) (B) and (A) Voltage Max. 3 V
Between FL06 (female) (C) and (A) Voltage Approx. 5 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position and perform troubleshooting.
4. Start engine, change articulation angle, and then return to step 3.
5 Defective transmission controller Approx. 2.4
Straight Voltage
Between TM39 (8) and V
(21) Fully to left (25°) Approx. 1 –
Voltage
Fully to right (25°) 3.8 V
Between TM39 (22) and (21) Voltage Approx. 5 V

40-300 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range

Circuit diagram related to articulation angle sensor 40-301

GD555-5,GD655-5,GD675-5 40-301
(01)
Troubleshooting by failurecode
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit

Failure code [DLF1KA] Transmission input shaft speed sensor: Open

circuit 40-302
Action code Failure code Transmission input shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLF1KA
Detail of failure q There is open circuit in transmission input shaft speed sensor circuit and speed signal is not input.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con-
q Keeps stopping output to lockup clutch.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission input shaft speed sensor can be check by using monitoring function
Related infor-
(Code: TRANSMISSION1-31200-T/M SPEED: IN).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

Defective transmission input shaft 1. Turn starting switch to OFF position.

1 speed sensor (Internal open cir-
cuit)
Defective adjustment of transmis- Transmission input shaft speed sensor may be adjusted defectively. Adjust it
2
sion input shaft speed sensor
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact)
6 Defective transmission controller
2. Disconnect connector T32 and connect T-adapter to male side.
Between T32 (male) (1) and (2) Resistance 500 – 1,000 z
according to Testing and adjusting, "Adjusting transmission speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (40) and (39) Resistance
1,000 z
a If causes 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T32, and connect T-adapter to each
female side.
Between TM40 (female) (40) and T32 (female) (1) Resistance Max. 1 z
Between TM40 (female) (39) and T32 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission input shaft speed sensor 40-302

40-302 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match

Failure code [DLF1LC] Transmission input shaft speed sensor: Speed

signal does not match 40-303
Action code Failure code Transmission input shaft speed sensor: Speed signal error
Failure
(Transmission controller system)
E03 DLF1LC
q While each clutch of L/U, FH, FL, R, 1st, 2nd, 3rd and 4th clutches is activated normally, speed
Detail of failure
signal from transmission input shaft speed sensor is abnormal.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con-
q Keeps stopping output to lockup clutch.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission input shaft speed sensor can be check by using monitoring function
Related infor-
(Code: TRANSMISSION1-31200-T/M SPEED: IN).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission input shaft 2. Disconnect connector T32 and connect T-adapter to male side.
1 speed sensor (Internal open circuit 500 –
Between T32 (male) (1) and (2) Resistance
or short circuit) 1,000 z
Between T32 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (40) and (39) Resistance
1,000 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and T32, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between ground and TM40 (female) (40) or T32
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T32 and connect T-adapter to female side.
Hot short in wiring harness
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T32 (female) (1) and (2) Voltage 3 – 4V

If no abnormality is found by above diagnoses, transmission controller may be

5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission input shaft speed sensor 40-303

GD555-5,GD655-5,GD675-5 40-303
(01)
Troubleshooting by failurecode
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit

Failure code [DLF2KA] Transmission intermediate shaft speed sensor:

Open circuit 40-304
Action code Failure code Transmission intermediate shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLF2KA
Detail of failure q Transmission intermediate shaft speed sensor circuit has open circuit and no speed signal is input.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Fixes relative speed to 300 rpm and continues control.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Slip of clutch cannot be judged.
machine
q Shaft speed input from transmission intermediate shaft speed sensor can be checked by using
Related infor-
monitoring function. (Code: TRANSMISSION1-31300-T/M SPEED:MID 1)
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission intermedi-
1 ate shaft speed sensor (internal 2. Disconnect connector T47 and connect T-adapter to male side.
open circuit) 500 –
Between T47 (male) (1) and (2) Resistance
1,000 z
Defective adjustment of transmis- Transmission intermediate shaft speed sensor may be adjusted incorrectly.
2 sion intermediate shaft speed sen- Adjust it referring to Testing and adjustment, “Adjusting transmission speed
sor sensor”.
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (20) and (29) Resistance
1,000 z
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T47, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (20) and T47 (female) (1) Resistance Max. 1 z
Between TM40 (female) (29) and T47 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission intermediate shaft speed sensor 40-304

40-304 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match

Failure code [DLF2LC] Transmission intermediate shaft speed sensor:

Speed signal does not match 40-305
Action code Failure code Transmission intermediate shaft speed sensor: Speed signal
Failure error
E03 DLF2LC (Transmission controller system)
q While each clutch of L/U, FH, FL, R, 1st, 2nd, 3rd and 4th clutches is activated normally, speed
Detail of failure
signal from transmission intermediate shaft speed sensor is abnormal.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Fixes relative speed to 300 rpm and continues control.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Slip of clutch cannot be judged.
machine
q Shaft speed input from transmission intermediate shaft speed sensor can be checked by using
Related infor-
monitoring function. (Code: TRANSMISSION1-31300-T/M SPEED:MID 1)
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission intermedi- 2. Disconnect connector T47 and connect T-adapter to male side.
1 ate shaft speed sensor (internal 500 –
Between T47 (male) (1) and (2) Resistance
open circuit or short circuit) 1,000 z
Between T47 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
2
ing harness is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (20) and (29) Resistance
1,000 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and T47, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between TM40 (female) (20) or T47 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T47 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T47 (female) (1) and (2) Voltage 3–4V
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission intermediate shaft speed sensor 40-305

GD555-5,GD655-5,GD675-5 40-305
(01)
Troubleshooting by failurecode
Failure code [DLM3KA] Fan speed sensor: Open circuit

Failure code [DLM3KA] Fan speed sensor: Open circuit 40-306

Action code Failure code Fan speed sensor: Open circuit
Failure
(Transmission controller system)
E01 DLM3KA
q No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor system.
q This failure code appears under the following conditions.
Detail of failure 1) Input voltage is 3 - 4 V.
2) There is no record of pulse input.
3) Engine is running.
Action of con-
q None in particular.
troller
Problem on
q The fan speed fails to accurately meet the specified speed.
machine
Related infor- q Input speed from fan speed sensor can be checked by using monitoring function (Code: TRANS-
mation MISSION 1-10009, FAN SPEED).

Cause Procedure, measuring location, criteria and remarks

Defective fan speed sensor adjust- a Fan speed sensor may be adjusted defectively. Check it directly.
1
ment (See Testing and adjusting, "Adjusting hydraulic fan speed sensor".)
1. Turn starting switch to OFF position.
2. Disconnect connector RT8 and connect T-adapter to male side.
Defective fan speed sensor (Inter-
2
nal open circuit or short circuit) Between RT8 (male) (1) and (2) Resistance 2 – 3 kz
Between RT8 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM40 (female) (10) and (39) Resistance 2 – 3 kz
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and RT8, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (39) and RT8 (female) (2) Resistance Max. 1 z
Between TM40 (female) (10) and RT8 (female) (1) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan speed sensor 40-306

40-306 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLM3LC] Fan speed sensor: Short circuit

Failure code [DLM3LC] Fan speed sensor: Short circuit 40-307

Action code Failure code Fan speed sensor: Short circuit
Failure
(Transmission controller system)
E01 DLM3LC
q No pulse voltage is input from fan speed sensor due to ground fault in fan speed sensor system.
q This failure code appears under the following conditions.
Detail of failure 1) Failure code [DLM3KA] is not indicated.
2) Engine speed is 500 rpm or above.
3) Fan is not in reverse control.
Action of con-
q None in particular.
troller
Problem on
q The fan speed fails to accurately meet the specified speed.
machine
Related infor- q Input speed from fan speed sensor can be checked by using monitoring function (Code: TRANS-
mation MISSION 1-10009, FAN SPEED).

Cause Procedure, measuring location, criteria and remarks

Defective fan speed sensor adjust- a Fan speed sensor may be adjusted defectively. Check it directly.
1
ment (See Testing and adjusting, "Adjusting hydraulic fan speed sensor".)
1. Turn starting switch to OFF position.
2. Disconnect connector RT8 and connect T-adapter to male side.
Defective fan speed sensor (Inter-
2
nal open circuit or short circuit) Between RT8 (male) (1) and (2) Resistance 2 – 3 kz
Between RT8 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM40 (female) (10) and (39) Resistance 2 – 3 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and RT8, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and TM40 (female) (10) or RT8
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector RT8 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT8 (female) (1) and (2) Voltage 3–4V
If no abnormality is found by above diagnoses, transmission controller may be
6 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan speed sensor 40-307

GD555-5,GD655-5,GD675-5 40-307
(01)
Troubleshooting by failurecode
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit

Failure code [DLT3KA] Transmission output shaft speed sensor: Open

circuit 40-308
Action code Failure code Transmission output shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLT3KA
Detail of failure q There is open circuit in transmission output shaft speed sensor circuit and speed signal is not input.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con- q If in automatic shift mode, current gear speed is kept.
troller q Keeps stopping output to lockup clutch.
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission output shaft speed sensor can be check by using monitoring func-
Related infor-
tion (Code: TRANSMISSION1-31400-T/M SPEED: OUT).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission output 2. Disconnect connector T33 and connect T-adapter to male side.
1 shaft speed sensor (Internal open
circuit) Approx. 500
Between T33 (male) (1) and (2) Resistance
- 1000 z
Defective adjustment of transmis- Transmission output shaft speed sensor may be adjusted defectively. Adjust it
2
sion output shaft speed sensor according to Testing and adjusting, "Adjusting transmission speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3 tance is 1 z or below, wiring harness has short circuit.
ing harness
Approx. 500
Between TM40 (female) (30) and (29) Resistance
- 1000 z
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T33, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (30) and T33 (female) (1) Resistance Max. 1 z
Between TM40 (female) (29) and T33 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission output shaft speed sensor 40-308

40-308 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit

GD555-5,GD655-5,GD675-5 40-309
(01)
Troubleshooting by failurecode
Failure code [DV00KB] Buzzer: Short circuit

Failure code [DV00KB] Buzzer: Short circuit 40-310

Action code Failure code Alarm buzzer: Short circuit
Failure
(Machine monitor system)
E01 DV00KB
Detail of failure q When machine monitor connects alarm buzzer circuit to GND, abnormal current flows.
Action of con-
q Machine monitor stops connecting alarm buzzer circuit to GND.
troller
Problem on
q Alarm buzzer does not sound.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position.
mation a If starting switch is turned to ON position, alarm buzzer operates (sounds) for two seconds.

Cause Procedure, measuring location, criteria and remarks

Defective alarm buzzer (internal
1 3. Turn starting switch to ON position.
open circuit or short circuit)
2 Short circuit in wiring harness
Hot short circuit in wiring harness
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
4 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect connector FP4.
If this failure code is not indicated, alarm buzzer is defective.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors FP1 and FP4, and connect T-adapter to each
female side.
Between FP4 (female) (1) and (2), or between FP1
Resistance Min. 1 Mz
(female) (1) and (18)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector FP4 and connect T-adapter to female side.
Between FP1 (female) (18) and ground Voltage Max. 1 V
If no abnormality is found by above diagnoses, machine monitor may be
defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connector FP1.
3. Set disconnect switch to ON.
4. Turn starting switch to ON position.
When
buzzer is Voltage 20 – 30 V
stopped
Between FP1 (18) and ground When
buzzer
Voltage Max. 3 V
operates
(sounds)

40-310 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DV00KB] Buzzer: Short circuit

Circuit diagram related to buzzer 40-31

GD555-5,GD655-5,GD675-5 40-311
(01)
Troubleshooting by failurecode
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit

Failure code [DW4BKA] Parking brake solenoid valve: Open circuit 40-312
Action code Failure code Parking brake solenoid valve: Open circuit
Failure
(Transmission controller system)
E03 DW4BKA
q Parking brake is not applied or released properly due to open circuit or hot short in parking brake
solenoid valve circuit.
Detail of failure
(No current flows when controller attempts to flow current to parking brake solenoid valve, or
current flows to parking brake solenoid valve from somewhere.)
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on
q Parking brake is not released or it is kept released.
machine
q Method of reproducing failure code: Start engine and operate gearshift lever (Position other than
P or P position).
Related infor-
q Parking brake can be released only when parking brake solenoid valve is actuated.
mation
q Output condition (ON/OFF) to parking brake solenoid valve can be checked by using monitoring
function (Code: TRANSMISSION1-40949 D-OUT-0).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective parking brake solenoid 2. Disconnect connector R11 and connect T-adapter to male side.
1
(Internal open circuit)
Between R11 (male) (1) and (2) Resistance 2 – 100 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (7) and ground Resistance 2 – 100 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness 2. Disconnect connectors TM41 and R11, and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM41 (female) (7) and R11 (female) (1) Resistance Max. 1 z
Between R11 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector R11 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between R11 (female) (1) and ground Voltage Max. 1 V
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-312 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit

Circuit diagram related to parking brake solenoid 40-313

GD555-5,GD655-5,GD675-5 40-313
(01)
Troubleshooting by failurecode
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit

Failure code [DW4BKB] Parking brake solenoid valve: Short circuit 40-314
Action code Failure code Parking brake solenoid valve: Short circuit
Failure
(Transmission controller system)
E03 DW4BKB
q Parking brake is not released due to short circuit in parking brake solenoid circuit.
Detail of failure
(Abnormal current flows when controller attempts to flow current to parking brake solenoid valve.)
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on
q Parking brake is not released.
machine
q Method of reproducing failure code: Start engine and operate gear shift lever (Position other than
P).
Related infor-
q Parking brake can be released only when parking brake solenoid valve is actuated.
mation
q Output condition (ON/OFF) to parking brake solenoid valve can be checked by using monitoring
function (Code: TRANSMISSION1-40949 D-OUT-0).

Cause Procedure, measuring location, criteria and remarks

Defective parking brake solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector R11 and connect T-adapter to male side.
Between R11 (male) (1) and (2) Resistance 2 – 100 z
Between R11 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and R11, and connect T-adapter to female
Between ground and TM41 (female) (7) or R11
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and R11, and connect a T-adapter to the
female side of R11.
Between R11 (female) (1) and (2) Resistance Min. 1 Mz
If no abnormality is found by above diagnoses , transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to parking brake solenoid 40-314

40-314 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKA] Fan reverse solenoid: Open circuit

Failure code [DW7BKA] Fan reverse solenoid: Open circuit 40-315

Action code Failure code Fan reverse solenoid: Open circuit
Failure
(Transmission controller system)
E01 DW7BKA
q When current is output to fan reverse solenoid, no current flows because of open circuit in fan re-
Detail of failure
verse solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
Problem on
q Fan does not turn in reverse by operating fan reverse switch.
machine
q Output condition (ON/OFF) to fan reverse solenoid can be checked by using monitoring function
Related infor- (Code: TRANSMISSION 1-40949 D-OUT-4).
mation q Method of reproducing failure code: Turn starting switch to ON position and set fan reverse switch
to ON.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fan reverse solenoid 2. Disconnect connector RT6 and connect T-adapter to male side.
1
(Internal open circuit)
Between RT6 (male) (1) and (2) Resistance 35 – 45 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
2
ing harness is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (28) and (13) Resistance 35 – 45 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness 2. Disconnect connectors TM41 and RT6, and connect T-adapters to female
3 (Wire breakage or defective con- side of them.
tact of connector) Between TM41 (female) (28) and RT6 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and RT6 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse solenoid 40-315

GD555-5,GD655-5,GD675-5 40-315
(01)
Troubleshooting by failurecode
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

Failure code [DW7BKB] Fan reverse solenoid: Short circuit 40-316

Action code Failure code Fan reverse solenoid: Short circuit
Failure
(Transmission controller system)
E01 DW7BKB
q Abnormal current flows when current is output to fan reverse solenoid due to short circuit in fan
Detail of failure
reverse solenoid system.
q Stops output to fan reverse solenoid.
Action of con- q Disables fan reverse function.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Fan does not turn in reverse by operating fan reverse switch.
machine
q Output (ON/OFF) to fan reverse solenoid can be checked by using monitoring function (Code:
Related infor-
TRANSMISSION1-40949 D-OUT-4).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fan reverse solenoid
1
(Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector RT6 and connect T-adapter to male side.
Between RT6 (male) (1) and (2) Resistance 35 – 45 z
Between RT6 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
Between TM41 (female) (18) and RT6 (female) (1) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
side of one of them.
Between TM41 (female) (28) and (13) or between
Resistance Min. 1 Mz
RT6 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse solenoid 40-316

40-316 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-317
(01)
Troubleshooting by failurecode
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line

Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power

supply line 40-318
Action code Failure code Fan reverse solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E01 DW7BKY
q When current is not output to fan reverse switch, abnormal voltage appears because of hot short
Detail of failure
in fan reverse solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.

Problem on q Fan does not rotate in normal direction.

machine q Machine may overheat.

q Output condition (ON/OFF) to fan reverse solenoid can be checked by using monitoring function
Related infor-
(Code: TRANSMISSION 1-40949 D-OUT-4).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector RT6 and connect T-adapter to male side.
Defective fan reverse solenoid
1
(Internal open circuit) Between RT6 (male) (1) and (2) Resistance 35 – 45 z
Between RT6 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit of wiring harness 2. Disconnect connector RT6 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT6 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (28) and each pin other No continuity (no sound
than (28) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM 39 through TM41 and RT6, and connect
T-adapters to female side of connectors TM 39 through TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (28) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (28) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-318 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line

Circuit diagram related to fan reverse solenoid 40-319

GD555-5,GD655-5,GD675-5 40-319
(01)
Troubleshooting by failurecode
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit

Failure code [DX16KA] Fan motor EPC solenoid: Open circuit 40-320
Action code Failure code Fan motor EPC solenoid: Open circuit
Failure
(Transmission controller system)
E01 DX16KA
q No current flows when controller attempts to flow current to fan motor EPC solenoid circuit due to
Detail of failure
open circuit in fan motor EPC solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
Problem on
q The fan speed is set to the maximum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION1-41400 FAN EPC DIR and
mation TRANSMISSION1-41401 FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fan motor EPC solenoid 2. Disconnect connector RT7 and connect T-adapter to male side.
1
(Internal open circuit)
Between RT7 (male) (1) and (2) Resistance 2 – 12 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has disconnection. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (37) and (13) Resistance 2 – 12 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
3 (Wire breakage or defective con- side of them.
tact of connector) Between TM41 (female) (37) and RT7 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and RT7 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan motor EPC solenoid 40-320

40-320 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit

Failure code [DX16KB] Fan motor EPC solenoid: Short circuit 40-321
Action code Failure code Fan motor EPC solenoid: Short circuit
Failure
(Transmission controller system)
E01 DX16KB
q Abnormal current flows when controller attempts to flow current to fan motor EPC solenoid circuit
Detail of failure
due to ground fault in fan motor EPC solenoid system.
q Stops outputting current to fan motor EPC solenoid.
Action of con- q Disables fan reverse function.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q The fan speed is set to the maximum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION 1-41400 FAN EPC DIR, 41401
mation FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fan motor EPC solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of either one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector RT7 and connect T-adapter to male side.
Between RT7 (male) (1) and (2) Resistance 2 – 12 z
Between RT7 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
Between TM41 (female) (37) or RT7 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
side of either one of them.
Between TM41 (female) (37) and (13) or between
Resistance Min. 1 Mz
RT7 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan motor EPC solenoid 40-321

GD555-5,GD655-5,GD675-5 40-321
(01)
Troubleshooting by failurecode
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line

Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power
supply line 40-32
Action code Failure code Fan motor EPC solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E01 DW16KY
q When current is not output to fan motor EPC solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in fan motor EPC solenoid system.
q Stops outputting current to fan motor EPC solenoid.
Action of con-
q Disables fan reverse function.
troller
q If failure disappears, system resets itself.
Problem on
q The fan speed is set to the minimum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION 1-41400 FAN EPC DIR, 41401
mation FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector RT7 and connect T-adapter to male side.
Defective fan motor EPC solenoid
1
(Internal open circuit) Between RT7 (male) (1) and (2) Resistance 2 – 12 z
Between RT7 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit of wiring harness 2. Disconnect connector RT7 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT7 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (37) and each pin other No continuity (no sound
than (37) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM 39 through TM41 and RT6, and connect
T-adapters to female side of connectors TM 39 through TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (37) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (37) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-322 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line

Circuit diagram related to fan motor EPC solenoid 40-323

GD555-5,GD655-5,GD675-5 40-323
(01)
Troubleshooting by failurecode
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit

Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit 40-324

Action code Failure code Lockup solenoid: Open circuit
Failure
E03 DXH1KA (Transmission controller system)
Detail of failure q When current is output to lockup clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Keeps stopping output to lockup clutch ECMV solenoid.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF power.
q Machine remains in torque converter drive auto mode even if direct drive mode is selected by using
Problem on
transmission mode selector switch.
machine
q Lockup clutch is disengaged.
q Command current value output to lockup clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation q Method of reproducing failure code:
Turn starting switch to ON position and operate transmission mode selector switch (select direct
drive mode).
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup solenoid
1 2. Disconnect connector T31 and connect T-adapter to male side.
(Internal disconnection)
Between T31 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit or short circuit in wir- 2. Disconnect connector TM41 and connect T-adapter to female side.
2
ing harness a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (38) and (13) Resistance 5 – 15 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
3 (Wire breakage or defective con- 2. Disconnect connectors TM41 and T31, and connect T-adapter to each
tact of connector) female side.
Between TM41 (female) (38) and T31 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and T31 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission may be defective.
4 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to lockup solenoid 40-324

40-324 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit

Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit 40-325

Action code Failure code Lockup solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH1KB
Detail of failure q When current is output to lockup clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to lockup clutch ECMV solenoid.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Torque converter mode (Mode 2) is kept on even when direct drive mode (Mode 1) is selected by
machine using transmission mode selector switch.
q Command current value output to lockup clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation q Method of reproducing failure code:
Turn starting switch to ON position and operate transmission mode selector switch (select direct
drive mode).

Cause Procedure, measuring location, criteria and remarks

Defective lockup solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
1. Turn starting switch to OFF position.
2. Disconnect connector T31 and connect T-adapter to male side.
Between T31 (male) (1) and (2) Resistance 5 – 15 z
Between T31 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
Between ground and TM41 (female) (38) or T31
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
side of one of them.
Between TM41 (female) (38) and (13), or between
Resistance Min. 1 Mz
T31 (female) (1) and (2)
If no abnormality is not found by above diagnoses, transmission controller
formed.)

Circuit diagram related to lockup solenoid 40-325

GD555-5,GD655-5,GD675-5 40-325
(01)
Troubleshooting by failurecode
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line

Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power

supply line 40-326
Action code Failure code Lockup ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH1KY
q When current is not output to lockup ECMV solenoid, abnomal voltage appears because of hot
Detail of failure
short circuit in lockup ECMV solenoid system.
q Lights up the centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
q The lock up clutch is always engaged.
Problem on
q Engine may stall.
machine
q Solenoid may burn up.
q Command current value output to lockup ECMV solenoid and detected value can be checked by
Related infor- using monitoring function (Code: TRANSMISSION1-31609 ECMV L/U DIR and
mation TRANSMISSION1-31642-ECMV L/U)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T31 and connect T-adapter to male side.
Defective lockup solenoid
1
(Internal short circuit) Between T31 (male) (1) and (2) Resistance 5 – 15 z
Between T31 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T31 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T31 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (38) and each pin other No continuity (no sound
than (38) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T31, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (38) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (38) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is not found by above diagnoses, transmission controller
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-326 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line

Circuit diagram related to lockup solenoid 40-327

GD555-5,GD655-5,GD675-5 40-327
(01)
Troubleshooting by failurecode
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit

Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit 40-328

Action code Failure code FH clutch ECMV solenoid: Open circuit
Failure
(Tramsmission controller system)
E03 DXH2KA
Detail of failure q No current flows when current is output to FH clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FH clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FH clutch is not engaged.
machine
q Output (current value) to FH clutch ECMV solenoid can be checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F2, F4, F6
or F8).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FH clutch ECMV sole- 2. Disconnect connector T25 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T25 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T25 (male) (36) and (3) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T25, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (36) and T25 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T25 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FH clutch ECMV solenoid 40-328

40-328 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit

Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit 40-329

Action code Failure code FH clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH2KB
Detail of failure q Abnormal current flows when current is output to FH clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to H clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FH clutch is not engaged.
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F2, F4, F6,
and F8).

Cause Procedure, measuring location, criteria and remarks

Defective FH clutch ECMV sole-
1
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T25 and connect T-adapter to male side.
Between T25 (male) (1) and (2) Resistance 5 – 15 z
Between T25 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
Between TM41 (female) (36) or T25 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
side of one of them.
Between TM41 (female) (36) and (3), or between
Resistance Min. 1 Mz
T25 (female) (1) and (2)
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FH clutch ECMV solenoid 40-329

GD555-5,GD655-5,GD675-5 40-329
(01)
Troubleshooting by failurecode
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power

supply line 40-3 0
Action code Failure code FH clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH2KY
q Abnormal voltage appears when no current is output to FH clutch ECMV solenoid due to hot short
Detail of failure
circuit in FH clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q FH clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to FH clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31600 ECMV H DIR and
mation TRANSMISSION1-31610-ECMV H)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FH clutch ECMV sole- 2. Disconnect connector T25 and connect T-adapter to male side.
1 noid Between T25 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T25 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T25 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T25 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnected switch to OFF.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
side of TM41.
a Check by using mulltimeter in continuity mode.
Between TM41 (female) (36) and each pin other No continuity (no sound
than (36) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnected switch to OFF.
2. Disconnect connectors TM39 to TM41 and T25, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (36) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (36) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-330 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to FH clutch ECMV solenoid 40-3 1

GD555-5,GD655-5,GD675-5 40-331
(01)
Troubleshooting by failurecode
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit

Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit 40-3 2

Action code Failure code FL clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH3KA
Detail of failure q No current flows when current is output to FL clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FL clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FL clutch is not engaged.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FL clutch ECMV sole- 2. Disconnect connector T24 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T24 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T24 (male) (26) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T24, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (26) and T24 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T24 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-332 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit

Circuit diagram related to FL clutch ECMV solenoid 40-3 3

GD555-5,GD655-5,GD675-5 40-333
(01)
Troubleshooting by failurecode
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit

Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit 40-3 4

Action code Failure code FL clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH3KB
Detail of failure q Abnormal current flows when current is output to FL clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FL clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FL clutch is not engaged.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV L DIR and TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

Defective FL clutch ECMV sole-
1 Between T24 (male) (1) and (2)
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T24 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T24 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
Between TM41 (female) (26) or T24 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
side of one of them.
Between TM41 (female) (26) and (23), or between
Resistance Min. 1 Mz
T24 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FL clutch ECMV solenoid 40-3 4

40-334 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-335
(01)
Troubleshooting by failurecode
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power

supply line 40-3 6
Action code Failure code FL clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH3KY
q Abnormal voltage appears when no current is output to FL clutch ECMV solenoid due to hot short
Detail of failure
circuit in FL clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q FL clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to FL clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31601 ECMV L DIR and
mation TRANSMISSION1-31611-ECMV L)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FL clutch ECMV sole- 2. Disconnect connector T24 and connect T-adapter to male side.
1 noid Between T24 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T24 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T24 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T24 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (26) and each pin other No continuity (no sound
than (26) is heard)
a Since T- adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T24, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (26) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (26) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality cause is found by above diagnoses, transmission controller
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-336 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to FL clutch ECMV solenoid 40-3 7

GD555-5,GD655-5,GD675-5 40-337
(01)
Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit

Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit 40-3 8
Action code Failure code 1st clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH4KA
Detail of failure q When current is output to 1st clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stooping output to 1st clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 1st clutch is not engaged.
machine
q Command current value output to 1st clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 1st clutch ECMV sole- 2. Disconnect connector T27 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T27 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (female) (5) and (13) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T27, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (5) and T27 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and T27 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-338 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit

Circuit diagram related to 1st clutch ECMV solenoid 40-3 9

GD555-5,GD655-5,GD675-5 40-339
(01)
Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit

Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit 40-340
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH4KB
Detail of failure q When current is output to 1st clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of8 con- q Keeps stopping output of power to 1st clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 1st clutch is not engaged.
machine
q Command current value output to 1st clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

Defective 1st clutch ECMV sole-
1
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T27 and connect T-adapter to male side.
Between T27 (male) (1) and (2) Resistance 5 – 15 z
Between T27 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
Between TM41 (female) (5) or T27 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
side of one of them.
Between TM41 (female) (5) and (13), or between
Resistance Min. 1 Mz
T27 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 1st clutch ECMV solenoid 40-340

40-340 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-341
(01)
Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power
supply line 40-342
Action code Failure code 1st clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH4KY
q When current is not output to 1st clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 1st clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 1st clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 1st clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31602-ECMV 1 DIR and
mation TRANSMISSION1-31612-ECMV 1)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T27 and connect T-adapter to male side.
Defective 1st clutch solenoid
1
(Internal short circuit) Between T27 (male) (1) and (2) Resistance 5 – 15 z
Between T27 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T27 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T27 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (5) and each pin other than No continuity (no sound
(5) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T27, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (5) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (5) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-342 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 1st clutch ECMV solenoid 40-343

GD555-5,GD655-5,GD675-5 40-343
(01)
Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit

Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit 40-34
Action code Failure code 2nd clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH5KA
Detail of failure q When current is output to 2nd clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 2nd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 2nd clutch is not engaged.
machine
q Command current value output to 2nd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31603-ECMV 2 DIR and TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F3, F4, and
R2)

Cause Procedure, measuring location, criteria and remarks

Defective 2nd clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T28 and connect T-adapter to male side.
(Internal short circuit) Between T28 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (male) (15) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T28, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (15) and T28 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T28 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-344 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit

Circuit diagram related to 2nd clutch ECMV solenoid 40-345

GD555-5,GD655-5,GD675-5 40-345
(01)
Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit

Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit 40-346
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Failure
(Transmission train controller system)
E03 DXH5KB
Detail of failure q When current is output to 2nd clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 2nd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 2nd clutch is not engaged.
machine
q Command current value output to 2nd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31603-ECMV 2 DIR and TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F3, F4, and
R2)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 2nd clutch ECMV sole- 2. Disconnect connector T28 and connect T-adapter to male side.
1 noid
Between T28 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T28 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Ground fault in wiring harness 2. Disconnect connectors TM41 and T28, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between TM41 (female) (15) or T28 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T28, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between TM41 (female) (15) and (23), or between
Resistance Min. 1 Mz
T28 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 2nd clutch ECMV solenoid 40-346

40-346 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-347
(01)
Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power
supply line 40-348
Action code Failure code 2nd clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission train controller system)
E03 DXH5KY
q Abnormal voltage appears when no current is output to 2nd clutch ECMV solenoid due to hot short
Detail of failure
circuit in 2nd clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 2nd clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 2nd clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31603-ECMV 2 DIR and
mation TRANSMISSION1-31613-ECMV 2)
q Method of reproducing failure code: Turn starting switch to ON position.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector T28 and connect T-adapter to male side.
Defective 2nd clutch solenoid
1
(Internal short circuit) Between T28 (male) (1) and (2) Resistance 5 – 15 z
Between T28 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T28 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T28 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T28, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (15) and each pin other No continuity (no sound
than (15) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T28, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (15) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (15) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-348 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 2nd clutch ECMV solenoid 40-349

GD555-5,GD655-5,GD675-5 40-349
(01)
Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit

Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit 40-350
Action code Failure code 3rd clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH6KA
Detail of failure q When current is output to 3rd clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 3rd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 3rd clutch is not engaged.
machine
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR and TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F5, F6, and
R3)

Cause Procedure, measuring location, criteria and remarks

Defective 3rd clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T29 and connect T-adapter to male side.
(Internal short circuit) Between T29 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (female) (25) and (3) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T29, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (25) and T29 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T29 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-350 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit

Circuit diagram related to 3rd clutch ECMV solenoid 40-351

GD555-5,GD655-5,GD675-5 40-351
(01)
Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit

Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit 40-352
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH6KB
Detail of failure q When current is output to 3rd clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 3rd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 3rd clutch is not engaged.
machine
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR and TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F5, F6, and
R3)
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd clutch ECMV sole- 2. Disconnect connector T29 and connect T-adapter to male side.
1 noid
Between T29 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T29 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Ground fault in wiring harness 2. Disconnect connectors TM41 and T29, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between TM41 (female) (25) or T29 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T29, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between TM41 (female) (25) and (3), or between
Resistance Min. 1 Mz
T29 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 3rd clutch ECMV solenoid 40-352

40-352 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-353
(01)
Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power
supply line 40-354
Action code Failure code 3rd clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH6KY
q When current is not output to 3rd clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 3rd clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 3rd clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION1-31604 ECMV 3 DIR and
mation TRANSMISSION1-31614-ECMV 3).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T29 and connect T-adapter to male side.
Defective 3rd clutch solenoid
1
(Internal short circuit) Between T29 (male) (1) and (2) Resistance 5 – 15 z
Between T29 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T29 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T29 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T29, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (25) and each pin other No continuity (no sound
than (25) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T29, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (25) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (25) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-354 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 3rd clutch ECMV solenoid 40-35

GD555-5,GD655-5,GD675-5 40-355
(01)
Troubleshooting by failurecode
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit

Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit 40-356

Action code Failure code R clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH7KA
Detail of failure q When power is output to R clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to R clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q R clutch is not engaged.
machine
q Command current value output to R clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective R clutch ECMV solenoid 2. Disconnect connector T26 and connect T-adapter to male side.
1
(Internal short circuit)
Between T26 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T26 (male) (16) and (3) Resistance 5 – 15 z
a If no abromality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T26, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (16) and T26 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T26 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to R clutch ECMV solenoid 40-356

40-356 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit

Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit 40-357

Action code Failure code R clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH7KB
Detail of failure q When current is output to R clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to R clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q R clutch is not engaged.
machine
q Command current value output to R clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

Defective R clutch ECMV solenoid
1 Between T26 (male) (1) and (2)
(Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T26 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T26 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
Between TM41 (female) (16) or T26 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
side of one of them.
Between TM41 (female) (16) and (3), or between
Resistance Min. 1 Mz
T26 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to R clutch ECMV solenoid 40-357

GD555-5,GD655-5,GD675-5 40-357
(01)
Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power

supply line 40-358
Action code Failure code R clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission train controller system)
E03 DXH7KY
q When current is not output to R clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in R clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q R clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to R clutch ECMV solenoid and sensed current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T26 and connect T-adapter to male side.
Defective R clutch solenoid
1 Between T26 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T26 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T26 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T26 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (16) and each pin other No continuity (no sound
than (16) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T26, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (16) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (16) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-358 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to R clutch ECMV solenoid 40-359

GD555-5,GD655-5,GD675-5 40-359
(01)
Troubleshooting by failurecode
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit

Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit 40-360
Action code Failure code 4th clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXHHKA
Detail of failure q When current is output to 4th clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 4th clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 4th clutch is not engaged.
machine
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31605-ECMV 4 DIR and TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, and
R4)

Cause Procedure, measuring location, criteria and remarks

Defective 4th clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T30 and connect T-adapter to male side.
(Internal short circuit) Between T30 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open cirucit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41(female)(35) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T30, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (35) and T30 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T30 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-360 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit

Circuit diagram related to 4th clutch ECMV solenoid 40-361

GD555-5,GD655-5,GD675-5 40-361
(01)
Troubleshooting by failurecode
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit

Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit 40-362
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXHHKB
Detail of failure q When current is output to 4th clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 4th clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 4th clutch is not engaged.
machine
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code:TRANSMISSION1-31605-ECMV 4 DIR and TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, and
R4).

Cause Procedure, measuring location, criteria and remarks

Defective 4th clutch ECMV sole-
1 Between T30 (male) (1) and (2)
noid (Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T30 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T30 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
Between TM41 (female) (35) and ground, or
Resistance Min. 1 Mz
between T30 (female) (1) and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
side of one of them.
Between TM41 (female) (35) and (23), or between
Resistance Min. 1 Mz
T30 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 4th clutch ECMV solenoid 40-362

40-362 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-363
(01)
Troubleshooting by failurecode
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power
supply line 40-364
Action code Failure code 4th clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXHHKY
q When current is not output to 4th clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 4th clutch ECMV solenoid system.
q Lights up the centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 4th clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T30 and connect T-adapter to male side.
Defective 4th clutch solenoid
1 Between T30 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T30 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T30 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T30 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (35) and each pin other No continuity (no sound
than (35) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T30, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (35) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (35) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-364 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 4th clutch ECMV solenoid 40-365

GD555-5,GD655-5,GD675-5 40-365
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Troubleshooting of electrical system (E-mode) 40-36

E-1 Engine does not start (starting motor does not turn) 40-36
Failure q Starting motor does not turn and accordingly engine does not start.
q Engine start circuit has safety function that allows engine to star only when gearshift lever is set in
P position.
q If starting switch is turned to START position with either right or left blade lift lever set in FLOAT
position, blade may drop, so engine is not allowed to start.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [DDB6L4], [DF10KA] or [DF10L4] is displayed, perform troubleshooting for it first.)
q In the case of "Battery relay does not make operating sound" when starting switch is turned to ON
position, perform troubleshooting for E-1 also.
q Operation of safety circuit that is activated depending on blade lift lever position (detecting lever in
FLOAT position)
Float ENG cancel switches: Output from FP14 and FP15 (lever in FLOAT: 0 V, lever in a position
other than FLOAT: 24 V)
---> Circuit between (3) for ACC input and (6) for 24 V output of float lamp relay SP39:
Closed (lever in FLOAT), Open (lever in a position other than FLOAT)
---> Circuit between (3) for 24 V input and (6) for 24 V output of FLOAT ENG cancel relay SP38:
Open (lever in FLOAT), Closed (lever in a position other than FLOAT)
q Operation of safety circuit that is activated depending on gearshift lever position (detecting lever in
Related infor-
PARK)
mation
Output from gearshift lever “P” (lever in PARK: 24 V, lever in a position other than PARK: 0 V)
---> Diode SP35
---> Circuit between (5) for C signal input and (3) for 24 V output of safety relay SP17:
Closed (lever in PARK), Open (lever in a position other than PARK)
q Flow of starting switch C signal:
C signal (from ST8 terminal) ---> Safety relay: to SP17 (5) for input and from (3) for output--->*
Float ENG cancel relay: to SP38 (3) for input and from (6) for output --->
Engine cut relay: to W60 (3) for input and from (6) for output--->
---> Diode R28 or R29
---> Safety relay: Connector E01
---> E20 terminal for input is connected to E19 terminal for output.
---> Electricity from slow-blow fuse E32 terminal flows to starting motor C terminal (E21 terminal)
*: Safety relay SP17 holding circuit: SP17 (3) for output ---> S. holding relay SP33 (5) for input and
from (3) for output ---> Diode SP34 ---> SP17 (1)
a Before checking proximity switches for blade lift lever position (detecting lever in FLOAT), check
float lamp relay SP39 and float ENG cancel switch SP38.
a Before checking gearshift lever, check diode.

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuses (two
If slow-blow fuse is open, circuit probably has ground fault. In this case, per-
1 120 A fuses in holder 2, and 30 A
form troubleshooting for cause 19 first.
fuse in holder 1)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuses (2) and (11) in FB1
shooting for cause 19 first.
1. Turn starting switch to OFF position.
Loose terminal or open circuit at
3 Check terminals of battery relay, alternator, starting motor and GNDs (FT10,
terminal
FT 11, FT13 and ET40B).
Battery voltage Min. 24 V
4 Low charge level of battery
Electrolyte specific gravity Min. 1.26

40-366 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective float ENG cancel relay 2. Replace float ENG cancel relay (connector SP38) with another relay (stop
5 SP38 (internal open circuit or short lamp relay connected to connector SP16).
circuit) 3. Turn starting switch to ON position.
If starting motor rotates, original float ENG cancel relay is defective.
1. Turn starting switch to OFF position.
Defective float lamp relay SP39 2. Replace float lamp relay (connector SP39) with another relay (stop lamp
6 (Internal open or short circuit in relay connected to connector SP16).
wiring) 3. Turn starting switch to ON position.
If starting motor rotates, original float lamp relay is defective.
1. Turn starting switch to OFF position.
2. Remove float lamp relay (connector SP39).
Defective safety circuit that is acti- 3. Set right and left blade lift levers to a position other than FLOAT.
vated depending on blade lift lever 4. Set gearshift lever in the "P" position.
7
position (detecting lever in FLOAT) 5. Start engine.
(circuit up to float lamp relay SP39) If starting motor rotates, safety circuit (up to float lamp relay SP39) that is acti-
vated depending on blade lift lever position (detecting lever in FLOAT) is
defective.
1. Turn starting switch to OFF position.
2. Replace safety relay (SP17) with another relay (stop lamp relay connected
to connector SP16).
8 Defective safety relay SP17
3. Start engine.
If engine starts, original safety relay (SP17) is defective.

1. Turn starting switch to OFF position.

9 Defective engine cut relay W40
10 Defective S. hold relay (SP33)
Defective diode SP34, SP35, R28,
R29, R18 or R19
11
(Internal open or short circuit in
wiring)
Defective gearshift lever
12 (internal defect or defective adjust-
ment)
2. Replace engine cut relay (W60) with another relay (stop lamp relay
connected to connector SP16).
3. Start engine.
If engine starts, original engine cut relay (W60) is defective.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Replace safety relay (SP33) with another relay (stop lamp relay connected
to connector SP16).
4. Set disconnect switch to ON.
5. Start engine.
If engine starts, original S. hold relay (SP33) is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP34, SP35, R28, R29, R18 and R19, and connect
T-adapter to each diode.
a Measure by using multimeter in diode range.
Between each diode (male) (1) (+) and (2) (-) No continuity
Between each diode (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to ON position.
2. Operate gearshift lever to perform troubleshooting.
Lever at position other Other than “P” is dis-
Gear position display on than PARK played.
machine monitor
Lever at PARK “P” is displayed.

GD555-5,GD655-5,GD675-5 40-367
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

Defective blade lift lever proximity 1. Turn starting switch to ON position.
switch (float ENG cancel switch) 2. Move each blade lift lever to perform troubleshooting.
13 FP 14 or FP15 Display of “blade FLOAT” Lever at FLOAT Pilot lamp lights up.
(internal defect or defective adjust- pilot lamp on machine mon- Lever at position other
Pilot lamp goes off.
ment) itor that FLOAT
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect wires from ST6 to ST9 terminals (put tags to show their destina-
tion).
4. Turn starting switch to ON, OFF and START positions to perform trouble-
shooting.
Switch: Resis-
Min. 1 Mz
OFF tance
Defective starting switch Between terminals ST6 and ST7
14 Resis-
(internal open circuit) Switch: ON Max. 1 z
tance
Switch: Resis-
Min. 1 Mz
OFF tance
Between terminals ST6 and ST9
Resis-
Switch: ON Max. 1 z
tance
Switch: Resis-
Min. 1 Mz
OFF tance
Between terminals ST6 and ST8
Switch: Resis-
Max. 1 z
START tance
Defective alternator 1. Turn starting switch to ON position.
15
(internal short circuit) R terminal – ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector E01.
3. Turn starting switch to ON and START positions to perform troubleshooting.
Power supply circuit: between E30 (B)
Switch: ON Voltage 20 – 30 V
terminal and ground
Detective starting motor(internal
16 Power supply circuit: between E01 (2)
defect) Switch: ON Voltage Max. 1 V
(R) terminal and ground
Power supply circuit: between E21 (C) Switch:
Voltage 20 – 30 V
terminal and ground START
When voltages of power supply, charging and starting circuits are normal but
starting motor does not rotate, starting motor is defective.
q Battery relay
1. Turn starting switch to OFF position.
Resis-
Between ET76 terminal and ground Max. 1 z
tance
q Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
17 Open circuit in wiring harness a Check to where 24 V power is supplied to isolate open section.
Between ST7 terminal and ground Voltage 20 – 30 V
Between ET75 terminal and ground Voltage 20 – 30 V
Between input terminal for battery relay secondary
Voltage 20 – 30 V
circuit and ground
Between output terminal for battery relay secondary
Voltage 20 – 30 V
circuit and ground

40-368 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

q Alternator and starting motor
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapters into connectors SP17, SP38, SP33, SP34, W60, E01 and
R28.
4. Set disconnect switch to ON.
5. Check that gearshift lever is positioned at a position other than PARK and
right and left blade lift levers are positioned at other than FLOAT.
6. Turn starting switch to START position and troubleshoot.
a Check to where 24 V power is supplied in order to isolate open section.
Between ST8 and ground Voltage 20 – 30V
Between ST17 (5) and ground Voltage 20 – 30 V
Between ST17 (1) and ground Voltage 20 – 30 V
Between SP38 (3) and ground Voltage 20 – 30 V
Between SP33 (1) and ground Voltage 20 – 30 V
Between SP34 (2) and ground Voltage 20 – 30 V
Between W60 (3) and ground Voltage 20 – 30 V
Between R28 (2) and ground Voltage 20 – 30 V
Between E01 (1) and ground Voltage 20 – 30 V
Between alternator B terminal and ground Voltage 20 – 30 V
Between E30 terminal and ground Voltage 20 – 30 V
q Primary circuits of relays SP17 and SP33
1. Turn starting switch to OFF position.
17 Open circuit in wiring harness 2. Insert T-adapter into connector SP17.
a Check ground terminals FT10 and FT11 for looseness and rust.
Resis-
Between SP17 (2) and ground Max. 1 z
tance
Between SP17 (2) and ground (to measure coil Resis-
200 - 400 z
resistance of S. holding relay SP33) tance
q Safety circuit by detecting blade lift lever position (detecting lever in FLOAT
position)
1. Turn starting switch to OFF position.
2. Disconnect connectors FP15 and FP14, and connect T-adapters to female
side of them.
a Check ground terminals ET89, FT10 and FT11 for looseness and rust.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector FP15 and FP14.
3. Turn starting switch to ON position.
Resis-
Between FP14 (female) (C) and ground Max. 1 z
tance
Resis-
Between FP15 (female) (C) and ground Max. 1 z
tance
Between FP14 (female) (A) and ground (to measure Resis-
200 - 400 z
coil resistance of float lamp relay SP39) tance
Between FP15 (female) (A) and ground (to measure Resis-
200 - 400 z
coil resistance of float lamp relay SP39) tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector FP15 and FP14.
3. Turn starting switch to ON position.
Between FP14 (B) and (C) Voltage 20 – 30 V
Between FP15 (B) and (C) Voltage 20 – 30 V

GD555-5,GD655-5,GD675-5 40-369
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)
Cause
Defective battery relay
18
(not activated)
Ground fault in wiring harness
19
(Contact with ground circuit)
Hot short circuit in wiring harness
20
(contact with 24 V circuit)
21 Defective transmission controller
40-370
Procedure, measuring location, criteria and remarks
If only voltages measured at output terminals to battery relay secondary circuit
are incorrect in checks on cause 17, battery relay is defective.
a If slow-blow fuse or fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF and disconnect wiring harnesses from battery
relay terminal ET75 and output terminal to battery relay secondary circuit.
3. Disconnect connector SP33 and connect T-adapter to female side.
Resis-
Between ST7 and ground Min. 1 Mz
tance
Resis-
Between ST8 and ground Min. 1 Mz
tance
Resis-
Between ET75 (wiring harness side) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect wiring harness from alternator R terminal.
3. Insert T-adapter into connector SP38.
4. Turn starting switch to ON position.
Between alternator R terminal (on harness) and
Voltage Max. 1 V
ground
Between SP38 (1) and (2) Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
If starting motor rotates, transmission controller is defective.
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Circuit diagram related to engine start circuit 40-371

GD555-5,GD655-5,GD675-5 40-371
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

E-2 Preheating does not work 40-372

Failure 1) Manual preheating does not work.
a This troubleshooting describes troubleshooting procedures to be followed when automatic and
manual preheating does not function to heat electrical intake air heater mounting section.
q Machine is equipped with "Automatic preheating" and "Manual preheating" functions. When either
function works, preheating monitor lights up.
(When only preheating monitor does not light up, perform troubleshooting for Failure "3) While
Related infor-
preheating is working, preheating monitor does not light up").
mation
q If "machine monitor displays nothing" or " battery relay does not make operating sound" when turn-
ing starting switch to ON position, main electric power supply system may be defective. So, per-
form troubleshooting for E-3 and E-1.
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, troubleshoot it first.)

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (holder 2, If slow-blow fuse (holder 2, 120 A) is open, circuit probably has ground fault. In
1
120 A) this case, perform troubleshooting for cause 7 first.

Loose terminal or open circuit at 1. Turn starting switch to OFF position.

2
terminal Check terminals of heater relay, battery relay, ground ET77, etc.
1. Turn starting switch to OFF position.
2. Remove connector R31 and connect T-adapter to diode.
Defective diode (R31)
a Measure by using multimeter in diode range.
3 (Internal open circuit or short cir-
cuit) Between R31 (male) (1) (+) and (2) (-) No continuity
Between R31 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
Defective electrical intake air
4 heater 2. Disconnect terminal E07.
(Internal open circuit) Between terminal E07 (on electrical intake air
Continuity
heater) and ground
1. Turn starting switch to OFF position.
2. Set disconnect to switch OFF.
5 Defective starting switch 3. Turn starting switch to OFF and HEAT position to perform troubleshooting.
Between terminals ST6 and ST10 OFF Resistance Min. 1 Mz
(both on switch) HEAT Resistance Max. 1 z
1. Turn starting switch to OFF position.
Between terminal ST10 and ground There is continuity
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Open circuit or ground fault in wir- Between heater relay terminal A and ground Voltage 20 – 30V
6
ing harness 1. Turn starting switch to OFF position.
2. Disconnect terminal ET54.
a To prevent current from flowing through heater when troubleshooting
with starting switch at HEAT position.
3. Turn starting switch to HEAT position (Connect R1).
Between terminal ET82 and ground Voltage 20 – 30V
a If no abnormality is found by check on cause 6, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R31 and terminals ET82 and E31.
7
(contact with ground circuit) Between heater relay terminal A and ground Resistance Min. 1 Mz
Between terminal ET82 (on wiring harness) and
Resistance Min. 1 Mz
ground
Defective heater relay If no abnormality is found by check on cause 6 and heater relay operation
8
(not activated) sound is not heard, heater relay is defective.

40-372 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Circuit diagram related to preheating of engine 40-373

GD555-5,GD655-5,GD675-5 40-373
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Failure 2) Automatic preheating does not work.

q Automatic preheating starts when boost temperature is below -4 °C.
q Boost temperature can be checked by using monitoring function. (Code: ENGING 18500 CHG
Related infor- TEMP)
mation q If automatic preheating does not work, check if manual preheating works.
q Engine controller checks primary (coil) circuit of preheat relay (connector SP40) and displays fail-
ure code [CA2555] or [CA2556] if abnormality is detected.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse FB1 (7)
Defective preheater relay
2 (Internal open circuit or short cir-
cuit)
Open circuit or ground fault in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
3
ing harness
Open circuit in wiring harness
4 (wire breakage or defective con- 3. Remove fuse FB1 (7).
tact)
Ground fault in wiring harness
5
(contact with ground circuit)
If fuse FB1 (7) is blown, circuit may have ground fault. Troubleshoot for cause
5 first.
1. Turn starting switch to OFF position.
2. Replace preheater relay (connector: SP40) with stop lamp relay
(connector: SP16).
3. Turn starting switch ON.
If automatic preheating starts with boost temperature below -4 °C, original pre-
heat relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and connect T-adapter to female side.
is below 1 z, wiring harness has short circuit.
a Preheater relay coil resistance
Resis-
Between EC2 (female) (40) and ground 200 - 400 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors SP40 and TM39, and connect T-adapter to female
side of SP40.
Between SP40 (female) (5) and ground There is continuity
Resis-
Between SP40 (female) (3) and FB1 (7) Max. 1 z
tance
If fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector SP40 and connect T-adapter to female side.
3. Remove fuse FB1 (7).
Resis-
Between SP40 (female) (3) and ground Min. 1 Mz
tance

40-374 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Circuit diagram related to preheating of engine 40-375

GD555-5,GD655-5,GD675-5 40-375
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Failure 3) While preheating is working, preheating monitor does not light up.
q Machine is equipped with "Automatic preheating" and "Manual preheating" functions. When either
Related infor- function is working, preheating monitor lights up.
mation q Preheating information is sent from transmission controller to machine monitor through CAN.
q For related circuit diagram, see previous page.

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring harness
1 (wire breakage or defective con-
tact)
Ground fault in wiring harness
2 female side of TM39.
(contact with ground circuit)
3 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors SP40 and TM39, and connect T-adapters to female
side of them.
Between SP40 (female) (5) and TM39 (female) (24) Resistance Max. 1 z
Between terminal ST10 and TM39 (female) (24) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and terminal ET82, and connect T-adapter to
Between TM39 (female) (24) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, transmission controller is defec-
tive.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Disconnect terminal ET54.
a To prevent current from flowing through heater when troubleshooting
with starting switch at HEAT position.
4. Turn starting switch to HEAT position.
Between TM39 (24) and (4) Resistance 20 – 30V

40-376 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

E-3 When starting switch is turned to ON position, machine monitor

displays nothing 40-37
Failure q When starting switch turned to ON position, machine monitor displays nothing
q If "the battery relay does not make operating sound" when starting switch is turned to ON position,
perform troubleshooting E-1.
q When starting switch is turned to ON position, machine monitor displays as follows.
1) Centralized warning lamp lights up for 2 seconds, and then goes out.
2) Monitor lamp lights up for 2 seconds, goes out for one second, and then starts normal display.
Related infor- 3) Speedometer displays "88" for 2 seconds, goes out for one second, and then starts normal
mation display.
4) After 2 seconds of system check, meter section switches to normal display.
5) Character display section displays "KOMATSU" for 3 seconds, and then switches to normal
display.
q When starting switch is turned to ON position, machine monitor sounds alarm buzzer for 2 sec-
onds, and then stops sounding.

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (30 A If slow-blow fuse is open, circuit probably has ground fault. In this case, per-
1
fuse in holder 1) form troubleshooting for cause 8 first.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuses (1) and (2) in FB1 shooting for cause 8 first.

Loose terminal or open circuit at 1. Turn starting switch to OFF position.

3
terminal Check terminals of battery, battery relay, etc.
1. Turn starting switch to OFF position.
4 Low charge level of battery Battery voltage (2 pieces) Min.24 V
Electrolyte specific gravity Min. 1.26
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector FP1, and connect T-adapter to female side.
4. Set disconnect switch to ON.
a If voltage is 0 V, wiring harness has open circuit or ground fault.
Open circuit or ground fault in wir- Between FP1 (5) (female) and (3) Voltage 20 – 30V
5 ing harness or defective starting
switch Between FP1 (6) (female) and (4) Voltage 20 – 30V
Steps 1 to 4 are same as above.
5.Turn starting switch to ON position (connect ACC).
Between FP1 (1) (female) and (3) Voltage 20 – 30V
Between FP1 (2) (female) and (4) Voltage 20 – 30V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect wiring harness from terminals ST6 and ST9.
4. Turn starting switch to ON and OFF positions to perform troubleshooting.
6 Defective starting switch Starting
switch at Resistance Min. 1 Mz
Between terminals ST6 and ST9 OFF
(On starting switch) Starting
switch at Resistance Max. 1 z
ON

GD555-5,GD655-5,GD675-5 40-377
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing
Cause
Open circuit in wiring harness
7 (wire breakage or defective con-
tact)
Ground fault in wiring harness
8 4. Disconnect connector FP1 and connect T-adapter to female side.
(contact with ground circuit)
9 Defective machine monitor
40-378
Procedure, measuring location, criteria and remarks
a If no abnormality is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. If fuse is blown, replace it with new one.
4. Disconnect connector FP1 and connect T-adapter to female side.
Between each of FP1 (female) (3) and (4) and
ground Resistance Max. 1 z
a Check ET89 terminal for looseness and rust.
Between each of FP1 (female) (5) and (6) and bat-
Resistance Max. 1 z
tery (+)
Steps 1 to 4 are same as above.
5. Turn starting switch to ON position (ACC connection with disconnect switch
at OFF).
Between each of FP1 (female) (1) and (2) and bat-
Resistance Max. 1 z
tery (+)
a If no abnormality is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. If fuse is blown, replace it with new one.
5. Turn starting switch to ON and OFF positions to perform troubleshooting
(with disconnect switch at OFF).
Between FA1 (female) (1) and ground Resistance Min. 1 Mz
If no abnormality is found by above check, machine monitor is defective.
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

Circuit diagram related to machine monitor 40-379

GD555-5,GD655-5,GD675-5 40-379
(01)
Troubleshooting of electrical system (E-mode)
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen

E-4 When starting switch is turned to ON position, machine monitor does

not reach standard screen 40-380
q When starting switch is turned to ON position, display of machine monitor does not display stan-
Failure
dard screen
q When starting switch is turned to ON position, display of machine monitor changes as follows.
1) Centralized warning lamp lights up for 2 seconds, and then goes out.
2) Monitor lamp lights up for 2 seconds, goes out for one second, and then is in normal display
condition.
3) Speedometer displays "88" for 2 seconds, goes out for one second, and then is in normal
Related infor-
display condition.
mation
4) After 2 seconds of system check, meter section switches to normal display.
5) Character display section displays "KOMATSU" for 3 seconds, and then switches to normal
display.
q When starting switch is turned to ON position, machine monitor sounds alarm buzzer for 2 sec-
onds, and then stops sounding.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

E-5 When starting switch is turned to ON position, caution monitor

flashes or lights up, or machine monitor does not display correct screen40-380
Failure 1) Only parking brake pilot lamp is not indicated correctly (parking brake works normally).
q When parking brake is applied: Pilot lamp lights up
When parking brake is released: Pilot lamp goes off
Related infor-
q Operation information of parking brake pilot lamp is sent from transmission controller through CAN.
mation
q When parking brake cannot be applied or cannot be released, see troubleshooting for failure codes
[DW4BKA] and [DW4BKB].

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)
Transmission controller may be defective. (Since this is internal failure, trou-
2 Defective transmission controller
bleshooting cannot be performed.)

Failure 2) Maintenance caution monitor blinks or lights up.

q Maintenance caution lamp blinks when remaining time to next replacement is 30 hours for maint-
Related infor-
erance item and lights up when replacement time is reached (for 30 seconds after starting switch
mation
is turned to ON position).

Cause Procedure, measuring location, criteria and remarks

Maintenance item is due for maint-
1 erance.
(when system is normal)
2 Defective machine monitor
Check display of character display section and perform maintenance of item
that needs maintenance.
If no item is found to be due for mainterance by check on cause 1, machine
monitor may be defective. (Since this is internal failure, troubleshooting cannot
be performed.)

40-380 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

E-6 Emergency stop monitor lights up while engine is running 40-381

Failure 1) Battery charge caution lamp lights up while engine is running.
q Battery charge caution lamp lights up and alarm buzzer sounds if abnormality is detected in battery
Related infor- charging circuit while engine is running.
mation q Input voltage from alternator can be checked by using monitoring function.
(Code: 04302-ALTERNATOR R)

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator system Perform troubleshooting for failure code [AB00MA].
If no abnormality is found by check on cause 1, machine monitor may be
2 Defective machine monitor
defective. (Since this is internal failure, troubleshooting cannot be performed.)

2) Engine coolant temperature caution lamp lights up (engine coolant temperature is 102°C and
Failure
above).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the data
Related infor- is transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: 04104-ENGINE COOLANT TEMPERATURE)

Cause Procedure, measuring location, criteria and remarks

Maintenance item is due for maint-
Check display on character display section and perform maintenance of item
1 erance.
that needs maintenance.
(when system is normal)
If no abnormality is found by check on cause 1, engine coolant temperature
Defective engine coolant tempera-
2 sensor system may be defective. Perform troubleshooting for failure codes
ture sensor system
[CA144] and [CA145].
If no abnormality is found by check on causes 1 and 2, machine monitor may
3 Defective machine monitor be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Failure 3) Engine oil pressure caution lamp lights up in red.

q Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor-
turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller to
mation
machine monitor through CAN.

Cause Procedure, measuring location, criteria and remarks

Dropped engine oil pressure
1
(when system is normal)
Defective engine oil pressure
2
switch system
Since engine oil pressure may be low, check it. If it is low, perform trouble-
shooting for "S-12 Oil pressure decreases".
If no abnormality is found by check on cause 1, engine oil pressure switch sys-
tem may be defective. Perform troubleshooting for failure codes [CA435].

GD555-5,GD655-5,GD675-5 40-381
(01)
Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

Failure 4) Brake pressure caution lamp lights up (brake pressure is 4.4 MPa or below).
q When wiring harness has short circuit or ground fault, caution lamp does not light up even if brake
Related infor- pressure drops.
mation q Brake pressure can be checked by using monitoring function.
q (Code: 40921 D_IN_4 Brake ACC HYD P SW F, D_IN_5 Brake ACC HYD P SW R)

Cause Procedure, measuring location, criteria and remarks

Dropped brake oil pressure
1 For details, see Testing and adjusting “Testing and adjusting brake oil
(when system is normal)
2 Defective brake pressure switch
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
Short circuit or ground fault in wir-
4
ing harness
5 Defective machine monitor
Drop in brake pressure is detected. Check brake pressure.
pressure”.
1. Turn starting switch to OFF position.
2. Disconnect connector R15 and connect T-adapter to male side.
3. Start engine and perform troubleshooting
4. Turn starting switch to OFF position.
5. Disconnect connector R16 and connect T-adapter to male side.
6. Start engine.
Between R15 (male) (1) and (2) Resistance Max. 1 z
Between R16 (male) (1) and (2) Resistance Max. 1 z
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Disconnect connectors FP1, R15 and R16, and connect T-adapters to
female side of them.
Between R15 (female) (2) and ground
a Check ground terminal FT13 for looseness and Resistance Max. 1 z
rust.
Between R16 (female) (2) and ground
a Check ground terminal FT13 for looseness and Resistance Max. 1 z
rust.
Between FP1 (female) (11) and R15 (female) (1) Resistance Max. 1 z
Between FP1 (female) (12) and R16 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Disconnect connectors FP1, R15 and R16, and connect T-adapters to
female side of R15 and R16.
Between R15 (female) (1) and (2) Resistance Min. 1 Mz
Between R16 (female) (1) and (2) Resistance Min. 1 Mz
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Loosen hydraulic tank cap gradually to release pressure.
3. Insert T-adapter into connector FP1.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between FP1 (11) and (3) Voltage Min. 5 V
Between FP1 (12) and (3) Voltage Min. 5 V
Steps 1 to 4 are same as above.
5. Close hydraulic tank cap.
6. Start engine.
Between FP1 (11) and (3) Voltage Max. 1 V
Between FP1 (12) and (3) Voltage Max. 1 V

40-382 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

Circuit diagram related to brake pressure switch 40-383

GD555-5,GD655-5,GD675-5 40-383
(01)
Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

5) Torque converter oil temperature caution lamp lights up (torque converter oil temperature is 120°
Failure
C and above).
q Torque converter oil temperature caution lamp lights up and alarm buzzer sounds if abnormal
torque converter oil temperature is detected while engine is running.
q Torque converter oil temperature caution lamp lights up and goes off in accordance with indication
Related infor- of torque converter oil temperature gauge.
mation q Signal voltage from torque converter oil temperature sensor is sent from transmission controller
through CAN.
q Torque converter oil temperature can be checked by using monitoring function.
(Code: TRANSMISSION1-30100-T/C OIL TEMP)

Cause Procedure, measuring location, criteria and remarks

Overheat of torque converter oil
1
(When system is normal.)
Defective torque converter oil tem-
2
perature gauge
3 Defective machine monitor
Overheat of torque converter oil is detected. Check torque converter oil for
overheat.
When torque converter oil temperature gauge indicates red range, perform
troubleshooting for failure code [DGT1KX].
See drawing shown below.
Oil temperature gauge: Green range
Oil temperature caution lamp: goes off
(G)
Oil temperature gauge: Red range (R) Oil temperature caution lamp: lights up
If no abnormality is found by check on causes 1 and 2, machine monitor may
be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Torque converter oil temperature gauge 40-384

6) Differential oil temperature caution lamp lights up (differential oil temperature is 120°C and
Failure
above).
q Differential oil temperature caution lamp lights up and alarm buzzer sounds if differential oil tem-
perature rises above 120°C while engine is running.
Related infor- q Differential oil temperature can be checked by using monitoring function.
mation (Code: MONITOR 31909 DIFF TEMP)
q Signal voltage from differential oil temperature sensor is sent from transmission controller through
CAN.

Cause Procedure, measuring location, criteria and remarks

Overheat of differential oil
1 Overheat of differential oil is detected. Check differential oil for overheat.
(when system is normal)
Defective differential oil tempera- If no abnormality is found by check on cause 1, perform troubleshooting for
2
ture sensor system failure code [B@CKNS].
If no abnormality is found by checks on causes 1 and 2, machine monitor may
3 Defective machine monitor be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-384 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-7 Speedometer or engine tachometer does not indicate correctly

E-7 Speedometer or engine tachometer does not indicate correctly 40-385

Failure 1) Speedometer does not indicate correctly.
Related infor- q Source information for speedometer (signal of transmission output shaft speed sensor) is sent from
mation transmission controller through CAN.

Cause Procedure, measuring location, criteria and remarks

Defective transmission output
1
shaft speed sensor
2 Slip of clutch
3 Defective machine monitor
4 Defective transmission controller
Check whether failure code [DLT3KA] is displayed. If it is displayed, perform
troubleshooting for it.
Check whether any of failure codes [15K0MW], [15L0MW], [15M0MW] or
[15N0MW] is displayed. If it is displayed, perform troubleshooting for it.
If no abnormality is found by check on cause 1, machine monitor may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no abnormality is found by check on cause 1, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Failure 2) Speedometer display pilot lamp is not displayed correctly.

q Signals of speedometer display pilot lamp are processed by machine monitor.
Related infor-
a When “km/h” is selected for display unit, speedometer pilot lamp lights up. When “MPH” is se-
mation
lected, selected gear speed is displayed.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
3 Defective machine monitor
ing cannot be performed.)

Failure 3) Engine tachometer is not displayed correctly.

q Information on engine speed (engine Ne speed sensor signal) is sent from engine controller to ma-
Related infor- chine monitor through CAN.
mation q Engine speed can be checked by using monitoring function.
(Code:: ENGINE 01002 - ENG SPEED)

Cause Procedure, measuring location, criteria and remarks

Defective engine Ne speed sen-
1
sor system
2 Defective machine monitor
3 Defective engine controller
Check whether failure code [CA238] is displayed. If it is displayed, perform
troubleshooting for it.
If no abnormality is found by check on cause 1, machine monitor may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no abnormality is found by check on cause 1, engine controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-385
(01)
Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

E-8 Engine coolant temperature gauge does not indicate correctly 40-386
1) While engine coolant temperature is rising normally, temperature gauge does not indicate above
white range (W).
Failure
2) While engine coolant temperature is stabilized in normal range, temperature gauge indicates red
range (R).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: MONITOR PANEL 04104-COOLANT TEMP)

Cause Procedure, measuring location, criteria and remarks

Defective engine coolant
1
temperature sensor system
2 Defective machine monitor
Engine coolant temperature sensor system may be defective. Perform troubleshoot-
ing for failure codes [CA144] and [CA145].
If no abnormality is found by check on cause 1, machine monitor may be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

3) Display of coolant temperature gauge does not correspond to actual engine coolant temperature.
Failure 4) Display of engine coolant temperature gauge does not correspond to display of engine coolant
temperature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: Code: MONITOR PANEL 04104-COOLANT TEMP)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine, and then perform trouble-
shooting.
Engine coolant tempera- Coolant temperature Color of coolant tempera-
ture gange level ture gauge
Segments 9 and below
105°C and above
light up
Red (R)
Segments 8 and below
102 – 105°C
light up
Segments 7 and below
100 – 102°C
light up
1 Defective machine monitor Segments 6 and below
95 – 98°C
light up
Segments 5 and below
80 – 90°C
light up
Green (G)
Segments 4 and below
75 – 80°C
light up
Segments 3 and below
65 – 70°C
light up
Segments 2 and below
55 – 60°C
light up
50°C or below Segment 1 alone lights up White (W)

40-386 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

Engine coolant temperature gauge and coolant temperature monitor 40-387

GD555-5,GD655-5,GD675-5 40-387
(01)
Troubleshooting of electrical system (E-mode)
E-9 Articulation angle indicator does not indicate correctly

E-9 Articulation angle indicator does not indicate correctly 40-38

Failure 1) Articulation angle indicator does not indicate correctly when machine is articulated.
q If articulation angle sensor system has abnormality, failure code [DKD0KX] may be displayed and
logged.
Related infor- q Data for articulation angle indicator (signal from articulation angle sensor) is sent from transmis-
mation sion controller through CAN.
q Input voltage from articulation angle sensor can be checked by using monitoring function. (Code:
TRANSMISSION1-43902-ARTICULATE)

Cause Procedure, measuring location, criteria and remarks

Defective articulation angle
1 Perform troubleshooting for failure code [DKD0KX].
sensor system
If no abnormality is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to articulation angle sensor 40-38

40-388 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-9 Articulation angle indicator does not indicate correctly

Failure 2) Indication of articulation angle indicator does not correspond to actual articulation angle.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Perform zero point adjustment for articulation angle indicator. For details, see
1 Improper zero point adjustment*
“Tuning” in “Special functions of machine monitor (EMS)”.
Start engine, and change articulation angle of machine to perform trouble-
shooting.
Articulation angle
Example of articulation
Articulation level (between front and rear
sensor output voltage
frames)
-25° or below
Segments 9 flash Min. approx. 3.75 V
(abnormal)
Segments 9 light up Approx. 3.6 – 3.75 V -22 to -25°
Segments 8 light up Approx. 3.25 – 3.4 V -16 to -19°
Segments 7 light up Approx. 2.8 – 3.0 V -8 to -12°
2 Defective machine monitor
Segments 6 light up Approx. 2.45 – 2.65 V -2 to -5°
Segments 5 light up Approx. 2.25 – 2.45 V * ± 2°
Segments 4 light up Approx. 2.1 – 2.25 V 2 to 5°
Segments 3 light up Approx. 1.7 – 1.9 V 8 to 12°
Segments 2 light up Approx. 1.4 –1.6V 16 to 19°
Segments 1 light up Approx. 0.95 – 1.15 V 22 – 25°
25° or higher
Segments 1 flash Max. approx. 0.95 V
(abnormal)
*: The "zero point adjustment" means to adjust the articulation sensor so that it has an output voltage of 2.5 V and
the segments 5 light up when the front and rear frames are set straight (0°).

Articulation angle indicator 40-389

GD555-5,GD655-5,GD675-5 40-389
(01)
Troubleshooting of electrical system (E-mode)
E-10 Torque converter oil temperature gauge does not indicate correctly

E-10 Torque converter oil temperature gauge does not indicate correctly40-390
1) While torque converter oil temperature is rising normally, temperature gauge does not indicate
above white range (W).
Failure
2) While torque converter oil temperature is stabilized in normal range, temperature gauge indicates
red range (R).
q If abnormality occurs in torque converter oil temperature sensor system, failure code [DGT1KX]
may be displayed and recorded.
q Information for torque converter oil temperature gauge (torque converter oil temperature sensor
Related infor-
signal) is sent from transmission controller to machine monitor through CAN.
mation
q Input voltage from torque converter oil temperature sensor can be checked by using monitoring
function.
(Code: TRANSMISSION1-30101-T/C OIL TEMP)

Cause Procedure, measuring location, criteria and remarks

Defective torque converter
1 oil temperature sensor sys- Perform troubleshooting for failure code [DGT1KX].
tem
If no abnormality is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)
Defective transmission con- If no abnormality is found by check on cause 1 transmission controller may be
3
troller defective. (Since this is internal failure, troubleshooting cannot be performed.)

3) Torque converter oil temperature gauge does not indicate correct torque converter oil tempera-
ture.
Failure
4) Indication of torque converter oil temperature gauge does not correspond to indication of torque
converter oil temperature caution lamp.
Related informa- q Torque converter oil temperature caution lamp lights up when torque converter oil temperature is
tion above 120°C.

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine, and then perform trouble-
shooting.
Color of torque converter Torque converter oil tem- Torque converter oil tem-
oil temperature gauge perature gauge lever perature
Segments 9 and below
120°C and above
light up
Red (R)
Segments 8 and below
110–120°C
light up
Segments 7 and below
100 –1 10°C
light up
1 Defective machine monitor Segments 6 and below
95 – 100°C
light up
Segments 5 and below
85 – 90°C
light up
Green (G)
Segments 4 and below
75 – 80°C
light up
Segments 3 and below
65 – 70°C
light up
Segments 2 and below
55 – 60°C
light up
White (W) Segment 1 alone lights up 50°C or below

40-390 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-10 Torque converter oil temperature gauge does not indicate correctly

Torque converter oil temperature gauge and torque converter oil temperature monitor 40-391

GD555-5,GD655-5,GD675-5 40-391
(01)
Troubleshooting of electrical system (E-mode)
E-11 Fuel level gauge does not indicate correctly

E-11 Fuel level gauge does not indicate correctly 40-392

Failure 1) Fuel gauge does not indicate correctly.
q If an abnormality occurs in fuel level sensor system, failure code [DJF1KA] may be displayed and
Related infor- recorded.
mation q Resistance and voltage values from fuel level sensor can be checked by using monitoring function.
(Code: MONITOR PANEL-04201-FUEL SENSOR, MONITOR PANEL-04200-FUEL SENSOR)

Cause Procedure, measuring location, criteria and remarks

Defective fuel level sensor
1 Perform troubleshooting for failure codes [DJF1KA].
system
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors FP2 and ET39 and connect T-adapter to female side of
2 ness either of them.
(contact with ground circuit) Between FP 2 (female) (10) or ET39 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors FP2 and ET39 and connect T-adapter to female side of
Short circuit in wiring har- FP2.
3
ness a Check by using multimeter in continuity mode.
Between FP2 (female) (10) and each pin other than No continuity
(10) (No sound is heard)
4 Defective machine monitor If no abnormality is found by above checks, machine monitor is defective.

Circuit diagram related to fuel level sensor 40-392

40-392 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-11 Fuel level gauge does not indicate correctly

Failure 2) Display of fuel level gauge does not correspond to actual fuel level.
Related informa- q Resistance of fuel level sensor can be measured between machine monitor connectors FP2 (fe-
tion male) (10) and FP1 (female) (3).

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine. and then perform trouble-
shooting.
Reading of fuel Color of fuel
Fuel level Resistance
level gauge level gauge
Segments 5
FULL 295 – 400 l and below light Max. 7 z
up
Segments 4
3/4 240 – 295 l and below light 7 - 10 z
1 Defective machine monitor
up
Green (G)
Segments 3
1/2 143 – 240 l and below light Approx. 32 z
up
Segments 2
1/4 89 – 143 l and below light Approx. 50 z
up
Segment 1
min. Max. 89 l Min. 85 z Red (R)
alone lights up

Fuel level gauge and fuel level monitor 40-393

GD555-5,GD655-5,GD675-5 40-393
(01)
Troubleshooting of electrical system (E-mode)
E-12 Character display does not display correctly

E-12 Character display does not display correctly 40-394

1) Service meter reading stays unchanged while engine is running.
Failure 2) Odometer reading stays unchanged while machine is traveling.
3) Character display section displays nothing.
Related infor- q Service meter uses signals from engine Ne speed sensor to read operating hours.
mation q Odometer calculates distance referring to signals from transmission output shaft speed sensor.

Cause Procedure, measuring location, criteria and remarks

Display panel of machine monitor may be defective. (Since this is internal fail-
1 Defective machine monitor
ure, troubleshooting cannot be performed.)

40-394 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-12 Character display does not display correctly

GD555-5,GD655-5,GD675-5 40-395
(01)
Troubleshooting of electrical system (E-mode)
E-13 Centralized warning lamp does not light up or does not go off

E-13 Centralized warning lamp does not light up or does not go off 40-396
Failure q Centralized warning lamp does not light up or does not go out.
qCentralized warning lamp lights up in following cases.
1) When any abnormality is found in emergency stop item
Related infor- 2) When action code [E02] or [E03] is displayed on character display section
mation 3) For 2 seconds after starting switch is turned to ON position
q When centralized warning lamp lights up, alarm buzzer is sounded intermittently at the same time.
a When machine overruns, only alarm buzzer sounds.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (15) in fuse box
1 If fuse is blown, circuit may have ground fault. (See cause 5.)
FB1
2 Broken bulb
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
3
defect)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
5 side of them.
(contact with ground circuit)
6 Defective machine monitor
Bulb of centralized warning lamp may be broken or may have defective con-
tact. Check it directly.
it directly.
1. Turn starting switch to OFF position.
2. Remove fuse (15) from fuse box FB1.
3. Disconnect connectors FP1 and FP3, and connect T-adapters to female
side of them.
Between terminal ST9 and FP3 (female) (1) Resistance Max. 1 z
Between FP3 (female) (11) and FP1 (female) (19) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse (15) from fuse box FB1.
3. Disconnect connectors FP1 and FP3, and connect T-adapters to female
Between FP3 (female) (1) and ground Resistance Max. 1 z
Between FP3 (female) (11) or FP1 (female) (19)
Resistance Max. 1 z
and ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
For 2 seconds after start-
ing switch is turned to Voltage Max. 1 V
Between FP1 (19) and ON position
ground When 2 seconds elapsed
since starting switch is Voltage 20 – 30V
turned to ON position.

40-396 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-13 Centralized warning lamp does not light up or does not go off

Circuit diagram related to machine monitor 40-397

GD555-5,GD655-5,GD675-5 40-397
(01)
Troubleshooting of electrical system (E-mode)
E-14 Alarm buzzer does not sound or does not stop sounding

E-14 Alarm buzzer does not sound or does not stop sounding 40-398
Failure q Alarm buzzer does not sound or does not stop sounding.
q When abnormality occurs in alarm buzzer system, failure code [DV00KB] may be displayed and
Related infor-
recorded.
mation
q When machine overruns, only alarm buzzer sounds.

Cause Procedure, measuring location, criteria and remarks

1 Defective alarm buzzer system
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of them.
(contact with ground circuit)
Defective alarm buzzer
4 ing switch is turned to
(internal defect)
5 Defective machine monitor
Perform troubleshooting for failure code [DV00KB] .
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP4, and connect T-adapters to female
side of them.
Between terminal ST9 and FP4 (female) (1) Resistance Max. 1 z
Between FP4 (female) (2) and FP1 (female) (18) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP4, and connect T-adapters to female
Between FP4 (female) (2) or FP1 (female) (18) and
Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP4.
3. Turn starting switch to ON position to perform troubleshooting.
For 2 seconds after start-
Voltage Max. 3 V
ON position
Between FP4 (1) and (2)
When 2 seconds elapsed
since starting switch is Voltage 20–30V
turned to ON position.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position to perform troubleshooting.
For 2 seconds after start-
ing switch is turned to Voltage Max. 3 V
Between FP1 (18) and ON position
ground When 2 seconds elapsed
since starting switch is Voltage 20–30V
turned to ON position.

40-398 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-14 Alarm buzzer does not sound or does not stop sounding

Circuit diagram related to alarm buzzer 40-39

GD555-5,GD655-5,GD675-5 40-399
(01)
Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

E-15 Machine monitor mode selector switch does not work 40-40
Failure 1) Machine monitor mode selector switch 1 does not work.
Related infor- q U (upper): To select (enter) desired mode and operation item
mation q t (lower): To cancel selected mode and operation item

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (1) in fuse box FB1 If fuse is blown, circuit may have ground fault. (See cause 5.)

1. Turn starting switch to OFF position.

2. Disconnect connector FP6 and connect T-adapter to male side.
Defective machine monitor mode
Between FP6 (male) (5) Switch 1: Neutral Resistance Min. 1 Mz
selector switch 1
2 and (6) Switch 1: U (upper) Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Between FP6 (male) (4) Switch 1: Neutral Resistance Min. 1 Mz
and (5) Switch 1: t (lower) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP6, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (Wire breakage or defective con- Between FP1 (female) (16) and FP6 (female) (6) Resistance Max. 1 z
tact of connector) Between FP1 (female) (17) and FP6 (female) (4) Resistance Max. 1 z
Between FP1 (female) (5) or (6) and FP6 (female)
Resistance Max. 1 z
(5)
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP6, and connect T-adapter to female side
Ground fault in wiring harness of FP1.
4
(contact with ground circuit) Between FP1 (female) (16) and (3) Resistance Min. 1 Mz
Between FP1 (female) (17) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP6 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
5
(contact with 24 V circuit) Between FP6 (female) (4) and ground Voltage Max. 1 V
Between FP6 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
6 Defective machine monitor 4. Operate machine monitor mode selector switch 1 to perform trouble-
shooting.
Between FP1 (17) and Switch 1: Neutral Voltage Max. 1 V
(3) Switch 1: U (upper) Voltage 20 – 30V

Between FP1 (16) and Switch 1: Neutral Voltage Max. 1 V

(4) Switch 1: t (lower) Voltage 20 – 30V

40-400 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Circuit diagram related to machine monitor mode selector switches 1 and 2 40-401

GD555-5,GD655-5,GD675-5 40-401
(01)
Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Failure 2) Machine monitor mode selector switch 2 does not work.

q > (upper)
Related infor- To move to next screen, move cursor forward, increase number for inputting numeral, etc.
mation q < (lower)
To move to previous screen, move cursor backward, decrease number for inputting numeral, etc.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector PF5 and connect T-adapter to male side.
Defective machine monitor mode
Between FP5 (male) (4) Switch 2: Neutral Resistance Min. 1 Mz
selector switch 2
1 and (5) Switch 2: < (lower) Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Between FP5 (male) (5) Switch 2: Neutral Resistance Min. 1 Mz
and (6) Switch 2: > (upper) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors FP1 and FP5, and connect T-adapters to female
2 (Wire breakage or defective con- side of them.
tact of connector) Between FP1 (female) (15) and FP5 (female) (6) Resistance Max. 1 z
Between FP1 (female) (14) and FP5 (female) (4) Resistance Max. 1 z
Between FP5 (female) (5) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP5, and connect T-adapter to female side
Ground fault in wiring harness of FP1.
3
(contact with ground circuit) Between FP1 (female) (14) and (3) Resistance Min. 1 Mz
Between FP1 (female) (15) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP5 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(contact with 24 V circuit) Between FP5 (female) (4) and (5) Voltage Max. 1 V
Between FP5 (female) (6) and (5) Voltage Max. 1 V
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
5 Defective machine monitor 4. Operate machine monitor mode selector switch 2 to perform trouble-
shooting.
Between FP1 (14) and Switch 2: Neutral Voltage 20 – 30V
(3) Switch 2: < (lower) Voltage Max. 1 V

Between FP1 (15) and Switch 2: Neutral Voltage 20 – 30V

(4) Switch 2: > (upper) Voltage Max. 1 V

40-402 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Circuit diagram related to machine monitor mode selector switches 1 and 2 40-403

GD555-5,GD655-5,GD675-5 40-403
(01)
Troubleshooting of electrical system (E-mode)
E-16 Transmission mode does not switch

E-16 Transmission mode does not switch 40-404

Failure q Transmission mode does not switch.
q Manual mode: Direct drive and power shift (HYDROSHIFT) mode
Related infor- Auto mode: Torque converter drive mode
mation q Input signal (ON/OFF) from transmission mode selector switch can be checked by using monitor-
ing function. (Code: TRANSMISSION-1-41700-SHIFT MODE SW)

Cause Procedure, measuring location, criteria and remarks

Defective transmission mode
selector switch
1 Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of either of them.
(contact with ground circuit)
Hot short circuit in wiring harness
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector TM30 and connect T-adapter to male side.
Switch: ON (Manual
Between TM30 (male) mode)
(5) and (6)
Switch: OFF (Auto mode) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM30 and TM39, and connect T-adapters to female
side of them.
3. Remove fuse (11) in fuse box FB1.
Between TM39 (female) (18) and TM30 (female) (6) Resistance Max. 1 z
Between FB1 (11) and TM30 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM30 and TM39, and connect T-adapter to female
Between TM39 (female) (18) or TM30 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM30 and connect T-adapter to female side.
Between TM30 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
4. Operate transmission mode selector switch to make diagnosis.
Switch: ON (Manual
Between TM39 (18) and mode) Voltage 20 – 30V
(4)
Switch: OFF (Auto mode) Voltage Max. 1 V

40-404 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-16 Transmission mode does not switch

Circuit diagram related to transmission mode selector switch 40-405

GD555-5,GD655-5,GD675-5 40-405
(01)
Troubleshooting of electrical system (E-mode)
E-17 Engine mode does not switch

E-17 Engine mode does not switch 40-406

Failure q Engine mode does not swtich.
q P-mode (Power mode): Switch at ON.
Related infor- E-mode (Economy mode): Switch at OFF
mation q Input (ON/OFF) from engine mode selector switch can be checked by using monitoring function.
(Code: TRANSMISSION1-40905 D-IN-7).

Cause Procedure, measuring location, criteria and remarks

Defective engine mode selector
switch
1 Switch: ON (P-mode)
(internal open circuit or short cir-
cuit)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of either of them.
(contact with ground circuit)
Hot short circuit in wiring harness
4 3. Turn starting switch ON.
(contact with 24 V circuit)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector TM45 and connect T-adapter to male side.
Resistance Max. 1 z
Between TM45 (male)
(5) and (6) Switch: OFF (E-mode) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM45 and TM39, and connect T-adapters to female
side of them.
3. Remove fuse (11) from fuse box FB1.
Between TM39 (female) (6) and TM45 (female) (6) Resistance Max. 1 z
Between FB1 (11) and TM45 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM45 and TM39, and connect T-adapter to female
Between TM39 (female) (6) or TM45 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM45 and connect T-adapter to female side.
Between TM45 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
4. Operate engine mode selector switch to perform troubleshooting.
Between TM39 (6) and Switch: ON (P-mode) Voltage 20 – 30 V
(4) Switch: OFF (E-mode) Voltage Max. 1 V

40-406 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-17 Engine mode does not switch

Circuit diagram related to engine mode selector switch 40-407

GD555-5,GD655-5,GD675-5 40-407
(01)
Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

E-18 Differential lock function does not work or cannot be reset [for
machine with differential lock specification] 40-408
Failure Differential lock function does not work or is not reset.
q Transmission controller monitors coil circuit (primary circuit) of differential lock relay to check for
failure in circuit. If open circuit or short circuit is detected, failure code [D19KKZ] is displayed.
q Input signal status (ON/OFF) from differential lock switch can be checked by using monitoring func-
Related infor-
tion.
mation
(Code: TRANSMISSION1-31904-DIFF LOCK SW)
q Activation status (ON/OFF) of differential lock relay can be checked by using monitoring function.
(Code: TRANSMISSION1-31903-DIFF RELAY)

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box 1
Defective differential lock switch
2 (Internal open or short circuit in
wiring)
Defective primary circuit of differ-
3 Perform troubleshooting for failure code [D19KKZ].
ential lock relay (TM43)
Defective differential lock solenoid 2. Disconnect connector R9 and connect T-adapter to male side.
4 valve (internal open circuit or short
circuit)
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
If fuse is blown, circuit may have ground fault. (See, description for causes 4
and 6.)
1. Turn starting switch to OFF position.
2. Disconnect connector FP12 and connect T-adapter to male side.
Switch: OFF Resistance Min. 1 Mz
Between FP12 (male) (5)
and (6) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Approx.
Between R9 (male) (1) and (2) Resistance
25 z
Between R9 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and TM43, and connect T-adapters to female
side of them.
3. Remove fuse (7) in fuse box FB1.
4. Set differential lock switch to ON.
Between TM40 (female) (28) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.
Between TM43 (female) (6) and ground
(to measure coil resistance of differential lock sole-
Approx.
noid valve) Resistance
25 z
a Check ground terminal ET77 for looseness and
rust.
Between FB1 (7) and TM43 (female) (3) Resistance Max. 1 z
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40, TM43, FP12 and R9, and connect
T-adapters to female side of them.
Between TM40 (female) (28) and FP12 (female) (6) Resistance Max. 1 z
Between FP12 (female) (5) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.
Between TM43 (female) (6) and R9 (female) (1) Resistance Max. 1 z
Between R9 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.

40-408 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

1. Turn starting switch to OFF position.

2. Disconnect connectors TM40, TM43, FP12 and R9, and connect
T-adapters to female side of them.
Ground fault or short circuit in wir- 3. Remove fuse (7) in fuse box FB1.
6 ing harness 4. Set differential lock switch to ON.
(contact with ground circuit) Between FP12 (female) (5) and (6) Resistance Min. 1 Mz
Between R9 (female) (1) and (2) Resistance Min. 1 Mz
Between TM43 (female) (3) and (2) Resistance Min. 1 Mz

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TM43 and connect T-adapter to female side.
7 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between TM43 (female) (6) and (2) Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
8 Defective transmission controller
3. Turn starting switch to ON position.
4. Operate differential lock switch to make diagnosis.
Between TM40 (28) and Switch: OFF Voltage 7–12V
ground Switch: ON Voltage Max. 1 V

2) Differential lock pilot lamp does not work correctly. (Differential lock is activated and reset nor-
Failure
mally.)
q When differential lock is activated: Pilot lamp lights up
Related infor-
When differential lock is canceled: Pilot lamp goes off
mation
q Operation signal of differential lock pilot lamp is sent from transmission controller through CAN.

Cause Procedure, measuring location, criteria and remarks

1 Defective machine monitor
2 Defective transmission controller
Machine monitor may be defective. (Since trouble is in system, troubleshoot-
ing cannot be performed.)
Transmission controller may be defective. (Since trouble is in system, trouble-
shooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-409
(01)
Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

Circuit diagram related to differential lock switch and differential lock solenoid valve 40-410

40-410 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

GD555-5,GD655-5,GD675-5 40-411
(01)
Troubleshooting of electrical system (E-mode)
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]

E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for
machine with lift arm specification] 40-412

Failure 1) Lift arm lock pin cannot lock or unlock lift arm
Related infor- q Lift arm lock switch is activated (pin unlocks lift arm) when it is pushed in, and is not activated (pin
mation locks lift arm) when it is popped up.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box FB1 When fuse is blown, ground fault may be in circuit. (See causes 3 and 5.)

1. Turn starting switch to OFF position.

2. Disconnect connector SP28 and connect T-adapter to male side.
Defective lift arm lock switch (inter-
2
nal open circuit or short circuit) Between SP28 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Defective lock solenoid valve for 2. Disconnect connector R10 and connect T-adapter to male side.
3 lift arm (internal open circuit or
Between R10 (male) (1) and (2) Resistance 2 – 100 z
short circuit)
Between R10 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP28 and R10, and connect T-adapters to female
side of them.
Open circuit in wiring harness 3. Remove fuse (7) from fuse box FB1.
4 (wire breakage or defective con- Between R10 (female) (1) and SP28 (2) Resistance Max. 1 z
tact of connector) Between R10 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.
Between FB1 (7) and SP28 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP11 and R10, and connect T-adapter to female
Ground fault or short circuit in wir- side of R10.
5 ing harness 3. Remove fuse (7) from fuse box FB1.
(contact with ground circuit)
4. Set lift arm lock switch to ON.
Between R10 (female) (1) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector R10 and connect T-adapter to female side.
6 3. Set starting switch to ON position.
(contact with 24 V circuit)
Between R10 (female) (1) and (2) Voltage Max. 1 V

40-412 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]

Failure 2) Only pilot lamp for lift arm lock pin is not indicated correctly (lift arm lock works normally).

q When lift arm is locked: Pilot lamp lights up

Related infor-
q When lift arm is unlocked: Pilot lamp goes off
mation
q If wiring harness has ground fault or hot short circuit, lift arm lock does not work normally.

Cause Procedure, measuring location, criteria and remarks

Bulb of pilot lamp for lift arm lock pin may be broken or may have defective
1 Broken bulb
contact. Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
2
defect) it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP28, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (wire breakage or defective con- Between FP3 (female) (9) and SP28 (2) Resistance Max. 1 z
tact of connector) Between FP3 (female) (12) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.

Circuit diagram related to lift arm lock switch and lock solenoid valve for lift arm 40-413

GD555-5,GD655-5,GD675-5 40-413
(01)
Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

E-20 Blade accumulator function does not work or is not reset [for
machine with blade accumulator specification] 40-414

Failure Blade accumulator function does not work or is not reset.

q If either of blade accumulator solenoid valves operates, related relay, diode, and switch are not de-
fective and ground fault and hot short circuit are not in wiring harnesses. Accordingly, check oper-
Related infor-
ation of blade accumulator solenoid valves.
mation
q Diode FL15 is a protection circuit to eliminate back electromotive force generated by solenoid
valve.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box FB1
Defective accumulator relay
2 (SP31) (internal open circuit or
short circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 8 first.
1. Turn starting switch to OFF position.
2. Replace accumulator relay (connected to connector SP31) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Start engine.
4. Set blade accumulator switch to ON.
5. Operate machine to check operation of blade accumulator function.

If blade accumulator functions properly, original accumulator relay is defective.

1. Turn starting switch to OFF position.

2. Disconnect connector FL15 and connect T-adapter to male side.
a Measure by using multimeter in diode range.
3 Defective diode (FL15)
Between FL15 (male) (1) (+) and (2) (-) No continuity
Between FL15 (male) (1) (-) and (2) (+) Continuity
1. Turn starting switch to OFF position.
Defective blade accumulator 2. Disconnect connector TM45 and connect T-adapter to male side.
4 switch (internal open circuit or
Between TM45 (male) Switch: ON Resistance Max. 1 z
short circuit)
(5) and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Defective right blade accumulator 2. Disconnect connector FL13 and connect T-adapter to male side.
5 solenoid valve (internal open cir- Approx.
Between FL13 (male) (1) and (2) Resistance
cuit or short circuit) 25 z
Between FL13 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Defective left blade accumulator 2. Disconnect connector FL14 and connect T-adapter to male side.
6 solenoid valve (internal open cir- Approx.
Between FL14 (male) (1) and (2) Resistance
cuit or short circuit) 25 z
Between FL14 (male) (1) and ground Resistance Min. 1 Mz

40-414 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector SP31 and connect T-adapter to female side.
3. Disconnect connector FP11 (to separate pilot lamp circuit).
4. Remove fuse (7) in fuse box FB1.
5. Set blade accumulator switch to ON (to connect TM45 (5) and (6)).
Between FB1 (7) and SP31 (female) (3) Resistance Max. 1 z
Between FB1 (7) and SP31 (female) (1) Resistance Max. 1 z
Between SP31 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP31 (female) (5) and ground
(to measure resistance of coils of left and right
blade accumulator solenoid valves connected in Approx.
Resistance
parallel: Resistance is half of one coil resistance) 13 z
a Check ground terminal FLG2 for looseness and
Open circuit in wiring harness rust.
7 (Wire breakage or defective con- a If no abnormality is found by above checks, this check is not required.
tact of connector) 1. Turn starting switch to OFF position.
2. Disconnect connectors FL13, FL14, SP31 and TM45, and connect
T-adapters to female side of them.
3. Disconnect connector FP11 (to separate pilot lamp circuit).
4. Remove fuse (7) from fuse box FB1.
Between FB1 (7) and TM45 (female) (5) Resistance Max. 1 z
Between TM45 (female) (6) and SP31 (female) (1) Resistance Max. 1 z
Between SP31 (female) (5) and FL13 (female) (1) Resistance Max. 1 z
Between FL13 (female) (1) and FL14 (female) (1) Resistance Max. 1 z
Between FL13 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
Between FL14 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors FL13 to F15 and SP31, and connect T-adapter to
female side of connector SP31
3. Disconnect connector FP11 (to separate pilot lamp circuit).
Ground fault or short circuit in wir- 4. Disconnect connector TM43 (to separate differential lock circuit).
8 ing harness
5. Remove fuse (7) in fuse box FB1.
(contact with ground circuit)
Between SP31 (female) (1) and (2) Resistance Min. 1 Mz
Between SP31 (female) (3) and (2) Resistance Min. 1 Mz
Between SP31 (female) (5) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP31 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
9
(contact with 24 V circuit) Between SP31 (female) (1) and (2) Voltage Max. 1 V
Between SP31 (female) (5) and (2) Voltage Max. 1 V

GD555-5,GD655-5,GD675-5 40-415
(01)
Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

2) Blade accumulator pilot lamp does not work correctly. (Blade accumulator function works or is reset
Failure
normally.)
q When blade accumulator is activated: Pilot lamp lights up
Related infor-
q When blade accumulator is canceled: Pilot lamp goes off
mation
q If wiring harness has ground fault or hot short circuit, blade accumulator does not work normally.

Cause Procedure, measuring location, criteria and remarks

Blade accumulator pilot lamp bulb may be broken or have poor contact. Check
1 Broken bulb
it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
2
defect) it directly.
1. Turn starting switch to OFF position.
2. Disconnect connector FP3 and connect T-adapter to female side.
Open circuit in wiring harness Between FP3 (female) (7) and ground
Resis- Approx.
3 (Wire breakage or defective con- a To measure resistance of right and left blade accumu-
tance 13 z
tact of connector) lator solenoid valves connected in parallel
Between FP3 (female) (12) and ground Resis-
Max. 1 z
a Check ground terminal ET89 for looseness and rust. tance

40-416 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

Circuit diagram related to blade accumulator 40-417

GD555-5,GD655-5,GD675-5 40-417
(01)
Troubleshooting of electrical system (E-mode)
E-21 Horn does not sound or does not stop sounding

E-21 Horn does not sound or does not stop sounding 40-418

Failure 1) Horn does not sound.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective fuse (14) in fuse box
1
FB1
Defective horn relay (SP27) (inter-
2 3. Turn starting switch to ON position.
nal open circuit or short circuit)
3 Defective horn RH (FL7)
4 Defective horn LH (FL8)
Defective horn switch (internal
5
open circuit or short circuit)
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
Short circuit or ground fault in wir-
7 ing harness
(contact with ground circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 7 first.
1. Turn starting switch to OFF position.
2. Replace horn relay (connected to connector SP27) with another relay
(head lamp relay or connector SP13, etc.)
4. Press horn switch to sound horn.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FL7 and connect T-adapter to male side.
Between FL7 (male) (1) and (2) Continuity
Between FL7 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FL8 and connect T-adapter to male side.
Between FL8 (male) (1) and (2) Continuity
Between FL8 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP9 and connect T-adapter to male side.
Between FP9 (male) (1) Switch: ON Resistance Max. 1 z
and ground Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP27, FP9, FL7 and FL8, and connect T-adapters
to female side of them.
3. Remove fuse (14) in fuse box FB1.
Between FP9 (female) (1) and SP27 (female) (6) Resistance Max. 1 z
Between FB1 (14) and SP27 (female) (5) Resistance Max. 1 z
Between SP27 (female) (2) and FL7 (female) (2) Resistance Max. 1 z
Between SP27 (female) (2) and FL8 (female) (2) Resistance Max. 1 z
Between FL7 (female) (1) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
Between FL8 (female) (1) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors FL7, FL8, and SP27 and connect T-adapters to
female side of them.
3. Remove fuse (14) in fuse box FB1.
Between FL7 (female) (1) and (2) Resistance Min. 1 Mz
Between SP27 (female) (1) and ground Resistance Min. 1 Mz

40-418 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-21 Horn does not sound or does not stop sounding

Failure 2) Horn does not stop sounding.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn relay (SP27) (inter- 2. Remove horn relay (connected to connector SP27).
1 3. Turn starting switch to ON position.
nal open circuit or short circuit)
If horn stops sounding, original horn relay is defective.
1. Turn starting switch to OFF position.
Defective horn switch (internal 2. Disconnect connector FP9.
2 3. Turn starting switch to ON position.
open circuit or short circuit)
If horn stops sounding, horn switch is defective.

Short circuit or ground fault in wir- 1. Turn starting switch to OFF position.
3 ing harness 2. Disconnect connector SP27 and connect T-adapter to female side.
(contact with ground circuit) Between SP27 (female)(6) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SP27 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between SP27 (female) (2) and ground Voltage Max. 1 V

Circuit diagram related to horn 40-419

GD555-5,GD655-5,GD675-5 40-419
(01)
Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

E-22 Backup alarm does not sound or does not stop sounding 40-420

Failure 1) Backup alarm does not sound.

q If backup lamp lights up when gearshift lever is set to “R” position, related fuses and relays are
not defective and wiring harnesses have not ground fault or hot short circuit. Check whether back-
Related infor- up lamp lights up or not.
mation q If fuse is blown, stop lamp does not light up either.
q Whether backup lamp relay is activated by transmission controller can be checked by using mon-
itoring function (code: TRANSMISSION1 40951 D-OUT-19).

Cause Procedure, measuring location, criteria and remarks

Defective fuse (13) in fuse box
1
FB1
Defective backup lamp relay
2 (TM42) (internal open circuit or
short circuit)
3 Defective backup alarm
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Replace backup lamp relay (connected to connector TM42) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
If backup alarm sounds, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector BZ and connect T-adapter to male side.
Between BZ (male) (1) and (2)
a Check backup alarm terminal for looseness and Continuity
rust.
Between BZ (male) (1) and ground Resistance Min. 1 Mz
q Primary circuit of backup lamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (18) and ground
(to measure coil resistance of backup lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
q Secondary circuit of backup lamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Disconnect connector RL1(to disconnect backup lamp circuit).
4. Remove fuse (13) in fuse box FB1.
Between TM42 (female) (3) and FB1 (13) Resistance Max. 1 z
Between TM42 (female) (5) and ground
a Check ground terminal ET77 for looseness and Continuity
rust.
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42 and BZ, and connect T-adapters to
female side of them.
3. Disconnect connector RL1 (to separate backup lamp circuit).
4. Remove fuse (13) in fuse box FB1.
Between TM41 (female) (18) and TM42 (female) (1) Resistance Max. 1 z
Between TM42 (female) (2) and ground Resistance Max. 1 z
Between TM42 (female) (5) and BZ (female) (1) Resistance Max. 1 z
Between BZ (female) (2) and ground Resistance Max. 1 z

40-420 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

Cause Procedure, measuring location, criteria and remarks

Short circuit or ground fault in wir- 3. Remove fuse (14) in fuse box FB1.
5 ing harness
(contact with ground circuit)
6 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42 and BZ, and connect T-adapter to
female side of TM42.
Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
Between TM42 (female) (3) and (2) Resistance Min. 1 Mz
Between TM42 (female) (5) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
a If input voltage to "Shift lever R" is correct but output voltage from "Back
lamp relay" is incorrect, transmission controller is defective.
Between TM41 (female) (16) and (21)
Voltage 20 – 30 V
(input voltage to "Shift lever R")
Between TM41 (female) (18) and (21)
Voltage 20 – 30 V
(to measure output voltage from "Back lamp relay")

Failure 2) Backup alarm does not stop sounding

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective backup lamp relay
1 (TM42) (internal open circuit or
short circuit)
Hot short circuit in wiring harness
2
(Contact with 24 V circuit)
1. Turn starting switch to OFF position.
2. Remove backup lamp relay (connector TM42).
3. Turn starting switch to ON position.
If backup alarm stops sounding, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between TM42 (female) (1) and (2) Voltage Max. 1 V
Between TM42 (female) (5) and (2) Voltage Max. 1 V

3 Defective transmission controller See Failure 1).

GD555-5,GD655-5,GD675-5 40-421
(01)
Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

Circuit diagram related to backup alarm 40-42

40-422 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go
off 40-423

Failure 1) None of headlamp, clearance lamp, and tail lamp light up or go off.
q If fuse (12) of FB1 is blown, none of headlamp, clearance lamp and tail lamp light up.
Related infor-
q If small lamp relay is defective or fuse (9) in FB2 is blown, headlamp lights up, but none of the clear-
mation
ance lamp, tail lamp, and night light of machine monitor light up.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (12) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
1
FB1 shooting for cause 4 first.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Switch: Clearance lamp
Between SP22 (male) (5) ON Resistance Max. 1 z
Defective headlamp switch (Inter- and (6)
2 Switch: OFF Resistance Min. 1 Mz
nal disconnection or short circuit)
Switch: Clearance lamp
Between SP22 (male) (4) ON Resistance Max. 1 z
and (5)
Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP22 and SP13, and connect T-adapters to female
side.
3. Remove fuse (12) in fuse box FB1.
Open circuit in wiring harness Between SP13 (female) (6) and ground
3 (Wire breakage or defective con- a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
tact of connector) looseness and rust.
Between FB1 (12) and SP22 (female) (5) Resistance Max. 1 z
Between FB1 (12) and SP13 (female) (1) Resistance Max. 1 z
Between FB1 (12) and SP13 (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP22 and SP13, and connect T-adapter to female
side of SP13.
Ground fault or short circuit in wir-
4 3. Remove fuse (12) in fuse box FB1.
ing harness
Between SP13 (female) (1) and (2) Resistance Min. 1 Mz
Between SP13 (female) (1) and (6) Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-423
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 2) Headlamp does not light up or does not go off

q If headlamp and clearance lamp do not light up, check turn signal lamp and hazard lamp. If none
Related infor-
of their front lamps light up, ground circuit (FLG1) may be defective (Tail lamp lights up).
mation
q Dimmer relay (SP11) switches between the high and low beam.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective headlamp relay (SP13)
2 (internal open circuit or short cir-
cuit)
Defective dimmer relay (SP11)
3 (internal open circuit or short cir-
cuit)
Defective headlamp switch (inter-
4 Max. 1 z
nal open circuit or short circuit) Between SP22 (male) (5) Switch: Head ON
and (6)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If specific working lamp does not light up, its bulb may be broken or may have
defective contact. Check it directly.
1. Turn starting switch to OFF position.
2. Replace headlamp relay (connector SP13) with another relay (horn relay
connected to connector SP27, etc.)
3. Turn starting switch to ON position.
4. Set headlamp switch to Head ON.
If headlamp lights up, original headlamp relay is defective.
1. Turn starting switch to OFF position.
2. Replace dimmer relay (connector SP11) with another relay (stop lamp relay
connected to connector SP16, etc.)
3. Turn starting switch to ON position.
4. Set headlamp switch to Head ON.
If headlamp lights up, original dimmer relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Resistance
Switch: OFF Resistance Min. 1 Mz
q Primary circuit of headlamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to female side.
Between SP22 (female) (6) and ground
(headlamp relay coil resistance)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
q Secondary circuit of headlamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP13 and connect T-adapter to female side.
a Check that dimmer (high beam) switch is at OFF position.
Between SP13 (female) (2) and (6)
a Check ground terminal FLG1 for looseness and
rust. Resistance Approx. 4 z
a Parallel resistance of lamps having resistance of
approx. 8 z each (8/2)
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, SP22, FL1, and FL2, and connect
T-adapters to female side of them.
Between SP22 (female) (6) and SP13 (female) (5) Resistance Max. 1 z
Between SP13 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (6) and FL1 (female) (A) Resistance Max. 1 z
Between SP11 (female) (6) and FL2 (female) (A) Resistance Max. 1 z
Between FL1 (female) (B) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
Between FL2 (female) (B) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.

40-424 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, SP22, FL1, and FL2, and connect
T-adapter to female side of SP13.
3. Remove fuse (12) in fuse box FB1.
Ground fault or short circuit in wir- Between SP13 (female) (2) and (6) Resistance Min. 1 Mz
6
ing harness
Between SP13 (female) (5) and (6) Resistance Min. 1 Mz
Between SP13 (female) (1) and (2) Resistance Min. 1 Mz
Between SP13 (female) (1) and (5) Resistance Min. 1 Mz

Circuit diagram related to headlamp, clearance lamp, tail lamp, and front working lamp 40-425

GD555-5,GD655-5,GD675-5 40-425
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 3) Headlamp beam direction cannot switch between high beam and low beam.
Related infor-
q Dimmer relay (SP11) switches between the high and low beam.
mation

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective dimmer relay (SP11)
2 (internal open circuit or short cir-
cuit)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
1. Turn starting switch to OFF position.
2. Replace dimmer relay (connector SP11) with another relay (stop lamp relay
connected to connector SP16, etc.)
3. Turn starting switch to ON position.
4. Turn on headlamp and turn dimmer switch to ON and OFF position.

If beam switches between high and low, original dimmer relay is defective.

1. Turn starting switch to OFF position.

Defective dimmer switch (internal
3
open circuit or short circuit)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir- Between SP11 (female) (1) and (2)
5
ing harness
2. Disconnect connector FP7 and connect T-adapter to male side.
Between FP7 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
q Primary circuit of dimmer relay
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11 and SP13, and connect T-adapters to female
side of them.
3. Set dimmer (high beam) switch to ON.
Between SP13 (female) (2) and SP11 (female) (1) Resistance Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
q Secondary circuit of dimmer relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP11 and connect T-adapter to female side.
a Parallel resistance of lamps having resistance of approx. 8 z each (8/2)
a Check ground terminal FLG1 for looseness and rust.
Between SP11 (female) (5) and (2) Resistance Approx. 4 z
Between SP11 (female) (6) and (2) Resistance Approx. 4 z
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, FP7, FL1 and FL2, and connect
T-adapter to each female side.
Between SP13 (female) (2) and FP7 (female) (6) Resistance Max. 1 z
Between SP11 (female) (1) and FP7 (female) (5) Resistance Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (5) and FL1 (female) (C) Resistance Max. 1 z
Between SP11 (female) (5) and FL2 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, FL1 and FL2, and connect T-adapter
to female side of SP11.
a Check that dimmer (high beam) switch is set to OFF.
Resistance Min. 1 Mz
Between SP11 (female) (1) and (5) Resistance Min. 1 Mz
Between SP11 (female) (2) and (5) Resistance Min. 1 Mz
Between SP11 (female) (3) and (5) Resistance Min. 1 Mz

40-426 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 4) High beam pilot lamp for headlamp does not light up or does not go off.
Related infor- q Headlamp cannot switch between high beam and low beam if ground fault or open circuit is in its
mation circuit.

Cause Procedure, measuring location, criteria and remarks

High beam pilot lamp bulb for headlamp may be broken or have defective con-
1 Broken bulb
tact. Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP11, and connect T-adapters to female
Breaking of harness
side of them.
3 (Wire breakage or defective con-
tact of connector) Between FP3 (female) (3) and SP11 (female) (1) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

Failure 5) Clearance lamp, tail lamp, and night light for machine monitor do not light up or do not go off
q If small lamp relay is defective or fuse (9) in FB2 is blown, headlamp lights up, but none of the clear-
ance lamp, tail lamp, and night light for machine monitor light up.
q If clearance lamp does not light up while tail lamp lights up, check headlamp, turn signal lamp, and
Related infor-
hazard lamp. If none of their front lamps light up, ground circuit (FLG1) may be defective.
mation
q If clearance lamp lights up but tail lamp does not light up, check headlamp, turn signal lamp, hazard
lamp, stop lamp, and backup lamp. If none of their rear lamps light up, ground circuit (ET77) may
be defective.

Cause Procedure, measuring location, criteria and remarks

If a specific working lamp does not light up, its bulb may be broken or may
1 Broken bulb
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse (9) in fuse box FB2
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Defective headlamp switch (inter-
3
nal open circuit or short circuit) Between SP22 (male) (4) Switch: Head ON Resistance Max. 1 z
and (5) Switch: OFF Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-427
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors SP22, SP12, SP13, and FP1, and connect
T-adapters to female side of them.
3. Remove fuse (9) in fuse box FB2.
Between SP12 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB2 (9) and SP12 (female) (3) Resistance Max. 1 z
Between SP12 (1) and SP13 (female) (4) Resistance Max. 1 z
Between SP12 (1) and SP2 (female) (4) Resistance Max. 1 z
Between SP12 (5) and FP1 (female) (8) Resistance Max. 1 z
Between SP12 (5) and (2)
Open circuit in wiring harness a Parallel resistance of 4 lamps having resistance
4 (wire breakage or defective con- Approx.
of approx. 125 z each (125/4) Resistance
tact of connector) 30 z
a Check ground terminals FLG1 and ET77 for
looseness snd rust.
a If no abnormality is found by above checks, this
check is not required.
1. Turn starting switch to OFF position.
Resistance Max. 1 z
2. Disconnect connectors SP12, FL3, FL4, RL2,
and RL3, and connect T-adapters to female side
of them.
Between SP12 (5) and FL3 (female) (A) Resistance Max. 1 z
Between SP12 (5) and FL4 (female) (A) Resistance Max. 1 z
Between SP12 (5) and RL2 (female) (6) Resistance Max. 1 z
Between SP12 (5) and RL3 (female) (6) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP12, SP13, FL3, FL4, RL2, and RL3, and connect
T-adapter to female side of SP12.
3. Disconnect connector FP1 (to separate circuit of night light for machine
monitor).
Ground fault or short circuit in wir- 4. Remove fuse (9) in fuse box FB2.
5
ing harness Between SP12 (female) (1) and (2) Resistance Min. 1 Mz
Between SP12 (female) (1) and (3) Resistance Min. 1 Mz
Between SP12 (female) (2) and (5) Resistance Min. 1 Mz
Between SP12 (female) (3) and (5) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
6 Defective machine monitor 4. Set clearance lamp switch to ON and OFF to perform troubleshooting.
Switch: ON Resistance 20 – 30 V
Between FP1 (8) and (3)
Switch: OFF Resistance Max. 1 V

40-428 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Circuit diagram related to headlamp, clearance lamp, tail lamp, and front working lamp 40-429

GD555-5,GD655-5,GD675-5 40-429
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

E-24 Working lamp does not light up or does not go off 40-430

Failure 1) Front working lamp and cab (MID) working lamp do not light up or do not go off.
Related infor- q Circuit for front working lamp and cab (MID) working lamp is completely independent from that for
mation headlamp, clearance lamp and tail lamp, having its own fuse and ground circuit.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective fuse (10) in fuse box
2
FB1
Defective front working lamp relay
3 (SP14) (internal open circuit or
short circuit)
Defective front working lamp
4 switch (internal open circuit or
short circuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace front working lamp relay (connected to connector SP14) with
another relay (horn relay connected to connector SP27, etc.).
3. Turn starting switch to ON position.
4. Set front working lamp switch to ON.
If front working lamp lights up, original front working lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP23 and connect T-adapter to male side.
Between SP23 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP14 and connect T-adapter to female side.
3. Remove fuse (10) in fuse box FB1.
4. Set front working lamp switch to ON.
Between SP14 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (10) and SP14 (female) (1) Resistance Max. 1 z
Between SP14 (female) (1) and (5)
Resistance Max. 1 z
a Front working lamp switch circuit
Between SP14 (female) (2) and (6)
a Check ground terminal FLG2 for looseness and
Approx. 8 z
rust.
Resistance (Approx.
a Resistance of one lamp is approx. 8 z. Total re-
4 z)
sistance is approx. 4 z if cab working lamp is in-
stalled in parallel.
Between SP14 (female) (4) and (6)
a Check ground terminal FLG2 for looseness and
Approx. 8 z
rust.
Resistance (Approx.
a Resistance of one lamp is approx. 8 z. Total re-
4 z)
sistance is approx. 4 z if cab working lamp is in-
stalled in parallel.

40-430 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

a If no abnormality is found by above checks, this
check is not required.
1. Turn starting switch to OFF position.
Resistance Max. 1 z
2. Disconnect connectors SP23, SP14, FP9, FL10,
FL11 and FL12, and connect T-adapter to each
female side.
Between SP23 (female) (5) and SP14 (female) (3) Resistance Max. 1 z
Between SP23 (female) (6) and SP14 (female) (5) Resistance Max. 1 z
Between SP14 (female) (1) and (3) Resistance Max. 1 z
Between SP14 (female) (2) and FL9 (female) (1) Resistance Max. 1 z
Between SP14 (female) (4) and FL10 (female) (1) Resistance Max. 1 z
Open circuit in wiring harness Between FL9 (female) (2) and ground
5 (Wire breakage or defective con- a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
tact of connector) rust.
Between FL10 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.

Between SP14 (female) (2) and FL11 (female) (1) Resistance Max. 1 z

Between SP14 (female) (4) and FL12 (female) (1) Resistance Max. 1 z

Between FL11 (female) (2) and ground

a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
Between FL12 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP14, FP3, FL9 and FL10, and connect T-adapter
to female side of SP14.
a Disconnect connectors FL11 and FL12 too if cab working lamp is in-
stalled.
3. Remove fuse (10) in fuse box FB1.
Between SP14 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
6 Between SP14 (female) (1) and (4) Resistance Min. 1 Mz
ing harness
Between SP14 (female) (1) and (5) Resistance Min. 1 Mz
Between SP14 (female) (1) and (6) Resistance Min. 1 Mz
Between SP14 (female) (6) and (2) Resistance Min. 1 Mz
Between SP14 (female) (6) and (4) Resistance Min. 1 Mz
Between SP14 (female) (6) and (5) Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-431
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Failure 2) Pilot lamp for working lamp does not lights up or does not go off
Related infor- q Front working lamp does not light up or does not go off normally if ground fault or open circuit is in
mation its circuit.

Cause Procedure, measuring location, criteria and remarks

Pilot lamp for working lamp may have broken bulb or have defective contact.
1 Broken bulb
Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP14, and connect T-adapters to female
Breaking of harness
side of them.
3 (Wire breakage or defective con-
tact of connector) Between FP3 (female) (5) and SP14 (female) (5) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

40-432 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Circuit diagram related to headlamp, clearance lamp, tail lamp, front working lamp and cab (MID)
working lamp 40-43

GD555-5,GD655-5,GD675-5 40-433
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Failure 3) Rear working lamp does not light up or does not go off.
q Rear working lamp relay shares power supply (fuse) in its primary circuit with front working lamp.
Related infor- Check whether front working lamp lights up and goes off normally.
mation q If tail lamp does not light up, grounding may be defective. In this case, see “E-23 Headlamp, clear-
ance lamp and tail lamp do not light up or do not go off”

Cause Procedure, measuring location, criteria and remarks

If a specific lamp does not light up, its bulb may be broken or may have defec-
1 Broken bulb
tive contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse (9) in fuse box FB1
shooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective rear working lamp relay 2. Replace rear working lamp relay (SP15) with another relay (stop lamp relay
3 (SP15) (internal open circuit or connected to connector SP16, etc.).
short circuit) 3. Turn on rear working lamp switch.
If rear working lamp lights up, original rear working lamp relay is defective.
1. Turn starting switch to OFF position.
Defective rear working lamp switch 2. Disconnect connector SP24 and connect T-adapter to male side.
4 (internal open circuit or short cir-
Between SP24 (male) (5) Switch: ON Resistance Max. 1 z
cuit)
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP15 and connect T-adapter to female side.
3. Remove fuses (9) and (10) in fuse box FB1.
4. Turn on rear working lamp switch.
Between SP15 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (10) and SP15 (female) (1) Resistance Max. 1 z
Between FB1 (9) and SP15 (female) (3) Resistance Max. 1 z
Between SP15 (female) (5) and ground
a Parallel resistance of lamps having resistance of Resistance Approx. 4 z
approx. 8 z each
Open circuit in wiring harness a If no abnormality is found by above checks, this check is not required.
5 (Wire breakage or defective con- 1. Turn starting switch to OFF position.
tact of connector) 2. Disconnect connectors SP15, SP24, SP14, RL4 and RL5, and connect
T-adapters to each female side of them.
3. Remove fuse (10) in fuse box FB1.
Between FB1 (10) and SP14 (female) (1) Resistance Max. 1 z
Between SP14 (female) (3) and SP24 (female) (5) Resistance Max. 1 z
Between SP15 (female) (1) and SP24 (female) (6) Resistance Max. 1 z
Between SP15 (female) (5) and RL5 (female) (1) Resistance Max. 1 z
Between SP15 (female) (5) and RL4 (female) (1) Resistance Max. 1 z
Between RL4 (female) (2) and ground Resistance Max. 1 z
Between RL5 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP15, SP24, RL4 and RL5, and connect T-adapter
to female side of SP15.
Ground fault or short circuit in wir- 3. Remove fuse (9) in fuse box FB1.
6
ing harness Between SP15 (female) (2) and (1) Resistance Min. 1 Mz
Between SP15 (female) (2) and (3) Resistance Min. 1 Mz
Between SP15 (female) (2) and (5) Resistance Min. 1 Mz

40-434 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Circuit diagram related to rear working lamp 40-435

GD555-5,GD655-5,GD675-5 40-435
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

E-25 Turn signal lamp and hazard lamp do not flash. 40-436

Failure 1) Neither of turn signal lamp and hazard lamp flash.

q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
(Turn signal lamp and hazard lamp have their respective fuses.)
q Circuit common to both turn signal lamp and hazard lamp is "flasher (connected connector SP26)"
that generates flashing.
Related infor- q When flasher is defective, every turn signal lamp may not flash but lights up even if right or left turn
mation signal lamp is turned on or hazard lamp is turned on.

q Troubleshoot flasher after troubleshooting of wiring harness.

q When front or rear lamps do not flash, ground circuit may be defective. In this case, see "E-23
Headlamp, clearance lamp, and tail lamp do not light up or do not go off".

Cause Procedure, measuring location, criteria and remarks

Defective hazard lamp relay 2
1 (SP19) (internal open circuit or
short circuit)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir-
3 Between SP26 (female) (1) and (3)
ing harness
4 Defective flasher (internal defect)
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 2 (connected to connector SP19) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 2 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP26, SP18 and SP19, and connect T-adapters to
female side of them.
Between SP26 (female) (1) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP26 (female) (3) and SP19 (female) (3) Resistance Max. 1 z
Between SP26 (female) (4) and SP18 (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector SP26 and connect T-adapter to female side.
3. Remove fuse (6) in fuse box FB1.
Resistance Min. 1 Mz
Between SP26 (female) (1) and (4) Resistance Min. 1 Mz
Between SP26 (female) (3) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector SP26.
3. Turn starting switch to ON position.
Between SP26 (3) and Power sup-
Voltage 20 – 30V
(1) ply
Between SP26 (4) and Pulse voltage of 20 to 30
Output Voltage
(1) V and 1 V or below

40-436 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Circuit diagram related to turn signal lamp and hazard lamp 40-437

GD555-5,GD655-5,GD675-5 40-437
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Failure 2) Turn signal lamp does not flash.

q Check that hazard lamp operates normally.
q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
Related infor-
q When right or left turn signal lamps do not flash, wiring harness is defective.
mation
q When front or rear lamps do not flash, ground circuit may be defective. In this case, see "E-23
Headlamp, clearance lamp, and tail lamp do not light up or do not go off".

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
2 Defective fuse (6) in fuse box FB1
Defective turn signal lever (internal
3 and (B)
open circuit or short circuit)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir- 3. Remove fuse (6) in fuse box FB1.
5
ing harness
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Disconnect connector FP8 and connect T-adapter to male side.
Lever: Left turn position
Between FP8 (male) (A) (upper position) Resistance Max. 1 z
Lever: Neutral position Resistance Min. 1 Mz
Lever: Right turn posi-
Between FP8 (male) (A) tion (lower position) Resistance Max. 1 z
and (C)
Lever: Neutral position Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, FP8, FL3, FL4, RL2 and RL3, and
connect T-adapters to female side of them.
3. Remove fuse (6) in fuse box FB1.
Between FB1 (6) and SP19 (female) (6) Resistance Max. 1 z
Between SP18 (female) (1) and (3) Resistance Max. 1 z
Between SP18 (female) (1) and FP8 (female) (A) Resistance Max. 1 z
Between FP8 (female) (B) and FL4 (female) (C) Resistance Max. 1 z
Between FP8 (female) (B) and RL3 (female) (1) Resistance Max. 1 z
Between FP8 (female) (C) and FL3 (female) (C) Resistance Max. 1 z
Between FP8 (female) (C) and RL2 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, SP26, FP8, FL3, FL4, RL2 and RL3,
and connect T-adapters to female side of SP19 and FP8.
Between SP19 (female) (2) and (6) Resistance Min. 1 Mz
Between FP8 (female) (B) and ground Resistance Min. 1 Mz
Between FP8 (female) (C) and ground Resistance Min. 1 Mz

40-438 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Circuit diagram related to turn signal lamp and hazard lamp 40-439

GD555-5,GD655-5,GD675-5 40-439
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Failure 3) Hazard lamp does not flash.

q Check that turn signal lamp operates normally.
q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
Related infor-
q When starting switch is turned to ON position and hazard lamp fhases, hazard lamp relay 2 (SP19)
mation
is defective.
q For related circuit diagram, see Failure 1) or 2).

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
2 Defective fuse (4) in fuse box FB1
Defective hazard lamp relay 2
3 (SP19) (internal open circuit or
short circuit)
Defective hazard lamp relay 1
4 (SP18) (internal open circuit or
short circuit)
Defective hazard lamp switch
5 (internal open circuit or short cir-
cuit)
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 7 first.
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 2 (connected to connector SP19) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 2 is defective.
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 1 (SP18) with another relay (horn relay
connected to connector SP27, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 1 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP25 and connect T-adapter to male side.
Between SP25 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, SP26, FL3, FL4, RL2 and RL3, and
connect T-adapters to female side of them.
3. Remove fuse (4) in fuse box FB1.
4. Set hazard lamp switch to ON.
Between SP19 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (4) and SP19 (female) (5) Resistance Max. 1 z
Between FB1 (4) and SP19 (female) (1) Resistance Max. 1 z
Between SP18 (female) (1) and (3) Resistance Max. 1 z
Between SP18 (female) (2) and FL4 (female) (C) Resistance Max. 1 z
Between SP18 (female) (2) and RL3 (female) (1) Resistance Max. 1 z
Between SP18 (female) (4) and FL3 (female) (C) Resistance Max. 1 z
Between SP18 (female) (4) and RL2 (female) (1) Resistance Max. 1 z

40-440 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Cause Procedure, measuring location, criteria and remarks

a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19 and SP25, and connect T-adapters to
female side of them.
3. Remove fuse (4) in fuse box FB1.
Open circuit in wiring harness Between FB1 (4) and SP25 (female) (5) Resistance Max. 1 z
6 (wire breakage or defective con- Between SP25 (female) (6) and SP18 (female) (5) Resistance Max. 1 z
tact of connector)
Between SP18 (female) (5) and SP19 (female) (1) Resistance Max. 1 z
Between SP18 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP18 (female) (6) and SP19 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18 and SP19, and connect T-adapter to female
side of SP18.
a Check that hazard lamp switch is in OFF position.
Between SP18 (female) (5) and (6) Resistance Min. 1 Mz
Between SP18 (female) (3) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
7
ing harness Between SP18 (female) (3) and (4) Resistance Min. 1 Mz
Between SP18 (female) (2) and (5) Resistance Min. 1 Mz
Between SP18 (female) (4) and (5) Resistance Min. 1 Mz
Between SP18 (female) (2) and (6) Resistance Min. 1 Mz
Between SP18 (female) (4) and (6) Resistance Min. 1 Mz

Failure 4) Turn signal pilot lamp does not flash.

Related infor-
q Turn signal lamp does not flash if ground fault or open circuit is in its circuit.
mation

Cause Procedure, measuring location, criteria and remarks

Bulb of turn signal pilot lamp that does not light up may be broken or have
1 Broken bulb
defective contact. Check it directly.
Defective lamp assembly (internal Lamp assembly may be internally defective (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and FP8, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (wire breakage or defective con- Between FP3 (female) (4) and FP8 (female) (B) Resistance Max. 1 z
tact of connector)
Between FP3 (female) (2) and FP8 (female) (C) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

GD555-5,GD655-5,GD675-5 40-441
(01)
Troubleshooting of electrical system (E-mode)
E-26 Stop lamp does not light up or does not go off

E-26 Stop lamp does not light up or does not go off 40-4 2

Failure Stop lamp does not light up or does not go off.

Related infor- q If neither tail lamp nor backup lamp light up, ground terminal (ET77) or fuse (13) in fuse box FB1
mation may be defective.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective fuse (13) in fuse box
2
FB1
Defective stop lamp relay (SP16)
3 (internal open circuit or short cir-
cuit)
Defective brake lamp switch
4 (internal open circuit or short cir-
cuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If a specific lamp does not light up, its bulb may be broken or may have defec-
tive contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace stop lamp relay (connected to connector SP16) with another relay
(small lamp relay connected to connector SP12, etc.).
3. Turn starting switch to ON position.
4. Depress brake pedal.
If stop lamp lights up, original stop lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapter to male side.
When brake pedal is
Resistance Max. 1 z
Between B13 (male) (1) depressed
and (2) When brake pedal is
Resistance Min. 1 Mz
released
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between B13 (female) (2) and ground
(to measure coil resistance of stop lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
loosenes and rust.
Between FB1 (13) and B13 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector SP16 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between FB1 (13) and SP16 (female) (3) Resistance Max. 1 z
Between SP16 (female) (5) and (2)
a Check ground terminal ET77 for looseness and
Approx.
rust. Resistance
12 z
a To measure resistance of lamps connected in
parallel having resistance of approx. 24 z each
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapters
to female side of them.
Between B13 (female) (2) and SP16 (female) (1) Resistance Max. 1 z
Between SP16 (female) (5) and RL2 (female) (5) Resistance Max. 1 z
Between SP16 (female) (5) and RL3 (female) (5) Resistance Max. 1 z
Between SP16 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.

40-442 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-26 Stop lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapter
to female side of SP16.
3. Remove fuse (13) in fuse box FB1.
Between SP16 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
6
ing harness Between SP16 (female) (2) and (3) Resistance Min. 1 Mz
Between SP16 (female) (2) and (5) Resistance Min. 1 Mz
Between SP16 (female) (1) and (3) Resistance Min. 1 Mz
Between SP16 (female) (3) and (5) Resistance Min. 1 Mz

Circuit diagram related to stop lamp 40-4 3

GD555-5,GD655-5,GD675-5 40-443
(01)
Troubleshooting of electrical system (E-mode)
E-27 Backup lamp does not light up or does not go off

E-27 Backup lamp does not light up or does not go off 40-4 4

Failure Backup lamp does not light up or does not go off

q If backup alarm sounds when gearshift lever is set to "R" position, related fuse and relay are not
defective and ground fault and hot short are not in wiring harness. Check whether backup alarm
sounds or not.
Related infor- q If fuse is blown, stop lamp does not light up too.
mation q If tail lamp and stop lamp do not light up too, ground circuit (ET77) may be defective.
q For troubleshooting of backup alarm, see E-22.
q Whether backup lamp relay is activated by transmission controller can be checked by using mon-
itoring function (code: TRANSMISSION1 40951 D-OUT-19).

Cause Procedure, measuring location, criteria and remarks

If a specific lamp does not light up, its bulb may be broken or may have defec-
1 Broken bulb
tive contact. Check it directly.
Defective fuse (13) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2
FB1 shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Replace backup lamp relay with another relay (small lamp relay connected
Defective backup lamp relay to connector SP12, etc.).
3 (TM42) (internal open circuit or 3. Start engine.
short circuit) 4. While depressing brake pedal, set gearshift lever to "R" position.

If backup lamp lights up, original backup lamp relay is defective.

1. Turn starting switch to OFF position.

Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
2. Disconnect connector TM41 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between TM41 (female) (18) and ground
(to measure coil resistance of backup lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between FB1 (13) and TM42 (female) (3) Resistance Max. 1 z
Between TM42 (female) (5) and (2)
a Check ground terminal ET77 for looseness and
Approx.
rust. Resistance
25 z
a To measure resistance of lamps connected in
parallel having resistance of approx. 50 z each
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42, RL2 and RL3, and connect
T-adapters to female side of them.
Between TM41 (female) (18) and TM42 (female) (1) Resistance Max. 1 z
Between TM42 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between TM42 (female) (5) and RL2 (female) (2) Resistance Max. 1 z
Between TM42 (female) (5) and RL3 (female) (2) Resistance Max. 1 z

40-444 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-27 Backup lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42, RL2 and RL3, and connect T-adapter
to female side of TM42.
3. Remove fuse (13) in fuse box FB1.
Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
5
ing harness Between TM42 (female) (2) and (3) Resistance Min. 1 Mz
Between TM42 (female) (2) and (5) Resistance Min. 1 Mz
Between TM42 (female) (1) and (3) Resistance Min. 1 Mz
Between TM42 (female) (3) and (5) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors TM40 and TM41.
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
a If input voltage to "Shift lever R" is correct but output voltage from "Back
6 Defective transmission controller lamp relay" is inccorect, transmission controller is defective.
Between TM40 (15) and TM41 (21)
Voltage 20 – 30 V
(to measure input voltage to "shift lever R")
Between TM40 (18) and (21)
Voltage 20 – 30 V
(to measure output voltage from "Back lamp relay)

Circuit diagram related to backup lamp 40-4 5

GD555-5,GD655-5,GD675-5 40-445
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

E-28 Windshield wiper does not operate 40-4 6

Failure 1) Front and rear windshield wipers do not operate.

Related infor- q If door wiper does not operate either, ground circuits (FT10 and FT11) may be defective.
mation q Power supply (fuse) for front and rear windshield wipers is separated from that for door wipers.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (15) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
1
FB2 shooting for cause 4 first.
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
Open circuit or ground fault in wir-
2 3. Turn starting switch to ON position.
ing harness
Between C15 (female) (6) and (3) Voltage 20 – 30 V
Between C16 (female) (1) and (4) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
3. Remove fuse (15) in fuse box FB2.
Between FB2 (female) (15) and C15 (6) Resistance Max. 1 z
Open circuit in wiring harness
3 (wire breakage or defective con- Between FB2 (female) (15) and C16 (1) Resistance Max. 1 z
tact of connector) Between C15 (female) (3) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between C16 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
Ground fault in wiring harness
4 3. Remove fuse (15) in fuse box FB2.
(contact with ground circuit)
Between C15 (female) (6) and ground Resistance Min. 1 Mz
Between C16 (female) (1) and ground Resistance Min. 1 Mz

40-446 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Circuit diagram related to wiper 40-4 7

GD555-5,GD655-5,GD675-5 40-447
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 2) Front windshield wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24V power is supplied to pin 4 of front wiper intermittent relay (C33), front windshield wiper op-
erates normally. If 24V power is supplied to pin 2, front windshield wiper operates intermittently.
Related infor- q Wiper relay (front wiper relay C14) switches destination of 24 V power for wiper intermittent relay
mation (front wiper intermittent relay C33) according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective front wiper motor 2. Disconnect connector C15 and connect T-adapter to male side.
1
(internal open circuit)
Between C15 (male) (2) and (3) Continuity
1. Turn starting switch to OFF position.
2. Replace front wiper relay (connected to connector C14) with rear wiper
Defective front wiper relay (C14) relay or door wiper relay.
2 (internal open circuit or short cir- 3. Turn starting switch to ON position.
cuit)
4. Set door wiper switch to ON.
If front windshield wiper operates, original front wiper relay is defective.
1. Turn starting switch to OFF position.
2. Replace front wiper intermittent relay (connected to connector C33) with
Defective front wiper intermittent rear wiper intermittent relay or door wiper intermittent relay.
3 relay (C33) (internal open circuit or 3. Turn starting switch to ON position.
short circuit) 4. Set door wiper switch to ON.
If front windshield wiper operates, original front wiper intermittent relay is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to male side.
Defective front wiper switch (inter-
4
nal open circuit) Between C17 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to female side.
Open circuit in wiring harness
5 (wire breakage or defective con- 3. Remove fuse (15) in fuse box FB2.
tact of connector) Between FB2 (15) and C17 (female) (3) Resistance Max. 1 z
q For power supply of wiper motor, see Failure 1).
1. Turn starting switch to OFF position.
2. Disconnect connectors C17, C15 and C33, and connect T-adapter to
female side of C17 and C15.
Ground fault or short circuit in wir-
6 Between C17 (female) (2) and ground Resistance Min. 1 Mz
ing harness
Between C15 (female) (2) and ground Resistance Min. 1 Mz
Between C15 (female) (5) and ground Resistance Min. 1 Mz

40-448 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Circuit diagram related to wiper 40-4 9

GD555-5,GD655-5,GD675-5 40-449
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Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 3) Rear windshield wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24V power is supplied to pin 4 of rear wiper intermittent relay (C34), rear windshield wiper oper-
ates normally. If 24V power is supplied to pin 2, rear windshield wiper operates intermittently.
Related infor- q Wiper relay (rear wiper relay C10) switches destination of 24 V power for wiper intermittent relay
mation (rear wiper intermittent relay C34) according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective rear wiper motor
1
(internal open circuit)
Defective rear wiper relay (C10)
2 (internal open circuit or short cir-
cuit)
Defective rear wiper intermittent
3 relay (C34) (internal open circuit or 3. Turn starting switch to ON position.
short circuit)
Defective rear wiper switch
4
(internal open circuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir-
6 Between C8 (female) (2) and ground
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C16 and connect T-adapter to male side.
Between C16 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace rear wiper relay (connector C10) with front wiper relay or door
wiper relay.
3. Turn starting switch to ON position.
4. Set rear wiper switch to ON.
If rear windshield wiper operates, original rear wiper relay is defective.
1. Turn starting switch to OFF position.
2. Replace rear wiper intermittent relay (connector C34) with front wiper inter-
mittent relay or door wiper intermittent relay.
4. Set rear wiper switch to ON.
If rear windshield wiper operates, original rear wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to male side.
Between C8 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between FB2 (15) and C8 (female) (3) Resistance Max. 1 z
q For power supply of wiper motor, see Failure 1).
1. Turn starting switch to OFF position.
2. Disconnect connectors C8, C16 and C34, and then connect T-adapters to
female side of C8 and C16.
Resistance Min. 1 Mz
Between C16 (female) (2) and (4) Resistance Min. 1 Mz
Between C16 (female) (3) and (4) Resistance Min. 1 Mz

40-450 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 4) Right and left door windshield wipers do not operate.

q If front and rear windshield wipers do not operate either, ground circuits (FT10 and FT11) may be
Related infor- defective.
mation q Power supply (fuse) for door wiper is separated from that for front and rear wipers.
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective fuse (14) in fuse box
1
FB2
Defective door wiper relay (C12)
2 (internal open circuit or short cir-
cuit)
Defective door wiper switch (inter-
3
nal open circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
Open circuit or ground fault in wir-
4 3. Turn starting switch to ON position.
ing harness
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6 3. Remove fuse (14) in fuse box FB2.
(contact with ground circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace door wiper relay (connected to connector C12) with front wiper
relay or rear wiper relay.
3. Turn starting switch to ON position.
4. Set door wiper switch to ON.
If door windshield wiper operates, original door wiper relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C9 and connect T-adapter to male side.
Between C9 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
side of them.
Between C11 (female) (1) and (4) Voltage 20 – 30 V
Between C13 (female) (1) and (4) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
side of them.
3. Remove fuse (14) in fuse box FB2.
Between FB2 (female) (14) and C11 (1) Resistance Max. 1 z
Between FB2 (female) (14) and C13 (1) Resistance Max. 1 z
Between C11 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between C13 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
side of them.
Between C11 (female) (1) and ground Resistance Min. 1 Mz
Between C13 (female) (1) and ground Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-451
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Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 5) Right door wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24 V power is supplied to pin 4 of wiper intermittent relay, windshield wiper operates normally. If
24 V power is supplied to pin 2, windshield wiper operates intermittently.
Related infor- q Wiper relay (door wiper relay C12) switches destination of 24 V power for wiper intermittent relay
mation according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective right door wiper motor
1
(internal open circuit)
Defective right door wiper intermit-
2 tent relay (C36) (internal open cir- 3. Turn starting switch to ON position.
cuit or short circuit)
Open circuit in wiring harness
3 (wire breakage or defective con- q For power supply of wiper motor, see Failure 4).
tact of connector)
Ground fault or short circuit in wir-
4
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C13 and connect T-adapter to male side.
Between C13 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace right door wiper intermittent relay (connector C36) with front wiper
intermittent relay or rear wiper intermittent relay.
4. Set right door wiper switch to ON.
If right door wiper operates, original right door wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connectors C13 and C36, and then connect T-adapter to
female side of C13.
Between C13 (female) (2) and (4) Resistance Min. 1 Mz
Between C13 (female) (3) and (4) Resistance Min. 1 Mz

Failure 6) Left door wiper does not operate.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective left door wiper motor
1
(internal open circuit)
Defective left door wiper intermit-
2 tent relay (C35) (internal open cir- 3. Turn starting switch to ON position.
cuit or short circuit)
Open circuit in wiring harness
3 (wire breakage or defective con- q For power supply of wiper motor, see Failure 4).
tact of connector)
Ground fault or short circuit in wir-
4
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C11 and connect T-adapter to male side.
Between C11 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace left door wiper intermittent relay (connector C35) with front wiper
intermittent relay or rear wiper intermittent relay.
4. Set left door wiper switch to ON.
If left door wiper operates, original left door wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C35, and then connect T-adapter to
female side of C11.
Between C11 (female) (2) and (4) Resistance Min. 1 Mz
Between C11 (female) (3) and (4) Resistance Min. 1 Mz

40-452 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 7) None of wipers operate intermittently.

Related infor- q T-adapter is not available for each wiper intermittent relay.
mation q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective intermittent wiper switch
1 Max. 1 z
(internal disconnection)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
1. Turn starting switch to OFF position.
2. Disconnect connector C37 and connect T-adapter to male side.
Between C37 (male) (5) Switch: ON Resistance
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C37 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between C37 (female) (6) and ground
(to measure resistance of three wiper relay coils Approx.
Resistance
connected in parallel) 100 z
a Resistance of coil unit: Approx. 290 z
Between FB2 (15) and C37 (female) (5) Resistance Max. 1 z

Failure 8) Some windshield wipers do not operate intermittently.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24 V power is supplied to pin 4 of wiper intermittent relay, windshield wiper operates normally. If
24 V power is supplied to pin 2, windshield wiper operates intermittently.
Related infor- q Each wiper relay switches destination of 24 V power for related wiper intermittent relay according
mation to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective wiper intermittent relay
1 (internal open circuit or short cir-
cuit)
Defective wiper relay (internal
2 relay.
open circuit or short circuit)
1. Turn starting switch to OFF position.
q Four wiper intermittent relays are installed for front window (C33), rear
window (C34), right door window (C35), and left door window(C36).
2. Replace wiper intermittent relay for wiper which does not operate with
another wiper intermittent relay.
3. Turn starting switch to ON position.
4. Set wiper switch for windshield wiper which does not operate to ON.
If windshield wiper operates, original wiper intermittent relay is defective.
1. Turn starting switch to OFF position.
q Three wiper relays are installed for front wiper (C12), rear wiper (C10),
and door wipers (C12).
2. Replace wiper relay for wiper which does not operate with another wiper
3. Turn starting switch to ON position.
4. Set wiper switch for windshield wiper which does not operate to ON.
If windshield wiper operates, original wiper relay is defective.

GD555-5,GD655-5,GD675-5 40-453
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Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

E-29 Window washer does not operate 40-454

Failure 1) Front window washer does not operate.
q If windshield wiper does not operate either, see Failure 1) or 2) of E-28.
Related infor-
q T-adapter is not available for window washer motor connector (troubleshooting is performed with-
mation
out using T-adapter).

Cause Procedure, measuring location, criteria and remarks

Defective front window washer
1 motor (Internal defect)
(internal open circuit)
2 Defective front wiper switch
Open circuit in wiring harness
3 (wire breakage or defective con-
tact)
Ground fault in wiring harness
4 female side of C17.
(contact with ground circuit)
a Check that rear window washer sprays water normally.
1. Turn starting switch to OFF position.
2. Connect connector B16 to counterpart of B17 and connect connector B17
to that of B16.
3. Turn starting switch to ON position.
4. Set front window washer switch to ON.
If rear window washer sprays water, original front window washer motor is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to male side.
3. Set front wiper switch to ON and OFF to perform troubleshooting.
Switch:
Resistance Min. 1 Mz
Between C17 (male) (5) and (6) OFF
Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between fuse box FB2 (15) (on harness side) and
Resistance Max. 1 z
C17 (female) (5)
Between C17 (female) (6) and ground Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors C17 and B16, and then connect T-adapter to
Between C17 (female) (6) and ground Resistance Min. 1 Mz

40-454 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Wiring harness between L22 (female) (7) – fuse No. 9 of fuse box B and chassis ground 40-45

GD555-5,GD655-5,GD675-5 40-455
(01)
Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Failure 2) Rear window washer does not operate.

q If windshield wiper does not operate either, see Failure 1) or 2) of E-28.
Related infor- q T-adapter is not available for window washer motor connector (troubleshooting is performed with-
mation out using T-adapter).
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective rear window washer
1 motor
(internal open circuit)
2 Defective rear wiper switch
Open circuit in wiring harness
3 (wire breakage or defective con-
tact)
Ground fault in wiring harness
4 side of C8.
(contact with ground circuit)
a Check that front window washer sprays water normally.
1. Turn starting switch to OFF position.
2. Connect connector B16 to counterpart of B17 and connect connector B17
to that of B16.
3. Turn starting switch to ON position.
4. Set rear window washer switch to ON.
If front window washer spouts water, original rear window washer motor is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to male side.
3. Set rear wiper switch to ON and OFF to perform troubleshooting.
Switch:
Resistance Min. 1 Mz
Between C8 (male) (5) and (6) OFF
Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between fuse box FB2 (15) (on harness side) and
Resistance Max. 1 z
C8 (female) (5)
Between C8 (female) (6) and ground Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors B16 and C8, and then connect T-adapter to female
Between C8 (female) (6) and ground Resistance Min. 1 Mz

40-456 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Failure 3) Door washer does not operate.

q If windshield wiper does not operate either, see Failure 4) to 6) of E-26.
Related infor-
q T-adapter is not available for washer motor connector.
mation
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector C9 and connect T-adapter to male side.
Defective door wiper switch (inter-
1
nal open circuit) Between C9 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B15.
Between B15 (male) (1) and (2) Continuity
q If door washer motor does not operate while check results of "A" and "B"
below are normal, door washer motor is defective.
q If check result of A is abnormal, open circuit is in wiring harness.
Defective door washer motor 1. Turn starting switch to OFF position.
2 (internal open circuit), or open cir- 2. Disconnect connector C9 and connect T-adapter to female side.
cuit in wiring harness
Between C9 (female) (6) and ground A Continuity
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector C9.
3. Turn starting switch to ON position.
4. Set door washer switch to ON.
Between C9 (female) (6) and ground B Voltage 20 – 30 V
1. Turn starting switch to OFF position.
Ground fault or short circuit in wir- 2. Disconnect connectors C9 and B15, and connect T-adapter to female side
3 of C9.
ing harness
Between C9 (female) (6) and ground Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-457
(01)
Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

E-30 KOMTRAX system does not operate correctly 40-458

q Standard specification
Failure q KOMTRAX system does not operate normally
q If KOMTRAX system administrator asks for checking whether system installed on machine has
Related infor-
trouble, perform following troubleshooting.
mation
q Even if KOMTRAX system has trouble, problem does not appear on machine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
1 Defective power supply 4. Set disconnect switch to ON.
Between L80 (39) and
Voltage 20 – 30 V
(37) Unswitched power sup-
Between L80 (40) and ply
Voltage 20 – 30 V
(38)
1. Start engine.
LED(1)* Normal condition ON
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
Defective starting switch ACC sig- 3. Insert T-adapter into connector L80.
2
nal or alternator R signal 4. Set disconnect switch to ON.
5. Start engine.
Between L80 (36) and
Starting switch ACC Voltage 20 – 30 V
(37)
Between L80 (28) and
Alternator R Voltage 20 – 30 V
(38)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between L80 (27) and
Starting switch C Voltage Max. 1 V
(37)
3 Defective starting switch C signal
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
Between L80 (27) and
Starting switch C Voltage 20 – 30 V
(37)
1. Turn starting switch ON.
LED(4)* Normal condition ON
1. Turn starting switch to OFF position.
4 Defective CAN connection
2. Set disconnect switch to OFF.
3. Disconnect connector L80 and connect T-adapter to female side.
Between L80 (female) (8)
CAN(KOMNET) Resistance 40 – 80 z
and (7)
1. Turn starting switch to ON position.
5 Number of unsent mails
7-segment LED (7)* Normal condition 0–9
1. Turn starting switch to ON position.
Dot LED (8)* Normal condition ON
6 Defective GPS positioning status
One or more minute may be taken until GPS positioning is completed after
starting switch is turned to ON position with machine in good reception area.
* For position of each LED, see next page.

40-458 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

LED display section of KOMTRAX terminal 40-459 L80 connector 40-459

LED for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download-writing state)
6. LED-C6 (Download-writing state)
7-segment and dot LED for CPU
7. 7-segment LED (number of unsent mails)
8. Dot LED (GPS positioning state)

GD555-5,GD655-5,GD675-5 40-459
(03)
Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

q Chinese specification
Failure q KOMTRAX system does not operate normally
q If KOMTRAX system administrator asks for checking whether system installed on machine has
Related infor-
trouble, perform following troubleshooting.
mation
q Even if KOMTRAX system has trouble, problem does not appear on machine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
1 Defective power supply 4. Set disconnect switch to ON.
Unswitched power sup-
Between V4 (6) and (2) Voltage 20 – 30 V
ply

1. Start engine.
LED(1)* Normal condition ON
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
Defective starting switch ACC sig-
2 3. Insert T-adapter into connector V4.
nal or alternator R signal
4. Set disconnect switch to ON.
5. Start engine.
Between V4 (3) and (2) Starting switch ACC Voltage 20 – 30 V
Between V4 (4) and (2) Alternator R Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between V4 (11) and (2) Starting switch C Voltage Max. 1 V
3 Defective starting switch C signal
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
Between V4 (11) and (2) Starting switch C Voltage 20 – 30 V
1. Turn starting switch ON.
LED(4)* Normal condition ON
1. Turn starting switch to OFF position.
4 Defective CAN connection
2. Set disconnect switch to OFF.
3. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female)
CAN(KOMNET) Resistance 40 – 80 z
(10) and (11)
1. Turn starting switch to ON position.
5 Number of unsent mails
7-segment LED (6)* Normal condition 0–9
1. Turn starting switch to ON position.
Dot LED (7)* Normal condition ON
6 Defective GPS positioning status
One or more minute may be taken until GPS positioning is completed after
starting switch is turned to ON position with machine in good reception area.
* For position of each LED, see next page.

40-459-1 GD555-5,GD655-5,GD675-5
(03)
 Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

LED display section of KOMTRAX terminal 40-459 connector 40-459

LED for CPU

1. LED-1 (State of R or ACC signal)
2. LED-2 (Starting output state)
3. LED-3 (State of S-NET or C signal)
4. LED-4 (CAN state)
5. LED-5 (Download-writing state)
7-segment and dot LED for CPU
6. 7-segment LED (Station opening or operating
state)
7. Dot LED (GPS positioning state or state of check
connector connection)

GD555-5,GD655-5,GD675-5 40-459-2
(03)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix
The simplified troubleshooting matrix is prepared to locate the failed portion from the given nature of machine
failure. Troubles are broadly classified based on the devices such as the steering system, hydraulic system
for work equipment, etc. Perform the following procedure to ensure correct and quick troubleshooting.
Step 1. Interview with operator
q The questions to be asked to the operator are
listed under the respective failure. If the answer
of the operator coincides with the listed failure,
the potential cause is the one written succeeding
to "o". Proceed to Steps 2 and 3 to locate the
true cause with the points of the operator's an-
swers and referencing the simplified trouble-
shooting matrix.
(Example) Machine does not turn
Ask the operator the following.
q Did the machine suddenly become unable to
steer?
oDamage on the steering related equipment
q Were there indications from before such as
steering wheel operating effort was felt heavy?
oInternal wear or defective seal on the steering
related equipment
Step 2. Check before troubleshooting
q Before starting an actual troubleshooting such
as measurement of oil pressure, check along the
check before starting items, check for oil leak-
age, and loosening of bolts, etc. must be per-
formed to avoid fruitless efforts. The items listed
in the checks before troubleshooting must be
checked with particular care prior to start of the
an actual troubleshooting of a given problem.
(Example) Check before troubleshooting
q Are the oil level in the hydraulic tank and the type
of oil used appropriate?
q Is the steering valve or demand valve free from
oil leakage?
q Is the steering cage correctly adjusted?
40-460
40-460
40-460
Step 3. How to read troubleshooting matrix
1. While operating the machine, perform the trou-
bleshooting along the items listed in the diag-
nosis column. If a failure is found in the
troubleshooting process, apply a checkmark to
the applicable diagnosis column.
a This diagnosis does not require to follow the
diagnosis number given in the column. Start
with the items easier to perform.
(Example)
Remedy
No.
Diagnosis
Machine does not turn in any of the left
1
and right direction.
2
Machine turns in either of the left or right
direction alone.
Steering wheel is felt heavy when turning
3
to any of the left and right side.
Steering wheel is heavy to operate and
4
not turnable to either left or right.
5 Work equipment works
2. Find the cause from the cause column.
The cause of the failure is indicated by Q situ-
ated at the intersection of the diagnosis column,
where the failure was identified, and cause
column. (The cause of diagnosis (2) shown in
the following figure is c or e)
[When the cause (marked with Q) identified in a
diagnosis is one]
Before proceeding to repair work, check whether
the same trouble was identified in other diag-
nosis (Q mark is indicated for the same cause).
[When two or more causes (marked with Q) are
identified in a diagnosis]
Go to 3 to narrow down the cause.
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

3. Operate the machine to perform diagnosis of
other than (2) and if a failure is found, apply a
checkmark in the corresponding diagnosis
column. (In the following figure, the same trouble
is identified in diagnosis (5).)
4. Find the cause from the cause column.
The cause of the failure is indicated by Q situ-
ating at the intersection of the diagnosis column,
where the trouble was identified, and cause
column. (The cause of diagnosis (5) shown in
the following figure is b or e)
6. Repeat the procedures 3 - 5 until the causes are
narrowed down to a single item (a single
common cause).
a It sometimes cannot be narrow down the
cause to a single one. In such case, repeat
the above procedure until the causes are
minimized.
7. Remedy
When the common cause is singled out, take
appropriate action according to the remedy
column.
[Symbols used in remedy column and corrective
actions]
x: Replacement E: Correction A: Adjustment C:
Cleaning

5. Narrowing down the cause.

Among the causes located in (2) and (5), the one
that is commonly observed in the both diagnosis
items (marked with Q on both of the same
vertical lines) becomes the cause commonly
identifiable in the procedure 2 and 3, too.
a The items that are not common (Q are not
duplicated on the vertical line) should be dis-
carded since they are most probably not the
cause. (The cause of diagnosis (2) shown in
the following figure is c or e, and the cause of
diagnosis (5) is b or e. Therefore, cause e is
regarded as the common cause.

GD555-5,GD655-5,GD675-5 40-461
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

40-462 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

GD555-5,GD655-5,GD675-5 40-463
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

40-464 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

GD555-5,GD655-5,GD675-5 40-465
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Engine speed lowers significantly or engine stalls.

H-1 Engine speed lowers significantly or engine stalls. 40-46

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e

Malfunction of piston pump (servo piston)

Malfunction of piston pump (PC valve)
Clogging of piston pump (orifice plug)

Internal defect of piston pump

Defective engine
Remedy A
No. C x A *
Diagnosis x
1 Piston pump is internally clogged. Q
2 PC valve is abnormal. Q
3 Main pump assembly is abnormal. Q
4 Piston pump unit is abnormal. Q
5 Engine unit is defective. Q
* Perform troubleshooting of engine unit (S mode).

40-466 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-2 Machine does not start

H-2 Machine does not start 40-467

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropri- a b c d e f g h i
ate.
q Oil pressure must be checked while the torque converter oil tem-
perature gauge is within the operating range.

Malfunction of main relief valve of torque converter

Clogging of suction strainer in transmission case
Air inhaled in suction circuit of power train pump

Malfunction of main relief valve of power train

Defective power train pump (drive system)

Internal defect of power train pump

Internal defect of torque converter

Internal defect of transmission
Internal defect of PTO
Remedy E E E E E E E E E
No.
Diagnosis x x C x x x x x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q
2 The machine does not start at a specific gear speed. Q
Unusual noise comes out from the strainer or transmission filter when the transmis-
3 Q Q
sion oil temperature is low.
4 Main relief valve of the power train is not normal. Q
5 Inlet pressure of torque converter relief is low. Q
6 Outlet pressure of torque converter is not normal. Q
7 Transmission is not normal. Q

GD555-5,GD655-5,GD675-5 40-467
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-3 Gear is not shifted.

H-3Gear is not shifted. 40-468

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropriate. a b c
q Oil pressure must be checked while the torque converter oil temperature gauge
is within the operating range.
Operate the gear shift lever to each gear speed and, before starting trouble-
shooting, check that gear cannot be shifted for forward or reverse only.

Defective operation of transmission clutch valve (ECMV)

Wear or damage on clutch disc or plate of transmission

Defective sealing of transmission clutch piston
Remedy E E E
No.
Diagnosis x x x
1 Forward or reverse travel of machine is not available. Q Q Q
2 Shift up or down of gear is not available. Q Q Q
3 Sealing of transmission clutch piston is defective. Q
4 Cluch disc plate of transmission is worn or damaged. Q

40-468 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

H-4 Travel lacks speed or power. 40-469

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is ap- a b c d e f g h i j
propriate.
q Oil pressure must be checked while the torque converter oil

Defective operation of the corresponding clutch valve (ECMV)

temperature gauge is within the operating range.
q Before performing troubleshooting, check that the wheel

Wear or damage on the corresponding clutch disc or plate

brake and parking brake do not drag.

Defective sealing of the corresponding clutch piston

Malfunction of main relief valve of torque converter
Clogging of suction strainer in transmission case
Internal defect of power train pump (pump unit)
Malfunction of main relief valve of power train

Internal defect of torque converter

Internal defect of transmission
Internal defect of final drive
Remedy C EEEEE
No. x * * *
Diagnosis x x x x x x
Metal particles (aluminum, copper, iron, etc.) are adhered to the transmission
1 filter or strainer. Q Q Q
(Aluminum, copper or iron, etc.) is sticking
Unusual noise comes out from the pump or transmission filter when the trans-
2 Q Q
mission oil temperature is low.
3 The torque converter oil temperature rises too high Q Q Q Q Q Q
4 The main relief pressure of power train is abnormal. Q Q
5 When measuring ECMV output oil pressure (clutch), the oil pressure is low. Q Q Q Q Q Q
6 Sealing of the lockup clutch piston of torque converter is defective. Q
7 The lockup clutch disc or plate of torque converter is worn or damaged. Q
8 Sealing of the transmission clutch piston is defective. Q
9 Clutch disc or plate of transmission is worn or damaged. Q
10 Main relief inlet pressure of torque converter is low. Q Q
11 The final drive is not normal. Q
* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

GD555-5,GD655-5,GD675-5 40-469
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
w w

Defective operation of the 2nd clutch ECMV (fill switch)

Defective operation of the 3rd clutch ECMV (fill switch)
F2

Defective operation of the 4th clutch ECMV (fill switch)

Defective operation of the FH clutch ECMV (fill switch)

Defective operation of the 1st clutch ECMV (fill switch)

Defective operation of the FL clutch ECMV (fill switch)

Defective operation of the R clutch ECMV (fill switch)

F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code displays 15SBL1 after troubleshooting, the failure code
3
is not displayed by disconnecting R fill switch connector (CN-T38). If the
(2) 15SBMA
failure code displays 15SBMA after troubleshooting, the failure code is
not displayed by replacing the ECMV other than R ECMV.
The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.

40-470 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-471
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of
machine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting

the engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RENGE
F1 w w

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
w w

Wear or seizing on R clutch disc, or wear on the piston seal

F2
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the
clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is
1
not displayed by disconnecting FL fill switch connector (CN-T36). If the
(2) 15SDMA Q
failure code is 15SDMA, the failure code is not displayed by replacing
the ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is
2
not displayed by disconnecting FH fill switch connector (CN-T37). If the
(2) 15SCMA Q
failure code is 15SCMA, the failure code is not displayed by replacing
the ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is
3
not displayed by disconnecting R fill switch connector (CN-T38). If the
(2) 15SBMA Q
failure code is 15SBMA, the failure code is not displayed by replacing
the ECMV other than R ECMV.

40-472 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

The failure code 15SEL1 is not displayed at F1 and F2, but it is dis-
(1) 15SEL1 Q
played at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is
4
not displayed by disconnecting 1st fill switch connector (CN-T39). If the
(2) 15SEMA Q
failure code is 15SEMA, the failure code is not displayed by replacing
the ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is dis-
(1) 15SFL1 Q
played at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the
(2) 15SFMA Q
failure code is 15SFMA, the failure code is not displayed by replacing
the ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is dis-
(1) 15SGL1 Q
played at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is
6
not displayed by disconnecting 3rd fill switch connector (CN-T41). If the
(2) 15SGMA Q
failure code is 15SGMA, the failure code is not displayed by replacing
the ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is dis-
(1) 15SHL1 Q
played at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is
7
not displayed by disconnecting 4th fill switch connector (CN-T42). If the
(2) 15SHMA Q
failure code is 15SHMA, the failure code is not displayed by replacing
the ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-473
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-5 Torque converter lockup does not work or is not released.

H-5 Torque converter lockup does not work or is not released. 40-474
Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropriate. a b c
q Oil pressure must be checked while the torque converter oil temperature gauge
is within the operating range.
q The torque converter lockup clutch operates only at the specific gear speed be-
ing selected by the transmission mode selector switch.

Wear or damage on lockup clutch disc or plate

Defective sealing of lockup clutch piston
Malfunction of lockup clutch ECMV
Remedy
No. x x x
Diagnosis
1 Lockup oil pressure is low or 0 Q Q
2 Clutch remains engaged even at 0 lockup oil pressure. Q

40-474 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

H-6 A large time lag results at start or in gear shift 40-475

Check before troubleshooting Cause
q Check whether the oil level of transmission case is appropriate. a b c

q Oil pressure must be checked while the torque converter oil temperature gauge

Wear or damage on the corresponding clutch disc or plate

is within the operating range.
q Before performing troubleshooting, operate the gear shift lever to each gear
speed to identify the gear speed or forward/reverse travel in which a large time

Defective sealing of the corresponding clutch piston

lag results.

Defective operation of the corresponding ECMV

q Before performing troubleshooting, check that the travel speed is normal.
(When not normal, perform troubleshooting of "H-4 Travel lacks speed or
power" before this troubleshooting.)

Remedy
No. * * *
Diagnosis
1 A large time lag results at a specific gear speed. Q Q
2 When measuring ECMV output oil pressure (clutch), the oil pressure is low at a specific gear speed. Q Q
3 Clutch disc or plate of transmission is worn or damaged. Q

* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

GD555-5,GD655-5,GD675-5 40-475
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
F2 w w
F3 w w

Defective operation of the 2nd clutch ECMV (fill switch)

w w

Defective operation of the 3rd clutch ECMV (fill switch)

Defective operation of the 4th clutch ECMV (fill switch)
Defective operation of the 1st clutch ECMV (fill switch)
Defective operation of the FH clutch ECMV (fill switch)
Defective operation of the FL clutch ECMV (fill switch)
F4

Defective operation of the R clutch ECMV (fill switch)

F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

40-476 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-477
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
w w

Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
F1

Wear or seizing on R clutch disc, or wear on the piston seal

F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Troubleshooting Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA Q
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA Q
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA Q
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

40-478 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA Q
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA Q
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA Q
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA Q
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-479
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

H-7 Oil temperature of torque converter is high. 40-480

Check before troubleshooting Cause
q Check whether the oil level of transmission case is appropri- a b c d e f g h i j
ate.

q Oil pressure must be checked while the torque converter oil

Defective operation of lockup clutch valve of torque converter (ECMV)

temperature gauge is within the operating range.
Before performing troubleshooting, check that the wheel brake

Wear or damage on lockup clutch disc or plate of torque converter

and parking brake do not drag.

Defective sealing of lock up clutch piston of torque converter

Wear or damage on the corresponding clutch disc or plate

Defective sealing of the corresponding clutch piston
Defective operation of torque converter relief valve

Defective operation of the corresponding ECMV

Malfunction of main relief valve of power train

Internal defect of torque converter

Internal defect of transmission

Remedy E E EEE E
No. x * * *
Diagnosis x x x x x x
Necessary travel speed, counteracting force, and gradability are not available at
1 Q Q Q Q Q Q Q Q Q Q
any gear speed.
Necessary travel speed, counteracting force, and gradeability are not available at
2 Q
a specific gear speed.
An abnormal engine speed is indicated when measuring speed at low idle and full
3 Q Q
speed.
4 When measuring torque converter stall speed, it is too high. Q Q Q Q Q Q Q Q Q Q
When measuring ECMV output oil pressure (clutch), it is low at a specific gear
5 Q
speed.
6 Main relief inlet pressure of torque converter is low. Q Q
* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

40-480 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
F2 w w
F3 w w

Defective operation of the 2nd clutch ECMV (fill switch)

w w

Defective operation of the 3rd clutch ECMV (fill switch)

Defective operation of the 4th clutch ECMV (fill switch)
Defective operation of the 1st clutch ECMV (fill switch)
Defective operation of the FH clutch ECMV (fill switch)
Defective operation of the FL clutch ECMV (fill switch)
F4

Defective operation of the R clutch ECMV (fill switch)

F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the failure
(2) 15SDMA
code is 15SDMA, the failure code is not displayed by replacing the ECMV
other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

GD555-5,GD655-5,GD675-5 40-481
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

40-482 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the ECMV
and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
w w

Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
F1

Wear or seizing on R clutch disc, or wear on the piston seal

F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the failure
(2) 15SDMA Q
code is 15SDMA, the failure code is not displayed by replacing the ECMV
other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA Q
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed at
(1) 15SBL1 Q
F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA Q
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

GD555-5,GD655-5,GD675-5 40-483
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA Q
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA Q
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA Q
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA Q
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

40-484 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-8 Differential lock-up function does not work or is not released

H-8 Differential lock-up function does not work or is not released 40-485
Check before troubleshooting Cause
q Check whether the oil level in the final drive case is appropriate. a b c d e f g

Defective operation or defective adjustment of differential lock-up valve

q Check the oil pressure when the final drive case oil temperature is be-
tween 60 and 80°C.

Defective connection of differential lock-up pump (drive system)

Wear or damage on clutch disc or plate of differential lock-up

Air sucked in suction circuit of differential lock-up pump
Internal defect of differential lock-up pump (pump unit)

Defective sealing of differential lock-up clutch piston

Clogging of suction strainer on final drive case
Remedy E C EEE
No. E x
Diagnosis x x x x x
1 Differential lock-up pump does not rotate Q Q Q Q Q Q Q
2 Unusual noise comes out from the strainer when the final drive case oil temperature is low. Q Q Q
3 Oil pressure of differential lock-up (pump outlet and valve outlet) is not normal. Q

GD555-5,GD655-5,GD675-5 40-485
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-9 Steering lacks speed or power.

H-9 Steering lacks speed or power. 40-486

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.
q Before performing troubleshooting, check that work equipment operates nor-

Defective operation of priority valve (relief valve)

mally.
(When not normal, perform troubleshooting of "H-15 All work equipment is oper-
ation lacks speed or power" before this troubleshooting.)
q Since the variable ratio type is used for steering valve (orbit-roll), the steering

Defective sealing of steering cylinder

speed varies depending on the rotating speed of the steering wheel.

Malfunction of steering valve

Remedy E E E
No.
Diagnosis x x x
1 Response of the steering wheel is poor independent of the turning direction, left or right. Q Q Q
2 Steering wheel is heavy to operate when turning to any of the left and right side. Q
3 Work equipment works. Q Q Q
When measuring the steering relief pressure, the oil pressure is low on both sides or no oil pressure is
4 Q Q
generated.

40-486 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-10 Steering wheel does not move

H-10 Steering wheel does not move 40-487

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c
q Before performing troubleshooting, check that work equipment operates nor-
mally.

Defective connection of steering wheel and steering valve

(When not normal, conduct troubleshooting of "H-16 Work equipment does not
work at all" before this troubleshooting.)

Deformation of steering cylinder

Malfunction of steering valve
Remedy E E
No. x
Diagnosis x x
1 Steering wheel is turning idle Q Q
2 Steering wheel is heavy to operate when turning to any of the left and right side. Q Q

GD555-5,GD655-5,GD675-5 40-487
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Wheel brake does not work at all or sufficiently

H-11 Wheel brake does not work at all or sufficiently 40-48

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f g h
q The oil pressure and cylinder oil leakage must be checked when hy-

Defective operation of charging valve of brake accumulator (pressure governor valve)

draulic oil temperature is between 45 and 55°C.
q Before performing troubleshooting, check that work equipment oper-

Defective operation of charging valve of brake accumulator (LS releasing valve)

ates normally.
(When not normal, conduct troubleshooting of "H-13 Speed or power
of all work equipment is low" or "H-16 Work equipment does not
work at all" prior to this troubleshooting.)

Low gas pressure of brake accumulator

Wear or damage on brake disc or plate

Insufficient air breeding of brake circuit
Defective seal of brake piston
Malfunction of slack adjuster
Malfunction of brake valve
Remedy E E E E E E E
No. E
Diagnosis x x x x x x x
1 Resistance resulting from depressing the brake pedal is low. Q Q Q Q Q Q
2 Brake pedal effort is heavy. Q
3 Unordinary depressing force is required to obtain the specified braking force. Q Q Q
4 When the brake is operated, unusual noise comes out from the axle brake. Q
5 Defective machine travel (insufficient traction force) Q
Outflow of air was observed in air bleeding of the brake circuit, but normal state was
6 Q
restored after air bleeding was over.
7 An abnormal quantity of brake oil leakage in the axle was found in the leak check. Q
Brake does not operate efficiently though no abnormality is found in depressing force of
8 Q
the brake pedal and stroke.
9 Frequency of effective braking applied is limited when the engine is stopped. Q Q Q Q Q
10 The buzzer sounds even when charging to the accumulator is not completed. Q Q Q
11 There is a time lag on the effective braking applied. Q

40-488 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-12 Wheel brake cannot be released or drags

H-12 Wheel brake cannot be released or drags 40-489

Check before troubleshooting Cause
q Is the brake pedal completely returned to the original position?
q Is the parking brake completely released?

Wheel brake
Check for abnormality

Brake valve
q Abnormal heat buildup on brake
q Is smooth coasting available on level ground?

a b c

Internal defect of brake valve (stuck piston)

Defective operation of brake piston in axle

Abnormality on brake lining in axle
Remedy E E E
No.
Diagnosis x x x
1 Brake is working after the brake pedal is released. Q Q Q
If oil is drained from the air bleeder after the brake pedal is released, the circuit pressure goes low and
2 Q
the brake is released.
If tires are rotated manually after the axle is placed on a bench when the engine is stopped and the park-
3 Q Q
ing is released, specific wheel is felt heavy.

GD555-5,GD655-5,GD675-5 40-489
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-13 Parking brake does not work at all or insufficiently

H-13 Parking brake does not work at all or insufficiently 40-490

Ask the operator the following points. Cause
q Did the brake stop working suddenly? oDamage on the related equip-
ment.
Did unusual noise come out then? Where on the brake did it come out?
q Did the brake lose braking force gradually? oWear or defective sealing
of the related equipment.

Parking brake
Check before troubleshooting

Solenoid
q Check whether the emergency release switch of parking brake is in the
ON position.

Valve
q Check whether the mechanical release operation is done for the parking
brake. a b c d e

Defective parking brake emergency release valve

Defective solenoid valve of parking brake

Malfunction of parking brake piston

Defective spring of parking brake

Wear of parking brake disc

Remedy E E
No. x x x
Diagnosis x x
1 The parking brake does not work after the engine is stopped. Q Q Q
2 When checking wear on the parking brake disc, the disc thickness is below the criteria. Q
the parking brake switch is in the ON position
3 Q Q
When measuring the inlet pressure of parking and no oil pressure is present (normal).
brake The parking brake switch is in the ON position
4 Q Q Q
and oil pressure is present.
the parking brake switch is in the ON position
5 Q Q
When measuring the parking brake solenoid and no oil pressure is present (normal).
valve The parking brake switch is in the ON position
6 Q
and oil pressure is present.

40-490 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-14 Parking brake (including emergency release system) cannot be released or drags.

H-14 Parking brake (including emergency release system) cannot be

released or drags. 40-491
Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e

Defective operation of bank valve (parking solenoid valve) of parking brake

q The oil pressure and cylinder oil leakage must be checked when hydraulic
oil temperature is between 45 and 55°C.
q Check that the wheel brake operates normally before starting trouble-
shooting.
(When not normal, perform troubleshooting of "H-11 Wheel brake does
not work at all or sufficiently" before this troubleshooting.)

Clogging of bank valve (filter) of parking brake

Defective adjustment of parking brake

Malfunction of parking brake caliper
Clogging of elbow filter
Remedy E E E
No.
Diagnosis x x x
1 The parking brake does not work after the engine is stopped. Q Q Q Q Q
When measuring output pressure of the solenoid valve of parking brake, the oil pressure is
2 Q
present at the parking brake switch being in the ON position.
3 Elbow filter is clogged Q
4 The parking brake caliper malfunctions. Q

GD555-5,GD655-5,GD675-5 40-491
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-15 All work equipment operation lacks speed or power.

H-15 All work equipment operation lacks speed or power. 40-492

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f g h i
q Oil pressure must be checked while the hydraulic oil temperature

Defective operation or adjustment of the control valve (main relief valve and LS relief valve)
is between 45 and 55°C.

Looseness of the piston pump suction pipe at the joint, or crack on the hose
Defective operation or adjustment of piston pump (PC valve)
Defective operation or adjustment of piston pump (LS valve)

Defective operation of the control valve (unload valve)

Defective operation of piston pump (servo piston)
Clogging of suction strainer in hydraulic tank

Internal defect of piston pump (pump unit)

Clogging of piston pump (orifice plug)

Remedy C E E E A E E A
No. x
Diagnosis x x x x x x x x
1 The hydraulic tank strainer is clogged. Q Q Q
Pipe joint between the hydraulic tank and pump is loosened or cracks are present on
2 Q
the hose.
3 Relief pressure of LS relief valve is not normal. Q Q Q
4 Large volumes of metal particles are attached on the discharge side filter of pump. Q Q
Oil does not appear when cranking after removing the pressure pickup plug of main
5 Q
pump.
6 Relief pressure of the main relief valve is not normal. Q

40-492 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-16 Work equipment does not work at all

H-16 Work equipment does not work at all 40-493

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q The oil pressure and cylinder oil leakage must be checked when hydraulic

Defective operation or adjustment of the control valve (main relief valve and LS relief valve)
oil temperature is between 45 and 55°C.

Defective operation of the control valve (unload valve)

Defective connection of piston pump (drive system)
Internal defect of piston pump (pump unit)
Internal defect of PTO
Remedy E E E
No. x A
Diagnosis x x x
1 Oil does not appear when cranking after removing the pressure pickup plug of main pump. Q Q
2 The piston pump does not rotate. Q
3 Measured unload pressure is abnormal Q
4 Adjustment of the unload valve does not restore the normal oil pressure. Q

GD555-5,GD655-5,GD675-5 40-493
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Unusual noise comes out from around hydraulic pump

H-17 Unusual noise comes out from around hydraulic pump 40-494
Cause
q Low oil level of hydraulic tank
q Mixing of air in hydraulic oil
q Clogging of hydraulic tank cap
q Clogging of hydraulic tank strainer
q Internal defect of piston pump
q Low oil level in transmission case
q Mixing of air in transmission oil
q Clogging of transmission case strainer
q Internal defect of power train pump

When none of the above is the cause, run the system for a while to see whether characteristics of the trouble
changes.

40-494 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Blade lift operation lacks speed or power

H-18 Blade lift operation lacks speed or power 40-495

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q The oil pressure and cylinder oil leakage must be checked when hydraulic
oil temperature is between 45 and 55°C.

Defective operation of blade lift control valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of blade lift control valve (spool)

Defective sealing of blade lift cylinder

Deformation of blade lift cylinder
A
Remedy EE
No. E x x
Diagnosis x x
x
1 Blade lift speed is low Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q

GD555-5,GD655-5,GD675-5 40-495
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-19 Hydraulic drift of blade lift cylinders is large.

H-19 Hydraulic drift of blade lift cylinders is large. 40-496

Check before troubleshooting
q Check whether the oil level in the hydraulic tank is appropriate.
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil temperature is between 45
and 55°C.

Cause
q Malfunction of pilot check valve (check valve)
q Malfunction of pilot check valve (relief valve)
q Defective sealing of blade lift cylinder

40-496 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-20 Drawbar side shift operation lacks speed or power

H-20 Drawbar side shift operation lacks speed or power 40-497

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil

Insufficient stroke of the control valve (spool) for the drawbar side sift operation
temperature is between 45 and 55°C.

Defective seal of the cylinder for the drawbar side sift operation
Deformation of the cylinder tfor the drawbar side sift operation
Defective operation of pilot check valve (check valve)
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of drawbar side sift operation is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

GD555-5,GD655-5,GD675-5 40-497
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 Blade side shift operation lacks speed or power

H-21 Blade side shift operation lacks speed or power 40-498

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d

Insufficient stroke of the control valve (spool) for the blade side shift operation
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Deformation of the cylinder for the blade side shift operation

Defective operation of pilot check valve (check valve)
Defective sealing of swivel joint
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of blade side shift operation is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

40-498 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Power tilt operation lacks speed or power

H-22 Power tilt operation lacks speed or power 40-49

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f
q The oil pressure and cylinder oil leakage must be checked when hydrau-
lic oil temperature is between 45 and 55°C.

Defective operation of pilot check valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of power tilt control valve (spool)

Defective sealing of power tilt cylinder

Deformation of blade lift cylinder
Defective sealing of swivel joint
A
Remedy EE
No. E x x x
Diagnosis x x
x
1 Speed of power tilt is low. Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q Q

GD555-5,GD655-5,GD675-5 40-499
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-23 Articulate operation lacks speed or power

H-23 Articulate operation lacks speed or power 40-50

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Insufficient stroke of the articulate control valve (spool)

Defective operation of pilot check valve
Defective sealing of articulate cylinder
Deformation of articulate cylinder
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of articulate is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

40-500 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-24 Leaning operation lacks speed or power

H-24 Leaning operation lacks speed or power 40-501

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Insufficient stroke of leaning control valve (spool)

Defective operation of pilot check valve
Defective sealing of leaning cylinder
Deformation of leaning cylinder
A
Remedy E
No. E x x
Diagnosis x
x
1 Leaning speed is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

GD555-5,GD655-5,GD675-5 40-501
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-25 Hydraulic drift of leaning cylinders (leaning) is large

H-25 Hydraulic drift of leaning cylinders (leaning) is large 40-502

Check before troubleshooting
q Check the oil level in the hydraulic tank is appropriate.
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil temperature is between 45
and 55°C.

Cause
q Malfunction of pilot check valve
q Defective sealing of leaning cylinder

40-502 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-26 Blade does not rotate

H-26 Blade does not rotate 40-503

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q Make sure that oil level is appropriate in the circle reverse gear case.

Defective operation of pilot check valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of blade lift control valve (spool)

Defective sealing of blade lift cylinder

Deformation of blade lift cylinder
A
Remedy EE
No. E x x
Diagnosis x x
x
1 Blade does not rotate. Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q

GD555-5,GD655-5,GD675-5 40-503
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)

H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for
machine with lift arm specification) 40-504
Check before troubleshooting Cause
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil a b c d
temperature is between 45 and 55°C.

Defective operation of bank valve (bank solenoid valve) of parking brake

Defective operation of internal defect of lift arm lock cylinder
Clogging of bank valve (filter) of parking brake
Improper positioning of lift arm and lock pin
A
Remedy EE
No. E x
Diagnosis x x
x
1 Lift arm lock pin does not lock lift arm. Q Q Q Q
2 Lift arm and lock pin are misaligned. Q
3 Filter of parking brake valve is clogged. Q
4 Cylinder head or bottom pressure of bank solenoid valve is normal. Q

40-504 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-28 Blade accumulator function does not work or cannot be released (for machine with blade accumulator float

H-28 Blade accumulator function does not work or cannot be released

(for machine with blade accumulator float specification) 40-505
Check before troubleshooting
q Check that both solenoid valves for blade accumulator (locating at left and right sides) work normally.

Cause
q Malfunction or internal defect of solenoid valves for blade accumulator
q Low gas pressure of blade accumulator

GD555-5,GD655-5,GD675-5 40-505
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-29 Blade float function does not work or cannot be released

H-29 Blade float function does not work or cannot be released 40-506
Check before troubleshooting
q Check that lever is shifted to the blade float position correctly and the function works normally.

Cause
q Malfunction or internal defect of control valve
q Defective adjustment of lever link

40-506 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)

H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats) 40-507
Check the following with the operator. Cause
q Did the fan start making the abnormal sound sudden- Tank to Charge
Fan motor Others
ly? Pump valve
oDamage of the devices related to the fan and fan a b c d e f g h i j k
motor
q Did the engine overheat after the fan had started mak-
ing the abnormal sound?
oInternal wear of the devices related to the fan pump
and fan motor, lowering of sealing performance or
dirt

Clogging or sucked air on pump suction side

Check for abnormality
Measure the fan speed to check for abnormality.

Seized forward-reverse selector valve

heck before troubleshooting

Malfunction of suction safety valve

Seized brake circuit selector spool

Malfunction of EPC solenoid valve

q Check the level and type of the oil in the hydraulic tank.

Lowering of engine performance

Seized ON/OFF solenoid valve
q Check the hydraulic hoses, pump and motor for oil
leakage.

Malfunction of relief valve

q Check the fan for damage.

Malfunction of controller
Defective fan motor
Defective fan pump
(Note): If “Lowering of engine performance” is judged,
go to the troubleshooting for the engine system (S
mode).

Note
Remedy c E E E E E E
No. x x x
Troubleshooting E x x x x x x
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q

GD555-5,GD655-5,GD675-5 40-507
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

Troubleshooting of engine (S-mode) 40-508

Method of using troubleshooting chart 40-508
The troubleshooting chart consists of the "Ques-
tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause.
Questions:
Questions placed in the sections A and B in the
table on the next page are those to be answered
by the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
Causes:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
Troubleshooting:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.

40-508 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w>Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.

GD555-5,GD655-5,GD675-5 40-509
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

<Example of troubleshooting>; Exhaust smoke is

black.
Let us assume that the exhaust gas is black due to the "clogging of air cleaner". In this case, there is a causal
relationship with 3 troubles such as "Exhaust gas gradually became black", "Power was lost gradually", and
"Caution lamp for clogging of air cleaner blinks".

40-510 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

If the cause column is viewed from the point of these 3 troubles, we can find the causal relationship with 5
troubles.
The following explains how to narrow down the probable causes by reviewing the causal relationship with
these troubles.

GD555-5,GD655-5,GD675-5 40-511
(01)
Troubleshooting of engine (S-mode)
S-1 Startability is poor

S-1 Startability is poor 40-512

General causes why startability is poor Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the fuel injection timing

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat

Defective alternator (generator section)

Defective alternator (regulator section)
electrically. Accordingly, even if the engine is cranked properly, the engine may

Stuck or seized supply pump plunger

not start until the crankshaft rotates two turns under the most disadvantageous

Defective intake air heater system

Defective or deteriorated battery

condition. This phenomenon does not mean a problem, however.

Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Defective injector
Check recent repair history.
Machine operation Operated for long period E E E
hours
Starting perfor- Became worse gradually Qw w Q
mance Engine starts easily when warm w w
Questions

Fuel other than specified one is used QQ Q

The filter was not replaced as specified by the Operation and Maintenance Manual. w wQ Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi- w
cate proper functioning of preheating system
(if installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator indicates a red zone (if indicator is installed) w
Air breather hole in fuel tank cap is clogged w
Fuel leaks from fuel piping w Q
When priming pump is operated, no resistance is felt or it is heavy w Q
Starting motor cranks engine slowly w
Even if air bleeding plug in fuel filter head is removed, fuel does
While engine is
not flow out
w
cranked:
w
Check items

Too many fuel is returned from injector

When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts. Q w Q
Blowby gas is excessive w
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
When air is bled from fuel system, air comes out. q
q
Troubleshooting

Check fuel filter.

Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q
Even if starting switch is turned to HEAT, intake air heater mount does not become q
warm.
Is voltage 20 - 30 V between alternator terminal B and terminal E when Yes q
engine is running at low idle speed? No q
Specific gravity of electrolyte and voltage of battery are low. q
Cleaning

Cleaning
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

40-512 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

S-2 Engine does not start 40-513

a) Engine does not crank. Cause

General causes why engine does not crank

Defective connection of battery cable terminal

q Internal parts of engine seized.
o See "S-4 Engine stops during operations".

Defective starting motor (motor section)

q Defective electrical system
q Defect in the power train component

Defective or deteriorated battery

Defective starting circuit wiring

Broken flywheel ring gear

Defective starting switch

Defective battery relay

Defective safety relay

Check recent repair history.
Machine operation
Questions

Operated for long period EE

hours
Condition of horn Horn does not sound. Q Q w
when starting switch is
Horn volume is low.
w
turned ON
Battery electrolyte is level low. w
Battery cable terminal is loose. w
When starting switch is turned ON, no operating sound is heard from battery relay. Q w
When starting switch is turned to START, starter pinion does not plunge. Q Q w
Check items

When starting switch Rotation speed is low. w

is turned to START, Unusual noise is heard around ring gear. w w
starter pinion plunges, Pinion returns halfway. w
but: Unusual noise is heard around relay and engine does not rotate. Q QQ
Check flywheel ring gear. q

Perform E-mode troubleshooting

Specific gravity of electrolyte and voltage of battery are low. q
Voltage (20 - 30 V) between battery relay terminal B and terminal E q
Troubleshooting

is not found.
Turn starting switch to When terminal B and terminal C of starting switch are connected, q
OFF position and con- engine cranks.
nect cable, and per- When terminal B at safety relay outlet and terminal C are con- q
form troubleshooting nected, engine cranks.
with starting switch at Even if terminal B at safety relay outlet and terminal C are con- q
ON nected, engine does not crank.
When terminal at safety switch and terminal B at starting motor are
connected, engine cranks. q
Replace
Replace

Replace
Replace
Replace
Replace
Repair

Remedy
–

GD555-5,GD655-5,GD675-5 40-513
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

b) Engine cranks but no exhaust smoke comes out. Cause

Leakage or clogging of fuel piping or air in the fuel piping

General causes why engine cranks but no exhaust smoke comes out

q Fuel is not being supplied.

q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)

Clogged air breather hole in fuel tank cap

Seized or prematurely worn feed pump

Defective common rail pressure limiter

Stuck or seized supply pump plunger

Malfunction of pressure relief valve

Defective IMV for supply pump
Broken supply pump shaft
Insufficient fuel in tank

Defective fuel injector

Clogging of fuel filter
Use of improper fuel
Check recent repair history.
Machine opera-
Questions

Operated for long period EE

tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short
w Q w w E
time stoppage).
Fuel other than specified one is used. w
The filter was not replaced as specified by the Operation & Maintenance
w E Q
Manual.
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. Q w
Rust and water are found when fuel tank is drained. Q E EE
There is no fuel in the removed fuel filter. w w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Check items

Even if air bleeding plug in fuel filter head is removed,

Q Q w Q
While engine is fuel does not flow out.
cranked: Even if spill hose from injector is disconnected, little fuel
Q w w w Q
spills.
When air is bled from fuel system, air comes out. q
Check fuel filter or strainer. q
Troubleshooting

Check feed pump. q

Perform troubleshooting for the error "Low rail pressure" according to fail- q q
ure code (*1).
Perform troubleshooting for the error "IMV/PCV1 short or open circuit" q
according to failure code (*2).
Check pressure relief valve. q
Fuel flows out when pressure limiter return piping is disconnected. q
Cleaning
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Add

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA271] and [CA272]

40-514 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

c) Exhaust smoke comes out but engine does not start (fuel is injected). Cause

Leakage or clogging of fuel piping or air in the fuel system

Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine does not start

q Lack of cranking force due to defective electrical system

q Insufficient supply of fuel

Worn valve system (valve, rocker lever, etc.)

Clogged injection nozzle, or defective spray

q Insufficient intake of air

Clogged air breather hole in fuel tank cap

q Improper selection of fuel

Stuck or seized supply pump plunger

Defective intake air heater system

Defective or deteriorated battery
Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Use of improper fuel
Check recent repair history.
Machine operation Operated for long period
E E E
hours
Suddenly became unstartable. w w Q
Questions

Fuel other than specified one is used. QQ

The filter was not replaced as specified by the Operation & Maintenance Man-
w w
ual.
Oil must be added more frequently. w
When engine is preheated or when temperature is low, preheating monitor
does not indicate proper functioning of preheating system (if monitor is w
installed).
Dust indicator indicates a red zone (if indicator is installed). w
Air breather hole in fuel tank cap is clogged. Q
Rust and water are found when fuel tank is drained. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Starting motor cranks engine slowly. w
When engine is cranked, unusual noise is heard around cylinder head. w
Check items

Even if air bleeding plug in fuel filter head is removed, fuel

Q w
While engine is does not flow out.
cranked: Even if spill hose from injector is disconnected, little fuel
w
spills.
Check air cleaner. q
Check valve system. q
When compression pressure is measured, it is found to be low. q
Troubleshooting

When air is bled from fuel system, air comes out. q

Check fuel filter or strainer. q
Perform troubleshooting for the error "Low rail pressure" according to failure q
code (*1).
Specific gravity of electrolyte and voltage of battery are low. q
Coolant temperature gauge indication is not correct (if the gauge is installed). q
Even if starting switch is turned to HEAT, intake air heater mount does not q
become warm.
Cleaning

Cleaning
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

GD555-5,GD655-5,GD675-5 40-515
(01)
Troubleshooting of engine (S-mode)
S-3 Engine does not pick up smoothly

S-3 Engine does not pick up smoothly 40-516

General causes why engine will not pick up smoothly Cause

Leakage or clogging of fuel piping or air in the fuel

q Insufficient intake of air
q Insufficient supply of fuel

Clogged injection nozzle, or defective spray

q Improper fuel injection

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
q Improper selection of fuel

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

q Controller is controlling in derate mode.
(limiting injection rate (power) because of an error in electrical system)

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogging of fuel filter

Check recent repair history.
Machine opera- Operated for long period EE E E
Questions

tion hours
Engine pickup suddenly became worse. w Q Q Q
Fuel other than specified one is used. ww w
The filter was not replaced as specified by the Operation & Maintenance Manual. w w
Engine oil must be added more frequently. w
Dust indicator indicates a red zone (if indicator is installed). w
Air breather hole in fuel tank cap is clogged w
Rust and water are found when fuel tank is drained. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
When exhaust manifold is touched immediately after starting engine, temperature of Q w
some cylinders is low.
Color of exhaust Blue under light load w
Check items

smoke: Black w Q w w
While engine is running, unusual noise is heard around cylinder head. w
While engine is running, interference sound is heard around turbocharger. w
High idle speed is normal, but speed suddenly drops when load is applied. Q w
Engine hunts. Q Q Q
Blowby gas is excessive. w
Check air cleaner. q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Check valve clearance. q

When turbocharger is rotated by hand, it is found to be heavy. q
When air is bled from fuel system, air comes out. q
Check fuel filter or strainer. q
Perform troubleshooting for the error "Low rail pressure" according to failure code q
(*1).
Even if a cylinder is cut out, engine speed does not change. q
Cleaning

Cleaning
Replace
Replace

Replace
Replace
Replace
Repair

Repair
Adjust

Remedy

*1: Failure code [CA559] and [CA2249]

40-516 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-4 Engine stops during operation

S-4 Engine stops during operation 40-517

General causes why engine stops during operation Cause

Broken auxiliary equipment (pump or air compressor, etc.)

q Internal parts of engine seized
q Insufficient supply of fuel

Damage of valve system (valve, rocker lever, etc.)

q Engine overheating

Defective engine controller power supply wiring

q Defect in hydraulic pump

Clogged air breather hole in fuel tank cap

Broken or seized piston connecting rod

Stuck or seized supply pump plunger

Broken or seized crankshaft bearing

Clogging of feed pump gauze filter

Defective starting switch wiring

Clogged or leaking fuel piping

Broken or seized feed pump

Broken or seized gear train

Broken supply pump shaft

Defective hydraulic pump

Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
hours
Operated for long period EE
Unusual noise was heard and engine stopped
suddenly.
wwww QwQww
Questions

Condition when engine Engine overheated and stopped. wQ Q

stopped
Engine stopped slowly. w QQ QQ
Engine hunted and stopped. wQ QQQ QQ
Fuel other than specified one is used. QQQ Q
The filter was not replaced as specified by the Operation & Maintenance
Manual.
ww
Fuel level monitor indicates low level. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Fuel is leaking from fuel piping. w
Rust and water are found when fuel tank is drained. ww
Metal particles are found in oil drained from oil pan. ww QQ
Check items

It does not rotate at all. ww

When engine is rotated It rotate only in opposite direction. w
by hand: Crankshaft moves by amount of gear backlash. w w
Supply pump shaft does not turn. w
Engine operates, but stops when load is applied from machine. w
q
Perform H-mode troubleshooting.

Check valve system.

Inspect piston connecting rod. q
Check crankshaft bearing. q
Check gear train. q
Troubleshooting

Check fuel filter. q

Check feed pump gauze filter. q
Check feed pump. q
Perform troubleshooting for the error "Low rail pressure" according to fail- qq
ure code (*1).
Engine operates if auxiliary equipment (pump, air compressor, etc.) is q
removed.
Check engine controller power supply wiring. q
Check starting switch wiring. q
Cleaning

Cleaning
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Replace
Repair

Repair
Repair
Add

Remedy
–

*1: Failure code [CA559] and [CA2249]

GD555-5,GD655-5,GD675-5 40-517
(01)
Troubleshooting of engine (S-mode)
S-5 Engine runs rough or is unstable

S-5 Engine runs rough or is unstable 40-518

General causes why engine runs rough or is unstable Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Air in fuel system
q Defective engine speed sensor (error at degree that does not generate failure code)

Clogged injector or defective spray (dirt in injector)

Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness
Clogged air breather hole in fuel tank cap
Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
Operated for long period
E
hours
Questions

Occurs at a certain speed range. Q Q

Occurs at low idle. Q Q Q Q Q
Hunting
Occurs even when speed is raised. Q Q Q
Occurs on slope. w
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Troubleshooting Check items

Rust and water are found when fuel tank is drained. Q

Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q

When air is bled from fuel system, air comes out. q

Check fuel filter or strainer. q
Even if a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1). q
q
Perform troubleshooting for "Eng Bkup Speed Sensor Error" according to failure code (*2).
Cleaning
Replace
Replace
Replace
Replace
Replace
Add

Remedy

*1: Failure code [CA689]

*2: Failure code [CA778]

40-518 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-6 Engine lacks power

S-6 Engine lacks power 40-519

General causes why engine lacks power Cause

q Insufficient intake of air

Clogged injector nozzle, or defective spray (dirt in injector)

q Insufficient supply of fuel

Defective installation of boost pressure sensor (air leak)

q Improper fuel injection

Defective boost pressure sensor or wiring harness

q Improper selection of fuel

Air leakage from air intake piping and aftercooler

q Engine overheating
o See "S-14 Coolant temperature becomes too high (overheating)".

Defective injector drive (signal or solenoid)

Clogged air breather hole in fuel tank cap
Defective contact of valve with valve seat
q Controller is controlling in derate mode.

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

(limiting injection rate (power) because of an error in electrical
system)

Clogged or leaking fuel piping

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogged fuel spill piping

Clogging of fuel filter
Check recent repair history.
Machine operation
Operated for long period E E E E
hours
Q Q Q Q Q
Questions

Suddenly w
Power was lost
Gradually Q Q Q Q Q Q
Fuel other than specified one is used. Q Q Q
The filter was not replaced as specified by the Operation & Maintenance Manual. w w
Oil must be added more frequently. Q Q
Dust indicator indicates a red zone (if indicator is installed). w w
Air breather hole in fuel tank cap is clogged. w w
Fuel is leaking from fuel piping. w
Power becomes insufficient after short stop of operation. w
Black w w
Color of exhaust gas:
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of
w w
some cylinders is low.
w
Check items

While engine is running, interference sound is heard around turbocharger.

While engine is running, unusual noise is heard around cylinder head. w
High idle speed is too high. Q
High idle speed is normal, but speed suddenly drops when load is applied. Q w Q Q
Engine does not pick up smoothly and combustion is irregular. w w Q Q w
Engine hunts. Q Q Q Q Q
Blowby gas is excessive. w w

Check air cleaner. q

Check air intake piping. q
When boost pressure is measured, it is found to be low. q q q
When compression pressure is measured, it is found to be low. q q
q
Troubleshooting

Check valve clearance.

Check fuel piping. q
Check fuel filter or strainer. q
Check spill port check valve. q
Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q q
Check boost pressure sensor mount. q
Perform troubleshooting for "Boost pressure sensor error" according to failure code
(*2).
q
Cleaning

Cleaning
Replace
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Repair

Repair

Repair
Adjust

Remedy

*1: Failure code [CA559] and [CA2249]

*2: Failure code [CA122] and [CA123]

GD555-5,GD655-5,GD675-5 40-519
(01)
Troubleshooting of engine (S-mode)
S-7 Exhaust smoke is black (incomplete combustion)

S-7 Exhaust smoke is black (incomplete combustion) 40-520

Cause
General causes why exhaust smoke is black

q Insufficient intake of air

q Improper fuel injection
q Improper selection of fuel

Defective coolant temperature sensor or wiring harness

q Engine overheating.

Air leak at tubing between turbo and cylinder head

o See "S-14 Coolant temperature becomes too high (overheating)".
q Controller is controlling in derate mode.

Defective contact of valve with valve seat

(limiting injection rate (power) because of an error in electrical system)

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

Improper fuel injection pressure

Clogged air cleaner element

Worn piston ring or cylinder

Crushed or clogged muffler

Clogged or seized injector

Prematurely worn injector
Improper valve clearance

Improper injection timing

Check recent repair history.
Machine operation Operated for long period E E E E
hours
Suddenly became black. w w QQQ
Color of exhaust
w Q Q
Questions

Gradually became black.

smoke
Is blue under light load w
Fuel other than specified one is used. QQ
Engine oil must be added more frequently. w
Suddenly w Q QQ
Power was lost
Gradually Q Q Q Q
Dust indicator indicates a red zone (if indicator is installed). w
Muffler is crushed. w
Air leak at tubing between turbocharger and cylinder head, and loose clamp w
Engine is operated in low-temperature mode at normal temperature. QQQ
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low. Qw
While engine is running, interference sound is heard around turbocharger. w
w
Check items

While engine is running, unusual noise is heard around cylinder head.

Torque converter stall speed or pump relief speed is high. (Fuel is injected excessively.)
Q
Exhaust noise is unusual. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q QQQ Qw
Blowby gas is excessive. w
Too much fuel is returned from injector. w
Inspect air cleaner. q
When turbocharger is rotated by hand, it is found to be heavy. q
When compression pressure is measured, it is found to be low. q q
Troubleshooting

Chack valve clearance. q

If muffler is removed, exhaust sound improves. q
Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q q
When a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Coolant temperature sensor error" according to failure code (*2). q
Check the condition by using monitoring function of the machine monitor. qq
Cleaning
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Repair
Adjust

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

40-520 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-8 Oil consumption is excessive (or exhaust smoke is blue)

S-8 Oil consumption is excessive (or exhaust smoke is blue) 40-521

General causes why oil consumption is excessive Cause

Turbocharger
q Excessive oil carry-over

Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle

Worn/damaged valve (stem, guide, seal)

(Do not idle the engine for more than 20 minutes continuously.)
q External leakage of oil

Dust sucked in at air intake system

Clogged breather or breather hose

q Wear of parts in lubrication system

Worn or damaged rear oil seal

Oil leakage from oil drain plug

Worn seal at compressor end

Worn piston ring or cylinder

Oil leakage from oil cooler

Oil leakage from oil piping

Worn seal at turbine end

Oil leakage from oil filter

Broken piston rings

Broken oil cooler

Check recent repair history.
Machine operation Operated for long period EEE E
Questions

hours
Oil consumption suddenly increased. w Q
Engine oil must be added more frequently. w Q
Oil becomes contaminated quickly. Q Q w
Outside of engine is dirty with oil. w w w w w
Loose hose clamps are found in air intake system. w
Inside of air outlet pipe at turbo compressor side is dirty with oil. w
Inside of turbo exhaust outlet pipe is dirty with oil. Q w
Check items

Oil in coolant w
Oil level in rear gear housing is increasing. w
Exhaust smoke is blue under light load. w w
Excessive Q Q w w
Amount of blowby gas
None w
When intake manifold is removed, dust is found inside. q
When intake manifold is removed, inside is abnormally dirty. q
Troubleshooting

Excessive play of turbocharger shaft q q

Check breather or breather hose. q
When compression pressure is measured, it is found to be low. q q
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q q
External leakage of oil from engine q q q q
Cleaning
Replace
Replace

Replace
Replace

Replace
Replace
Repair
Repair

Repair

Repair
Repair
Repair
Repair

Remedy

GD555-5,GD655-5,GD675-5 40-521
(01)
Troubleshooting of engine (S-mode)
S-9 Oil becomes contaminated early

S-9 Oil becomes contaminated early 40-52

General causes why oil becomes contaminated early Cause

Clogged turbocharger lubrication oil drain tube

Defective sealing at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil

Clogged breather or breather hose

q Operation under excessive load

Defective oil filter safety valve

Worn piston ring or cylinder
Worn valve or valve guide

Exhaust smoke is bad.

Clogged oil cooler
Clogged oil filter
Check recent repair history.
Questions

Machine operation hours Operated for long period EEE

Fuel other than specified one is used. Q Q
Oil must be added more frequently. w
Metal particles are found in the removed oil filter. Q Q w
Inside of exhaust pipe is dirty with oil. w
Engine oil temperature rises quickly. w
Blue under light load w
Check items

Color of exhaust smoke

Black w
Excessive Q Q w Q
Amount of blowby gas
None w

Excessive play of turbocharger shaft q

Troubleshooting

When compression pressure is measured, it is found to be low. q q

(See S-7)
Check breather or breather hose. q
Check oil cooler. q
Check oil filter. q
Spring of oil filter safety valve is stuck or broken. q
Check turbocharger lubrication oil drain tube. q
Cleaning

Cleaning
Replace
Replace
Replace

Replace
Replace
Replace

Remedy
–

40-522 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive 40-523

General causes why fuel consumption is excessive Cause

Defective coolant temperature sensor or wiring harness

q Leakage of fuel
q Improper fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel

Fuel leakage from fuel filter, piping, etc.

Defective atomization by injector

Improper common rail pressure
Defective supply pump plunger

Defective operation of injector

Fuel leakage at cylinder head

Defective feed pump oil seal

Improper injection timing

Check recent repair history.
Machine opera- EE E
Questions

Operated for long period

tion hours
Is more than that on other machines of same model. Q QQQ
Fuel consump-
Gradually increased. Q Q
tion:
Suddenly increased. QQ
External leakage of fuel from engine w
Combustion is irregular. w
Engine oil level raised and oil smells of diesel fuel. w w
When exhaust manifold is touched immediately after starting engine, temperature of w
Check items

some cylinders is low.

Low idle speed is high. Q
Torque converter stall speed or pump relief speed is high. Q
Color of exhaust Black QQ QQ
smoke White Q
Remove head cover and check for fuel leak. q
Check oil seal of supply pump. q
Troubleshooting

Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q
Too much fuel is returned from injector. q
Perform troubleshooting for "Coolant temperature sensor error" according to failure q
code (*2).
Check the condition by using monitoring function of machine monitor. q q
Replace
Replace

Replace
Replace
Replace
Replace
Repair
Repair

Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

GD555-5,GD655-5,GD675-5 40-523
(01)
Troubleshooting of engine (S-mode)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)

S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 40-524
General causes why oil is present in coolant Cause

q Internal leakage in lubrication system

q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler

Broken cylinder head or cylinder head gasket

Broken oil cooler core or O-ring

Internal cracks in cylinder block
Holes caused by pitting
Check recent repair history.
Machine operation
E E
Questions

Operated for long period

hours
Suddenly Q Q Q
Oil level rose:
Gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Unusual air bubbles are found in radiator, or coolant spurts. w
Troubleshooting Check items

Hydraulic oil or power train oil is milky. w

When hydraulic oil or power train oil is drained, water is found in oil.
w

Pressure tightness test result of cylinder head shows oil leakage. q

Check cylinder block. q q

Pressure tightness test result of oil cooler shows oil leakage. q

Replace
Replace
Replace
Replace
Replace

Remedy

40-524 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-12 Oil pressure drops

S-12 Oil pressure drops 40-525

General causes why oil pressure drops Cause

Defective coolant temperature sensor or wiring harness

q Leakage, clogging, or wear on lubrication system
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.
q Deterioration of oil due to overheating

Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
Clogged strainer in oil pan

Defective regulator valve

Coolant or fuel in oil
Lack of oil in oil pan
Worn main bearing

Defective oil pump

Clogged oil filter

Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Oil pressure monitor indicates low oil pressure (if monitor is installed). Qw
Non-specified oil is being used. Q Q
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Indicates pressure drop at low idle. w
Oil pressure
Indicates pressure drop at low and high idle. Q wwwQ
monitor:
Indicates pressure drop on slope. w
(if installed)
Sometimes indicates pressure drop. w Q
Oil pressure monitor indicates low oil pressure (if monitor is installed). w w
Oil level in oil pan is low. w
External lubrication piping is leaking or crushed. w
Troubleshooting Check items

Oil is milky or smells of diesel fuel. w

Metal particles are found in oil drained from oil pan. w
Metal particles are found in the removed oil filter. w Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe. qq
See S-13.

Oil pump rotation is heavy or there is play in oil pump. q

Valve and spring of regulator valve are fatigued or damaged. q
Check oil filter. q
If oil level sensor is replaced, oil level monitor indicates correct oil level. q
Cleaning
Cleaning
Replace

Replace

Replace

Replace
Repair
Adjust
Add

Remedy
–

GD555-5,GD655-5,GD675-5 40-525
(01)
Troubleshooting of engine (S-mode)
S-13 Oil level rises (coolant or fuel in oil)

S-13 Oil level rises (coolant or fuel in oil) 40-526

General causes why oil level rises Cause

Broken cylinder head or cylinder head gasket

q Coolant in oil (milky)
q Fuel in oil (oil smells of diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for "S-11 Oil is in coolant"

Internal cracks in cylinder block

Broken oil cooler core or O-ring

Worn or damaged rear oil seal

Defects in supply pump

Holes caused by pitting
Broken injector O-ring
Check recent repair history.
Questions

Machine opera- Operated for long period

E EE
tion hours
Fuel must be added more frequently. w w
Coolant must be added more frequently. Q Q
Oil in coolant QQQQ w
Oil smells of diesel fuel. w w
Oil is milky. Q Q
While engine is running, drops of water come from muffler. Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
Troubleshooting Check items

w Q
appears, or coolant spurts.
Exhaust smoke is white. Q
Oil level in rear gear housing decreases. w
Oil level in hydraulic tank decreases.
When compression pressure is measured, it is found to be low. q
Remove injector and check O-ring. q
Check cylinder block. qq
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q
Remove and check supply pump. q
Replace
Replace
Replace
Replace

Replace
Replace
Repair

Remedy

40-526 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-14 Coolant temperature rises too high (overheating)

S-14 Coolant temperature rises too high (overheating) 40-527

General causes why coolant temperature rises too high Cause
q Lack of cooling air (deformation or damage of fan)

Broken cylinder head or cylinder head gasket

q Drop in heat dissipation efficiency
q Problem in coolant circulation system

Defective radiator cap (pressure valve)

Defective coolant temperature gauge
q Rise in power train oil temperature

Rise of power train oil temperature

Clogged or crushed radiator fins
Internal cracks in cylinder block

Clogged or broken oil cooler

Holes caused by pitting

Clogged radiator core

Defective thermostat
Malfunction of fan
Lack of coolant
Check recent repair history.
Machine opera-
Operated for long period E E EE
tion hours
Questions

Suddenly occurred. Qw
Overheating
Tends to occur always. Q Qww
Coolant tem- Indicates quick temperature rise. Q Q w
perature gauge:
Does not go down from red range. w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed).
Engine oil level has risen and oil is milky. wwQ
Milky oil is floating on coolant. QQw
Unusual air bubbles are found in radiator or coolant spurts. w
When light bulb is held behind radiator core, no light passes through. w
Check items

Radiator shroud and inside of underguard are clogged with dirt or mud. w
Coolant is leaking because of cracks in hose or loose clamps. w
Coolant flows out from radiator overflow hose. w
Power train oil temperature gauge enters red range faster than engine
w
coolant temperature gauge (if gauges are installed).
When compression pressure is measured, it is found to be low. q Perform H-mode troubleshooting.
Check cylinder. qq
Check oil cooler. q
q
Troubleshooting

Temperature difference between upper and lower tanks of radiator is large.

When operation of thermostat is tested, it does not open at specified open-
q
ing temperature.
Temperature difference between upper and lower tanks of radiator is
q
slight.
Inspect radiator core. q
When operation of radiator cap is tested, its opening pressure is low. q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Repair

Repair
Repair
Add

Remedy
–

GD555-5,GD655-5,GD675-5 40-527
(01)
Troubleshooting of engine (S-mode)
S-15 Unusual noise is made

S-15 Unusual noise is made 40-528

General causes why unusual noise is heard Cause

Improper fuel injection timing (defect in low coolant temperature sensor or boost temperature sensor)
q Abnormality due to defective parts
q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting trouble-
shooting.
a The engine is operated in the low-temperature mode while it is not warmed up suf-
ficiently. Accordingly, the engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode and its
sound becomes a little larger for up to about three seconds. This does not indicate
abnormality, however.

Air leak at tubing between turbocharger and cylinder head

Defective inside of muffler (partition board out of position)

Damage of valve system (valve or rocker lever)

Excessively worn piston ring or cylinder

Seizure or interference at turbocharger

Dislocated or seized bushing

Improper gear train backlash

Clogged or seized injector

Improper valve clearance

Dirt caught in injector

Check recent repair history.
Machine operation hours Operated for long period E
Questions

Gradually occurred. Q
Abnormal noise
Suddenly occurred. QQ Q
Fuel other than specified one is used. Q
Engine oil must be added more frequently. w
Metal particles are found in the removed oil filter. w w
Air leaks at tubing between turbocharger and cylinder head. w
While engine is running, interference sound is heard from turbocharger. w
While engine is running, unusual noise is heard around cylinder head. w w
While engine is running, beat noise is heard around muffler. w
wQ
Check items

When exhaust manifold is tounched immediately after starting engine, temperature of some cylinders is
low.
Blue under light load w
Color of exhaust smoke
Black Qw Q
Engine does not pick up smoothly and combustion is irregular. w
Unusual noise is loud when engine is accelerated. Q Q Q
Blowby gas is excessive. w
When turbocharger is rotated by hand, it is found to be heavy. q
Check valve system. q
If muffler is removed, unusual noise disappears. q
Troubleshooting

Check valve clearance. q

If muffler is removed, unusual noise disappears. q
Check gear train. qq
Even if a cylinder is cut out, engine speed does not change. qq
Unusual noise is heard only when engine is cranked. q
Check by using monitoring function of machine monitor. q
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Adjust

Remedy

40-528 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

S-16 Vibration is excessive 40-529

General causes why vibration is excessive Cause

Improper fuel injection timing (problem with coolant or boost temperature sensor)
q Defective parts (premature wear or breakage)
q Misalignment between engine and chassis
q Abnormal combustion
a If unusual noise is made and vibration is excessive, carry out troubleshooting also
for "S-15 Unusual noise is made".

Loose engine mount bolts or broken cushions

Worn main bearing or connecting rod bearing
Stuck valve system (valve, rocker lever, etc.)

Broken parts in output shaft or gear housing

Misalignment of engine and chassis
Improper gear train backlash
Worn camshaft bushing
Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q
Non-specified oil is being used. Q Q
Metal particles are found in the removed oil filter. w w
Metal particles are found in oil drained from oil pan. w w
Oil pressure is low at low idle. Q Q
Check items

Vibration occurs at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust smoke is black. w Q

Check valve system. q

Check main bearing and connecting rod bearing. q
Troubleshooting

Check gear train. q

Check camshaft bushing. q
Check the condition by using monitoring function of machine monitor. q
Check engine mounting bolts and cushions. q
When axial and radial alignment is checked, misalignment is found. q
Check inside of output shaft and rear gear housing. q
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Adjust

Rem-
edy

GD555-5,GD655-5,GD675-5 40-529
(01)
Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

GD555-5,GD655-5,GD675-5
GD555-5,GD655-5,GD675-5
SEN0521527-00 50-1

MOTOR GRADER
Shop Manual 50-1

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

50 Disassembly and assembly 50-1

GD555-5,GD655-5,GD675-5 50-1
(02)
Table of contents

Table of contents 50-2

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- 233
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

50-2 GD555-5,GD655-5,GD675-5
(02)
 Table of contents

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

GD555-5,GD655-5,GD675-5 50-3
(02)
General information on disassembly and assembly
How to read this manual
General information on disassembly and assembly
How to read this manual
1. Removal and installation of assemblies
Special tools
q Special tools which are necessary for removal or
installation of parts are described as A1 ••• X1
etc. and their part numbers, part names and
quantities are described in the special tool list.
q In the special tools table, the follwing information
is described, as well as the above items.
1) Necessity
t: Special tools that cannot be substituted
and should always be used.
q: Special tools that will be useful if available
and are substitutable with tools available
on the market.
2) New/redesign
N : Tools newly developed for this model.
They have a new part number respec-
tively.
R : Tools made available by redesigning
the existing tools which were devel-
oped for other models. Each of them
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of “Sketches of special
tools”.
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).
50-4
50-4
50-4
(Rev. 2009. 01)
50-4
50-4 Removal 50-4
q In “Removal” section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be drained are de-
scribed.
q Common tools that are necessary for removal
are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not de-
scribed.
q Various symbols used in “Removal” section are
explained and listed below.
k : Precautions related to work safety
a : Know-how or precautions for work
[*1] : This mark shows that instructions or
precautions for parts installation work are
given in “Installation” section.
6 : This mark shows the amount of oil or
coolant to be drained
4 : Weight of part or component
Installation 50-4
q Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q Instructions and precautions for parts installation
is shown with the mark ([*1], [*2]...) which corre-
sponds to the mark in “Removal” section.
q Common tools that are necessary for installation
are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not de-
scribed.
q Marks shown in the "Installation" section stand
for the following.
k : Precautions related to work safety
a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replen-
ished
Sketches of special tools 50-4
q Various special tools are illustrated for the local
manufacture.
GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
How to read this manual

2. Disassembly and assembly of assemblies 50-5

Special tools 50-5 Assembly 50-5
q Special tools which are necessary for disassem- q In “Assembly” section, the work procedures, pre-
bly and assembly of parts are described as cautions and know-how to do the work, and the
A1•••X1 etc. and their part numbers, part names amount of oil and coolant to be replenished are
and quantities are described in the special tool described.
list. q Common tools that are necessary for assembly
q In the special tools table, the follwing information are described as [1], [2]••• etc. and their part
is described, as well as the above items. numbers, part names and quantities are not de-
1) Necessity scribed.
t: Special tools that cannot be substituted q The meanings of the symbols used in "Assem-
and should always be used. bly" section are as follows.
q: Special tools that will be useful if available k : Precautions related to work safety
and are substitutable with tools available a : Know-how or precautions for work
on the market. 2 : Type of coating material
2) New/redesign 3 : Tightening torque
N : Tools newly developed for this model. 5 : Amount of oil or coolant to be replen-
They have a new part number respec- ished
tively.
R : Tools made available by redesigning Sketches of special tools 50-5
the existing tools which were devel- q Various special tools are illustrated for the local
oped for other models. Each of them manufacture.
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of “Sketches of special
tools”.
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).

Disassembly 50-5
q In “Disassembly” section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disassem-
bly are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not de-
scribed.
q The meanings of the symbols used in "Disas-
sembly" section are as follows.
k : Precautions related to work safety
a : Know-how or precautions for work
6 : Amount of oil or coolant drained.

GD555-5,GD655-5,GD675-5 50-5
(02)
General information on disassembly and assembly
Coating materials list

Coating materials list 50-6

(Rev. 2009. 08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate
-gor Komatsu code Part No. Capacity Container Main features and applications
y
q Use to prevent rubber gaskets, rubber cushions, and
LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
q Use for plastic (except polyethylene, polypropylene,
20 g Polyethyl-
LT-1B 790-129-9050 (2 pcs. ene con- tetrafluoroethylene and vinyl chloride), rubber, metal,
contained ) tainer and non-metal parts which require immediate and
Polyethyl-
q Features: Resistance to heat and chemicals
LT-2 790-129-9040 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive

Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines
MH 705
q Instanetaneous adhesive
Polyethyl-
ThreeBond q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 q Use mainly to bond metals, rubbers, plastics, and
tainer
woods.
q Instanetaneous adhesive
Polyethyl-
Aron-alpha q Quick-curing type (max. strength is obtained after 30
790-129-9130 2g ene con-
201 minutes)
tainer
q Use mainly to bond rubbers, plastics, and metals.
Polyethyl-
q Features: Resistance to heat and chemicals
Loctite 648-50 79A-129-9110 50 cc ene con-
q Use for fitted portions subjected to high temperature.
tainer
q Use to seal various threaded portions, pipe joints,
Polyethyl-
and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for hy-
tainer
draulic piping.
q Features: Silicon-based heat and cold-resistant seal-
ant
LG-6 790-129-9160 200 g Tube q To be used to seal threaded portions on flange sur-
Liquid gasket

face
q Use to seal oil pan, final drive case, etc.
q Features: Silicon-based quick-curing sealant
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat-resistant, vibration-re-
ThreeBond 419-15-18131 100 g Tube sistant, impact-resistant sealant
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the weld
ThreeBond 790-129-9310 200 g Tube
which must be caulked, etc.
1206D
q Can be coated with paint.

50-6 GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
Coating materials list

Cate
-gor Komatsu code Part No. Capacity Container Main features and applications
y
LG-10 q Use as lubricant/sealant when installing the radiator
ThreeBond 790-129-9320 200 g Tube hoses to the water tubes.
Liquid gasket

1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steering
1121 case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine
1211
q Use to prevent galling and seizure of press-fitted por-
Molybdenum disulfide

tions, shrinkage-fitted portions, and threaded por-

LM-P 09940-00040 200 g Tube
tions.
lubricant

q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on met-
- 09995-00250 190 g Can al surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings, var-
ious link pins, bolts, etc.
prevention compound

q Feature: Seizure and galling prevention compound

Seizure

with metallic super-fine-grain, etc.

LC-G
- - Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharger,
etc.

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
G0-LI(*) SYGA-160CNL q Feature: Lithium grease with extreme pressure lubri-
Various Various
*: For cold dis- I cation performance, general purpose type
trict SYG0-400LI-A
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Bel-
Molybdenum Caution:
SYG2-400M 400 g × 10 lows-type
disulfide q Do not use this grease for rolling bearings like
SYG2-400M-A 400 g × 20 container
grease swing circle bearings, etc. and spline.
SYGA-16CNM 16 kg
LM-G (G2-M) q Use this grease for work equipment pins only
Can
when installing them, but do not use it afterward.
Grease

Hyper White SYG2-400T-A

Grease SYG2-16CNT Bel-
q Seizure resistance, heat resistance and water resis-
G2-T, SYG0-400T-A 400 g lows-type
tance higher than molybdenum disulfide grease
G0-T(*) (*) 16 kg container
q Not conspicuous on machine since color is white.
*: For cold dis- SYG0-16CNT Can
trict (*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB Bel-
G2-BT(*) q Since this grease is biodegradable in short period, it
SYG2-400BT 400 g lows-type
*: For use at has less impact on microorganisms, animals, and
(*) 16 kg container
high tempera- plants.
SYGA-16CNBT Can
ture and under
(*)
high load
q Feature: Silicone grease with wide usable tempera-
G2-S ture range, high resistance to thermal-oxidative deg-
ThreeBond - 200 g Tube radation and performance to prevent deterioration of
1855 rubber and plastic parts
q Use for oil seals of the transmission, etc.

GD555-5,GD655-5,GD675-5 50-7
(02)
General information on disassembly and assembly
Coating materials list

Cate
-gor Komatsu code Part No. Capacity Container Main features and applications
y
q Feature: Urea (organic system) grease with heat re-
sistance and long life, can be packed into the con-
Grease

G2-U-S
427-12-11871 2 kg Can fined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
q Use as primer for painted cab sheet metal sur-
SUNSTAR
Glass con- face.
PAINT 20 ml
tainer (Term of validity: 4 months after manufac-
PRIMER580
turing)
SUPER 417-926-3910
SUNSTAR q Use as primer for painted cab sheet metal sur-
GLASS Glass con- face.

For adhered window glass

20 ml
PRIMER580 tainer (Term of validity: 4 months after manufac-
SUPER turing)
SUNSTAR q Use as primer for painted metal surface on
Primer

PAINT Glass con- cab.

22M-54-27230 20 ml
PRIMER tainer (Term of validity: 4 months after manufac-
435-95 turing)
q Used as primer for black ceramic-coated sur-
SUNSTAR
face on glass side and for hard polycarbon-
GLASS
22M-54-27240 150 ml Can ate-coated surface.
PRIMER
(Term of validity: 4 months after manufac-
435-41
turing)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Term of validity: 4 months after manufac-
GP-402 turing)
SUNSTAR q Use “S" in high-temperature season and “W"
PENGUINE Polyethyl- in low-temperature season as adhesive for
SEAL580 417-926-3910 320 ml ene con- glass.
SUPER “ S" or tainer (Term of validity: 4 months after manufac-
Adhesive

“ W" turing)
Sika Japan, Polyethyl- q Use as adhesive for glass.
Sikaflex 20Y-54-39850 310 ml ene con- (Term of validity: 6 months after manufac-
For adhered window glass

256HV tainer turing)

SUNSTAR Ecocart q Use as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Term of validity: 6 months after manufac-
SUPER 560 container) turing)
SUNSTAR
Polyethyl- q Use to seal glass-to-glass joints.
PENGUINE
417-926-3920 320 ml ene con- (Term of validity: 4 months after manufac-
SEAL No.
Caulking material

tainer turing)
2505
SEKISUI SILI- Polyethyl- q Use to seal front window.
CONE SEAL- 20Y-54-55130 333 ml ene con- (Term of validity: 6 months after manufac-
ANT tainer turing)
q Use to seal glass-to-glass joint. Translucent
GE TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL381
manufacture)

50-8 GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
Special tools list

Special tools list 50-9

a Tool part number 79TQT-QQQ-QQQQ is not available from Komatsu Ltd. (they are the tools to be locally
manufactured).
a Necessity:
t ……Cannot be substituted, must always be used.
q ……Extremely useful if available and substitutable with tools available on the masket.
a New/redesign:
N……Tools with new part numbers, newly developed for this model
R……Tools with upgraded part numbers, remodeled from items already available for other models
Blank……Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketch-
es of special tools)

New/redesign
Sketch
Necessity
Sym-

Q'ty
Component Part No. Part name Nature of work, remarks
bol

Removal and
installation of
fuel injector
assembly,
1 795-799 -1131 Gear t 1 Cranking engine
Removal and
installation of
cylinder head
assembly
Removal and
installation of
fuel injector
assembly,
2 795-502-1590 Puller t 1 Removal of fuel injector assembly
Removal and
installation of
cylinder head
assembly
Removal and A
installation of
engine front oil
Removal of engine front and rear oil
seal, Removal 3 795-931-1100 Seal puller assembly q 1
seals
and installation
of engine rear
oil seal
Removal and
installation of
4 795-799-6400 Seal driver q 1 N Installation of engine front oil seal
engine front
seal
Removal and
installation of 5 795-799-6500 Seal driver q 1 N Installation of engine rear oil seal
engine rear seal
Removal and
installation of
6 795-799-6130 Support t 1 Removal of supply pump gear
fuel supply
pump assembly

GD555-5,GD655-5,GD675-5 50-9
(02)
General information on disassembly and assembly
Special tools list

New/redesign
Sketch
Necessity
Sym-

Q'ty
Component Part No. Part name Nature of work, remarks
bol

Unit repair stand (AC100

790-501-5000 q 1
V)
Unit repair stands (AC110
Disassembly 790-501-5200 q 1 Disassembly and assembly of
1 and 220 V)
and assembly of torque converter assembly
C 790-901-2110 Bracket q 1
torque converter
assembly
793-310-2131 Plate q 1
793-310-2141 Plate q 1
Removal and installation of stator
2 792-390-1210 Wrench t 1
shaft round head nut
790-201-2740 Spacer t 1
1 796T-426-1140 Spacer t 1 Press fitting of 4th clutch bearing
790-101-5201 Push tool kit t 1
790-201-2740 Spacer t 1
Press fitting of FH and 1st clutch
2
790-101-5201 Push tool kit t 1 bearing, 2nd and 3rd clutch bearing

797T-423-1320 Push tool t 1 Q Press fitting of FL and R clutch

3
790-101-5201 Push tool kit t 1 bearing
794T-423-1110 Push tool t 1 Q
Press fitting of coupling cage oil
4 790-101-5221 Grip t 1
Disassembly seal
01010 – 51225 Bolt t 1
and assembly of
D
transmission 794T-423-1110 Push tool t 1 Q
assembly
5 794T-423-1120 Spacer t 1 Q Press fitting of coupling cage dust
seal
790-101-5221 Grip t 1
01010 – 51225 Bolt t 1
794T-423-1180 Push tool t 1 Q
6 790-101-5221 Grip t 1 Press fitting of coupling cover
01010 – 51225 Bolt t 1
7 793-310-2100 Lifting tool t 1 Lifting of clutch assembly
Centering of transmission and final
8 792-271-2000 Centering tool t 1 drive
9 799-301-1600 Oil leak checker t 1 Operation check of piston
Disassembly
and assembly of
1 792-571-1600 Chain puller t 1 Removal and installation of chain
tandem drive
assembly
790-101-5401 Push tool kit t 1
790-101-5551 q Plate 1
J 2 Press fitting of cage oil seal
Disassembly 790-101-5421 q Grip 1
and assembly of
01010-51240 q Bolt 1
wheel brake
assembly 794T-425-1110 Push tool t 1 Q Press fitting of bearing inner race of
3
793T-659-1110 Push tool t 1 Q drive shaft
4 799-301-1600 Oil leak checker t 1 Operation check of piston
1 794T-646-1010 Push tool t 1 Q
Removal and
2 794T-646-1021 Push tool t 1 N Q
installation of K Press fit of bearing
center hinge pin
3 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
4 790 - 101 - 1102 Pump t 1

50-10 GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
Special tools list

New/redesign
Sketch
Necessity
Sym-

Q'ty
Component Part No. Part name Nature of work, remarks
bol

790-502-1003 Cylinder repair stand t 1 Disassembly and assembly of

1
790 - 101 - 1102 Hydraulic pump t 1 hydraulic cylinder assembly
Removal, installation of cylinder
2 790-330-1100 Wrench assembly t 1
head
Socket
Available on the
(width across flats: 30 t 1 Steering
market
mm)
Socket
Available on the
(width across flats: 36 t 2 Leaning (*1)
market
mm)
Blade lift
(right and left)
Socket
Available on the Blade side shift
(width across flats: 41 t 1 Removal,
market Drawbar shift
mm) installation
3 Leaning (*2)
of piston
Power tilt
nut
Socket
Available on the
(Width across flats : 46 t 1 Scarifier
market
mm)
Socket
790-302-1270 (width across flats: 50 t 1 Articulate
mm)
Socket
790-302-1290 (width across flats: 60 t 1 Ripper
Disassembly mm)
and assembly of
U 790-201-1702 Push tool kit t 1
hydraulic cylin- Press fitting of cylinder head bush-
der assembly 790-101-5021 q Grip 1
ing
01010-50816 q Bolt 1
790-201-1731 q Push tool 1 Steering
Leaning
790-201-1741 q Push tool 1
Power tilt
4 Drawbar shift
790-201-1751 q Push tool 1
Articulate
Blade lift
(right and left)
790-201-1761 q Push tool 1
Blade side shift
Scarifier
790-201-1771 q Push tool 1 Ripper
790-201-1500 Push tool kit t 1 Press fitting of cylinder head dust
790-101-5021 q Grip 1
seal
01010-50816 q Bolt 1
790-201-1540 q Plate 1 Steering
Leaning
790-201-1550 q Plate 1
Power tilt
5 Drawbar shift
790-201-1560 q Plate 1
Articulate
Blade lift
(right and left)
790-201-1570 q Plate 1
Blade side shift
Scarifier
790-201-1580 q Plate 1 Ripper
(*1): GD555-5
(*2): GD6555, 675-5

GD555-5,GD655-5,GD675-5 50-11
(02)
General information on disassembly and assembly
Special tools list

New/redesign
Sketch
Necessity
Sym-

Q'ty
Component Part No. Part name Nature of work, remarks
bol

Installation of piston
6 790-720-1000 Expander q 1
ring
796-720-1620 Ring q 1
Steering
07281-00609 Clamp q 1
796-720-1640 Ring q 1 Blade lift
(right and left)
Disassembly Blade side shift
and assembly of U Drawbar shift
07281-00909 Clamp q 1 Leaning
hydraulic cylin- 7
der assembly Power tilt
Articulate
796-720-1650 Ring q 1
Scarifier
07281-01029 Clamp q 1
796-720-1670 Ring q 1
Ripper
07281-01279 Clamp q 1
Removal and Installation of adhered window
installation of
1 793–498–1210 Lifter (Suction cup) t 2
glass
operator’s cab X
glass (adhesed 2 20Y-54-13180 Stopper rubber t 2 Fixing of glass
glass)

50-12 GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
Sketches of special tools

Sketches of special tools 50-13

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D3 Push tool

D4 and D5 push tool

GD555-5,GD655-5,GD675-5 50-13
(02)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D5 spacer

D6 push tool

50-14 GD555-5,GD655-5,GD675-5
(02)
 General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
J3 Push tool

J3 Push tool

GD555-5,GD655-5,GD675-5 50-15
(02)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
K1 push tool

K2 push tool

50-16 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

Engine and cooling system 50-17

Removal and installation of fuel 2. Open side covers (4) and (5) on the right side of
supply pump assembly 50-17 the engine.

Special tools 50-17

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

A 6 795-799-6130 Support t 1

Removal
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.
50-17
3. Remove the cooling fan pump assembly. For
details, see "Removal and installation of cooling
fan pump assembly."
a Above is necessary to secure the working
place in removal of the fuel supply pump as-
sembly.
4. Disconnect connector (6) from fuel supply pump
(7).
5. Disconnect hoses (8) and (9) between the fuel
filters and also fuel return hose (10) from fuel
supply pump (7).

a Clean mud on the hose connection previous-

1. Set lock pin (3) on the frame. ly. (Mud sometimes stiffens the lock portion
(a))
a Disconnect the hoses while pushing locks (a)
of the hose fittings from both sides.
a When disconnecting the hoses, fuel will flow
out. Stop the flow by inserting plugs into the
hose fittings
a Use of a wooden plug is prohibited since
woodchip can infiltrate into the fuel line.

GD555-5,GD655-5,GD675-5 50-17
(02)
Engine and cooling system
Removal and installation of fuel supply pump assembly

6. Remove the high-pressure tube between the
fuel supply pump and common rail according to
the following procedures.
1) Remove nut (11) for the clamp, then discon-
nect fuel hoses (8) and (9) (used between the
fuel filter and fuel supply pump) from fuel filter
(12).
[*1]
a The opposite side ones of hoses (8) and
(9) are disconnected already from the fuel
supply pump in step 5.
2) Remove two clamps (14) and (15) for
harness (13) from fuel filter bracket (16).
3) Remove joint bolts (17) and (18) and remove
fuel return hoses (10) and (19) from the fuel
filter bracket.
[*2]
a The fuel supply pump side of fuel return
hose (10) is already disconnected in step
5.

4) Remove two bolts (20) and one stud bolt

a Clean mud on the hose connection previ- (21), then remove the fuel filter as an
ously. (Mud sometimes stiffens the lock assembly installed with the bracket (22).
portion (a)) [*3]
a Disconnect the hoses while pushing locks
(a) of the hose fittings from both sides.
a When disconnecting the hoses, fuel will
flow out. Stop the flow by inserting plugs
into the hose fittings.
a Use of a wooden plug is prohibited since
woodchip can infiltrate into the fuel line.

50-18 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

5) Remove clamp (24) for harness (23), then
remove clamp bracket (26) mounting bolt for
high-pressure tube (25).
[*4]
8. Remove the three mounting nuts for fuel supply
pump and remove fuel supply pump assembly
(7).
[*8]
a You can remove fuel supply pump assembly
(7), together with gear (30).
a When removing a inner side nut, such re-
moved nut sometimes falls to the floor due a
limited space. Therefore, it is advisable to
spread a piece of cloth on the floor to prevent
losing the nuts.

6) Remove clamp bracket (27) mounting bolt for

high-pressure tube (25).
[*5]
7) Remove the fuel spray prevention caps, then
loosen sleeve nut (28) and remove
high-pressure tubes (25).
[*6]
a Remove the fuel spray prevention cap on
the common rail side, too, and loosen
sleeve nut.
7. Disconnect fuel supply hose (29) from fuel
supply pump (7).
[*7]
a When disconnecting the hoses, fuel will flow
out. Stop the flow by inserting plugs into the
hose fittings.
a Use of a wooden plug is prohibited since
woodchip can infiltrate into the fuel line.

9. When removing gear (30) from the fuel supply

pump, follow the procedure described below.
[*9]
1) Fix the gear using tool A6 and 1/2-inch
spindle handle [1], and loosen nut (35).
a Do not remove nut (35) from the shaft.

GD555-5,GD655-5,GD675-5 50-19
(02)
Engine and cooling system
Removal and installation of fuel supply pump assembly
2) Install puller [2] between the flange and gear
(30) of the pump.
3) Install puller [3] on the shaft and puller [2],
and install center bolt [4] to the front-end of
the shaft.
4) Tighten center bolt [4] until the gear is disen-
gaged from the shaft.
5) Remove pullers [2] and [3] and center bolt [4].
6) Remove nut (35), lock washer (36) and gear
(30) from shaft (37).
50-20
Installation 50-20
q Carry out installation in the reverse order to re-
moval.
k Removed hoses are principally not reused
since the internal parts of the fitting are in
many cases damaged during removal. They
must be replaced with new ones when as-
sembling.
[*1]
3 Nut (11) for fuel hose clamp:
32 ± 4 Nm {3.2 ± 0.4 kgm}
[*2]
3 Joint bolt for fuel return hose:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*3]
3 Mounting bolt for fuel filter bracket:
32 ± 4 Nm {3.2 ± 0.4 kgm}
3 Mounting stud bolt for fuel filter bracket:
32 ± 4 Nm {3.2 ± 0.4 kgm}
[*4] [*5] [*6]
a High-pressure tube installation procedure
1. Manually tighten the high-pressure tube sleeve
nut on the fuel supply pump side and common
rail side.
2. Tighten the high-pressure tube sleeve nut on the
fuel supply pump side and common rail side, in
this order, to the following torque.
3 Sleeve nut :
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
3. Install two mounting clamp brackets (26) and
(27) for high-pressure tube (25).
a If rubber clamp (31) is hardened, replace it
with another one.
3 Clamp bracket mounting bolt (32):
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Rubber clamp lock bolt (33):
10 ± 2 Nm {1.0 ± 0.2 kgm}
GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

4. Install fuel spray prevention cap (34). 3 Mounting nut (35) for fuel supply
a When installing the fuel spray prevention pump gear:
caps, direct their slits outward and down- 105 ± 5 Nm {10.7 ± 0.51 kgm}
ward.
a The fuel spray prevention caps are prepared
as a fire defense means. Namely, if fuel leak-
age happened, they protect the hot parts of
the engine from being directly exposed to the
flying direction of leaked fuel.

q Air bleeding of fuel circuit

Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".

[*7]
3 Joint bolt for fuel supply hose:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*8]
a When installing a inner side nut for the fuel sup-
ply pump, such nut sometimes falls to the floor
due a limited space. Therefore, it is advisable to
spread a piece of cloth on the floor to prevent
losing the nuts.
3 Fuel supply pump mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*9]
Fuel supply pump gear installation procedure
a The shaft and gear mating face must be clean
(without dirt or foreign material) and dry prior to
assembly.
1) Install gear (30) to shaft (37).
2) Install lock washer (36) and nut (35) and
tighten nut (35) lightly with your hands.

3) Fix the gear using tool A6 and 1/2-inch

spindle handle [1], and tighten nut (35).

GD555-5,GD655-5,GD675-5 50-21
(02)
Engine and cooling system
Removal and installation of fuel injector assembly

Removal and installation of fuel injector assembly 50-2

2. Remove the engine hood assembly. For details,
Special tools 50-2 see "Removal and installation of engine hood
assembly".

New/redesign
Necessity
3. Remove the muffler assembly according to the

Sketch
Q'ty
Symbol Part No. Part name following procedures.
1) Remove muffler drain tube (4).
2) Remove plates (5) and (6).
1 795-799 -1131 Gear t 1 a Cover (7) can be removed only by remov-
A
2 795-502-1590 Puller t 1 ing bolt (8) which is used for installing
cover (7) to plate (5).
Removal 50-2
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota- 3) Remove the mounting bolt and lift off muffler
tion. assembly (9).
4 Muffler assembly:
35 kg

1. Set lock pin (3) on the frame.

50-22 GD555-5,GD655-5,GD675-5
(02)

4. Remove the muffler mounting bracket according
to the following procedures.
1) Remove clamp (10) and U-bolt (11), then
disconnect tube (12) from air intake
connector (13).
[*1]
2) Remove clamp (14) and remove plate (15)
from muffler mounting bracket (16).
3) Remove bracket (17) from muffler mounting
bracket (16).
4) Remove the mounting bolts and remove
muffler mounting bracket (16).
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of fuel injector assembly
5. Remove two clamps (19) and (20) for harness
(18), then disconnect three connectors from the
cylinder head and a connector from common rail
(21) and place them on your left side.
[*2]
a When disconnecting the connectors, insert a
screwdriver into the clearance of a connector
while pushing the connector lock by use of a
flat head screwdriver, then pull it out gradual-
ly prying the connector using the inserted
screwdriver.
6. Remove the intake air connector according to
the following procedures.
1) Disconnect terminal E07 (22) for the elec-
trical intake air heater from electrical intake
air heater (23).
2) Remove the mounting bolts, then remove air
intake connector (13) and electrical intake air
heater (23).
[*3]
50-23
Engine and cooling system
Removal and installation of fuel injector assembly

7. Using a hexagonal wrench (3 mm), remove two

bolts to remove blowby duct (24) from head
cover (25).
[*4]
8. Remove six nuts (26), then remove head cover
(25).
[*5]
a Clean the surrounding area in advance to
prevent intrusion of mud and dirt.

11. Using tool A1, rotate the crankshaft in normal

9. Remove fuel spray prevention cap (28) of
high-pressure tube (27).
[*6]
10. Loosen the sleeve nut and remove six high-pres-
sure tubes (27).
[*7]
a Loosen the sleeve nut on the cylinder head
side and common rail side.
a Removal of fuel pressure sensor (21a) and
relief valve (21b) on common rail (21) is al-
lowed for the replacement purpose alone.
[*8]
direction until the wide slit portion (b) of pulley
(30) with the speed sensing slit, which is located
in the rear side of dumper (29), is aligned with
the top (a) of the front cover protruding portion
(installed with the crank position sensor).
a Above operation is acceptable if the top (a) of
the protruding portion comes inside the wide
slit (b) range.
a Note that the cylinder does not reach the top
dead center when this position adjustment is
done. (Before top dead center of No.1 or
No.6 cylinder ranges from 76 to 88°C)

50-24 GD555-5,GD655-5,GD675-5
(02)

12. Loosen lock nut (31), then loosen adjustment
screw (32) by two to three turns.
a This work must be performed so that an ex-
cessive force is not applied to the push rod
when the rocker arm is installed.
13. Remove mounting bolt (33) and remove rocker
arm (34).
14. Remove crosshead (35).
a Record the crosshead installation position
and direction (shape of hole in a and b por-
tions). (It must be installed in the same direc-
tion in the assembly.)
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of fuel injector assembly
15. Remove retaining nut (36), then remove inlet
connector (37).
a Clean the surrounding area in advance to
prevent intrusion of mud and dirt.
a Do not remove injector harness connector
(51) from rocker housing unless your work re-
quires its removal.
[*9]
16. Remove nut (39) for the harness from fuel
injector (38).
17. Remove two mounting bolts (40) for fuel injector
(38), then remove holder (41).
50-25
Engine and cooling system
Removal and installation of fuel injector assembly

18. Using tool A2, remove fuel injector assembly Installation 50-26
(38). 1. Fuel injector assembly
a Be careful not to let any dust or contaminant a Check that the fuel injector sleeve is free
enter the fuel injector assembly mounting from flaw and dirt.
portion. 1) Install O-ring (42) and gasket (43) to fuel
injector (38).
2 O-ring and injector mounting hole:
Engine oil (E015W-40)
2) Fit concave portion (B) of holder (41) to
convex portion (A) of fuel injector (38) to
install holder (41).

3) Direct the fuel inlet hole of fuel injector (38) to

the air intake manifold side and install it to the
cylinder head.
4) Tighten two mounting bolts (40) for fuel
injector (38) by three to four threads with your
hands.
5) Install the harness to fuel injector (38) and
tighten nut (39).
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Installed positions of harnesses
Harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6

50-26 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of fuel injector assembly

2. Inlet connector
a Whenever replacing the fuel injector assem-
bly with a new one, you must replace inlet
connector (37) with a new one, too.

1) Install O-ring (44) to inlet connector (37).

a Check the inlet connector visually. If it has
any of the following faults, replace it with a
new one.
q Burrs or wear is recognizable in the inlet
connector front-end (a) and back-end (b)
portions.
q Foreign substances are caught in the
edge filter of the inlet connector back-end
(c) portion.
q Cracks or deterioration is recognizable in
O-ring of the inlet connector upper (d)
portion.
2 O-ring and inlet connector mount-
ing hole:
Engine oil (E015W-40)
2) Insert the convex portion (f) of the inlet
connector fully into the lateral groove of the
cylinder head, then install inlet connector
(37) temporarily using retaining nut (36).
3 Retaining nut:
14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}

3) Tighten mounting bolts (40) for fuel injector

(38) alternately, and tighten the bolts to the
specified torque.
3 Fuel injector mounting bolt
8 ± 0.8 Nm {0.8 ± 0.08 kgm}

a Check the inlet connector visually and if the

following trouble were found, replace the inlet
connector with a new one together with the
fuel injector assembly.
q Wear or nonuniform contact of seat sur-
face is observed on the sealing surface
(e) at the inlet connector front-end por-
tion.
a If high-pressure fuel leaks through the in-
let connector, the seal face has fine
streaks or cracks.

GD555-5,GD655-5,GD675-5 50-27
(02)
Engine and cooling system
Removal and installation of fuel injector assembly

4) Tighten inlet connector (37) using retaining
nut (36) to the specified torque.
3 Retaining nut:
50 ± 5 Nm {5.1 ± 0.5 kgm}
2) Install rocker arm (34), tighten bolt (33) with
your hands, then check the following.
a Make sure that the ball of adjustment
screw (32) is securely placed in the push
rod socket.
a Make sure that the flat surface of the
crosshead side cap of the rocker arm is in
contact with the contact surface of the
crosshead. (The contact should not be at
a slant.)
a Make sure that the injector harness does
not interfere with the rocker arm.
2 Threaded portion of mounting bolt
and seating surface:
Engine oil (E015W-40)
3) Tighten mounting bolt (33) for rocker arm
(34) to the specified torque.
3 Rocker arm mounting bolt:

3. Crosshead and rocker arm 36 ± 5 Nm {3.6 ± 0.5 kgm}

a Since the shape of holes on the crosshead is 4) Adjust the valve clearance. For details, see
not identical between (a) and (b) portions, Testing and adjusting, "Testing and adjusting
valve clearance".
3 Lock nut (31):
you must install it in the same direction using
the same intake and exhaust valves when re-
use it. 24 ± 4 Nm {2.45 ± 0.41 kgm}
a When installing the crosshead, make sure
that a valve is inserted into the holes (a) and
(b).

q Carry out the rest of installation in the reverse or-

der to removal.

[*1]
3
1) Install crosshead (35).
Tube mounting clamp:
7 ± 1 Nm {0.7 ± 0.1 kgm}
3 Retaining nut for tube mounting U-bolt:
14 Nm {1.4 kgm}

[*2]
k When installing, keep the distance of more
than 10 mm between the high-pressure tube
and the harness.

50-28 GD555-5,GD655-5,GD675-5
(02)

[*3]
3 Air intake connector mounting bolt :
34 ± 4 Nm {3.7 ± 0.4 kgm}
2 Air intake connector mounting bolt :
Adhesive (Loctite 516 or equivalent)
a Apply adhesive 10 mm minimum in width ex-
cept the first and second screw thread.
[*4]
3 Blowby duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*5]
3 Head cover mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*6] [*7]
High-pressure tube
k Do not renovate the fuel high-pressure tube
by bending before installing.
k Be sure to use the genuine fuel high-pres-
sure tube clamps and observe the specified
tightening torque.
a Before installing the high-pressure tube, check
the following points. If any trouble is found in the
following check, replace the high-pressure tube
with a new one to prevent fuel leakage.
q Make sure with visual check that the taper seal
portion of the connection ((a) portion: 2 mm
away from the front-end) is free from longitudinal
slits (b) or pits (c).
q Make sure that your fingernail does not get a
scratch in steps in (d) portion ( back-end of taper
seal portion: 2 mm away from the front-end).
(Namely, this portion must be free from fatigue.)
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of fuel injector assembly
1. Lightly tighten the cylinder head side and
common rail side (21) sleeve nuts for high-pres-
sure tubes (45) through (50).
3 Sleeve nut :
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2. Tighten high-pressure tubes (45) through (50) in
the following order.
3 Sleeve nut :
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
1) Cylinder head side of high-pressure tubes
(45) and (50)
2) Common rail side of high-pressure tubes (50)
and (45)
3) Tighten the cylinder head side in the order of
high-pressure tubes (46), (47), (48) and (49).
4) Tighten the common rail side in the order of
high-pressure tubes (46), (47), (48) and (49).
3. Install fuel spray prevention cap (28) to each
high-pressure tube.
a When installing the fuel spray prevention
caps, direct their slits outward and down-
ward.
a The fuel spray prevention caps are prepared
as a fire defense means. Namely, if fuel leak-
age happened, they protect the hot parts of
the engine from being directly exposed to the
flying direction of leaked fuel.
50-29
Engine and cooling system
Removal and installation of fuel injector assembly
[*8]
Fuel pressure sensor and relief valve
1. To replace fuel pressure sensor (21a), follow the
procedures below.
a Removal of fuel pressure sensor (21a) from
common rail (21) is allowed for the replace-
ment purpose alone.
a A fuel pressure sensor removed from the
common rail must be replaced with a new
fuel pressure sensor.
1) Before removing the fuel pressure sensor,
clean mud and dust of the area surrounding
the sensor.
2) Remove fuel pressure sensor (21a).
3) Check the fuel pressure sensor connector for
cracks, damages, damages on the sealing
portion and presence of foreign substances
in the pinned portion as well as corrosion,
bending and breakage of the pins.
4) Replace fuel pressure sensor (21a) with a
new one.
2 Threaded part of fuel pressure sen-
sor:
Gear oil (#90)
3 Fuel pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5) Connect the engine harness. At this time,
take care not to connect the harness in
reverse.
6) Start the engine and make sure that fuel
leakage is not present.
a For the testing procedure, see Testing
and adjusting, "Testing fuel circuit for
leakage".
50-30
2. To replace relief valve (21b), follow the proce-
dures below.
1) Before removing the relief valve, clean mud
and dust of the area surrounding the valve.
2) Remove relief valve (21b).
3) You must not reuse a relief valve when the
leakage through it is beyond the specified
value.
4) Make sure that the relief valve and high-pres-
sure sealing surface (A) on the common rail
are free from damages.
5) Install relief valve (21b).
2 Threaded part of relief valve:
Gear oil (#90)
3 Relief valve:
100 ± 4 Nm {10.2 ± 0.4 kgm}
a Avoid excessive tightening since it can in-
duce leakage.
6) Start the engine and make sure that fuel
leakage is not present.
a For the testing procedure, see Testing
and adjusting, "Testing fuel circuit for
leakage".
GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of fuel injector assembly

[*9]
Injector harness connector
q To install a removed injector harness connector,
perform the following procedures.
1) Apply liquid gasket (LG-7) to O-ring (53) and
flanged surface (n) of injector harness
connector (51).
a Apply liquid gasket (LG-7) (with 3 mm
width) until the groove for O-ring is fully
filled.
a If O-ring is damaged, the entire injector
harness assembly must be replaced.

2) Install injector harness connector (51) to

rocker housing (52), then tighten them using
mounting bolt (53).
3 Mounting bolt (53) of injector har-
ness connector:
10 ± 2 Nm {1.0 ± 0.2 kgm}

q Air bleeding of fuel circuit

Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".

GD555-5,GD655-5,GD675-5 50-31
(02)
Engine and cooling system
Removal and installation of cylinder head assembly

Removal and installation of cylinder head assembly 50-32

2. Drain the coolant through coolant drain valve (4).
Special tools 50-32 6 Coolant:
39.5 l

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

1 795-799 -1131 Gear t 1

A
2 795-502-1590 Puller t 1

Removal
k Park the machine on a level ground, and low
the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.
50-32
3. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
4. Remove the muffler assembly according to the
following procedures.
1) Remove muffler drain tube (5).
2) Remove plates (6) and (7).
a Cover (8) can be removed only by remov-
ing bolt (9) which is used for installing
cover (8) to plate (6).

1. Set lock pin (3) on the frame. 3) Remove the mounting bolt and lift off muffler
assembly (10).
4 Muffler assembly:
35 kg

50-32 GD555-5,GD655-5,GD675-5
(02)

5. Remove the muffler mounting bracket according
to the following procedures.
1) Remove clamp (11) and U-bolt (12), then
disconnect tube (13) from air intake
connector (14).
[*1]
2) Remove clamp (15) and remove plate (16)
from muffler mounting bracket (17).
3) Remove bracket (18) from muffler mounting
bracket (17).
4) Remove the mounting bolts and remove
muffler mounting bracket (17).
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of cylinder head assembly
6. Remove two clamps (20) and (21) of harness
(19), then disconnect three connectors from the
cylinder head and a connector from common rail
(22).
[*2]
a When disconnecting the connectors, insert a
screwdriver into the clearance of a connector
while pushing the connector lock by use of a
flat head screwdriver, then pull it out gradual-
ly prying the connector using the inserted
screwdriver.
50-33
Engine and cooling system
Removal and installation of cylinder head assembly

7. Disconnect ambient pressure sensor connector 10. Remove the mounting bolts, then remove air
(23). intake connector (14) and electrical intake air
[*3] heater (25).
a When disconnecting the ambient pressure [*4]
sensor connector, move the lock (a) toward
the right side and pull the connector out while
pressing (b) portion.
a Move harness (19) to the left side before
starting the job.

11. Remove the high-pressure tube between the

fuel supply pump and common rail according to
the following procedures.
1) Remove the cooling fan pump assembly. For
details, see "Removal and installation of
cooling fan pump assembly."
a Above is necessary to secure the working
space for removing the high-pressure
tube.
2) Remove nut (27) for the clamp, then discon-
nect fuel hoses (28) and (29) (used between
the fuel filter and fuel supply pump) from fuel
filter (30).
[*5]

8. Disconnect terminal E07 (24) for the electrical

intake air heater from electrical intake air heater
(25).
9. Disconnect boost pressure sensor connector
(26).

50-34 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

a Clean mud on the hose connection previ- 5) Remove two joint bolts (33) and a joint bolt
ously. (Mud sometimes stiffens the lock (34), then disconnect fuel return hoses (35)
portion (a)) and (36) from fuel filter bracket (37).
a Disconnect the hoses while pushing locks [*7]
(a) of the hose fittings from both sides.
a When disconnecting the hoses, fuel will
flow out. Stop the flow by inserting plugs
into the fittings.
a Use of a wooden plug is prohibited since
woodchip can infiltrate into the fuel line.

6) Remove two bolts (38) and one stud bolt

(39), then remove the fuel filter as an
assembly installed with the bracket (40).
[*8]

3) Remove the clamp and remove harness (31).

4) Remove six bolts to remove bracket (32).
[*6]

7) Remove clamp (42) for harness (41), then

remove clamp bracket (44) mounting bolt of
high-pressure tube (43).
[*9]

GD555-5,GD655-5,GD675-5 50-35
(02)
Engine and cooling system
Removal and installation of cylinder head assembly

8) Remove clamp bracket (45) mounting bolt for
high-pressure tube (43).
[*10]
9) Remove fuel spray prevention cap (46),
loosen the sleeve nut, then remove
high-pressure tube (43) from fuel supply
pump (47).
[*11]
a Remove the fuel spray prevention cap on
the common rail side, too, and loosen
sleeve nut.
13. Remove four bolts and remove common rail
(22).
[*13]
a Removal of fuel pressure sensor (22a) and
relief valve (22b) on common rail (22) is al-
lowed for the replacement purpose alone.
[*14]

14. Disconnect radiator upper hose (49).

[*15]
15. Disconnect coolant temperature sensor
connector (50).
12. Remove the fuel spray prevention caps, then
remove six high-pressure tubes (48).
[*12]

16. Disconnect tube and hose assembly (51) from

turbocharger (52).
[*16]

50-36 GD555-5,GD655-5,GD675-5
(02)

17. Remove covers (8) and (53).
a The muffler side bolt of cover (8) is removed
already in step 4.
18. Remove cover mounting brackets (54), (55) and
(56).
19. Remove the alternator assembly and alternator
mounting bracket according to the following
procedures.
1) Remove the clamp and disconnect harness
terminals (57), (58) and (59) from alternator
(60).
2) Remove alternator cover (61).
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of cylinder head assembly
3) Remove alternator belt (62).
a Insert wrench [1] to hole (A) portion on
tensioner (63), then drive in the tensioner
by rotating the wrench to loosen the ten-
sion of alternator belt (62) and remove it.
k Before driving in the wrench, make
sure that it is securely inserted to hole
(A) of the tensioner. (Since the spring
force of the tensioner is strong, the
wrench can disengage from the hole if
not inserted securely, potentially lead-
ing to serious personal injury.)
k After removing the alternator belt, re-
turn the tensioner gradually and with
care.
k Be careful during work not to get your
fingers caught between the pulley and
alternator belt.
50-37
Engine and cooling system
Removal and installation of cylinder head assembly

4) Sling alternator (60) and remove alternator 7) Disconnect tube (69).

lower mounting bolt (64). [*17] [*20]
a Clean the surrounding area in advance to
prevent intrusion of mud and dirt inside
the thermostat.

5) Loosen nut (65) of alternator (60) upper

mounting bolt, and remove mounting bolt
(66) to lifting off alternator assembly (60).
[*18] 20. Disconnect heater hose (70).
4 Alternator assembly:
20 kg

21. Disconnect turbocharger lubrication inlet tube

a When mounting bolt (66) interferes (71) and lubrication outlet tube (72).
with fuel prefilter hose (67), change [*21]
the direction of the hose beforehand.

6) Remove four bolts, then remove alternator

mounting bracket (68).
[*19]

50-38 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

22. Remove two bolts (74) of turbocharger mounting
bracket (73).
25. Remove six nuts (78), then remove head cover
(77).
[*24]
a Clean the surrounding area in advance to
prevent intrusion of mud and dirt.

23. Sling exhaust manifold and turbocharger

assembly (75), then remove the mounting bolt
and lift off the assembly.
[*22] 26. Using tool A1, rotate the crankshaft in normal
4 Exhaust manifold and turbocharger direction until the wide slit portion (b) of pulley
assembly: (80) with the speed sensing slit, which is located
40 kg in the rear side of dumper (79), is aligned with
the top (a) of the front cover protruding portion
(installed with the crank position sensor).
a Above operation is acceptable if the top (a) of
the protruding portion comes inside the wide
slit (b) range.
a Note that the cylinder does not reach the top
dead center when this position adjustment is
done. (Before top dead center of No.1 or
No.6 cylinder ranges from 76° to 88°)

24. Using a hexagonal wrench (3 mm), remove two

bolts to remove blowby duct (76) from head
cover (77).
[*23]

27. Loosen lock nut (81), then loosen adjustment

screw (82) by two to three turns.
a This work must be performed so that an ex-
cessive force will not be applied to the push
rod when the rocker arm is installed.

GD555-5,GD655-5,GD675-5 50-39
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Engine and cooling system
Removal and installation of cylinder head assembly

28. Remove mounting bolt (83) and remove rocker 30. Remove retaining nut (86), then remove inlet
arm (84). connector (87).
a Clean the surrounding area in advance to
prevent intrusion of mud and dirt.
a Do not remove injector harness connector
(111) from rocker housing unless your work
requires its removal.
[*25]

29. Remove crosshead (85).

a Record the crosshead installation position
and direction (shape of hole in a and b por-
tions). (It must be installed in the same direc-
tion in the assembly.)

31. Remove nut (89) for harness from fuel injector

(88).
32. Remove two mounting bolts (90) of fuel injector
(88), then remove holder (91).

50-40 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of cylinder head assembly

33. Using tool A2, remove fuel injector assembly
(88).
a Be careful not to let any dust or contaminant
enter the fuel injector assembly mounting
portion.
Installation 50-41
1. Cylinder head assembly
1) Measure stem length "a" of every cylinder
head mounting bolt to make sure that the
measured lengths are shorter than the using
limit.
q Bolt using limit ."a": Max. 132.1 mm
a If a bolt is longer than the using limit, do
not reuse it but replace it.

34. Remove push rods (92).

35. Remove rocker housing assembly (93).

2) Set cylinder head gasket (96) on the cylinder

block.
a Make sure that the cylinder head mount-
ing face and inside the cylinder are free
from dirt or contaminant.
a Make sure that the cylinder gasket is fit-
ted to the hole on the cylinder head.
3) Sling cylinder head assembly (95) and set it
on the cylinder block, then drive in mounting
bolt (94) by rotating it two to three turns with
your hand.

36. Remove mounting bolt (94) and lift off cylinder

head assembly (95).
4 Cylinder head assembly:
80 kg
37. Remove cylinder head gasket (96).

GD555-5,GD655-5,GD675-5 50-41
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Engine and cooling system
Removal and installation of cylinder head assembly
4) Tighten cylinder head mounting bolts [1] to
[26] sequentially according to the following
procedures.
2 Threaded portion of mounting bolt
and seating surface of head:
Engineoil (EO15W-40)
1] Tighten to 70 ± 6 Nm {7 ± 0.6 kgm}
2] Loosen all the bolts by 360° ± 5°
3] Tighten to 105 ± 3 Nm {10.7 ± 0.3
kgm}
4] Retighten by 90° ± 5°
a Use angle tightening tool for 2], 4]
a When an angle tightening tool is not
used:
q After applying a mark to the cylinder
head and bolts using a marker pen
and the like, retighten the bolts by 90 °
± 5 °.
50-42
2. Rocker housing
a Use care in the installation since rocker hous-
ing (93) mounting bolts of various lengths are
used.
Rocker housing mounting bolt (93a)
q M8x1. 25-50 (two bolts)
Rocker housing mounting bolt (93b)
q M8x1.25-70 (five bolts)
3 Rocker housing mounting bolts
(93a) and (93b): 24 ± 4m {2.4 ± 0.4
kgm}
3. Fuel injector assembly
a Check that the fuel injector sleeve is free
from flaw and dirt.
1) Install O-ring (97) and gasket (98) to fuel
injector (88).
2 O-ring and injector mounting hole:
Engine oil (EO15W-40)
2) Fit concave portion (B) of holder (91) to
convex portion (A) of fuel injector (88) to
install holder (91).
GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of cylinder head assembly

3) Direct the fuel inlet hole of fuel injector (88) to
the air intake manifold side and install it to the
cylinder head.
4) Tighten two mounting bolts (90) of fuel
injector (88) by 3 to 4 threads with your
hands.
5) Install the harness to fuel injector (88) and
tighten nut (89).
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Installed positions of harnesses
Harness color Cylinder No.
a Check the inlet connector visually. If it has
any of the following faults, replace it with a
new one.
q Burrs or wear is recognizable in the inlet
connector front-end (a) and back-end (b)
portions.
q Foreign substances are caught in the
edge filter of the inlet connector back-end
(c) portion.
q Cracks or deterioration is recognizable in
O-ring of the inlet connector upper (d)
portion.

White 1, 3, 5
Black 2, 4, 6

a Check the inlet connector visually and if the

4. Inlet connector
a Whenever replacing the fuel injector assem-
bly with a new one, you must replace inlet
connector (87) with a new one, too.
following trouble were found, replace the inlet
connector with a new one together with the
fuel injector assembly.
q Wear or nonuniform contact of seat sur-
face is observed on the sealing surface
(e) at the inlet connector front-end por-
tion.
a If high-pressure fuel leaks through the in-
let connector, the seal face has fine
streaks or cracks.

GD555-5,GD655-5,GD675-5 50-43
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Engine and cooling system
Removal and installation of cylinder head assembly
1) Install O-ring (99) to inlet connector (87).
2 O-ring and inlet connector mount-
ing hole:
Engine oil (E015W-40)
2) Insert the convex portion (f) of the inlet
connector fully into the lateral groove of the
cylinder head, then install inlet connector
(87) temporarily using retaining nut (86).
3 Retaining nut:
14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}
3) Tighten mounting bolts (90) for fuel injector
(88) alternately, and tighten the boits to the
specified torque.
3 Fuel injector mounting bolt
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
4) Tighten inlet connector (87) using retaining
nut (86) to the specified torque.
3 Retainer:
50 ± 5 Nm {5.1 ± 0.5 kgm}
50-44
5. Crosshead and rocker arm
a Since the shape of holes on the crosshead is
not identical between (a) and (b) portions,
you must install it in the same direction using
the same intake and exhaust valves when in-
stall it.
a When installing the crosshead, make sure
that a valve is inserted into the holes (a) and
(b).
1) Install crosshead (85).
2) Install rocker arm (84), tighten bolt (83) with
your hands, then confirm the following.
a The ball of adjustment screw (82) is se-
curely placed in the push rod socket.
a The flat surface of the crosshead side cap
of the rocker arm is in contact with the
contact surface of the crosshead. (The
contact should not be at a slant.)
a Make sure that the injector harness does
not interfere with the rocker arm.
2 Threaded portion of mounting bolt
and seating surface:
Engine oil (E015W-40)
3) Tighten mounting bolt (83) for rocker arm
(84) to the specified torque.
3 Rocker arm mounting bolt:
36 ± 5 Nm {3.6 ± 0.5 kgm}
GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

4) Adjust the valve clearance. For details, see [*4]

Testing and adjusting, "Testing and adjusting 3 Air intake connector mounting bolt :
valve clearance". 34 ± 4 Nm {3.7 ± 0.4 kgm}
3 Lock nut (81): 2 Air intake connector mounting bolt :
24 ± 4 Nm {2.4 ± 0.4 kgm} Adhesive (Loctite 516 or equivalent)
a Apply adhesive 10 mm minimum in width ex-
cept the first and second screw thread.
[*5]
3 Nut for fuel hose clamp:
32 ± 4 Nm {3.2 ± 0.4 kgm}
[*6]
3 Bracket mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*7]
3 Joint bolt for fuel return hose:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*8]
3 Fuel filter bracket Mounting bolt:
32 ± 4 Nm {3.2 ± 0.4 kgm}
3 Mounting stud bolt for fuel filter bracket:
q Carry out the rest of installation in the reverse or-
der to removal. 32 ± 4 Nm {3.2 ± 0.4 kgm}
[*9] [*10] [*11] [*12] [*13]
High-pressure tube
k Do not renovate the fuel high-pressure tube
[*1]
3 Tube mounting clamp:
by bending before installing.
k Be sure to use the genuine fuel high-pres-
7 ± 1 Nm {0.7 ± 0.1 kgm}
3 Retaining nut for tube mounting U-bolt:
14 Nm {1.4 kgm} sure tube clamps and observe the specified
[*2] tightening torque.
k When installing, keep the distance of more a Before installing the high-pressure tube, check
than 10 mm between the high-pressure tube the following points. If any trouble is found in the
and the harness. following check, replace the high-pressure tube
[*3] with a new one to prevent fuel leakage.
q Make sure with visual check that the taper seal
a After connecting ambient pressure sensor con-
nector (23), move lock (a) to the left side. portion of the connection ((a) portion: 2 mm
away from the front-end)is free from longitudinal
slits (b) or pits (c).
q Make sure that your fingernail does not get a
scratch in steps in (d) portion ( back-end of taper
seal portion: 2 mm away from the front-end).
(Namely, this portion must be free from fatigue.)

GD555-5,GD655-5,GD675-5 50-45
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Engine and cooling system
Removal and installation of cylinder head assembly

1. Lightly tighten common rail (22) mounting bolt

and the cylinder head side and common rail side
(22) sleeve nuts of high-pressure tubes (100)
through (105).
3 Common rail mounting bolt (installed
temporarily):
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
3 Sleeve nut of high-pressure tube (in-
stalled temporarily):
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2. Tighten high-pressure tubes (100) through (105)
in the following order.
3 Sleeve nut :
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
1) Cylinder head side of high-pressure tubes 3) Install two mounting clamp brackets (44) and
(100) and (105) (45) for high-pressure tube (43).
2) Common rail side of high-pressure tubes a If rubber clamp (106) is hardened, re-
(105) and (100) place it with a new one.
3 Clamp bracket mounting bolt (107):
3) Tighten the cylinder head side in the order of
high-pressure tubes (101), (102), (103) and 24 ± 4 Nm {2.45 ± 0.4 kgm}
3 Rubber clamp lock bolt (108):
(104).
4) Tighten the common rail side in the order of 10 ± 2 Nm {1.0 ± 0.2 kgm}
high-pressure tubes (101), (102), (103) and
(104). 4. Tighten the mounting bolt for common rail (22) to
the specified torque.
3 Common rail mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

3. Install high-pressure tube (43) (between fuel

supply pump and common rail (22)) according to
the following procedures.
1) Tighten high-pressure tube (43) sleeve nut
on the fuel supply pump side and common
rail side by your hand.
2) Tighten high-pressure tube (43) sleeve nut
on the fuel supply pump side and common
rail side, in this order, to the following torque.
3 Sleeve nut :
35 ± 3.5 Nm {3.6 ± 0.4 kgm}

50-46 GD555-5,GD655-5,GD675-5
(02)

5. Install fuel spray prevention cap (46).
a When installing the fuel spray prevention
caps, direct their slits outward and down-
ward.
a The fuel spray prevention caps are prepared
as a fire defense means. Namely, if fuel leak-
age happened, they protect the hot parts of
the engine from being directly exposed to the
flying direction of leaked fuel.
2. To replace relief valve (22b), follow the proce-
[*14]
Fuel pressure sensor and relief valve
1. To replace fuel pressure sensor (22a), follow the
procedures below.
a Removal of fuel pressure sensor (22a) from
common rail (22) is allowed for the replace-
ment purpose alone.
a A fuel pressure sensor removed from the
common rail must be replaced with a new
fuel pressure sensor.
1) Before removing the fuel pressure sensor,
clean mud and dust of the area surrounding
the sensor.
2) Remove fuel pressure sensor (22a).
3) Check the fuel pressure sensor connector for
cracks, damages, damages on the sealing
portion and presence of foreign substances
in the pinned portion as well as corrosion,
bending and breakage of the pins.
4) Replace fuel pressure sensor (22a) with a
new one.
2 Threaded part of fuel pressure sen-
sor:
Gear oil (#90)
3 Fuel pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of cylinder head assembly
5) Connect the engine harness. At this time,
take care not to connect the harness in
reverse.
6) Start the engine and make sure that fuel
leakage is not present.
a For the testing procedure, see Testing
and adjusting, "Testing fuel circuit for
leakage".
dures below.
1) Before removing the relief valve, clean mud
and dust of the area surrounding the valve.
2) Remove relief valve (22b).
3) You must not reuse a relief valve when the
leakage through it is beyond the standard
value.
4) Make sure that the relief valve and high-pres-
sure sealing surface (A) on the common rail
are free from damages.
5) Install relief valve (22b).
2 Threaded part of relief valve:
Gear oil (#90)
3 Relief valve:
100 ± 4 Nm {10.2 ± 0.4 kgm}
a Avoid excessive tightening since it
can induce leakage.
50-47
Engine and cooling system
Removal and installation of cylinder head assembly

6) Start the engine and make sure that fuel

leakage is not present.
a For the testing procedure, see Testing
and adjusting, "Testing fuel circuit for
leakage".

[*19]
3 Mounting bolt for alternator mounting
bracket:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*20]
[*15] 3 Tube mounting bolt:
3 Mounting clamp for radiator upper hose: 10 ± 2 Nm {1.0 ± 0.2 kgm}
8.8 ± 0.5 Nm {90 ± 5 kgcm} [*21]
[*16] 3 Turbocharger lubrication inlet tube:
3 Tube mounting clamp 35 ± 5 Nm {3.5 ± 0.5 kgm}
7 ± 1 Nm {0.7 ± 0.1 kgm} [*22]
[*17] a Tighten the exhaust manifold mounting bolt in
a Tighten alternator lower mounting bolt (64) to- the sequence shown in the figure.
gether with cover mounting plate (109). 3 Exhaust manifold mounting bolt
3 Alternator lower mounting bolt (64): 1st time: In the order from [1] to [12]
77 ± 12 Nm {7.8 ± 1.2 kgm} 24 ± 4 Nm {2.4 ± 0.4 kgm}
2nd time: In the order from [1] to [12]
53 ± 5 Nm {5.4 ± 0.5 kgm}
3rd time: From [1] to [4] alone in this
order
53 ± 5 Nm {5.4 ± 0.5 kgm}

[*18]
a Tighten alternator upper mounting bolt (66) to-
gether with cover mounting plate (110).
3 Alternator upper mounting bolt (66):
59 – 74 Nm {6.0 – 7.5 kgm}
[*23]
3 Blowby duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*24]
3 Head cover mounting nut :
24 ± 4 Nm {2.4 ± 0.4 kgm}

50-48 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of cylinder head assembly

[*25]
Injector harness connector
q To install a removed injector harness connector,
perform the following procedures.
1) Apply liquid gasket (LG-7) to O-ring (112)
and flanged surface (n) of injector harness
connector (111).
a Apply liquid gasket (LG-7) (with 3 mm
width) until the groove for O-ring is fully
filled.
a If O-ring is damaged, the entire injector
harness assembly must be replaced.

2) Install injector harness connector (111) to

rocker housing (93), then tighten them using
mounting bolt (113).
3 Mounting bolt (113) for injector har-
ness connector:
10 ± 2 Nm {1.0 ± 0.2 kgm}

q Refilling of coolant
Refill coolant through the coolant filler port up to
the specified level. Start the engine and circulate
the coolant, and then check the coolant level.
5 Coolant:
39.5 l

q Air bleeding of fuel circuit

Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".

GD555-5,GD655-5,GD675-5 50-49
(02)
Engine and cooling system
Removal and installation of engine front oil seal

Removal and installation of engine front oil seal 50-50

2. Remove the engine and transmission/torque
Special tools 50-50 converter assemblies. For details, see "Removal
and installation of engine and transmission/

New/redesign
Necessity
torque converter assemblies".

Sketch
a Place engine and transmission/torque con-

Q'ty
Symbol Part No. Part name
verter assemblies (1) on a stable block.
3. Remove alternator belt (4).
Seal puller
3 795-931-1100 q 1
A assembly
4 795-799-6400 Seal driver q 1 N

Removal
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.
50-50
a Insert wrench [1] to hole (A) portion on ten-
sioner (5), then drive in the tensioner by rotat-
ing it using the wrench to loosen the tension
of alternator belt (4) and remove it.
k Before driving in the wrench, make sure
that it is securely inserted to hole (A) of
the tensioner. (Since the spring force of
the tensioner is strong, the wrench can
disengage from the hole if not inserted se-
curely, potentially leading to serious per-
sonal injury.)
k After removing the alternator belt, return
the tensioner gradually and with care.
k Be careful during work not to get your fin-
gers caught between the pulley and alter-
nator belt.

1. Set lock pin (3) on the frame.

50-50 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of engine front oil seal

4. Remove six mounting bolts (6), and remove
flange (7) and damper (8).
[*1]
5. Remove pulley (9) with the speed sensing slit.
6. Remove the front oil seal according to the
following procedures.
a Before removing, tap front oil seal (10) once
to unstick it.
a Take care not to damage the contact surfac-
es of front oil seal of front cover (11) and
crankshaft (12).
1) Drill several holes approximately 3 mm in
diameter into front oil seal (10).
2) Replace the tip of tool A3 with the drill-type
tip and insert it in one of the holes drilled in
the above step.
3) Using tool A3 hammer [2], remove with
impact force.
a Perform the above procedure at several
places so that the front oil seal is not
slant.

q Tool A3 (drill-type tip)

GD555-5,GD655-5,GD675-5 50-51
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Engine and cooling system
Removal and installation of engine front oil seal

Installation 50-52 [*1]

q Using tool A4, install front oil seal (10) to front
cover (11).
a Before installation, check that crankshaft end
surface corners, sliding surfaces of front oil
seal lip, and front cover are free from flaws,
burrs, rust, etc.
a Clean, degrease and then dry the lip surface
on the front oil seal.
a Before inserting the front oil seal, clean, de-
grease and then dry the contact surface of
the crankshaft seal.
a Install the pulley with the speed sensing slit,
damper, and flange while aligning with dowel pin
(13) of crankshaft (12), and tighten mounting
bolts.
3 Mounting bolt:
Tighten mounting bolts in the following
order.
1] Tighten to 55 ± 5 Nm {5.6 ± 0.5 kgm} in a
diagonal order.
2] Loosen the bolts by 180°.
3] Tighten to 55 ± 5 Nm {5.6 ± 0.5 kgm} in a
diagonal order.
4] Tighten the bolt by turning if by 90° ± 5°
(using an angle tightening tool).

a The displacement of front oil seal (10) from front

cover (11) must meet the following criteria.
q Overhang from front cover (x):
Max. 0.38 mm
q Facial runout of front oil seal (TIR) (y):
Max. 0.25 mm

q Carry out the rest of installation in the reverse or-

der to removal.

50-52 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of engine rear oil seal

Removal and installation of engine rear oil seal 50-53

2. Remove the engine and transmission/torque
Special tools 50-53 converter assemblies. For details, see "Removal
and installation of engine and transmission/

New/redesign
Necessity
torque converter assemblies".

Sketch
Q'ty
Symbol Part No. Part name 3. Disconnect the engine and transmission/torque
converter assemblies. For details, see "Discon-
nection and connection of engine and transmis-
Seal puller sion/torque converter assemblies".
3 795-931-1100 q 1
A assembly 4. Place engine assembly (4) on a stable block [1].
5 795-799-6500 Seal driver q 1 N 5. Using a bolt, sling flywheel assembly (5).
6. Remove eight mounting bolts (6), set a guide
bolt, and lift off flywheel assembly (5).
Removal 50-53
k Park the machine on a level ground, and low-
[*1]
4 Flywheel assembly:
er the work equipment to the ground with the 55 kg
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.

7. Remove the rear oil seal according to the

following procedures.
a Before removing, tap rear oil seal (7) once to
unstick it.
a Take care not to damage the contact surfac-
es of rear oil seal of flywheel housing (8) and
crankshaft (9).
1) Drill several holes approximately 3 mm in
diameter into rear oil seal (7).
a Remove all the chips.
2) Replace the tip of tool A3 with the drill-type
tip and insert it in one of the holes drilled in
the above step.
1. Set lock pin (3) on the frame.

GD555-5,GD655-5,GD675-5 50-53
(02)
Engine and cooling system
Removal and installation of engine rear oil seal

3) Using tool A3 hammer [2], remove with Installation 50-54

impact force. 1. Insert pilot [3] into rear oil seal (7).
a Perform the above procedure at several a Before inserting the pilot, clean, degrease
places so that the rear oil seal is not slant. and then dry the lip surface on the rear oil
seal.

q Tool A3 (drill-type tip)

2. Insert rear oil seal (7), together with pilot [3] to
crankshaft (9), and push in the seal carrier
portion of rear oil seal (7) to flywheel housing (8).
a Before inserting the rear oil seal, clean, de-
grease and then dry the contact surface of
the crankshaft seal.
3. Pull out pilot [3], and further push in rear oil seal
(7).

50-54 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of engine rear oil seal

4. Using tool A5, insert the rear oil seal until it [*1]
flushes with flywheel housing (8) end surface. a Using a box-end combination wrench [4], fix fly-
wheel assembly (5) to flywheel housing (8) and
tighten mounting bolts (6).

a Push in while checking that the seal carrier is

not bent.
a Rear oil seal (7) overhang from flywheel
housing (8) (x): a Tighten the flywheel mounting bolts in the se-
Max. 0.38 mm quence shown in the figure.
3 Flywheel mounting bolt:
a Facial runout of rear oil seal (TIR) (y): 137 ± 7 Nm {14.0 ± 0.7 kgm}
Max. 0.25 mm

a Measure radial runout and facial runout of the

q Carry out the rest of installation in the reverse or-
der to removal.
flywheel.
q Measurement of radial runout
1] Install dial gauge [5] to the flywheel (5).
2] Set the probe of dial gauge [5] perpendic-
ular to the faucet joint portion (a) of
flywheel housing (8).
3] Set the dial gauge [5] reading to "0",
rotate the flywheel by one turn, and
measure the difference between the indi-
cated lowest and highest values.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360 °.

GD555-5,GD655-5,GD675-5 50-55
(02)
Engine and cooling system
Removal and installation of engine rear oil seal

q Radial runout: Max. 0.13 mm

q Measuring facial runout

1] Install dial gauge [5] to the flywheel (5).
2] Set the probe of dial gauge [5] perpendic-
ular to the end surface (b) around the
periphery of flywheel housing (8).
3] Set the dial gauge [5] reading to "0",
rotate the flywheel by one turn, and
measure the difference between the indi-
cated lowest and highest values.
a When measuring, push the crankshaft
to the front or rear so that an error is
not caused by the end play.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360 °.
q Facial runout: Max. 0.20 mm

50-56 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of cooling fan pump assembly

Removal and installation of cooling fan pump assembly 50-57

Removal
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Loosen the hydraulic tank cap to release the
pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.
3. Disconnect the following hoses in order to
50-57 secure the space necessary for removing the
cooling fan pump assembly.
1) Disconnect hoses (5) and (6) used between
the brake accumulators from charge
valve.(4).
[*1]
q Tape color of hose (5): White
q Tape color of hose (6): Red

1. Set lock pin (1) on the frame.

2) Remove clamp (7) and disconnect hose (8)

from charge valve (4).
3) Disconnect hose (9) from strainer (10).

2. Open side covers (2) and (3) on the right side of

the engine.

4. Disconnect tube (11) from cooling fan pump

(12).

GD555-5,GD655-5,GD675-5 50-57
(02)
Engine and cooling system
Removal and installation of cooling fan pump assembly

5. Disconnect hose (13) from cooling fan pump

(12).

6. Remove two mounting bolts (14) for cooling fan
pump and remove cooling fan pump assembly
(12).
a The assembly must be removed to prevent a
spanner from interfering with bolt (15) when
removing the bottom side mounting bolts for
cooling fan pump.
Installation 50-58
q Carry out installation in the reverse order to re-
moval.
[*1]
a Start the engine to pressurize the oil in the brake
accumulator.
q Refilling (hydraulic tank)
Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.

50-58 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of cooling fan and fan motor assembly

Removal and installation of cooling fan and fan motor assembly 50-59
2. Remove the engine hood assembly. For details,
Removal 50-59 see "Removal and installation of engine hood
k Park the machine on a level ground, and low- assembly".
er the work equipment to the ground with the 3. Remove the radiator guard assembly according
gear shift lever at the P position. to the following procedures.
k Stop the engine and set chocks under the 1) Sling radiator grille (4), and remove the
tires. mounting bolt to remove the radiator grille.
k Shut off the battery (negative) circuit by turn- 4 Radiator grille:
ing and removing lever (2) of disconnect 16 kg
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.

2) Disconnect connector CN-RL1 (5) on the

right side of the machine.

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.
1. Set lock pin (3) on the frame.

GD555-5,GD655-5,GD675-5 50-59
(02)
Engine and cooling system
Removal and installation of cooling fan and fan motor assembly

3) Remove clamp (7) of harness (6) on the left 6) Lift off radiator guard assembly (10).
side of the machine. 4 Radiator guard and assembly:
a The harness must be attached to the radi- 80 kg
ator guard when you remove it.

4. Remove clamps (11) in three places and remove

4) Remove backup buzzer (8) from the rear of cover (12).
the machine.

5. Disconnect three hoses (13), (14) and (15).

5) Remove four radiator guard mounting bolts 6. Remove U bolt (16) and remove tube (17).
(9) being provided on each side.

50-60 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of cooling fan and fan motor assembly

7. Disconnect three connectors CN-RT6 (18), 12. Remove nut (26).

CN-RT7 (19) and CN-RT8 (20). [*2]

8. Remove seven mounting bolts of fan guard (21). 13. Using puller [1], pull out cooling fan (27).
[*3]
4 Cooling fan:
17 kg

9. Sling cooling fan and fan motor assembly (22).

10. Remove four mounting bolts of mounting bracket
(23) and lift off cooling fan and fan motor pump
assembly (22). 14. Remove fan guard (21) from mounting bracket
4 Cooling fan and fan motor assembly: (23).
(Including fan guard): [*4]
55 kg a Put a mark on the fan guard installation posi-
tion.

11. Remove bolt (24) to remove lock plate (25).

[*1]

GD555-5,GD655-5,GD675-5 50-61
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Engine and cooling system
Removal and installation of cooling fan and fan motor assembly

15. Remove the clamp and disconnect three Installation 50-62

connectors CN-RT6 (28), CN-RT7 (29) and q Carry out installation in the reverse order to re-
CN-RT8 (30). moval.
a Above three connectors are the female side
ones being disconnected in step 7. [*1] [*2]
3 Nut (26):
98 – 128 Nm {10 – 13 kgm}
a Tighten nut (26) to 98 through 128 Nm {10
through 13 kgm}, and at the nearest position in
the nut retightening direction, align the pin hole
with the nut on both the front and back sides of
lock plate (25). Then retighten the nut, align the
lock plate bolt hole position and tighten bolt (24).
2 Bolt (24):
Adhesive (LT-2)
3 Bolt (24):
59 – 74 Nm {6 – 7.5 kgm}

16. Remove four mounting bolts (31) of cooling fan

motor from mounting bracket (23).

[*3]
a Make sure that key (33) is firmly set in the shaft
key groove of cooling fan motor (32).
17. Remove cooling fan motor assembly (32) from a Install the cooling fan aligning it to key (33).
the mounting bracket.
4 Cooling fan motor assembly:
18 kg

[*4]
a When installing the fan guard, align it to the mark
being put when it was removed.

50-62 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of radiator assembly

Removal and installation of radiator assembly 50-63

2. Drain the coolant through coolant drain valve (4).
Removal 50-63 6 Coolant:
k Park the machine on a level ground, and low- 39.5 l
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.
3. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
4. Remove the radiator guard assembly according
to the following procedures.
1) Sling radiator grille (5), and remove the
mounting bolt to remove the radiator grille.
4 Radiator grille:
16 kg

1. Set lock pin (3) on the frame.

2) Disconnect connector CN-RL1 (6) on the

right side of the machine.

GD555-5,GD655-5,GD675-5 50-63
(02)
Engine and cooling system
Removal and installation of radiator assembly

3) Remove clamp (8) of harness (7) on the left 6) Lift off radiator guard assembly (11).
side of the machine. 4 Radiator guard and assembly:
a The harness must be attached to the radi- 80 kg
ator guard when you remove it.

5. Disconnect upper hose (12) from the radiator.

4) Remove backup buzzer (9) from the rear of [*1]
the machine.

6. Disconnect overflow hose (13).

5) Remove four radiator guard mounting bolts
(10) being provided on each side.

50-64 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of radiator assembly

7. Disconnect lower hose (14) from the radiator.

[*2]
8. Disconnect drain hose (15) from the radiator.

13. Remove one mounting bolt (21) from the lower

front side of the radiator.

9. Remove the aftercooler assembly. For details,

see "Removal and installation of aftercooler
assembly."
a Since you need to move the radiator side-
ways when removing it,
10. Remove two radiator upper mounting bolts (16).
11. Remove two mounting bolts (18) for plate (17).

14. Remove one mounting bolt (22) from the lower

rear side of the radiator.

12. Remove plate (17), then remove plate (19) and

cushion (20) situated inside.

GD555-5,GD655-5,GD675-5 50-65
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Engine and cooling system
Removal and installation of radiator assembly

15. Remove two mounting bolt (23) from the lower 18. Remove two bolts and plate (29) from radiator
left side of the radiator. (28).

16. Loosen the mounting bolts for mounting

brackets (26) and (27) for air conditioner
condenser (24) and cooling fan oil cooler (25),
four each at the left and right, and pull the
bracket toward you.
a When removing the radiator, make sure that
the lower hose mounting pipe does not inter-
fere with the bracket.

Installation 50-6
q Carry out installation in the reverse order to re-
moval.

17. Lift off radiator assembly (28).
a Use care in the removal so that a piece of
sponge provided on both sides of the radiator
is not damaged.
4 Radiator assembly:
22 kg
[*1]
3 Upper hose mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3 Lower hose mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
q Refilling of coolant
Refill coolant through the coolant filler port up to
the specified level. Start the engine and circulate
the coolant, and then check the coolant level
again.
5 Coolant:
39.5 l

50-66 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of aftercooler assembly

Removal and installation of aftercooler assembly 50-67

3. Remove the radiator guard assembly according
Removal 50-67 to the following procedures.
k Park the machine on a level ground, and low- 1) Sling radiator grille (4), and remove the
er the work equipment to the ground with the mounting bolt to remove the radiator grille.
gear shift lever at the P position. 4 Radiator grille:
k Stop the engine and set chocks under the 16 kg
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.

2) Disconnect connector CN-RL1 (5) on the

right side of the machine.

1. Set lock pin (3) on the frame.

3) Remove clamp (7) of harness (6) on the left

side of the machine.
a The harness must be attached to the radi-
ator guard when you remove it.

2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".

GD555-5,GD655-5,GD675-5 50-67
(02)
Engine and cooling system
Removal and installation of aftercooler assembly

4) Remove backup buzzer (8) from the rear of 4. Disconnect upper hose (11) from the aftercooler.
the machine. [*1]

5) Remove four radiator guard mounting bolts 5. Disconnect lower hose (12) from the aftercooler.
(9) being provided on each side. [*2]

6) Lift off radiator guard assembly (10). 6. Remove two aftercooler upper mounting bolts
4 Radiator guard and assembly: (13).
80 kg

50-68 GD555-5,GD655-5,GD675-5
(02)

7. Loosen the mounting bolts for mounting
brackets (16) and (17) for air conditioner
condenser (14) and cooling fan oil cooler (15),
four each at the left and right, and pull the
bracket toward you.
a When removing the aftercooler, make sure
that the lower hose mounting pipe does not
interfere with the bracket.
8. Lift off aftercooler assembly (18).
[*3]
4 Aftercooler assembly:
15 kg
GD555-5,GD655-5,GD675-5
(02)
Engine and cooling system
Removal and installation of aftercooler assembly
Installation 50-69
q Carry out installation in the reverse order to re-
moval.
[*1]
a Set the threaded portions of the double clamps
after inverting their positions 180° from each oth-
er.
3 Upper hose mounting clamp:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2]
a Set the threaded portions of the double clamps
after inverting their positions 180° from each oth-
er.
3 Lower hose mounting clamp:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*3]
a Sling the aftercooler to make sure the convex
parts (a) in the aftercooler mounting side match-
es with the concave parts (b) of the frame side.
50-69
Engine and cooling system
Removal and installation of power train oil cooler assembly

Removal and installation of power train oil cooler assembly 50-70

3. Remove the radiator guard assembly according
Removal 50-70 to the following procedures.
k Park the machine on a level ground, and low- 1) Sling radiator grille (4), and remove the
er the work equipment to the ground with the mounting bolt to remove the radiator grille.
gear shift lever at the P position. 4 Radiator grille:
k Stop the engine and set chocks under the 16 kg
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.

2) Disconnect connector CN-RL1 (5) on the

right side of the machine.

a Prepare an oil container since oil flows out when

the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.

1. Set lock pin (3) on the frame.

3) Remove clamp (6) of harness (7) on the left
side of the machine.
a The harness must be attached to the radi-
ator guard when you remove it.

2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".

50-70 GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of power train oil cooler assembly

4) Remove backup buzzer (8) from the rear of 4. Disconnect upper hose (11) from the power train
the machine. oil cooler.

5) Remove four radiator guard mounting bolts 5. Disconnect lower hose (12) from the power train
(9) being provided on each side. oil cooler.

6) Lift off radiator guard assembly (10). 6. Remove two upper mounting bolts (13) for
4 Radiator guard assembly: power train oil cooler.
80 kg

GD555-5,GD655-5,GD675-5 50-71
(02)
Engine and cooling system
Removal and installation of power train oil cooler assembly

7. Remove two lower mounting bolts (14) for power Installation 50-72
train oil cooler. q Carry out installation in the reverse order to re-
moval.

[*1]
a Insert the power train oil cooler and tighten lower
mounting bolts (14) while aligning them with
mounting bolt holes (a).

8. Loosen the mounting bolts of mounting brackets

(17) and (18) for air conditioner condenser (15)
and cooling fan oil cooler (16), four each at the
left and right, and pull the bracket toward you.
a When removing the power train oil cooler,
make sure that the lower hose mounting pipe
does not interfere with the bracket.

q Refilling with oil (transmission case)

Refill hydraulic oil through the oil filler port to the
9. Lift off power train oil cooler assembly (19). specified level. Let the oil circulate in the
[*1] hydraulic system by starting the engine. Then
check the oil level again.
5 Transmission case
45 l

50-72 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of fuel tank assembly

Removal and installation of fuel tank assembly 50-73

3. Set lock pin (3) on the frame.
Removal 50-73
1. For the machine with ripper, remove the ripper
assembly and ripper bracket. For details, see
"Removal and installation of ripper assembly".
a For the machine with rear counterweight, re-
move the rear counterweight.
2. Place the rear wheel on stand [1] with a height of
approximately 400 mm.
a This is to secure enough space when lower-
ing the fuel tank.
a Fuel tank height (tank only): 600 mm
a Ground clearance to fuel tank bottom: 390
mm

4. Open side covers (4) and (5) on the right and left
side of the engine.

k Set the gear shift lever to the P position

and lower the work equipment to the
ground.
k Stop the engine and set chocks under the 5. Drain fuel through fuel tank drain valve (6)
tires.
k
located at the bottom in the rear left of the
Shut off the battery (negative) circuit by machine.
6 Fuel tank:
turning and removing lever (2) of discon-
nect switch (1) (front left side of the en- 416 l (at full)
gine room) being installed on the battery
and hydraulic tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it
is turned ON if you attach and rotate
the lever of circuit breaker, and fix it af-
ter rotation.

GD555-5,GD655-5,GD675-5 50-73
(02)
Engine and cooling system
Removal and installation of fuel tank assembly

6. Sling radiator grille (7), and remove the 9. Remove clamps (10) and (11) at the top of the
mounting bolt to remove the radiator grille. fuel tank.
4 Radiator grille: 10. Remove fuel filler port (12).
16 kg

11. Remove clamps (13), (14), (15) and (16) at the

7. Remove backup buzzer (8) from the rear of the top of the fuel tank.
machine. 12. Remove clamp (17) and disconnect connector
CN-ET39 (18).

8. Remove one fuel tank mounting bolt (9) which is

located below the backup buzzer. 13. Remove bolt (20) of clamp (19) after slightly
[*1] lowering the fuel tank.

50-74 GD555-5,GD655-5,GD675-5
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 Engine and cooling system
Removal and installation of fuel tank assembly

14. Remove the clamp from the fuel tank, and 18. Remove clamps (28) of two ripper hoses (27)
disconnect hose (21) used between the fuel located at the left side of the fuel tank.
prefilters.
15. Remove the clamp from the fuel tank, and
disconnect fuel return hose (22).

19. Remove engine oil drain valve (29) from the right
side of the fuel tank.

16. Remove clamp (24) for hose (23) used between

the fuel prefilter and fuel supply pump, from the
fuel tank.

20. Remove radiator overflow hose (30) from the left

side of the fuel tank.
21. Remove fuel drain valve cover (31).

17. Remove clamps (26) for two upper and lower

hoses (25) of the cooling fan located at the right
side of the fuel tank.

GD555-5,GD655-5,GD675-5 50-75
(02)
Engine and cooling system
Removal and installation of fuel tank assembly
22. Using a forklift truck, support the fuel tank
assembly.
23. Remove fuel tank mounting bolts, one each from
the left (32) and right (33).
[*2]
24. Lower the fuel tank assembly by using a forklift
truck, and remove bolt (20) of clamp (19). Follow
the procedure of step 13.
[*3]
25. Using a forklift truck, gradually lower fuel tank
assembly (34), and pull it toward you to remove.
4 Fuel tank assembly:
210 kg
50-76
Installation 50-76
q Carry out installation in the reverse order to re-
moval.
[*1]
3 Fuel tank mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*2]
3 Fuel tank mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*3]
a Lift the fuel tank assembly by using a forklift
truck, and install bolt (20) for clamp (19) before
installing the mounting bolt.
q Air bleeding of fuel circuit
Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".
GD555-5,GD655-5,GD675-5
(02)
 Engine and cooling system
Removal and installation of engine hood assembly

Removal and installation of engine hood assembly 50-7

3. Remove the clamp and disconnect air duct hose
Removal 50-7 (4) from air cleaner (5).
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.

1. Set lock pin (1) on the frame.

4. Disconnect dust indicator hose (6) from air

cleaner (5).

2. Remove side covers (2) and (3) on the the right

and left side of engine.
4 Engine side cover (2):
20 kg
4 Engine side cover (3):
16 kg

5. Remove cover (7) which is installed above the

radiator oil filler port.

GD555-5,GD655-5,GD675-5 50-77
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Engine and cooling system
Removal and installation of engine hood assembly

6. Remove two rubber caps (8) at the right and left. Installation 50-78
Remove mounting bolts (9). q Carry out installation in the reverse order to re-
moval.

[*1]
q Align the exhaust pipe with the muffler while in-
stalling the engine hood.

7. Remove two mounting bolts (10), one each from

the left and right sides, at the front of the engine
hood.

8. Lift off engine hood assembly (11).

[*1]
4 Engine hood assembly:
90 kg

50-78 GD555-5,GD655-5,GD675-5
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 Power train
Removal and installation of engine and transmission/torque converter assembly

Power train 50-79

Removal and installation of engine and transmission/torque converter
assembly
Removal 50-79
k Park the machine on a level ground, and low-
er the work equipment to the ground with the
gear shift lever at the P position.
k Stop the engine and set chocks under the
tires.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is turned
OFF when the lever is removed. And it is
turned ON if you attach and rotate the le-
ver of circuit breaker, and fix it after rota-
tion.
50-79
1. Collect the refrigerant (R134a) from the air
conditioner circuit.
a Ask a qualified distributor for collection
and charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a)
into the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves
and long sleeved work clothes when col-
lecting or charging the refrigerant.
q Amount of air conditioner refrigerant (R134a)
to be collected:
1,050 ± 50 g
2. Set lock pin (3) on the frame.

3. Drain the coolant through coolant drain valve (4).

k Loosen the hydraulic tank cap to release the 6 Coolant:
pressure inside the hydraulic tank. 39.5 l
a Record the currently installed positions of the
hoses and wires so that they are not installed in
wrong positions.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.
k If you drain the coolant or disconnect the
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.

GD555-5,GD655-5,GD675-5 50-79
(02)
Power train
Removal and installation of engine and transmission/torque converter assembly

4. Drain the hydraulic oil through the hydraulic tank 3) Remove the mounting bolt and lift off muffler
drain valve (5). assembly (11).
6 Hydraulic oil: 4 Muffler assembly:
69 l 35 kg

5. Remove the engine hood assembly. For details, 8. Remove the following parts from the right side of
see "Removal and installation of engine hood the machine.
assembly". 1) Remove clamp (12) and U-bolt (13), then
6. Remove hydraulic tank, battery, and angle disconnect tube (14) from air intake
assembly. For details, see "Removal and instal- connector (15).
lation of hydraulic tank, battery, and angle [*1]
assembly."
7. Remove the muffler assembly according to the
following procedures.
1) Remove muffler drain tube (6).
2) Remove plates (7) and (8).
a Cover (9) can be removed only by remov-
ing bolt (10) which is used for installing
cover (9) to plate (7).

2) Remove two clamps (17) of upper hose (16)

for power train oil cooler.

50-80 GD555-5,GD655-5,GD675-5
(02)
 Power train
Removal and installation of engine and transmission/torque converter assembly

3) Disconnect upper hose (16) for power train 6) Remove the clamp for bracket (26) located
oil cooler from the power train oil cooler (18). under the air conditioner compressor, and
a Disconnect the lower hose of power train remove hose (27) used between the receiver
oil cooler from the transmission side. dryer and air conditioner unit.

4) Disconnect return hose (20) from cooling fan 7) Disconnect hose (29) from cooling fan pump
oil cooler (19). (28).

5) Remove two clamps (21) and (22), and 8) Disconnect fuel supply hose (31) from fuel
disconnect air conditioner tube (24) and hose supply pump (30).
(25) from air conditioner compressor (23). [*3]
[*2]
a Plug the air conditioner tube, hose, and
compressor to prevent entry of dirt, dust,
etc. after disconnection.

GD555-5,GD655-5,GD675-5 50-81
(02)
Power train
Removal and installation of engine and transmission/torque converter assembly

9) Disconnect PLs port hose (33) and Pp port 12)Remove clamp (40), and remove engine oil
hose (34) from hydraulic pump (32). drain valve (41).
q Tape color of hose (33): Blue a Remove the drain valve together with the
q Tape color of hose (34): Orange engine assembly.

10)Remove two clamps (35) and (36), and 9. Remove the following parts from the left side of
disconnect harness (37) from charge valve the machine.
(38). 1) Disconnect tube and hose assembly (42)
11)Remove the mounting bolt, and remove from turbocharger (43).
charge valve assembly (38) from the frame. [*4]
a Pull cartridge (39) of charge valve (38) to-
ward you so as not to interfere with the
engine.

2) Disconnect radiator upper hose (44) from

tube (45).
[*5]

50-82 GD555-5,GD655-5,GD675-5
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Removal and installation of engine and transmission/torque converter assembly
3) Disconnect radiator lower hose (46) from the
engine side.
[*6]
4) Remove the clamp and disconnect heater
hose (47) from the engine side.
5) Remove the bolt, and disconnect connectors
CN-T20 (48), CN-T21 (49), and CN-T22 (50).
6) Disconnect two hoses (52) and (53) from
power train pump (51).
GD555-5,GD655-5,GD675-5
(02)
Power train
7) Remove three clamps (54), (55), and (56) for
hoses (52) and (53).
8) Remove engine ground terminal (57).
9) Remove ground harness terminals CN-FT13
(58) and CN-ET77 (59) and remove the
clamp. Pull harness (60) toward you so as
not to interfere with the engine.
10)Disconnect tube (61) and hose (62) from
power train pump (51).
a This is to prevent interference with the
tool when removing the engine mounting
bolt.
11)Remove connector cover (63).
50-83
Power train
Removal and installation of engine and transmission/torque converter assembly

12)Remove the clamp and disconnect three
connectors CN-ER02 (64), CN-ER3 (65),
and CN-ER1 (66).
15)Remove three clamps (73), (74), and (75) for
hoses (70), (71), and (72) from the transmis-
sion.
a Remove all the clamps for hoses (70),
(71), and (72) being fixed to the transmis-
sion.
a Remove clamp (75) to prevent interfer-
ence of the hose with the engine. (Pull the
hoses toward you.)

13)Disconnect hose (67) from priority valve (port

EF).

10. Remove front undercover (76) and rear under-

cover (77).
[*7]
4 Undercover (76):
25 kg
4 Undercover (77):
25 kg

14)Disconnect Ls port hose (69) from priority

valve (68).
q Tape color of hose (69): White

50-84 GD555-5,GD655-5,GD675-5
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 Power train
Removal and installation of engine and transmission/torque converter assembly

11. Disconnect lower hose (78) for power train oil 14. Remove two mounting bolts (81) on transmis-
cooler from the bottom of the transmission. sion side each at the right and left.
[*10]
a Take care not to lose nut (82) at the bottom.

12. Remove universal joint (79) between the trans-

mission and final drive.
[*8]

15. Lift off engine and transmission/torque converter

assembly (83).
13. Remove mounting bolts (80) on engine side, one a Make sure that all the piping and harnesses
each from the right and left. are disconnected before lifting them off.
[*9] 4 Engine and transmission/torque con-
verter assembly:
1,800 kg

GD555-5,GD655-5,GD675-5 50-85
(02)
Power train
Removal and installation of engine and transmission/torque converter assembly

Installation 50-86 [*5]

q Carry out installation in the reverse order to re- 3 Mounting clamp for radiator upper hose:
moval. 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*1]
3 Tube mounting clamp: [*6]
7 ± 1 Nm {0.7 ± 0.1 kgm} 3 Mounting clamp for radiator lower hose:
3 Retaining nut for tube mounting U-bolt: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
14 Nm {1.4 kgm} [*7]
[*2] 2 Undercover mounting bolt:
a When installing the air conditioner hoses and Adhesive (LT-2)
tubes, take care that dirt, dust, water, etc. do not 3 Undercover mounting bolt:
enter them. 98 – 123 Nm {10 – 12.5 kgm}
a When installing the air conditioner hoses and
tubes, check that O-ring is fitted to each of their [*8]
fittings. 2 Universal joint mounting bolt:
a Check that there is no defect or deterioration on Adhesive (LT-2)
the O-ring. 3 Universal joint mounting bolt:
a When connecting air conditioner tube (24) and 98 – 123 Nm {10 – 12.5 kgm}
hose (25), apply compressor oil for refrigerant [*9]
(R134a) (DENSO: ND-OIL8 or VALEO THER- 2 Mounting bolts on engine side
MAL SYSTEMS: ZXL100PG (equivalent to Adhesive (LT-2)
PAG 46)) to O-ring (84). 3 Mounting bolts on engine side
98 – 123 Nm {10 – 12.5 kgm}
[*10]
2 Mounting bolt on transmission side:
Adhesive (LT-2)
3 Mounting bolt on transmission side:
98 – 123 Nm {10 – 12.5 kgm}

q Refilling with coolant

Refill coolant through the coolant filler port up to
the specified level. Start the engine and circulate
the coolant, and then check the coolant level
again.
5 Coolant:
39.5 l
3 Air conditioner tube mounting bolt
q Refilling (hydraulic tank)
20 – 25 Nm {2.0 – 2.5 kgm}
3
Refill hydraulic oil through the oil filler port up to
Air conditioner hose mounting bolt
the specified level. Start the engine and let the oil
20 – 25 Nm {2.0 – 2.5 kgm}
circulate in the hydraulic system. Then check the
[*3]
3
oil level again.
5 Hydraulic oil:
Fuel supply hose joint bolt
24 ± 4 Nm {2.4 ± 0.4 kgm}
69 l
[*4]
3 Tube mounting clamp
q Charging of refrigerant (R134a)
7 ± 1 Nm {0.7 ± 0.1 kgm}
Charge the air conditioner circuit with refrigerant
(R134a).
a Amount of refrigerant: 1,050 ± 50 g

50-86 GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of engine and transmission/torque converter assembly

Disassembly and assembly of engine and transmission/torque converter

assembly 50-87
6. Sling engine assembly (5).
Disassembly 50-87
1. Remove the engine and transmission/torque
converter assemblies. For details, see "Removal
and installation of engine and transmis-
sion/torque converter assemblies".
4 Engine and transmission/torque con-
verter assemblies:
1,800 kg

2. Place engine and transmission/torque converter

assemblies (1) on a stable block [1].

7. Remove 12 mounting bolts (7) for engine

assembly (5) and transmission/ torque converter
assembly (6).
[*2]

3. Disconnect hose (2) for power train oil cooler

from the transmission.
4. Disconnect hose (3) from the flywheel housing,
and drain oil.
a Prepare an oil container.
5. Remove elbow (4).
[*1]
a This is to place a block after disconnection. 8. Using forcing screws [2] one each at the right
and left, disconnect engine assembly (5) and
transmission/torque converter assembly (6).
[*3]

GD555-5,GD655-5,GD675-5 50-87
(02)
Power train
Disassembly and assembly of engine and transmission/torque converter assembly

9. Lift off engine assembly (5) from transmission/ Assembly 50-8

torque converter assembly (6). q Carry out assembly in the reverse order to disas-
4 Engine assembly: sembly.
700 kg
4 Transmission/torque converter as- [*1]
sembly: 2 Elbow:
1,100 kg Adhesive (LT-2)
3 Elbow:
45 ± 4 Nm {4.6 ± 0.4 kgm}
[*2]
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
54 – 74 Nm {6 – 7.5 kgm}

[*3]
a When connecting engine assembly (5) and
transmission/torque converter assembly (6),
make sure O-ring (7) is attached to the mating
surface of the transmission.
a Take care the O-ring is not twisted during con-
nection.

50-88 GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of torque converter assembly

Disassembly and assembly of torque converter assembly 50-89

2. Torque converter lockup housing
Special tools 50-89 1) Remove snap ring (4) and spacer (5).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

Unit repair stand

790-501-5000 q 1
(AC100 V)
Unit repair stand
790-501-5200 q 1
(AC110 V, 220 V)
1
C 790-901-2110 Bracket q 1
793-310-2131 Plate q 1
793-310-2141 Plate q 1
2 792-390-1210 Wrench t 1
2) Remove mounting bolts (6) of the housing.

Disassembly 50-89
1. Pilot
1) Set torque converter assembly (1) to the
work stand with the pilot side up.
2) Remove mounting bolts (2) and remove pilot
(3) using forcing screw.

3) Using puller [1], remove torque converter

lockup housing (7).

GD555-5,GD655-5,GD675-5 50-89
(02)
Power train
Disassembly and assembly of torque converter assembly
4) Remove bearing (8) from housing (7).
5) Remove piston (9) from housing (7).
6) Remove seal ring (10) from piston (9).
7) Remove seal ring (11) from housing (7).
3. Drive case
1) Remove disc (12).
2) Remove mounting bolts (22) and remove
drive case (23) using eyebolts [2].
50-90
4. Turbine assembly
Remove turbine assembly (24).
5. Stator assembly
1) Remove stator assembly (13).
a While rotating the stator assembly clock-
wise as viewed from above, lift it.
2) Disassembly of stator assembly
1] Remove snap ring (14) to remove race
and free wheel assembly (15) from stator
(16).
2] Remove snap ring (17) from stator (16).
3] Remove bushings (18) and (19) and
remove free wheel (20) from race (21).
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of torque converter assembly

6. Stator shaft 2) Remove bearing (32) from collar (34).

1) Using tool C2, remove nut (25). 3) Using forcing screws [5], remove collar (34)
from gear (27).

2) Remove spacer (29).

3) Support pump and gear (27) of stator shaft
assembly (26) with block [3], and remove
stator shaft (28) using push tool [4].

4) Remove seal ring (30) from stator shaft (28).

7. Disassembly of pump assembly

1) Remove mounting bolts (31) and push
bearing (32) from the opposite side to
remove it together with gear (27) and collar
(34) from pump assembly (35).

GD555-5,GD655-5,GD675-5 50-91
(02)
Power train
Disassembly and assembly of torque converter assembly

Assembly 50-92 a When assembling, check the assembly

a Clean all parts, and check them for dirt and dam- accuracy as shown below.
age before installing.
a Check that the snap ring securely fit into the
groove.
a After assembling, drop power line oil TO10 or
TO30 about 6 cc to the bearing and rotate the
bearing 10 turns.

1. Pump assembly
1) Install collar (34) to gear (27).
a Align the bolt holes.
2) Install bearing (32) to collar (34).
a Check the stamp of "SF1634C3". Do not
install turbine bearing "711-90-19310".

2. Stator shaft
1) Install seal ring (30) to stator shaft (28).
2 Periphery of seal ring:
Grease (G2-LI)

3) Set gear (27) and bearing (32) to pump (35)

and tighten mounting bolts (31).
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}

2) Set stator shaft (28) onto the work stand and

install it to pump assembly (35).
a Press fit the inner race of the bearing.
3) Install spacer (29).

50-92 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of torque converter assembly

4) Using tool C2, tighten nut (25). 2] Install snap ring (17) to stator (16).
2 Nut:
Adhesive (LT-2)
a Apply adhesive (LT-2) to the male thread
portion of the stator shaft.
3 Nut:
161.8 ± 14.7 Nm {16.5 ± 1.5 kgm}

3] Install race and free wheel assembly (15)

to stator (16), then install snap ring (14).
a Install free wheel "711-61-12160", set-
ting the arrow indicated on the cage
end surface toward the output side,
and check the rotation direction of sta-
3. Stator assembly tor "23B-13-72110" as viewed from
1) Assembly of stator assembly the input side.
1] Fit free wheel (20) to race (21) and install q Clockwise: no load
bushings (18) and (19) by expansion fit. q Counterclockwise: lock
a Check the direction of the arrow indi-
cated on the end surface of the free
wheel.
a Apply power line oil to the sliding sur-
faces of the bushing and free wheel.
a Use care not to damage the free
wheel sprag.

GD555-5,GD655-5,GD675-5 50-93
(02)
Power train
Disassembly and assembly of torque converter assembly

2) Install stator assembly (13) while rotating it 4. Turbine case

clockwise. Putt turbine assembly (24) on block [6] and set
a Check the rotation direction of the stator drive case (23) to turbine assembly (24).
as viewed from the turbine side (input a Height of block [6] (h): Approximately 90 mm
side).
q Clockwise: no load
q Counterclockwise: lock
a If the rotation direction of the stator is dif-
ferent from the mentioned above, install
the race and free wheel assembly re-
versely to the stator and check the rota-
tion direction again.

5. Disc
Install disc (12).
a Apply engine oil to the sliding surfaces of the
disc before installing .

a Take care of the installed direction of sta-

tor "23B-13-72110".
Referring to the figure, direct the large
diameter shell end toward turbine
"23B-13-71511".
A: Stator, B: Turbine side

6. Complete housing assembly

1) Assembly of complete housing assembly.
1] Install seal ring (11) to complete housing
(7).
2 Periphery of seal ring:
Grease (G0-LI or G2-LI)
2] Install seal ring (10) to piston (9) and
install piston to complete housing (7).
a Pay attention to the mounting direction of
the seal rings (10) and (11) as shown in
the following figure.
2 Periphery of seal ring:
Grease (G0-LI or G2-LI)

50-94 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of torque converter assembly

7. Bearing
Using push tool [7], install bearing (8).
a Check the stamp of "6216L1C4". Do not in-
stall pump bearing "711-16-11560".
a Press fit the outer race and inner race at the
same time.

a When assembling, check the assembly accu-

racy as shown below.

2) Using eyebolts [2], install complete housing

assembly (7) to the drive case (23).
3) Tighten mounting bolts (6).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}

8. Plate and snap ring

Fit spacer (5) and install snap ring (4).
a Check that the snap ring is fitted to the
groove securely.

GD555-5,GD655-5,GD675-5 50-95
(02)
Power train
Disassembly and assembly of torque converter assembly

9. Housing and case assembly

1) Using eyebolts [2], install housing and case
assembly (7) to pump assembly (35).
2) Tighten mounting bolt (22).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}

10. Pilot
Install pilot (3) and tighten mounting bolts (2).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}

50-96 GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

Disassembly and assembly of transmission assembly 50-97

Disassembly 50-97
Special tools 50-97 a Record the installed positions of disconnected
wires and connectors.

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name 1. Preparation work
1) Using blocks, fix the torque converter and
transmission assembly.
k Fix the assembly securely so that it
790-201-2740 Spacer t 1
does not tip over.
1 790-201-2750 Spacer t 1 2) Drain the transmission oil from the transmis-
sion case.
t 1
6 Transmission case
790-101-5201 Push tool kit
790-201-2740 Spacer t 1 45 l
2
790-101-5201 Push tool kit t 1
2. Work equipment pump assembly
797T-423-1320 Push tool t 1 Q 1) Disconnect hoses (1) and (2) and lubrication
3
790-101-5201 Push tool kit t 1 tube (3) from work equipment pump (4).
794T-423-1110 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010 – 51225 Bolt t 1
D
794T-423-1110 Push tool t 1 Q
794T-423-1120 Spacer t 1 Q
5
790-101-5221 Grip t 1
01010 – 51225 Bolt t 1
794T-423-1180 Push tool t 1 Q
6 790-101-5221 Grip t 1
01010 – 51225 Bolt t 1
7 793-310-2100 Lifting tool t 1 2) Disconnect hose (5) from work equipment
pump (4).
8 792-271-2000 Centering tool t 1
3) Remove work equipment pump assembly
9 799-301-1600 Oil leak tester t 1 (4).
4 Work equipment pump assembly:
45 kg

GD555-5,GD655-5,GD675-5 50-97
(02)
Power train
Disassembly and assembly of transmission assembly

3. Power train pump assembly 5. Connectors and sensors on right side of

Remove power train pump assembly (6). transmission
Disconnect connector T32 (23) from the right
side of the transmission and remove transmis-
sion input shaft speed sensor (24).

4. Connectors and wiring harnesses on top of

transmission
Disconnect the connectors on the top of the
transmission and remove wiring harness (22).
q CN-T39 (7): 1st clutch oil pressure
q CN-T27 (8): 1st solenoid
q CN-T37 (9): FH clutch oil pressure
q CN-T25 (10): FH solenoid
q CN-T38 (11): R clutch oil pressure
q CN-T26 (12): R solenoid
q CN-T40 (13): 2nd clutch oil pressure
q CN-T28 (14): 2nd solenoid
q CN-T41 (15): 3rd clutch oil pressure
q CN-T29 (16): 3rd solenoid
q CN-T42 (17): 4th clutch oil pressure
q CN-T30 (18): 4th solenoid
q CN-T36 (19): FL clutch oil pressure
q CN-T24 (20): FL solenoid
q CN-T31(21): L/U solenoid

50-98 GD555-5,GD655-5,GD675-5
(02)

6. Sensors, connectors, wiring harnesses, and
tubes on left side of transmission
Remove the following parts from the left side of
the transmission.
1) Disconnect connector T47 (25) and remove
transmission intermediate shaft speed
sensor (26).
2) Disconnect connector T35 (27) and remove
transmission lubricating oil temperature
sensor (28).
3) Disconnect connector T33 (29) of transmis-
sion output shaft speed sensor.
4) Remove wiring harness (22).
a Wiring harness (22) is the same as the
one in item 4.
5) Remove transmission output shaft speed
sensor (30).
6) Remove transmission case ground terminal
TG1 (31).
7) Remove power train inlet tube (32).
GD555-5,GD655-5,GD675-5
(02)
Power train
Disassembly and assembly of transmission assembly
7. Hoses, connectors, sensors, tubes, and
strainers at rear of transmission
Remove the following parts from the rear of the
transmission.
1) Disconnect damper hose (33).
2) Disconnect connector T34 (34) and remove
torque converter outlet oil temperature
sensor (35).
3) Remove block (36).
4) Remove oil filler tube (37) and power train
pump tube (38).
5) Remove strainer (39).
8. Lubrication tubes, priority valve, main relief
valve, and ECMV on top of transmission
Remove the following parts from the top of the
transmission.
1) Remove four lubrication tubes (40), (41), (42)
and (42A).
2) Remove priority valve (43).
3) Remove transmission main relief valve (44).
50-99
Power train
Disassembly and assembly of transmission assembly

4) Remove ECMV as assembly installed with 10. Transmission cover assembly

the seat (45). 1) Remove the mounting bolts of cover
assembly (52) and disconnect the assembly
from the transmission case by using forcing
screws [4].

9. Coupling and retainer

1) Remove coupling (46).
2) Remove the mounting bolts and remove
retainer (47) using forcing screw.
2) Using eyebolts [5], remove cover assembly
(52).
a Using the lever block, adjust the clear-
ance with the transmission case evenly.

3) Remove dust seal (48) and oil seal (49) from

retainer (47).

3) Remove outer races (53) and (54) and

bearing (55) from cover (52).

50-100 GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

11. Idler gear (for reverse travel) 12. 4th clutch assembly
1) Remove bolts (62) to remove plate (63). 1) Remove oil guides (67) and (68).
2) Using gear puller [6], remove bearing (64)
together with gear (65).

2) Using two wire ropes, remove 4th clutch

assembly (69).
3) Remove bearing (64) from gear (65).
4) Remove spacer (66), bearing (64), and collar
(97) from the shaft.
a The collar is installed under the bearing.

3) Disassembly of 4th clutch assembly

1] Remove seal ring (70).
2] Using the press, remove bearing (71) and
gear (72).
a Support the gear and push shaft (73).
a Receive the falling clutch assembly
with a cushion.

GD555-5,GD655-5,GD675-5 50-101
(02)
Power train
Disassembly and assembly of transmission assembly
3] Remove snap ring (74) from shaft (73).
4] Using the press, remove bearing (75),
spacer (76), thrust washer (77), and
clutch assembly (78) on the clutch side
from shaft (73).
a Support the drum side of clutch as-
sembly (78) and push shaft (73).
a Receive the falling shaft with a cush-
ion.
50-102
5] Remove thrust washer (77) and seal ring
(79) from shaft (73).
6] Remove needle bearing (80) from 4th
clutch gear (137).
7] Push end plate (81) by using bar handle
[7], etc. to remove snap ring (82).
8] Remove end plate (81).
9] Remove seven plates (83), six springs
(84), and six discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

10] Remove piston assembly (86). 3) Disassembly of 2nd and 3rd clutch assembly
a If the piston is slanted, you cannot re- 1] Remove seal ring (70).
move it. Accordingly, remove it hori-
zontally.
a Note that removing it by force may
damage the inside wall of the cylinder.
11] Remove seal rings (87) and (88) from
piston assembly (86).

2] Using the bearing race puller, remove

bearing (95) on the 3rd gear speed side.
3] Remove spacer (76) and thrust washer
(77).

13. 2nd and 3rd clutch assembly

1) Using gear puller [8], remove bearing (90)
and gear (91) from the shaft on the 1st gear
speed side.
a Remove them so that gear (91) may not
prevent removal of the 2nd clutch gear.
2) Using two wire ropes, remove 2nd and 3rd
clutch assembly (92).

4] Remove 3rd clutch gear (96).

5] Remove needle bearing (80) from 3rd
clutch gear (96).

GD555-5,GD655-5,GD675-5 50-103
(02)
Power train
Disassembly and assembly of transmission assembly

9] Remove thrust washer (77).

10] Remove piston assembly (86).
a If the piston is slanted, you cannot re-
move it. Accordingly, remove it hori-
zontally.
a Note that removing it by force may
damage the inside wall of the cylinder.
11] Remove seal rings (87) and (88) from
piston assembly (86).

6] Push in end plate (81) by using push tool

[10] to remove snap ring (82).
7] Remove end plate (81).

12] Using gear puller [11], remove inner race

(98) and intermediate gear (99) on the
2nd gear speed side and remove snap
ring (89) from the gear.

8] Remove eight plates (83), seven springs

(84), and seven discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.

50-104 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of transmission assembly

13] Remove thrust washer (77) and 2nd 17] Remove thrust washer (77) and piston
clutch gear (100). assembly (101).
14] Remove needle bearing (80) from 2nd a If the piston is slanted, you cannot re-
clutch gear (100). move it. Accordingly, remove it hori-
zontally.
a Note that removing it by force may
damage the inside wall of the cylinder.
18] Remove seal rings (87) and (88) from
piston assembly (101).

15] Push in end plate (81) by using bearing

race puller [12] and forcing screw [13] and
remove snap ring (82) and end plate (81).

14. 1st and FH clutch assembly and reverse and

FL clutch assembly
1) Using eyebolts [14], remove 1st and FH
clutch assembly (102) and reverse and FL
clutch assembly (103) simultaneously.
a These two clutch assemblies must be re-
moved simultaneously, since their gears
engage with each other.
a Sling both of these two clutch assemblies
vertically.

16] Remove 15 plates (83), 14 springs (84),

and 14 discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.

GD555-5,GD655-5,GD675-5 50-105
(02)
Power train
Disassembly and assembly of transmission assembly

2) Disassembly of 1st and FH clutch assembly

a The bearing and intermediate gear at the
shaft end on the 1st gear speed side were
removed in "procedure 13.1".
1] Remove seal ring (70).
2] Remove snap ring (104) and thrust
washer (77).
3] Remove 1st clutch gear (105).

4] Remove bushing (80) from 1st clutch

gear (105).

8] Remove thrust washer (77).

9] Remove piston assembly (86).
a If the piston is slanted, you cannot re-
move it. Accordingly, remove it hori-
zontally.
a Note that removing it by force may
damage the inside wall of the cylinder.
10] Remove seal rings (87) and (88) from
piston assembly (86).

5] Push in end plate (81) by using push tool

[10] to remove snap ring (82).
6] Remove end plate (81).
7] Remove six plates (83), five springs (84),
and five discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.

50-106 GD555-5,GD655-5,GD675-5
(02)

Disassembly and assembly of transmission assembly
11] Pull out FH gear (106) by using forcing
screw [15], and remove bearing (107),
spacer (108), and thrust washer (77)
together.
12] Remove thrust bearing (109) and needle
bearing (80) from FH clutch gear (106).
13] Push in end plate (81) by using bar
handle [7], etc. to remove snap ring (82),
and remove the bar handle and end plate
(81).
GD555-5,GD655-5,GD675-5
(02)
Power train
14] Remove 13 plates (83), 12 springs (84),
and 12 discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.
15] Remove piston assembly (110).
a Since there is a sleeve inside, you can
remove the piston assembly smooth-
ly.
16] Remove seal rings (112) and (88) from
piston assembly (110).
17] Remove snap ring (111) and remove
sleeve (137) from the piston assembly.
50-107
Power train
Disassembly and assembly of transmission assembly

3) Disassembly of R and FL clutch assembly

1] Remove seal rings (70) and (113).

6] Remove thrust bearing (109).

2] Using bearing race puller [16], remove

bearing (114) and gear (115) on the FL
clutch side.
3] Remove snap ring (116) to remove thrust
washer (77).

7] Push in end plate (81) by using bar

handle [7], etc. to remove snap ring (82),
and remove the bar handle and end plate
(81).

4] Remove FL clutch gear (117).

5] Remove needle bearing (80) and seal
ring (135) from gear (117).

50-108 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of transmission assembly

8] Remove nine plates (83), eight springs
(84), and eight discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.
12] Using bearing race puller [17], remove R
clutch gear (121), bearing (122), spacer
(108), and thrust washer (123).
13] Remove needle bearing (124) from R
clutch gear (121).

9] Remove piston assembly (118).

a Since there is a sleeve inside, you can
remove the piston assembly smooth-
ly.

14] Remove thrust bearing (109).

15] Push in end plate (81) by using bar
handle [7], etc. to remove snap ring (82),
and remove the bar handle and end plate
10] Remove seal rings (120) and (88) from (81).
piston assembly (118).
11] Remove snap ring (111) to remove
sleeve (119).

GD555-5,GD655-5,GD675-5 50-109
(02)
Power train
Disassembly and assembly of transmission assembly
16] Remove nine plates (83), eight springs
(84), and eight discs (85) alternately.
a Keep the disc and plate on a flat place
so that they do not warp.
17] Remove piston assembly (118).
a Since there is a sleeve inside, you can
remove the piston assembly smooth-
ly.
18] Remove seal rings (120) and (88) from
piston assembly (118).
19] Remove snap ring (111) to remove
sleeve (119).
50-110
15. Torque converter assembly
1) Securely place transmission case (126) on
block [18] sized 400 mm or higher.
2) Remove eight mounting bolts (123) of the
torque converter assembly from under the
case.
3) Using eyebolts [19], remove torque converter
assembly (127) from the transmission case.
16. PTO idler gear and drive gear
1) Reverse the transmission case and set it on
the block securely.
2) Remove cover (132).
a Remove only the cover on idler gear
(128) side.
a The removal procedures for the idler gear
and drive gear are the same. The one for
idler gear (129) is explained below.
q (128): Idler gear
q (129): Idler gear
q (130): Drive gear (power train pump)
q (131): Drive gear (work equipment
pump)
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

5) Remove spacer (134B) between the bear-

ings and bearing (134A) from gear (129).

3) Using hook wrench [21], remove nut (133).

a While the gear is being held from turning,
remove the nut. 6) Remove bearing (134C) and two outer races
(134D) from the transmission case.

4) Drive out gear (129).

17. Outer race (for FH clutch shaft)
Remove outer race (135) from the transmission
case.

GD555-5,GD655-5,GD675-5 50-111
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Power train
Disassembly and assembly of transmission assembly

Assembly 50-1 2 1) Using the push tool, press fit bearing (134A)
a Clean all parts, and check them for dirt and dam- to gear (129) and install spacer (134B)
age before installing. between the bearings.
a Apply engine oil to the sliding portions of each
part before installing.
a After assembling, drop power line oil TO10 or
TO30 about 6 cc to the bearing and rotate the
bearing 10 turns.
a When installing the bearing by expansion fit,
drop TO30 or TO10 about 6 cc to the bearing
and rotate the bearing approximately 10 turns
before cooling it in dry ice, etc.

1. Outer race (for FH clutch shaft)

Install outer race (135) to the transmission case.

2) Install two outer races (134D) to the trans-

mission case.

2. PTO idler gear and drive gear

a The installation procedures for the idler gear
and drive gear are the same. The one for
idler gear (129) is explained below.
q (128): Idler gear
3) Install gear (129) to the outer race of the
q (129): Idler gear
transmission case.
q (130): Drive gear (power train pump)
4) Install bearing (134C) to gear (129) from the
q (131): Drive gear (work equipment pump)
opposite side.

a Combine the inner and outer races of the

bearing and the spacer with the same serial
number and use them in a set.

50-112 GD555-5,GD655-5,GD675-5
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5) Tighten nut (133) by using hook wrench [21].
2 Nut:
Adhesive (LT-2)
a Apply adhesive (LT-2) to the male thread
portion of the gear.
3 Nut:
314 – 392 Nm {32 – 40 kgm}
a After tightening the nut, drop power train
oil (T030) by 6 cc and rotate approximate-
ly 10 turns, then check the tightening
torque again.
6) Install the O-ring and install cover (132).
a Install only the cover on idler gear (128)
side.
GD555-5,GD655-5,GD675-5
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Power train
Disassembly and assembly of transmission assembly
3. Torque converter assembly
1) Place transmission case (126) on block [18]
with the torque converter side up.
a Since the mounting bolts of the torque
converter assembly are to be tightened
temporarily from under side, use a block
sized 400 mm or higher.
2) Check the position of the oil hole and install
guide bolt [22] to the stator shaft.
a Make a mark at the bolt hole for the guide
bolt.
3) Using eyebolts [19], install torque converter
assembly (127).
a Engage the PTO gear of the torque con-
verter with the idler gear.
4) Install two or three mounting bolts tempo-
rarily from the underside.
50-113
Power train
Disassembly and assembly of transmission assembly

5) Reverse transmission case (121) and place it
on block [18].
2] Install seal rings (120) and (88) to the
piston.
a When installing the seal rings, be
careful of the direction of the pressure
receiving side.
a Use new seal rings.

6) Tighten mounting bolts (123).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm} 3] Install piston assembly (118) to the
cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.

4. R and FL clutch assembly and 1st and FH

clutch assembly
1) Assembly of R and FL clutch assembly
1] Set sleeve (119) to the piston and install
snap ring (111).
a Check that the snap ring is fitted to the
groove securely.

50-114 GD555-5,GD655-5,GD675-5
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Disassembly and assembly of transmission assembly
4] Install nine plates (83), eight springs (84),
and eight discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.
5] Install end plate (81) and push it in by
using bar handle [7], etc., then install
snap ring (82).
a Check that the snap ring is fitted to the
groove securely.
GD555-5,GD655-5,GD675-5
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Power train
6] Install thrust bearing (109).
a Install the thicker race near the clutch.
7] Install needle bearing (124) to R clutch
gear (121).
8] Arrange the internal teeth of the discs
correctly and install R clutch gear (121).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
9] Install thrust washer (123) and spacer
(108).
50-115
Power train
Disassembly and assembly of transmission assembly

10] Using pushing tool [23], press fit bearing
(122) to the shaft.
12] Install seal rings (120) and (88) to the
piston.
a When installing the seal rings, be
careful of the direction of the pressure
receiving side.
a Use new seal rings.

a After press-fitting the bearing, check

that there is no clearance in portion
(P).
a After press-fitting the bearing, check
clearance (e) between the thrust
washer and spacer.
q Clearance (e): 0.11 - 0.99 mm
13] Install piston assembly (118) to the
cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.

11] Set sleeve (119) to the piston and install

snap ring (111).
a Check that the snap ring is fitted to the
groove securely.

50-116 GD555-5,GD655-5,GD675-5
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Disassembly and assembly of transmission assembly
14] Install nine plates (83), eight springs (84),
and eight discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.
15] Install end plate (81) and push it in by
using bar handle [7], etc., then install
snap ring (82).
a Check that the snap ring is fitted to the
groove securely.
GD555-5,GD655-5,GD675-5
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Power train
16] Install thrust bearing (109).
a Install the thicker race near the clutch.
17] Install needle bearing (80) and seal ring
(135) to FL clutch gear (117).
a Apply grease (G2-LI) to the outside of
the seal ring and install it evenly.
18] Arrange the internal teeth of the discs
correctly and install FL clutch gear (117).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
50-117
Power train
Disassembly and assembly of transmission assembly

19] Install thrust washer (77) and install snap
ring (116).
20] Install gear (115), and install bearing
(114) by using the push tool.
22] Using tool D9, supply air through the oil
hole of the shaft and check the operation
of the clutch.
a If the gear on the side to which the air
was supplied is fixed, the clutches are
operating normally.
q Air pressure:

0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

a After press-fitting the bearing, check

that there is no clearance in portion
(Q).
a After press-fitting the bearing, check
clearance (e) between the thrust
washer and gear. 2) Assembly of 1st and FH clutch assembly
q Clearance (e): 0.06 - 1.24 mm 1] Set sleeve (137) to the piston and install
snap ring (111).
a Check that the snap ring is fitted to the
groove securely.

21] Install seal rings (70) and (113) to the

shaft.
a Apply grease (G2-LI) to the outside of
the seal rings and install them evenly.

50-118 GD555-5,GD655-5,GD675-5
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Disassembly and assembly of transmission assembly
2] Install seal rings (112) and (88) to piston
assembly (110).
a When installing the seal rings, be
careful of the direction of the pressure
receiving side.
a Use new seal rings.
3] Install piston assembly (110) to the
cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.
GD555-5,GD655-5,GD675-5
(02)
Power train
4] Install 13 plates (83), 12 springs (84), and
12 discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.
5] Install end plate (81) and push it in by
using bar handle [7], etc., then install
snap ring (82).
a Check that the snap ring is fitted to the
groove securely.
50-119
Power train
Disassembly and assembly of transmission assembly
6] Install thrust bearing (109).
a Install the thicker race near the clutch.
7] Install needle bearing (80) to FH clutch
gear (106).
8] Arrange the internal teeth of the discs
correctly and install FH clutch gear (106).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
9] Install thrust washer (77) and spacer
(108).
10] Using the push tool, install bearing (107).
50-120
a After press-fitting the bearing, check
that there is no clearance in portion
(P).
a After press-fitting the bearing, check
clearance (e) between the thrust
washer and spacer.
q Clearance (e): 0.11 - 0.99 mm
11] Install seal rings (88) and (87) to piston
assembly (86).
a When installing the piston, be careful
of the direction of the pressure receiv-
ing side.
a Use new seal rings.
GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of transmission assembly

12] Install piston assembly (86) to the
cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.
13] Install thrust washer (77).
15] Install end plate (81).
16] Push the end plate by using push tool [10]
and install snap ring (82).
a Check that the snap ring is fitted to the
groove securely.

17] Install bushing (80) to 1st clutch gear

(105).
14] Install six plates (83), five springs (84),
and five discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.

GD555-5,GD655-5,GD675-5 50-121
(02)
Power train
Disassembly and assembly of transmission assembly
18] Arrange the internal teeth of the discs
correctly and install 1st clutch gear (105).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
a When inserting 1st gear (105) to the
shaft, be careful not to damage the
bushing.
19] Fit thrust washer (77) and install snap ring
(104).
20] Install seal ring (70) to the shaft.
a Apply grease (G2-LI) to the outside of
the seal ring and install it evenly.
5. 2nd and 3rd clutch assembly
21] Using tool D9, supply air through the oil
hole of the shaft and check the operation
of the clutch.
a If the gear on the side to which the air
was supplied is fixed, the clutches are
operating normally.
q Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
50-122
3) Using eyebolts [14], install 1st and FH clutch
assembly (102) and reverse and FL clutch
assembly (103) simultaneously.
a Sling both of these two clutch assemblies
vertically.
a If the bearing of the 1st and FH clutch as-
sembly is difficult to install, remove the
outer race on the transmission case, and
assemble it with the bearing of the shaft
and install them.
1) Assembly of 2nd and 3rd clutch assembly
1] Install seal rings (88) and (87) to piston
assembly (101).
a When installing the piston, be careful
of the direction of the pressure receiv-
ing side.
a Use new seal rings.
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

2] Install piston assembly (101) to the

cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.
3] Install thrust washer (77).

8] Arrange the internal teeth of the discs

correctly and install 2nd clutch gear (100).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
9] Install thrust washer (77).
4] Install 15 plates (83), 14 springs (84), and
14 discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.

5] Install end plate (81).

6] Push bearing race puller [12] by using
forcing screws [13] and install snap ring
(82).
a Check that the snap ring is fitted to the
groove securely.
7] Install needle bearing (80) to 2nd clutch
gear (100).

GD555-5,GD655-5,GD675-5 50-123
(02)
Power train
Disassembly and assembly of transmission assembly
10] Install snap ring (89) to intermediate gear
(99), and install them to the shaft.
11] Using a press, install inner race (98).
a After press-fitting the inner race,
check that there is no clearance in
portion (Q).
a After press-fitting the inner race,
check clearance (e) between the gear
and thrust washer.
q Clearance (e): 0.01 - 1.19 mm
50-124
12] Install seal rings (88) and (87) to piston
assembly (86).
a When installing the piston, be careful
of the direction of the pressure receiv-
ing side.
a Use new seal rings.
13] Install piston assembly (86) to the
cylinder.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.
14] Install thrust washer (77).
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of transmission assembly

15] Install eight plates (83), seven springs

(84), and seven discs (85) alternately.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.

21] Using a press, install bearing (95).

16] Install end plate (81).

17] Push in the end plate by using push tool
[10] and install snap ring (82).
a Check that the snap ring is fitted to the
groove securely.
18] Install needle bearing (80) to 3rd clutch
gear (96).

a After press-fitting the bearing, check

that there is no clearance in portion
(P).
a After press-fitting the bearing, check
clearance (e) between the thrust
washer and spacer.
q Clearance (e): 0.17 - 1.03 mm

19] Arrange the internal teeth of the discs

correctly and install 3rd clutch gear (96).
a When installing the gear, slowly move
it horizontally and vertically little by lit-
tle to match it with the internal teeth of
the discs.
20] Install thrust washer (77) and spacer (76).

GD555-5,GD655-5,GD675-5 50-125
(02)
Power train
Disassembly and assembly of transmission assembly

22] Install seal ring (70) to the shaft. 3) Install gear (91) to the 1st clutch shaft.
4) Using push tool [24], install bearing (90).

23] Using tool D9, supply air through the oil a After press-fitting the bearing, check
hole of the shaft and check the operation clearance (e) between the thrust washer
of the clutch. and gear.
a If the gear on the side to which the air q Clearance (e): 0.02 - 1.18mm
was supplied is fixed, the clutches are
operating normally.
q Air pressure:

0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

6. 4th clutch assembly

1) Assembly of 4th clutch assembly
1] Install seal rings (88) and (87) to piston
assembly (86).
2) Using two wire ropes, install 2nd and 3rd a When installing the piston, be careful
clutch assembly (92). of the direction of the pressure receiv-
ing side.
a Use new seal rings.

50-126 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of transmission assembly

2] Install piston assembly (86) to the 8] Press fit bearing (75) to the shaft.
cylinder portion of the 4th clutch gear.
a When installing the piston assembly,
apply power train oil to the inside, out-
side, and contact surfaces of the seal
rings.
3] Install needle bearing (80) to 4th clutch
gear (137).

a After press-fitting the bearing, check

that there is no clearance in portion
(P).
a After press-fitting the bearing, check
clearance (e) between the thrust
washer and spacer.
q Clearance (e): 0.10 - 0.90 mm

4] Install thrust washer (77) and seal ring

(79) to shaft (73).
a Apply grease (G2-LI) to the outside of
the seal ring and install it evenly.

5] Support shaft (73) on the block with the

spline side up.
a Support the shaft with the hand since
it is unstable.
6] Install 4th clutch gear (137) to shaft (73).
a Be careful of the piston assembly
which will fall.
7] Install thrust washer (77) and spacer (76).
9] Reverse the 4th clutch and shaft
assembly and install seven plates (83),
six springs (84), and six discs (85) alter-
nately.
a Support the assembly with the hand
since it is unstable.
a Soak the discs in clean power train oil
for at least 2 minutes beforehand.
a Be careful not to allow the spring and
disc to overlap each other.

GD555-5,GD655-5,GD675-5 50-127
(02)
Power train
Disassembly and assembly of transmission assembly

13] Using a press, press fit bearing (71).

14] Install seal ring (70).
a Apply grease (G2-LI) to the outside of
the seal ring and install it evenly.

10] Install end plate (81) and push it in by

using bar handle [7], then install snap ring
(82).
a Check that the snap ring is fitted to the
groove securely. a After press-fitting the bearing, check
that there is no clearance in portion
(P).

11] Install snap ring (74) to shaft end (73) on

the opposite side to the clutch.
a Check that the snap ring is fitted to the
groove securely.
12] Install gear (72).

50-128 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of transmission assembly

15] Using tool D9, supply air through the oil 3) Install oil guides (68) and (67).
hole of the shaft and check the operation
of the clutch.
a If the gear on the side to which the air
was supplied is fixed, the clutches are
operating normally.
q Air pressure:

0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

7. Idler gear (for reverse travel)

1) Using the push tool, install outer race (64a) to
gear (65).
a Check the serial Nos. and match-marks
of the inner race and outer race of the
bearing, and put "matchmarks" to them.
2) Install spacer (97) to the shaft.
2) Using two wire ropes, install 4th clutch a Direct the largely cut inside end down-
assembly (69). ward.
3) Using push tool [24], push bearing (64) and
spacer (66) to install them to the shaft.

GD555-5,GD655-5,GD675-5 50-129
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Power train
Disassembly and assembly of transmission assembly
4) Align the matchmarks and install gear (65),
and install bearing (64) by using the push
tool.
a Align with the match mark of the outer
race installed to the gear.
5) Install plate (63) and tighten bolts (62).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
8. Transmission cover assembly
1) Using the push tool, install bearing (55) and
outer races (54) and (53) to transmission
cover (52).
9. Coupling and retainer
50-130
2) Referring to the following figure, apply the
liquid gasket to the transmission case.
2 Mounting face of case:
Adhesive (LG-8)
a Apply the liquid gasket so that it will be not
squeezed to inside of the case and take
care not to apply too much.
a Check the front cover for a scratch, etc.
a Mark (A) indicates that the mating case
has a forcing tap.
3) Using eyebolts [5] and a lever block, lift up
transmission cover assembly (52) horizon-
tally.
4) While matching the bearings and outer races
on the cover with each clutch shaft, lower
cover assembly (52) slowly to install.
5) Tighten the mounting bolts of cover
assembly (52).
3 Mounting bolt:
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
1) Install oil seal (49) and dust seal (48) to
retainer (47).
a Fill the space between the main lip and
dust lip of the oil seal with silicone grease
(G2-S) to 40 - 60%.
Apply silicone grease to the clearance
between the oil seal and dust seal, too.
GD555-5,GD655-5,GD675-5
(02)

Thinly apply LG-5 to the mating surface of
peripheral press-fitting and wipe off the
squeezed portion after press-fitting.
2) Install retainer (47) to the case.
3) Install coupling (46).
GD555-5,GD655-5,GD675-5
(02)
Power train
Disassembly and assembly of transmission assembly
10. Lubrication tubes, priority valve, and main
relief valve on top of transmission
Install the following parts to the top of the trans-
mission.
1) Install ECMV as assembly installed with the
seat (45).
2) Install transmission main relief valve (44).
3) Install four lubrication tubes (40), (41), (42)
and (42A).
3 Mounting joint bolt of lubrication
tube:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
4) Install priority valve (43).
50-131
Power train
Disassembly and assembly of transmission assembly

11. Hoses, connectors, sensors, tubes, and

strainers at rear of transmission
Install the following parts to the rear of the trans-
mission.
1) Install strainer (39).
2) Install oil filler tube (37) and power train pump
tube (38).
3) Install block (36).
4) Install torque converter outlet oil temperature
sensor (35) and connect connector T34 (34).
5) Connect damper hose (33).

4) Install wiring harness (22).

5) Connect connector T33 (29) of transmission
output shaft speed sensor.
6) Install transmission lubricating inlet oil
temperature sensor (28) and connect
connector T35 (27).
7) Install transmission intermediate shaft speed
sensor (26) and connect connector T47 (25).
a To adjust the clearance of the speed sen-
sor, apply the sensor end to the gear
tooth tip lightly, return the sensor from
that position by 1/2 - 1 turn, and tighten
12. Sensors, connectors, wiring harnesses, and the lock nut so that the angle formed by
tubes on left side of transmission the lead wire of sensor is within the angle
Install the following parts to the left side of the range A (180 °) shown in the figure below.
transmission. a Lock nut:
1) Install power train lubricating inlet tube (32). 49.0 – 68.6 Nm {5 – 7 kgm}
2) Install transmission case ground terminal
TG1 (31).
3) Install transmission output shaft speed
sensor (30).
a To adjust the clearance of the speed sen-
sor, apply the sensor end to the gear
tooth tip lightly, return the sensor from
that position by 1/2 - 1 turn, and tighten
the lock nut so that the angle formed by
the lead wire of sensor is within the angle
range A (180 °) shown in the figure below.
3 Lock nut:
49.0 – 68.6 Nm {5 – 7 kgm}

50-132 GD555-5,GD655-5,GD675-5
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13. Connectors and sensors on right side of
transmission
Install transmission input shaft speed sensor
(24) to the right side of the transmission and
connect connector T32 (23).
a To adjust the clearance of the speed sensor,
apply the sensor end to the gear tooth tip
lightly, return the sensor from that position by
1/2 - 1 turn, and tighten the lock nut so that
the angle formed by the lead wire of sensor is
within the angle range A (180 °) shown in the
figure below.
3 Lock nut:
49.0–68.6 Nm {5–7 kgm}
GD555-5,GD655-5,GD675-5
(02)
Power train
Disassembly and assembly of transmission assembly
14. Connectors and wiring harnesses on top of
transmission
Install wiring harness (22) to the top of the trans-
mission and connect the connector.
a Wiring harness (22) is the same as the one in
item 12.4).
q CN-T39 (7): 1st clutch oil pressure
q CN-T27 (8): 1st solenoid
q CN-T37 (9): FH clutch oil pressure
q CN-T25 (10): FH solenoid
q CN-T38 (11): R clutch oil pressure
q CN-T26 (12): R solenoid
q CN-T40 (13): 2nd clutch oil pressure
q CN-T28 (14): 2nd solenoid
q CN-T41 (15): 3rd clutch oil pressure
q CN-T29 (16): 3rd solenoid
q CN-T42 (17): 4th clutch oil pressure
q CN-T30 (18): 4th solenoid
q CN-T36 (19): FL clutch oil pressure
q CN-T24 (20): FL solenoid
q CN-T31(21): L/U solenoid
50-133
Power train
Disassembly and assembly of transmission assembly

15. Power train pump assembly q Refilling (transmission case)

Install power train pump assembly (6).
Add oil through the oil filler to the specified
level. After installing the transmission
assembly, start the engine to circulate the oil
through the piping. Then, check the oil level
again.
5 Transmission case
45 l

16. Work equipment pump assembly

1) Install work equipment pump assembly (4).
4 Work equipment pump assembly:
45 kg
2) Connect hose (5) to work equipment pump
(4).

3) Connect hoses (1) and (2) and lubrication

tube (3) to work equipment pump (4).

50-134 GD555-5,GD655-5,GD675-5
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 Power train
Removal and installation of tandem drive and final drive assembly

Removal and installation of tandem drive and final drive assembly 50-135
4. Support the front-end of the rear frame with
Removal 50-135 sturdy stand [2].
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k After the engine is stopped, depress the
brake pedal slowly at least 30 times to re-
lease the pressure from the accumulator cir-
cuit.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is 5. Support the back-end of the rear frame with
closed if you attach and rotate the lever of sturdy stand [3].
circuit breaker, and fix it after rotation. a For the specification machine with ripper,
lower the ripper to the ground.

1. Remove the fuel tank assembly. For details, see

"Removal and installation of fuel tank assembly." 6. Lower blade (3) to the ground.
2. Jack up the whole machine until the bottom of
the rear frame back-end is lifted to a position
approximately 1 m above the ground.
3. Support the bottom of the front axle with sturdy
stand [1].

GD555-5,GD655-5,GD675-5 50-135
(02)
Power train
Removal and installation of tandem drive and final drive assembly

7. Sling wheel assembly (4), and remove 10 10. Disconnect differential lock solenoid connector
mounting bolts to remove wheel assembly (4). R9 (6) and two connectors R8 (7) of differential
Remove four rear wheel assemblies. oil temperature sensor.
[*1]
k Since the tandem case inclines after the
wheels on one side are removed, insert
blocks previously under the tandem case.
k Make sure to apply the sling to the center
of a wheel and place the removed wheels
in a safe place.
4 Wheel assembly:
160 kg (14.00-24-12PR)
200 kg (17.5R25)

11. Remove clamp (8A) and disconnect hose (8)

from strainer (9).
12. Remove two clamps (10) and disconnect hose
(11) from differential lock-up solenoid valve (12).
13. Remove oil filler port tube (13).
[*3]

8. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
9. Loosen drain plug (5) and drain oil in the final
drive case.
[*2]
6 Final drive case:
15 l

50-136 GD555-5,GD655-5,GD675-5
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Removal and installation of tandem drive and final drive assembly
14. Disconnect parking brake hose (14).
[*4]
15. Remove cover (15A) and remove universal joint
(15) between the transmission and final drive.
[*5]
16. Remove left and right covers (16) on the top of
the tandem case.
17. Disconnect two brake hoses (17) of the front and
rear wheels each at the left and right.
a Apply a plug to the disconnected hoses to
prevent outflow of oil.
GD555-5,GD655-5,GD675-5
(02)
Power train
18. Remove the tandem drive and final drive
assembly according to the following procedures.
4 Tandem drive and final drive
2,600 kg
a Several approaches are available for the low-
ering, for example 4-point lifting by crane and
use of a forklift truck. The following describes
the approach by using a jack for the lowering.
1) Place sturdy blocks under the bottom of the
left and right tandem cases.
2) Sling one of the tandem cases using a crane
and support the other using a jack.
3) Remove four mounting bolts (18) each at the
left and right of final drive case.
[*6]
4) Lower the crane slowly and lower the jack,
too, in line with move of the crane.
k Pay attention to the balance during the
work and do not wander into a space
under the tandem drive and final drive
assembly.
a Replace the block being set in item 1) with
a lower one.
5) Replace the jack and crane with jack for floor
[4] and pull the tandem drive and final drive
assembly (19) out from the machine.
50-137
Power train
Removal and installation of tandem drive and final drive assembly

Installation 50-138
q Perform installation in the reverse order to re-
moval.

[*1]
3 Wheel mounting bolt:
610 – 765 Nm {62.5 – 78.0 kgm}

[*2]
3 Drain plug:
58.8 – 78.4 Nm {6.0 – 8.0 kgm}

[*3]
2 Threaded portion of oil filler port tube:
Adhesive (LT-2)
3 Oil filler port tube:
165 – 270 Nm {16.8 – 27.5 kgm}

[*4]
a Install the parking brake hose without twisting it.

[*5]
3 Universal joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

[*6]
3 Final drive mounting bolt:
927 – 1,133m {94.5 – 115.5 kgm}

q Air bleeding (brake circuit)

Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".

q Refilling (Final drive case)

Add hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Final drive case:
15 l (T030)

50-138 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of tandem drive assembly

Disassembly and assembly of tandem drive assembly 50-139

3. Remove tubes for brake (2) and (3) from the left
Special tools 50-139 and right of the tandem drive case.

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

J 1 792-571-1600 Chain puller t 1

Disassembly 50-139
1. Remove the tandem drive and final drive
assembly. For details, see "Removal and instal-
lation of tandem drive and final drive assembly".
2. Remove drain plug (1) to drain oil from the left
and right of the tandem drive case.
6 Tandem drive case:
57 l (one side) 4. Remove two top covers (4) and four side covers
(5) (two each from outside and inside) from the
left and right of the tandem drive case.

GD555-5,GD655-5,GD675-5 50-139
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Power train
Disassembly and assembly of tandem drive assembly
5. Remove the chain according to the following
procedures.
1) Release parking brake (6) using hand pump
[1].
2) Align master portion (8) of the chain to the
service hole while rotating disc (7) .
3) Stretch chain (9) using tool J1. Pull out cotter
pin (10) and remove plate (11), master pin
(12) from chain (9).
4) Pull out chain (9) from the sprocket and
remove it.
5) Remove the chain from the opposite side in
the same way.
50-140
6. Sling wheel brake assembly (13). Remove the
mounting bolts which mount the assembly to
tandem drive case(14), and remove four wheel
brake assemblies (13) at the front, back, left and
right.
7. Sling tandem drive assembly (14), and remove
17 mounting bolts to remove the tandem drive
assembly from final drive assembly (15).
4 Tandem drive assembly (each side):
800 kg
4 Final drive assembly:
950 kg
GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of tandem drive assembly

Assembly 50-141
1. Sling tandem drive assembly (14) to install to
final drive assembly (15).
4 Tandem drive assembly (each side):
800 kg
2 Mounting bolt threaded section:
Gasket sealant (LG-11)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}

3. Install the chain according to the following proce-

dures.
a Install the chain of the front of the machine to
the sprocket closer to the center of machine,
and the other chain of the rear of the machine
to the sprocket farther from the center.
1) Insert chain (9) to tandem drive case (14),
and engage the chain end with the sprocket.
2) Rotate the parking brake disc, and wind up
2. Lift up wheel brake assembly (13) to install to the chain to align with the master pin
tandem drive case (14) at four locations (front, mounting hole (A).
back, left and right).
a Align two A marks with the position as
shown in the figure to install.
q Part No. of mounting bolt for A mark:
01010-61635 (2 bolts)
q Part No. of mounting bolt except for A
mark:
01010-61660 (12 bolts)
2 Mounting bolt threaded section:
Gasket sealant (LG-11)
3 Mounting bolt (except for A):
245 – 309 Nm {25.0 – 31.5 kgm}

GD555-5,GD655-5,GD675-5 50-141
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Power train
Disassembly and assembly of tandem drive assembly
3) Using tool J1, stretch chain (9) and install
master pin (12).
4) Install plate (11) and cotter pin (10), and
connect chain (9).
a Replace the cotter pin with a new one,
and bend it securely.
5) Install the chain of the opposite side in the
same way.
4. Release parking brake (6) using hand pump [1].
5. For adjustment of the parking brake, see Testing
and adjusting, "Testing and adjusting parking
brake pad clearance".
50-142
6. Install the gasket and install two top covers (4)
and four side covers (5) (two each from outside
and inside) on the left and right of the tandem
drive case.
2 Gasket (both of case and cover sides):
Liquid gasket (LG-8)
2 Cover mounting bolt:
Liquid gasket (LG-11)
7. Install tubes (2) for brake and (3) to the left and
right of the tandem drive case.
8. Tighten left and right drain plugs (1).
3 Drain plug :
59 – 78 Nm {6.0 – 8.0 kgm}
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of tandem drive assembly

9. Remove left and right oil filler plugs (16) and

supply oil.
5 Tandem drive case (each side):
57 l (T030)
3 Oil filler plug:
59 – 78 Nm {6.0 – 8.0 kgm}

q Air bleeding (brake circuit)

Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from brake
circuit".

GD555-5,GD655-5,GD675-5 50-143
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Power train
Disassembly and assembly of final drive assembly

Disassembly and assembly of final drive assembly 50-14

7) Sling planetary carrier assembly (12) and
Disassembly 50-14 remove it.
1. Side case assembly
1) Disconnect hose (1) and remove differential
lock solenoid valve (2).
2) Remove strainer assembly (3) and hose
(3A).
3) Remove cover assembly (4).
4) Remove bolts (5) and (6), and remove side
case assemblies (7) and (8) from center case
assembly (9).

8) Remove ring gear (14) from side case

assembly (7) by pulling out evenly using
puller [2].
a Install spacer [3] to the end of puller bolt
to adjust height.
a Take care the claws of puller do not come
off ring gear.

5) Lift up side case assembly (7) and lower it to

the sprocket side and place it on block [1].
6) Remove mounting bolt (10) to remove holder
(11).

9) Reverse side case assembly (7) to set the

sprocket side up.

50-144 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

10)Remove mounting bolt (15) to remove holder 14)Remove washer (23).

(16) and shim (17). 15)Remove plug (27A).
a Check and record the number and thick-
ness of shims.
11)Remove sprockets (18) and (19).

16)Remove bearing (25) from shaft (28).

17)Remove bearing (25).

12)Remove shaft (24) using a press. 18)Sling flange (27) and remove it from side
a Be careful not to fall the shaft on the floor case (26).
when it was removed.

19)Remove bearing outer races (25A) and (28A)

13)Remove bolt (20) to remove plate (21) and from side case (26).
shim (22). 20)Remove oil seal (29).
a Check and record the number and thick- 21)Remove bushings (31), (32) and washer
ness of shims. (33).

GD555-5,GD655-5,GD675-5 50-145
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Power train
Disassembly and assembly of final drive assembly

22)Remove seal (30) from flange (27). 4) Remove pinion gear (81) and spacer (82)
from planetary carrier (78).

23)Disassemble the side case assembly on the

opposite side according to the same proce- 5) Remove bearing (83) from pinion gear (81).
dures.

2. Planetary carrier assembly

1) Drive in the spring pin (79) of planetary
carrier (78) until it is in the range of shaft (80).
a Take care not to drive in the spring pin too
deep.

3. Bevel pinion and cage assembly

1) Remove the mounting bolt of parking brake
(34) to remove the disc.
2) Remove the mounting bolt, and lift up bevel
pinion and cage assembly (35) and remove
it.
a Shims are installed, so check and record
2) Pull out the shaft (80) using a press. numbers and thicknesses of shims.
3) Pull out the spring pin (79) from removed
shaft (80).

50-146 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

3) Remove mounting bolt (36) to remove holder 6) Remove bearing (41) from bevel pinion (40).
(37) and coupling (39).
a Check and record the number and thick-
ness of shims (38).

7) Remove oil seal (43) from cage (42).

8) Remove bearing (44) and bearing outer race
(44A).
9) Remove bearing outer race (41A).

4) Set bevel pinion and cage assembly (35) on

the press stand.
5) Using push tool [2], press down bevel pinion
(40) to remove from cage assembly (35).
a Be careful not to fall the bevel pinion on
the floor when it was removed.

GD555-5,GD655-5,GD675-5 50-147
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Power train
Disassembly and assembly of final drive assembly

4. Bevel gear and differential assembly
1) Remove tube (45), nipple (46) and adapter
(46A).
6) Remove bearing (51) from the right and left
sides of bearing cage (48).
a The figure shows the right side bearing
cage.
a (a) are threaded holes for removal.

2) Sling bevel gear and differential assembly

(47).
3) Remove the mounting bolts from the right
and left sides of bearing cage (48), and pull
out bearing cage (48) by using guide bolt [3]
and forcing screw [4].
7) Place differential assembly (47) on the block
and remove the mounting bolt to remove
cage (52).

8) Remove bearing outer race (51A) from cage

4) Lift up bevel gear and differential assembly (52).
(47) and remove it.
5) Remove the right and left sides of bearing
cage (48) and shim (50).
a Check and record the number and thick-
ness of shims.

50-148 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

9) Remove washer (53), nine plates (54) and 16)Remove spider assembly (61).
eight discs (55).
10)Remove gear (56) and piston (57).
11)Remove seal rings (71) and (72) from piston
(57).

1] Remove washer (69) and pinion (68) from

spider assembly (61).

12)Reverse differential assembly (47), and

remove the mounting bolt to remove spider
case (58).
13)Remove washer (59) and gear (60).
14)Remove two seal rings (70).

2] Remove snap ring (66) and bushing (67)

from pinion (68).

15)Remove bearing outer race (51B) from

spider case (58).

GD555-5,GD655-5,GD675-5 50-149
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Power train
Disassembly and assembly of final drive assembly

17)Remove 12 mounting bolts (64) from differ- Assembly 50-150

ential case (62) to remove bevel gear (65).
18)Pull out four dowel pins (63) from bevel gear
(65).
a Clean all parts, and check them for dirt and dam-
age before installing.
a Apply power line oil (T030) to the sliding portion.
1. Bevel gear and differential assembly
1) Press fit bearing (51) to the right and left
bearing cages (48).
2 Bearing roller:
Power train oil (TO30)
a The figure shows the right side bearing
cage.

2) Press fit bearing outer race (51A) to cage

(52).

50-150 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

3) Press fit bearing outer race (51B) to spider 6) Assembly of spider

case (58). 1] Assemble snap ring (66) to pinion (68)
and press fit bushing (67) to pinion.
a Check that bushing end is not project-
ed from the gear end.

4) Tighten bevel gear (65) to differential case

(62) using 12 mounting bolts (64) tempo-
rarily.
5) Drive in four dowel pins (63) and tighten 2] Install pinion assembly (68) and washer
mounting bolt (64) to the specified torque. (69) to spider (61).
a Drive in the dowel pin, then caulk it at two
places.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
157–196 Nm {16–20 kgm}

7) Reverse the case to install spider assembly

(61).

8) Install gear (60) to spider assembly (61) and

install washer (59).

GD555-5,GD655-5,GD675-5 50-151
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Power train
Disassembly and assembly of final drive assembly

9) Install two seal rings (70) to spider case (58). 2 Disc (both sides):
2 Seal ring (outer and side surfaces): Power train oil (TO30)
Molybdenum disulphide lubricant
(LM-P)
10)Install spider case (58) to differential case
(62).
3 Spider case mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

14)Install washer (53) to cage (52) and install it

to differential case (62).

11)Reverse differential case (62).

12)Install seal rings (71) and (72) to piston (57)
and insert it in differential case (62).
a Pay attention to the mounting direction of
the seal ring.

15)Install cage (52) to differential case (62)

using the mounting bolts, and tighten them to
the specified torque.
3 Cage mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

13)Install gear (56) to the differential case and

insert nine plates (54) and eight discs (55)
alternately.

50-152 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

16)Place center case (73) on the block.

17)Lift up differential assembly (47), place it in
center case (73), install the guide bolt and
hold them as they are.
18)Install shim (50) to a guide bolt.
a Insert the same number of shims of the
same thickness as those removed.

2. Bevel pinion and cage assembly

1) Press fit bearing outer races (41A) and (44A)
to cage (42).

19)Install a guide bolt to the opposite side as

well and install shim (50) to the guide bolt.
a Install the same number of shims of the
same thickness as those removed.
20)Install right and left side of bearing cages (48)
and (49) to center case (73).

2) Using push tool [2], press-fit bearing (41) to

bevel pinion (40).
2 Bearing roller:
Power line oil (TO30)

21)Install bearing cages (48) and (49), and

tighten mounting bolts to the specified
torque.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

GD555-5,GD655-5,GD675-5 50-153
(02)
Power train
Disassembly and assembly of final drive assembly
3) Place bevel pinion (40) on the press stand
and install cage (42) to it.
4) Press fit bearing (44) to bevel pinion (40).
2 Bearing roller:
Power train oil (TO30)
7) Measure the starting torque of bevel pinion.
5) Press-fit oil seal (43) to cage (42).
2 (a) portion:
Filling (a) with grease (G2-LI)
2 (b) portion:
Applying gasket sealant (LG-5)
6) Install coupling (39), O-ring (74), shim (38)
and holder (37) to bevel pinion (40) and
tighten mounting bolt (36).
a Install the same number of shims of the
same thickness as those removed.
2 Coupling and bearing contact sur-
face:
Molybdenum disulphide lubricant
(LM-P)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
50-154
1] Using torque wrench [4], measure the
starting torque with coupling mounting
bolt (36).
q Starting torque:
1.1 – 4.7 Nm {0.11 – 0.48 kgm}
a When the starting torque is different
from the standard value, adjust the
bearing preload by increasing or de-
creasing the number of shims (38),
and then measure the starting torque
again.
q Available shim thickness:
0.1 mm, 0.2 mm, 0.5 mm and 0.15
mm
2] After adjusting the preload, tighten
mounting bolt (36) again.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
GD555-5,GD655-5,GD675-5
(02)
 Power train
Disassembly and assembly of final drive assembly

a Adjust preloads, backlashes and tooth con-

tacts at the same time.
a Engage bevel gear with bevel pinion for the
measurement.
1) Preload adjustment
Using torque wrench [3], measure the
starting torque of the bevel pinion.
a Adjust shims at the right and left side of
the bearing cage so that the starting
torque (1.1 - 4.7 Nm {0.11 - 0.48 kgm}) of
the unit of bevel pinion is increased to (0.7
- 1.5 Nm {0.07 - 0.15 kgm}).
q Standard shim thickness: 1.5 mm (one
side)
q Available shim thickness:
8) Lift up bevel pinion and cage assembly (35),
0.05 mm, 0.1 mm, 0.2 mm and 0.5 mm
install shims (75) to them and install center
case assembly (9).
a Install the same number of shims of the
same thickness as those removed.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

2) Measurement of backlash
Measure backlash of bevel gear using dial
gauge [5].
a Standard value of backlash: 0.25 – 0.31
mm
a Measure the backlash at three places on
the periphery of bevel gear, and check
that the dispersion of measured values
shall be 0.1 mm or less.

3. Adjustment of preload, measurement and

adjustment of backlash and tooth contact
a Adjust preload of the taper roller bearing,
backlashes and tooth contacts of the bevel
gear and the bevel pinion. 3) Adjustment of backlash
a Adjust the starting torque of unit of bevel pin- When the backlash is out of the standard
ion assembly to (1.1 – 4.7 Nm {0.11 – 0.48 range, adjust it by moving shims (50A) or
kgm}). (50B) toward right or left.
q It has already been adjusted in item 2.7).

GD555-5,GD655-5,GD675-5 50-155
(02)
Power train
Disassembly and assembly of final drive assembly
a Adjust the backlash only by moving shims
(50A) and (50B) and do not change the
total thickness of right and left shims in or-
der not to change the preload of bearing
(51A) and (51B).
a If the backlash is too large, decrease
thickness of shim (50A) and add the
equivalent thickness to shim (50B).
a If the backlash is too small, decrease
thickness of shim (50B) and add the
equivalent thickness to shim (50A).
4) Checking tooth contact
1] Apply a small amount of rouge compound
on seven or more tooth surfaces of the
bevel gear.
2] Rotate bevel gear forward and backward
and check the tooth contact pattern on
tooth surfaces of bevel gear.
a The center position of the tooth con-
tact shall be as follows.
q The center of tooth height
q Length (x) is 23 mm ± 4 mm from the
small end portion(C)
a Width of the tooth contact (y) shall be
35 mm ± 4 mm.
a Check that there is not a strong con-
tact at tooth tip (A), bottom (B), small
end (C), or large end (D).
50-156
5) Adjusting tooth contact
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
following procedure.
a Adjust the tooth contact by increasing or
decreasing shims (50A) or (50B) (to move
bevel gear) and shim (75) (to move the
bevel pinion).
a Do not change the total thickness of
shims (50A) and (50B) in order not to
change the preload of bearing (51A) and
(51B).
a After adjusting tooth contact, check the
backlash again.
If bevel pinion is too far from bevel gear
a The tooth contact pattern is as follows.
1) Reduce thickness of shim (75) to move bevel
pinion to direction(C).
2) Adjust thickness of shim (50A) or (50B) to
move bevel gear to direction (D).
If bevel pinion is too close to bevel gear
a The tooth contact pattern is as follows.
1) Increase thickness of shim (75) to move
bevel pinion to direction (E).
2) Adjust thickness of shim (50A) or (50B) to
move bevel gear to direction (F).
GD555-5,GD655-5,GD675-5
(02)

If bevel gear is too close to bevel pinion
a The tooth contact pattern is as follows.
1) Reduce thickness of shim (75) to move bevel
pinion to direction (C).
2) Adjust thickness of shim (50A) or (50B) to
move bevel gear to direction (D).
If bevel gear is too far from bevel pinion
a The tooth contact pattern is as follows.
1) Increase thickness of shim (75) to move
bevel pinion to direction (E).
2) Adjust thickness of shim (50A) or (50B) to
move bevel gear to direction (F).
GD555-5,GD655-5,GD675-5
(02)
Power train
Disassembly and assembly of final drive assembly
4. Tube and parking brake
1) Install adapter (46A) and nipple (46), then
install tube (45).
2) Install parking brake disc (34).
3 Parking brake disc mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
5. Side case assembly
1) Install ring gear (14) to side case (26) and
drive in pin (13).
50-157
Power train
Disassembly and assembly of final drive assembly

2) Install washer (33), bushings (32) and (31) to

side case (26).
2 Both surfaces of bushing and
washer:
Molybdenum disulphide lubricant
(LM-P)

3) Press fit seal (30) to flange (27).

2 Oil seal press-fitting portion:
Adhesive (Loctite No. 648)
2 Oil seal lip space 50%:
Grease (G2-LI)

a Install bushings (31) and (32) directing

the slits (E) and (F) as shown in the figure.
q Slit (E) of bushing (31): Install bushing
so that slit is positioned on the top side
of machine.
q Slit (F) of bushing (32): Install bushing
so that slit is positioned on the bottom
side of machine.

4) Press fit oil seal (29) to side case (26).

2 (c) portion:
Applying gasket sealant (LG-5)
2 Oil seal lip space 80%:
Grease (G2-LI)
5) Press fit bearing outer races (25A) and (28A)
to side case (26).

a When installing washer (33), turn the in- 6) Sling flange (27) and install it to side case
side edge with larger chamfer downward. (26) .

50-158 GD555-5,GD655-5,GD675-5
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 Power train
Disassembly and assembly of final drive assembly

2] While aligning shaft (80) with spring pin

hole (79a), press fit shaft (80) into plane-
tary carrier (78).
2 Shaft:
Power train oil (TO30)

7) Press fit bearing (28) to shaft (24).

a Direct the planetary carrier side (where a
bolt hole is found on the shaft end sur-
face) of the shaft upward, and press fit it
up to dimension (L).
q (L) dimension: 60 ± 2 mm 3] After aligning shaft (80) with spring pin
hole (79a), drive spring pin (79) into plan-
etary carrier (78) until it becomes flush
with the carrier (j).

8) Assemble planetary carrier assembly.

1] Install bearing (83) to gear (81) and install
gear to planetary carrier (78). 4] Tap end of shaft (80) and differential side
of gear (81) and check the gear (81) turns
lightly by pressing back bearing (83).

GD555-5,GD655-5,GD675-5 50-159
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Power train
Disassembly and assembly of final drive assembly

5] Install planetary carrier assembly (12) 9) Install washer (23) to side case assembly (7).
and holder (11) to shaft (24), tighten 2 Both surfaces of washer:
mounting bolt (10) and at the same time Molybdenum disulphide lubricant
press fit bearing (28). (LM-P)
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}

a Take care the chamfered side is posi-

tioned as shown in the figure below when
installing washer.

6] Install shaft assembly (24) with planetary

carrier to side case assembly (7), and
press fit bearing (25).
2 Roller of bearings (25) and (28):
Power train oil (TO30)
7] Install plug (27A).
2 Plug:
Gasket sealant (LG-5)
3 Plug:
2.9 – 5.9 Nm {0.3 – 0.6 kgm}

10)Install shim (22) and plate (21), and tighten

bolt (20).

a Measure step difference (b) between

washer (23) on flange (27) side and side
case (26) end surface, and adjust the
thickness of shim (22). Install them as fol-
lows:
q Shim thickness: (b + 0.1)mm
q Available shim thickness: 0.1 mm, 0.2
mm and 0.5 mm

50-160 GD555-5,GD655-5,GD675-5
(02)

a Before measuring the (b) dimension, in-
stall plate (21) first temporarily and then
measure it.
11)Install sprockets (19) and (18).
12)Install shim (17) and holder (16) and tighten
mounting bolt (15).
a Measure the thickness of holder.
q Standard holder thickness: 14 mm
a Install the same number of shims of the
same thickness as those removed.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
13)Preload adjustment
1] Remove shims (17) for adjusting bearing
preload, and then tighten three mounting
bolts (15) to equal torque so that the
starting torque becomes as shown below:
q Starting torque:
5.2 - 13.0 Nm {0.5 - 1.3 kgm}
3 Mounting bolt:
58.8 Nm {6.0 kgm} or lower
GD555-5,GD655-5,GD675-5
(02)
Power train
Disassembly and assembly of final drive assembly
2] Rotate bearings (25) and (28) three or
four times to fit in.
2 Roller of bearings (25) and (28):
Power train oil (TO30)
3] Repeat 2] and 3] until the starting toque
stabilizes.
4] When the starting toque stabilized,
measure the dimension (b) from the hole
for measuring on holder (16) to shaft (24)
end surface.
q The difference dimension (a) between
dimension (b) and holder thickness is
within the range of 0.3 - 3.3 mm.
5] Loosen three mounting bolts (15).
6] Install shims (17) of the measured dimen-
sion (a), and tighten three mounting bolts
(15).
q Available of shim thickness: 0.1 mm,
0.2 mm and 0.5 mm
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
7] Measure the starting torque, and check
that the torque is within the following
torques:
q Starting torque:
5.2 – 13.0 Nm {0.5 – 1.3 kgm}
50-161
Power train
Disassembly and assembly of final drive assembly

14)Install shaft (76) to center case assembly (9).

a Insert shaft (76) in the spider.

15)Assemble the side case on the opposite side

as per the same procedures.
16)Install side case assemblies (7) and (8) to
center case assembly (9) and tighten
mounting bolts (5) and (6).
2 Mating face of side case and center
case:
Adhesive (Loctite No. 515)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
17)Install cover assembly (4).
2 Mating face of center case and cov-
er assembly:
Adhesive (LG-8)
18)Install strainer (3).
19)Install differential lockup solenoid valve (2)
and connect hoses (1) and (3A).

a The procedures to apply liquid adhesive

to the mating faces of side case and cen-
ter case or of center case and cover as-
sembly are as shown in the figure.

50-162 GD555-5,GD655-5,GD675-5
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 Steering system
Removal and installation of steering valve (orbit-roll) assembly

Steering system 50-163

Removal and installation of steering valve (orbit-roll) assembly 50-163
Removal 50-163 2. Remove floor mat (4).
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker, and fix it after rotation.

3. Move the left and right work equipment lock

levers (5) to the LOCK position, and fix them.
(EVspecification)

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent 4. Remove four bolts and remove cover (6) of
oil from flowing out. machine monitor.
1. Install lock pin (3) to the frame.

GD555-5,GD655-5,GD675-5 50-163
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Steering system
Removal and installation of steering valve (orbit-roll) assembly

5. Disconnect connector CN-FP3 (7). 8. Loosen band (15) of the turn signal switch.

6. Disconnect three connectors CN-FP1 (8), 9. Disconnect connector CN-FP8 (16).

CN-FP2 (9) and CN-FP12 (10), and remove
machine monitor assembly (11).

10. Disconnect connector CN-FP9 (17).

7. Disconnect two connectors CN-FP6 (12) and

CN-FP5 (13), and remove cover (14).

50-164 GD555-5,GD655-5,GD675-5
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 Steering system
Removal and installation of steering valve (orbit-roll) assembly

11. Depress tilt pedal (18) to move steering column a Two washers (21) and three washers (22)
(19) to the maximum tilt in the arrow direction. are installed. Use care not to lose them.

13. Loosen knob (23) to provide a clearance

between case (24) and steering post (25).
a From the operator's seat, lower the handle
and raise the steering valve.

a Following work must be done by a pair of two

workers.

12. Using a hexagonal wrench (14 mm), remove

joint bolt (20) one each from the left and right.
[*1] 14. Remove clamp (27) of wiring harness (26).
a The steering valve, handle assembly mount-
ing bracket and string post are free by remov-
ing the left and right joint bolts. So one of the
workers must support the steering valve and
handle assembly.

GD555-5,GD655-5,GD675-5 50-165
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Steering system
Removal and installation of steering valve (orbit-roll) assembly

15. Remove clamp (28) of wiring harness (26) from 18. Remove the cotter pin and nut (31).
steering post (25). 19. Remove mounting pin (32) to remove steering
post (25).
[*3]

16. Remove clamp (29) of wiring harness (26) from

the bottom of steering post (25).
20. Insert temporarily one joint bolt (20) each at the
left and right, that have been removed in item 12,
to support steering valve mounting bracket (33).
a Above is necessary to fix the steering valve
and disconnect the hose.

17. Remove gas damper (30) from steering post

(25).
[*2]
a Fix the gas damper piston using wire and the
like to prevent its extending.
21. Disconnect P port hose (34), R port hose (35)
and nipple (36) from the steering valve.
q Tape color of hose (34): Brown
q Tape color of hose (35): Gray

22. Disconnect LS port hose (37) and joint (38) from

the steering valve.

50-166 GD555-5,GD655-5,GD675-5
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 Steering system
Removal and installation of steering valve (orbit-roll) assembly

23. Disconnect T port hose (39), L port hose (40) 25. Remove steering valve and handle assembly
and nipple (41) from the steering valve. (42).
q Tape color of hose (39): White 4 Steering valve and handle assembly:
q Tape color of hose (40): Orange 14 kg

24. Remove knob (23) and temporarily inserted left 26. Remove mounting pin (43) to remove steering
and right joint bolts (20). valve (44).
a The steering valve and handle assembly are
free by removing the left and right joint bolts.
So one of the workers must support the
steering valve and handle assembly.

GD555-5,GD655-5,GD675-5 50-167
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Steering system
Removal and installation of steering valve (orbit-roll) assembly

Installation 50-168 [*3]

q Perform installation in the reverse order to re- a Bend cotter pin (46) securely after tightening
moval. mounting pin (32) and nut (31).

[*1]
3 Joint bolt (20):
235 – 285 Nm {23.5 – 29.5 kgm}
2 Threaded portion of joint bolt (20):
Adhesive (LT-1B)
a Be sure to install two washers (21) and three
washers (22).

[*2]
a Gas damper installation procedure
1) Adjust the pitch of gas damper (30) mounting
pins to 335 - 400 mm.
q Maximum extended dimension of gas
damper (reference): 407.5 mm
2) Install gas damper (30) to steering post (25).
3) Adjust the angle of steering post (25) and
steering cover (45) and install steering post
(25).
a After the installation, lay the steering post for-
ward and make sure that the stopper of the
steering post is touched faster than by the
gas damper piston being extended to the
maximum.
2 Gas damper mounting pin: Grease
(G2-LI)

50-168 GD555-5,GD655-5,GD675-5
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 Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

Disassembly and assembly of steering valve (orbit-roll) assembly 50-169

Tools necessary for disassembly and assembly

q Torque wrench (Torque capacity: 49 Nm {5 q Plastic hammer
kgm}) q Small amount of grease
q Socket for 5/12in, 12 points q Vise
q Flat-head screwdriver (large) q Permanent marker
q Flat-head screwdriver (small) q Tweezers
q Spring installation tool (P/N: 600057)
q 3/16" hexagonal wrench

GD555-5,GD655-5,GD675-5 50-169
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Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

Parts list
Part No. Part name Q'ty Remarks
1 Screw 6 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 6
Centering spring 4 For standard input torque specification
13
Centering spring (2) For low input torque specification
14 Flat spring 2 Only for low input torque specification
15 Race bearing 1
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1

Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A

50-170 GD555-5,GD655-5,GD675-5
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 Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

Disassembly 50-171 2. Gerotor

a Disassemble the steering valve in a clean place
since it requires particularly cleanliness.
a In the following explanation diagrams, it is not
absolutely necessary to hold the unit in a vise,
but it is recommended to use a vise as far as
possible.
k Take extreme care not to hurt yourself with
an edge of the machined portions of the
sleeve, spool, housing, etc.
1) Remove spacer (5) from the internal spline of
the star of gerotor (4).
2) Remove gerotor (4).
a Take care not to let the star fall from the
ring around the gerotor.
3) Remove O-ring (22) from the gerotor.

1. End cap
1) Grip the sides of the housing in vise [8] lined
with copper plates with end cap (3) up.
a Do not grip too strongly.

3. Drive and spacer plate

1) Remove drive (8) and spacer plate (7).
2) Remove O-ring (23) from the housing.

2) Remove six screws (1) and one retainer

screw (2) to remove end cap (3).
3) Remove O-ring (22) from end cap (3).

GD555-5,GD655-5,GD675-5 50-171
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Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly
4. Ball
1) Using the flat-head screwdriver, remove
adapter screw (39).
2) Remove the housing from the vise, direct the
end cap mounting side down, and take out
ball (40).
a Take care not to let the ball fall or lose it.
5. Disassembly of anti-cavitation check valve
Remove two springs (31), two retainer plugs
(30), and two balls (32).
a Take care not to let the parts fall or lose them.
50-172
6. Seal gland bushing
1) Place the housing on a clean cloth with the
flange side up so that the finished surface will
not be damaged.
2) Raise the end of retaining ring (20) by using
a flat-head screwdriver and remove it from
the housing.
k Be sure to put on safety glasses since
the retaining ring may jump out of the
housing.
3) Place the housing on a clean cloth so that the
axis of the valve body will be level.
4) Rotate the spool and sleeve assembly to
position the sleeve pin to the level, then push
out the spool and sleeve assembly a little and
remove seal gland bushing (21) from the
housing.
5) Remove the oil seal and dust seal from the
gland bushing.
a When removing the seal, take care not to
damage the seal gland bushing.
GD555-5,GD655-5,GD675-5
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 Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

7. Race bearing and thrust needle 3) Push out the spool forward a little from inside
Remove two race bearings (15) and thrust of the sleeve and remove centering spring
needle (16). (13) from the spool carefully with your hand.

8. Spool and sleeve 4) While rotating the spool slowly, pull out spool
1) Push the internal spline of the spool with your (11) from sleeve (10).
thumb to pull out the spool and sleeve 5) Remove the O-ring from the housing.
assembly from the housing.
k Be sure to put on safety glasses since
center spring (13) may jump out of the
spool.
a Take care that the outer rim of the sleeve
will not be caught in the inner rim of the
housing.
a If spool and sleeve (43) are misaligned
180 degrees from each other when as-
sembled, they may not operate normally,
depending on their combination. To avoid
this, mark matchmarks on their positions.
2) Pull out pin (12).

GD555-5,GD655-5,GD675-5 50-173
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Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly
9. Disassembly of steering relief valve
1) Using a hexagonal wrench (width across
flats: 3/16 in.), remove plug (28).
2) Remove O-ring (29) from the plug.
3) Using tweezers , remove spring (27) and
poppet (26).
a You cannot remove the valve seat since it
is stuck to the housing.
10. Disassembly of overload relief valve
1) Using a hexagonal wrench (width across
flats: 3/16 in.), remove two plugs (37).
2) Remove O-ring (38) from the plug.
3) Using tweezers, remove two springs (36),
two ball holders (35), and two balls (34).
a You cannot remove the valve seat since it
is stuck to the housing.
50-174
Assembly 50-174
k Take care not to hurt yourself with an edge of
the machined portions of the sleeve, spool,
housing, etc.
a Check all the joining parts.
If any part has a scratch or a burr, replace it with
a new one since it can cause oil leakage.
Clean the metallic parts in clean solvent and dry
them with air blow (If they are wiped with cloth or
paper, fiber or lint may enter the valve and cause
a trouble). Do not grind the parts with a file or
sandpaper.
a As a rule, use new O-rings and seals after disas-
sembly, and apply a small amount of clean
grease to the O-rings before assembly.
a Since the O-rings on the two sides of the spacer
plate are very similar to each other in size, check
their part Nos. before opening the seal kit and
avoid mixing them up.
1. Spool and sleeve
1) While rotating spool (11) slowly, insert it into
sleeve (10).
a Hold the spline portion of the spool and
check that the spool rotates smoothly in-
side the sleeve.
a Match the matchmarks marked during as-
sembly.
GD555-5,GD655-5,GD675-5
(02)
 Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

2) Stand the spool and sleeve on a flat plate

while matching the two spring grooves at 180
degrees.
3) Put spring installation tool (P/N: 600057) in
the spring groove and install it so that the
notches at both ends of the centering spring
will be directed downward.
a If you raise the spool a little from the
sleeve, you can insert easily.
4) While raising the spool a little from the sleeve
and compressing the opposite end of the
centering spring with a finger, push the
spring into the grooves of the spool and
sleeve.
a Slide the installation tool at the same
2. Race bearing and needle
speed as the spring pushed in.
1) Place the housing on a clean and flat place
a After installation, align the spring end with
and install O-ring (17).
the external rim of the sleeve.
2) Install two race bearings (15) and thrust
a Insert the sleeve pin in the hole of the
needle (16).
sleeve and align its both ends with the
a Be sure to put the thrust needle between
outside surface of the sleeve.
k Be sure to put on safety glasses since
the race bearings.
the centering spring may jump out of
the spool.

5) Place the housing on a clean cloth so that the

axis of the valve body will be level, and insert
the spool and sleeve assembly from the
opposite end to the flange of the housing.
a Check that the spool and sleeve assem-
bly rotate smoothly inside the housing.
a If the spool and sleeve assembly are
slanted when you insert them, they cut
into the valve body. Take care.
a While keeping the pin about level, insert it
by rotating it to the right and left little by lit-
tle.
a Insert the spool and sleeve assembly until
they are aligned with the end face of the
housing. If they are inserted further, the
pin may fall in the housing. Accordingly
stop when they are aligned with the end
face of the housing.

GD555-5,GD655-5,GD675-5 50-175
(02)
Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

3. Seal gland bushing
a There are two types of seal: Teflon seal and
standard seal.
1) Install dust seal (19) to seal gland bushing
(21).
a Install the dust seal so that the flat surface
will be on the seal gland bushing side.
2) Install oil seal (18) to the seal gland bushing.
a When installing the oil seal, take care that
it will not be twisted or deformed.
a The following figure shows the specifica-
tions of the Teflon seal. (44) is the distinc-
tion groove.
3) Install seal gland bushing (21) (to which all
the seals have been installed) to the spool,
while rotating it.
a Install the seal gland bushing to the spec-
ified position by hitting it lightly with a
plastic hammer, etc.
4) Install retaining ring (20) to the housing.
a Expand the retaining ring with a flat-head
screwdriver so that all the periphery of the
retaining ring will be fitted to the grove of
the housing.
k Be sure to put on safety glasses since
the retaining ring may jump out of the
housing.

a The figure below shows the standard seal

specification. a Seal assembly drawing
Screwdriver [9]
Dust seal (19)
Retaining ring (20)
Seal gland bushing (21)
Oil seal (18)
O-ring (17)

50-176 GD555-5,GD655-5,GD675-5
(02)

Disassembly and assembly of steering valve (orbit-roll) assembly
4. Assembly of steering relief valve
1) Install O-ring (29) to plug (28).
2) Using tweezers , install spring (27) and
poppet (26) to the housing.
3) Using a hexagonal wrench (width across
flats: 3/16 in.), install plug (28) to the housing.
5. Assembly of overload relief valve
1) Install O-ring (38) to plug (37).
2) Apply grease to ball holder (35), and install
ball (34).
3) Using tweezers , install ball holder (35) and
spring (36) to the housing.
4) Using a hexagonal wrench (width across
flats: 3/16 in.), install plug (37) to the housing.
a The ball size of the overload relief valve
and that of the anti-cavitation check valve
are different. Take care not to mix up
them.
GD555-5,GD655-5,GD675-5
(02)
Steering system
6. Assembly of anti-cavitation check valve
1) Grip the port surface and side surface of the
housing in a vise lined with copper plates.
a Do not grip too strongly.
2) Put one spring (31), one retainer plug (30),
and one ball (32) each in the two of the seven
bolt holes at the end face of the housing
shown in the figure.
a Take care not to let the ball fall or lose it.
a Be careful of the assembly direction of the
retainer plug.
7. Assembly on gerotor side
1) Grip the port surface and side surface of the
housing in a vise lined with copper plates,
etc. ((45) = 25 mm).
a Do not grip too strongly.
50-177
Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

2) Put balls (40) in the ones of the seven bolt

holes on the end face of the housing shown
in the figure, and install adapter screw (39).

7) Install O-ring (22) to gerotor (4).

3) Install O-ring (23) to the housing.

4) Place spacer plate (7) and align the bolt
holes.
a The pitch circle diameter of the bolt holes
is different from that of the oil holes.

8) Direct the end of the O-ring side of gerotor (4)

9) When installing, match roots gullet (48) of the
5) Rotate the spool and sleeve assembly to
position pin (12) in parallel with port face (46)
of the housing.
a Check that (47) are in parallel.
6) Insert drive (8).
a Draw a line with a permanent marker on
the end face of drive (8) in parallel with pin
(12) to determine the engaging portion of
the yoke for the drive and pin (12).
toward spacer plate (7).
gerotor star with pin (12) and match them
with the line drawn on the end face of drive
(8).
a Check carefully that lines A, B, C, and D
are in parallel as shown in the figure.
a Match the bolt holes by rotating the gero-
tor ring without disengaging the drive and
the gerotor star.
a The above is an important procedure for
matching the valve timing.

50-178 GD555-5,GD655-5,GD675-5
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 Steering system
Disassembly and assembly of steering valve (orbit-roll) assembly

8. Spacer and end cap a After tightening to the following torque, in-
1) Install spacer (5) to the internal spline of stall the handle to the spool and check
gerotor star. that the spool rotates.
a Do not install the spacer for the orbit-rolls Tightening torque of screw
specified delivery rate of 51 cc/rev and 69 Tightening torque Nm
Delivery rate (cc/rev)
cc/rev. {kgm}
Install two spacers for the orbit-roll speci- 51 – 230 22.5 {2.3}
fied delivery rate of 184 cc/rev.
277 23.5 {2.4}
2) Install O-ring (22) to end cap (3).
3) Apply oil to the thread parts of six screws (1) 369 – 737 28.4 {2.9}
and one retainer screw assembly (2) and
install them to the end cap.
a Install the retainer screw assembly to the Delivery rate and spacer table
bolt hole in which the adapter screw was Thickness of
Symbol for deliv- Delivery rate
spacer
installed in the previous step. ery (cc/rev)
(mm)
a Tighten the seven screws to about 14.7
A 51 -
Nm {about 1.5 kgm}, then tighten to the
torque and in the sequence shown below. B 69 -
C 96 3.6
D 120 6.1
E 159 12.2
12.2
G 184
3.6
K 230 22.0
M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
U 737 91.8
a Tighten the end cap mounting screws in
the following numerical sequence.

GD555-5,GD655-5,GD675-5 50-179
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Brake system
Disassembly and assembly of wheel brake assembly

Brake system 50-180

Disassembly and assembly of wheel brake assembly 50-180
3. Gear and shaft
Special tools 50-180 1) Remove gear (8).
2) Remove shaft (9) from cage (10).

New/redesign
Necessity
3) Remove bearing (11) and spacer (13) from

Sketch
Q'ty
Symbol Part No. Part name shaft (9).

790-101-5401 Push tool kit t 1

790-101-5551 q Plate 1
2
790-101-5421 q Grip 1
J 01010-51240 q Bolt 1
794T-425-1110 Push tool t 1 Q
3
793T-659-1110 Push tool t 1 Q
4 799-301-1600 Oil leak checker t 1

Disassembly 50-180
1. Sprocket and cage 4. Guide and spring
1) Remove mounting bolt (1). Remove guide (14) and spring (15).
2) Remove holder (2), shim (3), sprocket (4) 5. Piston
and cage (5). Remove piston (16).

2. Brake plate and brake disc

Remove six brake plates (6) and five brake discs
(7).

50-180 GD555-5,GD655-5,GD675-5
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 Brake system
Disassembly and assembly of wheel brake assembly

6. Seal Assembly 50-181

Remove seal (17) from cage (10). a Clean all parts, and check them for dirt and dam-
7. Disc wear gauge age before installing.
Remove disc wear gauge (18) from cage (10).
1. Shaft
Install an O-ring to the inside of spacer (13) and
install it to shaft (9), and press fit bearing (11).
2 Bearing:
Power train oil (TO30)

2. Seal
Place cage (10) on a stable stand and press fit
oil seal (17).

a Press fit oil seal (17) to the position of dimen-

sion (a) from the end surface of cage (10).
Dimension (a): 6 ± 0.3 mm
2 Oil seal lip space (b) (80% filling):
Grease (G2-LI)
2 Between bearing and oil seal:
Filling with grease (G2-LI)

GD555-5,GD655-5,GD675-5 50-181
(02)
Brake system
Disassembly and assembly of wheel brake assembly

4. Guide and brake spring

1) Install a washer to guide (14) and install
brake spring (15).
q Brake spring installed height: 60.5 mm
q Brake spring free height: 76.5 mm
q Load at installed length of brake spring:
735 Nm {75 kg}

3. Brake piston
1) Install O-ring (19) to brake piston (16).
2 O-ring and piston groove:
Grease (G2-LI)

2) Tighten guide (14) using torque wrench [1].

2 Threads of guide:
Adhesive (LT-2)
3 Guide:
49 ± 7.4 Nm {5 ± 0.75 kgm}

2) Install brake piston (16) to cage (10).

2 Contact surface of piston and cage:
Grease (G2-LI)

5. Cage
Install cage (10) to shaft (9).

50-182 GD555-5,GD655-5,GD675-5
(02)
 Brake system
Disassembly and assembly of wheel brake assembly

6. Bleeder and plug 9. Cage

Install bleeder (20) and plug (21). 1) Install O-rings (23) to inside and outside cage
3 Plug: (5), and install cage (5) to cage (10).
58.8–78.4 Nm {6.0–8.0 kgm}

2) Install a collar and press fit bearing (24).

7. Gear 2 Bearing:
Assemble the collar and install gear (8). Power train oil (TO30)

8. Brake plate and brake disc 10. Sprocket

Assemble six brake plates (6) and five brake
discs (7) alternately.
1) Install a collar and install sprocket (4).
2) Install shims (3) and holder (2) and tighten
mounting bolt (1).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a After adjusting the bearing preload, apply
adhesive (LT-2) to the mounting bolt and
tighten it again.

GD555-5,GD655-5,GD675-5 50-183
(02)
Brake system
Disassembly and assembly of wheel brake assembly
11. Plate
Install plate (12).
12. Pre-load adjustment
1) Using push-pull gauge [2], measure dragging
starting torque (A) of the shaft.
Adjust the pre-load of right and left bearing
with shims (3) so that the above dragging
starting toque comes to (A) + 11 – 16 Nm
{1.15 – 1.65 kgm}.
a When adjusting pre-load of bearings,
keep the tightening torque of holder
mounting bolt (1) below 58.8 Nm {6.0
kgm}.
q Standard shim thickness: 2 mm
q Available shim thickness: 0.1 mm, 0.2
mm and 0.5 mm
2) After adjusting the pre-load, tighten holder
mounting bolt (1) again.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
50-184
13. Disc wear gauge
Install the disc wear gauge according to the
following procedures.
1) Keep the brake operating (by depressing
piston (16)) and push gauge (18A) in until it
contact to piston (16).
2) Rotate guide (18B) until the guide (18B)
upper surface (G) comes to the edge line of
underside of the groove (H) of gauge (18A)
3) Tighten nut (18C) to fix guide (18B).
4) Install cap (18D).
a Brake airtightness inspection procedures
Pressure drop is checked under the following
test pressure when the brake hydraulic oil
pipings are shut off.
q High pressure oil leak test
Bleed air completely from bleeder (25).
1] Test pressure: 3,920 kPa {40 kg/cm2}
2] Criteria: When the hydraulic oil
pipings are shut off, the pressure
drops not more than 98 kPa
{1 kg/cm2} in five minutes.
q Low pressure oil leak test
Bleed air completely from bleeder (25).
1] Test pressure: 98 kPa {1 kg/cm2}
2] Criteria: When the hydraulic oil
pipings are shut off, any pressure drop
can not be observed in five minutes.
GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

Undercarriage and frame 50-185

Removal and installation of center hinge pin 50-185
1. Set lock pin (3) on the frame.
Special tools 50-185

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

1 794T-646-1010 Push tool t 1 Q

2 794T-646-1021 Push tool q 1 N Q
K
Puller
3 790-101-2102 t 1
(294 kN 30 ton)
4 790-101-1102 Pump t 1

Removal 50-185
k Park the machine on level ground, and lower
2. Remove the operator’s cab assembly. For
details, see "Removal and installation of oper-
the work equipment to the ground by operat-
ator’s cab assembly."
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
3. Remove the floor frame assembly. For details,
k Shut off the battery (negative) circuit by turn-
see "Removal and installation of floor frame
assembly."
ing and removing lever (2) of disconnect
4. Remove the following parts from the right side of
switch (1) (front left side of the engine room)
the machine.
being installed on the battery and hydraulic
1) Disconnect hose (5) on the head side and
tank mounting frame.
hose (6) on the bottom side from articulate
a The battery (negative) circuit is shut off when
cylinder (4).
the lever is removed. And it is closed if you
attach and rotate the lever of the circuit
breaker and fix it after rotation.

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Record the currently installed positions of the
hoses and wires so that they are not installed in
wrong positions.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.

GD555-5,GD655-5,GD675-5 50-185
(02)
Undercarriage and frame
Removal and installation of center hinge pin
2) Pull out pin (7) on the rod side of articulate
cylinder (4).
a Reverse the rod side of the articulate cyl-
inder to the front side and fix it.
3) Remove two clamps (8) from the front frame,
and release two air conditioner drain hoses
(9).
4) Remove clamp (10), and release two air
conditioner hoses (11) from the frame.
50-186
5) Remove clamp (12) and release 11 hoses
(13).
a Record the installed positions with the
hose tape color.
a Move the hoses (five brake hoses and
two air conditioner hoses) already re-
leased to the rear frame side.
6) Release two hoses (14) from the clamp (15).
7) Remove the bolts, and remove clamp (16)
from the frame.
GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

8) Disconnect connector CN-FL9 (17). a Remove the disconnected hoses from the
9) Remove right front work clamp (18). front frame and move them to the rear
frame side.

10)Remove two clamps (19) and (20), and

release the hoses. 13)Disconnect two hoses (26) and (27) from
a Record the installed positions with the bank pin (28).
hose tape colors. a Remove the disconnected hoses from the
front frame and move them to the rear
frame side.

11)Disconnect drain hose (22) from block (21)

under the work equipment valve.
a Since tools cannot be put inside, keep
hose (23) away from block (21).
a Remove the disconnected hoses from the
front frame and move them to the rear
frame side.

12)Disconnect hose (24) under the work equip-

ment valve from tube (25).

GD555-5,GD655-5,GD675-5 50-187
(02)
Undercarriage and frame
Removal and installation of center hinge pin
5. Remove the following parts from the left side of
the machine.
1) Disconnect hose (30) on the bottom side and
hose (31) on the head side from articulate
cylinder (29).
2) Pull out pin (32) on the rod side of articulate
cylinder (29).
a Reverse the rod side of the articulate cyl-
inder to the front side and fix it.
50-188
3) Remove clamp (33), two wiring harnesses
(34), two heater hoses (35) and eight hoses
(36).
a Record the installed positions with the
hose tape colors.
a Move two wiring harnesses already re-
leased to the rear frame side.
4) Remove clamps (37) of two wiring harnesses
(34) from the rear frame.
GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

5) Remove clamp (38) and release two heater 8) Remove clamp (45) and release six hoses
hoses (35) from the front frame. (46).
a Move the released heater hoses to the a Record the installed positions with the
rear frame side. hose tape colors.
6) Disconnect three hoses (40), (41) and (42)
from valve (39).
a Remove the disconnected hoses from the
front frame and move them to the rear
frame side.

9) Disconnect connector CN-FL10 (47).

10)Remove left front work clamp (48).
11)Remove two clamps (49) and (50), and
release the hoses.
a Record the installed positions with the
hose tape colors.
7) Disconnect hose (44) from block (43).
a Remove the disconnected hose from the
front frame and move it to the rear frame
side.

12)Remove two clamps (51) and (52).

GD555-5,GD655-5,GD675-5 50-189
(02)
Undercarriage and frame
Removal and installation of center hinge pin

13)Disconnect hose (53) of port P1 and hose
(54) of port P2 of the control valve.
a Remove the disconnected hoses from the
front frame and move them to the rear
frame side.
7. Disconnect rod (58) of articulate sensor.
[*1]
a Measure the distance between the rod pins
and record it.

8. Remove the center hinge pin according to the

14)Disconnect hose (55) of port B9 and hose following procedures.
(56) of port A9 of the control valve. 1) Check that chocks [1] are securely set to the
a The control valve shown is the 9-spool both right and left front wheels.
valve on the machine with ripper.
a Remove the disconnected hoses from the
front frame and move them to the rear
frame side.

2) Remove lock pin (3) on the frame.

6. Remove articulate sensor cover (57) in the rear

side of the front frame.

50-190 GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

3) Set a jack [2] (490 kN {50 ton}) in the rear of 6) Remove six mounting bolts (60) and four
the rear frame. mounting bolts (61) from the lower part of the
rear frame lower hinge.

4) Set two jacks [3] (294 kN {30 ton}) in the front

of the rear frame. 7) Remove cover (62) and shim (63).
a Check and record the number and thick-
ness of the shims.

5) Use sling [4] to sling the rear of front frame

(59).
8) Remove spacer (64).
a The spacer is inserted in the rear and
front frame hinges, and the front frame
and the rear frame cannot be separated
without removing the spacer.
a If the front frame and the rear frame are
misaligned and the spacer cannot be re-
moved, slightly adjust their positions us-
ing jacks [2], [3] or sling [4].

GD555-5,GD655-5,GD675-5 50-191
(02)
Undercarriage and frame
Removal and installation of center hinge pin
9) Remove lower hinge pin (65) using jack [5]
(98 kN {10 ton}).
a If the front frame and the rear frame are
misaligned and the lower hinge pin can-
not be removed, slightly adjust their posi-
tions using jacks [2], [3] or sling [4].
50-192
10)Remove lock bolt (67) of upper hinge pin
(66).
11)Remove the upper hinge pin using jack [6]
(98 kN {10 ton}).
a If the front frame and the rear frame are
misaligned and the upper hinge pin can-
not be removed, slightly adjust their posi-
tions using jacks [2], [3] or sling [4].
GD555-5,GD655-5,GD675-5
(02)

12)Remove chocks [1] set to the right and left
front wheels.
13)Pull front frame (59) in the arrow (front) direc-
tion while lifting the rear part of front frame
(59), and disconnect the front frame from
rear frame (68).
10. Disassemble the front frame upper hinge
9. Disassemble the front frame lower hinge
according to the following procedures.
1) Remove spacer (69) from the upper part.
11. Disassemble the rear frame upper hinge
GD555-5,GD655-5,GD675-5
(02)
Undercarriage and frame
Removal and installation of center hinge pin
2) Remove 10 mounting bolts (70) from the
lower part, and remove retainer (71) and
shims (72).
a Check and record the number and thick-
ness of shims.
3) Remove dust seal (73) from retainer (71).
4) Remove bearing (74) and dust seal (75).
according to the following procedures.
1) Remove dust seals (76) and (77).
2) Remove bushing (78).
according to the following procedures.
q Remove two bushings (79) and (80).
50-193
Undercarriage and frame
Removal and installation of center hinge pin
Installation 50-194
1. Assemble the rear frame upper hinge according
to the following procedures.
q Press-fit two bushings (80) and (79).
2 Inside surface of bushing (pin con-
tact surface):
Molybdenum disulphide lubricant
(LM-P)
2. Assemble the front frame upper hinge according
to the following procedures.
1) Press-fit bushing (78).
2 Inside surface of bushing (pin con-
tact surface):
Molybdenum disulphide lubricant
(LM-P)
2) Install dust seals (77) and (76).
50-194
3. Assemble the front frame lower hinge according
to the following procedures.
1) Use tool K2 and two retainer mounting bolts
(70) to press-fit bearing outer race (74A) in
the front frame upper hinge.
k The clearance is adjusted between the
bearing and the spacer, so do not
change the combination.
2) Remove tool K2, install bearing inner race
(74B) and use tools K1 and K3 to press-fit
bearing outer race (74C).
2 Inside surface of bearing (pin con-
tact surface):
Molybdenum disulphide lubricant
(LM-P)
GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

3) Install dust seal (73) to retainer (71) and 7) Install dust seal (75) to the upper part of the
install it to the front frame lower hinge with front frame lower hinge and insert spacer
three mounting bolts (70) partially tightened. (69) in it.
a Tighten three mounting bolts equally a Insert the spacer with tapered portion
leaving spaces of "108°, 108° and 144°" downward.
between them. 2 Inside surface of spacer (pin con-
3 Mounting bolt: tact surface):
20 ± 2 Nm {2.0 ± 0.2 kgm} Molybdenum disulphide lubricant
4) Measure the clearance (a) between front (LM-P)
frame lower hinge (59A) and retainer (71).
5) Select proper shims (72) so that the clear-
ance comes to the standard value.
q Clearance standard value: Max. 0.1 mm
q Shim thickness: 0.1 and 0.5 mm
6) Loosen three mounting bolts (70) of
partially-tightened retainer (71), insert
selected shims (72) and tighten 10 mounting
bolts (70) of retainer (71) to the specified
torque.
q Standard shim thickness: 2.5 mm
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

4. Assemble the center hinge pin according to the

following procedures.
1) Install one lever block [7] to the right and left
sides of front frame (59) and rear frame (68)
respectively, pull front frame (59) close to
rear frame (68) and align the centers of the
hinge pin holes of the front frame and the rear
frame.

GD555-5,GD655-5,GD675-5 50-195
(02)
Undercarriage and frame
Removal and installation of center hinge pin

2) Insert spacer (64) in the rear frame lower

hinge from the bottom.
a Insert the spacer with the tapered portion
upward.
a The spacer is inserted in the rear and
front frame hinges.
a If the front frame and the rear frame are
misaligned and the spacer cannot be in-
serted, slightly adjust their positions using
jacks [2], [3] or sling [4].
2 Inside surface of spacer (pin con-
tact surface):
Molybdenum disulphide lubricant
(LM-P)
4) Install washers to four mounting bolts (61)
and install cover (62) temporarily to rear
frame hinge (68A) from the bottom.
3 Mounting bolt:
20 ± 2 Nm {2.0 ± 0.2 kgm}
5) Measure the clearance (b) between rear
frame lower hinge (68A) and cover (62).
a Measure the clearance at three mounting
bolt holes out of six.
6) Select proper shim (63) so that the clearance
comes to the standard value.
q Clearance standard value: Max. 0.2 mm
q Shim thickness: 0.2, 0.5 and 1.0 mm
7) Loosen partially-tightened four mounting
3) Insert lower hinge pin (65) using jack [5] (98 bolts (61) of cover (62), insert selected shims
kN {10 ton}). from the top. (63) and tighten six mounting bolts (60).
a If the front frame and the rear frame are q Standard shim thickness: 2.5 mm
misaligned and the lower hinge pin can- 2 Mounting bolt (60):
not be inserted, slightly adjust their posi- Adhesive (LT-2)
tions using jacks [2], [3] or sling [4]. 3 Mounting bolt (60):
2 Periphery of lower hinge pin: 98 – 123 Nm {10 – 12.5 kgm}
Molybdenum disulphide lubricant
(LM-P)

50-196 GD555-5,GD655-5,GD675-5
(02)
 Undercarriage and frame
Removal and installation of center hinge pin

8) Tighten four mounting bolts (61) to the spec- q Perform the following installation in the reverse
ified torque. order to removal.
2 Mounting bolt (61): [*1]
Adhesive (LT-2) a For the details of adjustment procedures, see
3 Mounting bolt (61): Testing adjusting, "Zero point adjustment proce-
206 ± 20 Nm {21 ± 2 kgm} dures of articulate meter".
q Dimension (d) between the pins of rod (58):
238 mm(standard value)

9) Insert upper hinge pin (66) from the top.

a If the front frame and the rear frame are
misaligned and the lower hinge pin can-
not be inserted, slightly adjust their posi- q Air bleeding (steering circuit)
tions using jacks [2], [3] or sling [4]. Bleed air from the steering circuit. For details,
2 Periphery of upper hinge pin: see Testing and adjusting "Bleeding air from
Molybdenum disulphide lubricant steering circuit".
(LM-P)

10)Install lock bolt (67) of upper hinge pin (66).

GD555-5,GD655-5,GD675-5 50-197
(02)
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

Hydraulic system 50-198

Removal and installation of hydraulic tank, battery and frame assembly50-198
2. Drain the oil through the hydraulic tank drain
Removal 50-198 valve (5).
k Park the machine on level ground, and lower 6 Hydraulic oil:
the work equipment to the ground by operat- 69 l
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
the circuit breaker, and fix it after rotation.

3. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
4. Remove right side cover (6) on the hydraulic
tank side.

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Record the currently installed positions of the
hoses and wires so that they are not installed in
wrong positions.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out. 5. Remove cover (7) above the accumulator.
1. Set lock pin (3) on the frame.

50-198 GD555-5,GD655-5,GD675-5
(02)

Removal and installation of hydraulic tank, battery and frame assembly
6. Remove plate (8) at the bottom of the accumu-
lator to remove left and right covers (9) and (10).
7. Remove cover (11) in the front and lower left
side cover (12) on the battery side.
a Don't remove upper left side cover (13).
8. Disconnect three hoses (14), (15) and (16) from
the hydraulic tank.
GD555-5,GD655-5,GD675-5
(02)
Hydraulic system
9. Disconnect two hoses (17) and (18) from the
hydraulic tank.
10. Disconnect hose (19) between the hydraulic
tank and cooling fan pump from the cooling fan
pump.
a Remove hose (19) along with the hydraulic
tank without disconnecting it from the tank.
11. Remove strainer (20) from frame (21).
50-199
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

12. Disconnect pump suction hose (22) from the

hydraulic tank.
[*1]

18. Disconnect hose (35) used between priority

valves from strainer (34).

13. Remove the clamp for hoses (24) and (25) used
between accumulator (23) and the brake valve
from frame (21), then disconnect the hoses from
accumulator (23).
q Tape color of hose (24): White
q Tape color of hose (25): Red
14. Remove the clamp for hoses (26) and (27) used
between accumulator (23) and the charge valve
from frame (21), then disconnect the hoses from
accumulator (23).
[*2]
q Tape color of hose (26): White
q Tape color of hose (27): Red

19. Disconnect hose (36) from strainer (34).

q Tape color of hose (36): Brown

15. Remove clamp (28) for hoses (26) and (27) used
between the accumulator and charge valve.
a Remove all the clamps for hoses (26) and
(27), being fixed to frame (21).
16. Remove clamps (29) and (30).
17. Remove hydraulic oil drain valve (31) and
disconnect tube (32) from the hydraulic tank.
[*3]
a Loosen tube (32), and after removing bolts
(33) and drain valve (31), remove tube (32).

50-200 GD555-5,GD655-5,GD675-5
(02)
 Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

20. Disconnect hoses (38) and (39) from transmis- 24. Remove clamp (43) for hose (42) being
sion filter (37). connected to the priority valve (LS port).

21. Remove three bolts and remove transmission
filter assembly (37).
22. Disconnect heater hose (40).
25. Remove clamp (45) for hose (17) used between
the hydraulic tank and priority valve (44).
a Hose (17) is already disconnected from the
hydraulic tank in step 9.
a Keep hose (17) in a place near priority valve
(44).

23. Remove clamp (41) for hose (18) under the

hydraulic tank.
a Hose (18) is the one disconnected from the
hydraulic tank in step 9.
26. Remove slow-blow fuse (46).
27. Disconnect the connectors of diodes CN-R19
(47) and CN-R18 (48).
28. Disconnect wiring harness terminal CN-ET49
(49) from the battery relay.
29. Disconnect connector CN-R21 (50).
30. Remove two clamps for wiring harness (51).

GD555-5,GD655-5,GD675-5 50-201
(02)
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

33. Disconnect connectors CN-R15 (52) and

CN-R16 (53) for the accumulator oil pressure
switch.

31. Remove the clamp for wiring harness (49).

32. Remove two clamps for wiring harness (51).

34. Remove all the clamps for wiring harnesses (49)

and (51) from frame (21).
a Move wiring harnesses (49) and (51) to a
place where your work is not disturbed.
35. Remove all the clamps for heater hose (40) from
frame (21).
a The heater hose is already disconnected
from the engine in the step 22.

50-202 GD555-5,GD655-5,GD675-5
(02)
 Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

36. Remove bolt (54) from frame (21) in the front left, 40. Lift off hydraulic tank, battery and frame
then remove mounting plate (58) for connectors assembly (62).
CN-T20 (55), CN-T21 (56) and CN-T22(57). a Make sure that all the piping and wiring har-
37. Remove two mounting bolts (59) each in the nesses are disconnected before lifting them
right front and left front of the frame. off.
[*4] 4 Hydraulic tank, battery and frame as-
sembly:
380 kg

38. Disconnect battery grounding terminal (60) at

the bottom of frame (21) in the rear left.
a The wiring harness of the negative battery
terminal is connected via the battery and cir-
cuit breaker.
39. Remove two frame mounting bolts (61) each in
the rear right and left.
[*5]

GD555-5,GD655-5,GD675-5 50-203
(02)
Hydraulic system
Removal and installation of hydraulic tank, battery and frame assembly

Installation 50-204
q Perform installation in the reverse order to re-
moval.

[*1]
a Install the double clamps with their fastening
screws at 180° apart each other.
3 Suction hose mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
a Start the engine to pressurize oil in the brake ac-
cumulator.
[*3]
a Install the shorter side (A) of tube (32) to the hy-
draulic tank.

[*4] [*5]
3 Frame mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}

q Refilling of oil (hydraulic tank)

Refill the hydraulic tank with hydraulic oil through
the oil filler port to the specified level. Let the oil
circulate in the hydraulic system by running the
engine. Then check the oil level again.
5 Hydraulic oil:
69 l

q Air bleeding (brake circuit)

Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from brake
circuit".

50-204 GD555-5,GD655-5,GD675-5
(02)
 Hydraulic system
Removal and installation of hydraulic tank assembly

Removal and installation of hydraulic tank assembly 50-205

1. Set lock pin (3) on the frame.
Removal 50-205
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
the circuit breaker, and fix it after rotation.
2. Drain the oil through the hydraulic tank drain
valve (5).
6 Hydraulic oil:
69 l

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Record the currently installed positions of the
hoses and wires so that they are not installed in
wrong positions. 3. Remove the engine hood assembly. For details,
a Prepare an oil container since oil flows out when see "Removal and installation of engine hood
the hydraulic hose and tube are disconnected. assembly".
a Plug the disconnected hose and tube to prevent 4. Remove right side cover (6) on the hydraulic
oil from flowing out. tank side.
a When removing the hydraulic tank, first remove
parts installed on the frame such as battery, then
turn the tank 45° to remove.
a This section describes the procedures for "re-
moving and installing the hydraulic tank" when it
stays on the machine.
a It is allowed to remove the assembly of the hy-
draulic tank, battery and frame once refering to
"Removal and installation of hydraulic tank, bat-
tery and frame assembly" and remove the hy-
draulic tank refering to this section.

GD555-5,GD655-5,GD675-5 50-205
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Hydraulic system
Removal and installation of hydraulic tank assembly
5. Remove cover (7) over the accumulator.
6. Remove plate (8) under the accumulator to
remove left and right covers (9) and (10).
7. Remove cover (11) in the front and lower left
side cover (12) on the battery side.
50-206
8. Disconnect three hoses (13), (14) and (15) from
the hydraulic tank.
9. Disconnect two hoses (16) and (17) from the
hydraulic tank.
10. Disconnect hose (18) between the hydraulic
tank and cooling fan pump from cooling fan
pump (19).
a Remove hose (19) along with the hydraulic
tank without disconnecting it from the tank.
GD555-5,GD655-5,GD675-5
(02)

11. Remove hydraulic oil drain valve (20) and
disconnect tube (21) from the hydraulic tank.
[*1]
a Loosen tube (21), and after removing bolts
(22) and drain valve (20), remove tube (21).
12. Remove clamp (23) for hose (18) used between
the hydraulic tank and cooling fan pump.
13. Disconnect pump suction hose (24) from the
hydraulic tank.
[*2]
GD555-5,GD655-5,GD675-5
(02)
Hydraulic system
Removal and installation of hydraulic tank assembly
14. Disconnect hoses (26) and (27) used between
accumulator (25) and the brake valve from accu-
mulator (25).
q Tape color of hose (26): White
q Tape color of hose (27): Red
15. Disconnect hoses (28) and (29) used between
accumulator (25) and the charge valve from
accumulator (25).
[*3]
q Tape color of hose (28): White
q Tape color of hose (29): Red
16. Open cover (30) over the battery.
17. Remove two clamps (31) and three mounting
bolts (32) to remove cover (30) over the battery.
50-207
Hydraulic system
Removal and installation of hydraulic tank assembly

18. Remove two batteries (33). a Remove in advance the wiring harness from
4 Battery (1 piece): clamp (45).
50 kg

19. Remove slow-blow fuse (34). 27. Remove the clamp for wiring harness (37).
20. Disconnect the connectors of diodes CN-R19 28. Remove two clamps for wiring harness (39).
(35) and CN-R18 (36).
21. Remove wiring harness terminal ET49 (37) from
the battery relay.
22. Disconnect connector CN-R21 (38).
23. Remove two clamps for wiring harness (39).
24. Remove all the clamps for wiring harnesses (40)
and (41) from cover (42).

29. Disconnect connectors CN-R15 (46) and

CN-R16 (47) of the accumulator oil pressure
switch.

25. Disconnect connector CN-R20 (43) of the dust

indicator.

26. Disconnect connector CN-R17 (44) of the

hydraulic oil temperature sensor.

50-208 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Removal and installation of hydraulic tank assembly

30. Remove cover (48). 33. Lift off accumulator and mounting plate
assembly (52).
4 Accumulator and mounting plate as-
sembly:
55 kg

31. Remove three bolts and remove relay mounting

plate (49).

34. Lift off battery installation plate (53).

4 Battery installation plate:
20 kg

32. Sling accumulator (25) and mounting plate (50)

in an assembly, then remove three mounting
bolts (51) on the upper side and two mounting
bolts (51) on the lower side.

35. Remove clamp (55) from mounting bracket (54)

for battery installation plate.

GD555-5,GD655-5,GD675-5 50-209
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Hydraulic system
Removal and installation of hydraulic tank assembly

36. Lift off mounting bracket (54) of battery installa- 39. Remove three elbows (58), (59) and (60) from
tion plate. the hydraulic tank.
4 Mounting bracket of battery installa-
tion plate:
20 kg

40. Remove two front mounting bolts (61) of the

hydraulic tank.

37. Remove dust indicator (56).

41. Remove two rear mounting bolts (62) of the

hydraulic tank.
38. Remove the clamp for vinyl tube (57) from the
frame.

50-210 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Removal and installation of hydraulic tank assembly

42. Turn hydraulic tank assembly (63) 45° and lift it Installation 50-21
off. q Perform installation in the reverse order to re-
4 Hydraulic tank assembly: moval.
90 kg
[*1]
a Install the shorter side (A) of tube (21) to the hy-
draulic tank.

[*2]
a Install the double clamps with their fastening
screws at 180° apart each other.
3 Suction hose mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*3]
a Run the engine to pressurize oil in the brake ac-
cumulator.

q Refilling of oil (hydraulic tank)

Refill the hydraulic tank with hydraulic oil through
the oil filler port to the specified level. Let the oil
circulate in the hydraulic system by running the
engine. Then check the oil level again.
5 Hydraulic oil:
69 l

q Air bleeding (brake circuit)

Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from brake
circuit".

GD555-5,GD655-5,GD675-5 50-211
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Hydraulic system
Removal and installation of control valve assembly

Removal and installation of control valve assembly 50-212

3. Remove the cover of control valve assembly
Removal 50-212 according to the following procedures.
a "Removal and installation of control valve as- 1) Remove right and left rubber covers (3), and
sembly" is described in "9-spool valve with rip- remove plate (4).
per".
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Loosen the hydraulic tank cap to release the
pressure inside the hydraulic tank.
a Record the currently installed position of the
hoses so that they are not installed in wrong po-
sition.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.
2) Remove cover (5).
1. Set lock pin (1) on the frame.

3) Remove upper cover (6) and remove right

2. Drain the oil through the hydraulic tank drain and left covers (7).
valve (2).
6 Hydraulic oil:
69 l

50-212 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Removal and installation of control valve assembly

4) Remove cover (8). q (13): Port PP hose

[*1] (tape color: yellow)

4. Disconnect every linkage (9) of the control valve. q (14): Port B9 hose (if equipped)
[*2] (tape color: red)
a Record the size of every linkage. q (15): Port A9 hose (if equipped)
(tape color: white)
q (16): Port B8 hose
(tape color: green (2 tapes))

5. Disconnect the following hoses and tubes from

the control valve.
q (10): Port P2 hose
q (11): Port P1 hose q (17): Port B7 hose
q (12): Port T2 hose (tape color: orange (2 tapes))
q (18): Port B6 hose
(tape color: blue (2 tapes))
q (19): Port B5 hose
(tape color: red (2 tapes))
q (20): Port B4 hose (tape color: red)
q (21): Port B3 hose (tape color: green)
q (22): Port B2 hose (tape color: blue)
q (23): Port B1 hose (tape color: red)

GD555-5,GD655-5,GD675-5 50-213
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Hydraulic system
Removal and installation of control valve assembly

q (31): Port LS tube

q (32): Port A4 hose (tape color: white)

q (24): Port A8 hose

(tape color: brown (2 tapes)) q (33): Port T1 hose
q (25): Port A7 hose
(tape color: gray (2 tapes))
q (26): Port A6 hose
(tape color: yellow (2 tapes))
q (27): Port A5 hose
(tape color: white (2 tapes))
q (28): Port A3 hose (tape color: brown)
q (29): Port A2 hose (tape color: yellow)
q (30): Port A1 hose (tape color: white)

6. Remove bolt (34) and disconnect tube (35).

a Hose (12) is a port T2 hose, which is already
disconnected from the control valve.
7. Disconnect port TS hose (36). (tape color: gray)
8. Remove clamp (38) for port TS tube (37).
a Remove tube (37) together with the control
valve.

50-214 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Removal and installation of control valve assembly

a The figure shows the other side (right side of 11. Disconnect tube (37) from the control valve.
machine) of tube (35). 12. Remove rod link (44) from each valve spool (43).

9. Install eyebolts to sling control valve mounting
bracket (39), and remove two control valve
mounting bolts (40) each on the right and left.
[*3]
a Put a mark (a) on plate (41) to indicate the
mounting position of bracket (39).
13. Remove tube (45).
14. Using a hexagonal wrench (6 mm), remove
flanges (46) and (47).
15. Remove the bolt, and remove bracket (39)
together with shaft assembly (48).

10. Lift off control valve assembly (42) together with

bracket (39).
4 Control valve assembly (including
bracket):
75 kg

GD555-5,GD655-5,GD675-5 50-215
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Hydraulic system
Removal and installation of control valve assembly

Installation 50-216
q Perform installation in the reverse order to removal.
a Install the hoses in the correct positions.

Port name Actuator name Tape color Port name Actuator name Tape color
A1 Right side of blade lift (bottom) White B1 Right side of blade lift (head) Red
A2 Leaning (head) Yellow B2 Leaning (bottom) Blue
A3 Drawbar shift (head) Brown B3 Drawbar shift (bottom) Green
A4 Articulate White B4 Articulate Red
White (2 Red (2
A5 Power tilt (bottom) B5 Power tilt (head)
tapes) tapes)
Yellow (2 Blue (2
A6 Circle motor (port A) B6 Circle motor (port B)
tapes) tapes)
Gray (2 Orange (2
A7 Blade shift (bottom) B7 Blade shift (head)
tapes) tapes)
Brown (2 Green (2
A8 Left side of blade lift (bottom) B8 Left side of blade lift (head)
tapes) tapes)
Ripper (head) Ripper (bottom)
A9 White B9 Red
(If equipped) (If equipped)
P1 From hydraulic pump T1 Hydraulic tank drain
P2 From hydraulic pump T2 Hydraulic tank drain
PP Port PP Yellow LS Port LS
TS Hydraulic tank drain Gray

50-216 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Removal and installation of control valve assembly

[*1] q Refilling of oil (hydraulic tank)

a Check that sponge (49) is adhered securely
while installing cover (8).
Refill the hydraulic tank with hydraulic oil through
the oil filler port to the specified level. Let the oil
circulate in the hydraulic system by running the
engine. Then check the oil level again.
5 Hydraulic oil:
69 l
a Check the oil level again just after stopping
engine since oil level becomes higher by re-
turned oil after a while engine stopped.

q Air bleeding (work equipment circuit)

Bleed air from the work equipment circuit. For
details, see Testing and adjusting, "Bleeding air
from work equipment circuit".

[*2]
a Installation must be done according to the di-
mensions recorded in removal.
a Check that notch (51) comes to the correct posi-
tion when the right and left work equipment lock
levers (50) are set to the LOCK position. (EV
specification)

[*3]
a Tighten mounting bolt (40) while matching
bracket (39) with a mark (a) put on plate (41) to
indicate the mounting position of bracket (39).

GD555-5,GD655-5,GD675-5 50-217
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Hydraulic system
Disassembly and assembly of control valve assembly

Disassembly and assembly of control valve assembly 50-218

a This section provides only the precautions when
assembling the control valve assembly.
a The explanation in this section is for the 9-spool
control valve, and it can apply to the 10-spool
control valve.

Assembly of control valve 50-218

q When loosening or tightening bolts (1)
(01252-60610), be sure to keep the spool in the
valve block.
3 Bolt (1):
9.8 – 12.7 Nm {1 – 1.3 kgm}
3 Bolt (2):
9.8 – 12.7 Nm {1 – 1.3 kgm}
3 Bolt (3):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
q Apply engine oil to the sliding surfaces of the
spool before installing.

50-218 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Disassembly and assembly of control valve assembly

q Spool * For details and measurement method of play,

a The play in spools (2) to (10) must not exceed see performance specifications "Hydraulic
0.15 mm. Component Group Performance Specifica-
(2): Ripper spool (if equipped) tions VS-0061".
(3): Blade lift spool (left) Retainer thickness: (L1)
(4): Blade side shift spool 723-11-37860: 9.7 mm (standard retainer)
(5): Circle rotation spool 723-11-37910: 9.8 mm (adjustment retainer)
(6): Power tilt spool 723-11-37920: 9.6 mm (adjustment retainer)
(7): Articulate spool Retainer thickness: (L2)
(8): Drawbar side shift spool 723-11-37930: 9.7 mm (standard retainer)
(9): Leaning spool 723-11-37940: 9.8 mm (adjustment retainer)
(10): Blade lift spool (right) 723-11-37950: 9.6 mm (adjustment retainer)
a When standard retainers (11) (L1: Retainer thickness: (L3)
723-11-37860), (12) (L2: 723-11-37930), and 723-11-37960: 11.4 mm (standard retainer)
(13) (L3: 723-11-37960) are used, if the spool 723-11-37970: 11.3 mm (adjustment retainer)
plays are not set in the standard value, select 723-11-37980: 11.5 mm (adjustment retainer)
one of the adjustment retainers and adjust the
play.

q Precautions for installing plugs

(723-11-38630, 723-11-38640)
a When installing plugs (18) and (19) of block
(16) and ripper valve (17) (if equipped), take
care of the installing directions of O-ring (20)
and backup ring (21).

GD555-5,GD655-5,GD675-5 50-219
(02)
Hydraulic system
Disassembly and assembly of control valve assembly

50-220 GD555-5,GD655-5,GD675-5
(02)
 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Disassembly and assembly of hydraulic cylinder assembly 50-2 1

Special tools 50-2 1 Assembly 50-2 1
a Be careful not to damage the packings, dust

New/Redesign
seals, O-rings, etc.

Necessity

Sketch
Sym-b a Clean all the parts. After installing the parts, cov-

Q'ty
Part No. Part name
ol er the piping ports and pin holes to prevent dirt
from entering.
1. Cylinder
Cylinder repair
790-502-1003 t 2 Steering cylinder and power tilt cylinder
1 stand
Press-fit bushing (1) and install snap ring (2).
790-101-1102 Hydraulic pump t 2
a The figure shows the steering cylinder as an
2 790-330-1100 Wrench assembly t 2 example.
Socket
Available on
(width across flats: t 2
the market
30 mm)
Socket
Available on
(Width across t 2
the market
flats: 36 mm)
Socket
Available on
(width across flats: t 2
the market
41 mm)
3
Socket
Available on
(width across flats: t 2
the market
46 mm)
Socket
790-302-1270 (width across flats: t 2
50 mm)
Socket
790-302-1290 (Width across t 2 Leaning cylinder, articulate cylinder, and
flats: 60 mm)
scarifier cylinder
790-201-1702 Push tool kit t 2
Press-fit bushing (3) and dust seal (4).
790-101-5021 q Grip 2
a The figure shows the leaning cylinder as an
U 01010-50810 q Bolt 2
example.
790-201-1731 q Push tool 2
4
790-201-1741 q Push tool 2
790-201-1751 q Push tool 2
790-201-1761 q Push tool 2
790-201-1771 q Push tool 2
790-201-1500 Push tool kit t 2
790-101-5021 q Grip 2
01010-50816 q Bolt 2
790-201-1540 q Plate 2
5
790-201-1550 q Plate 2
790-201-1560 q Plate 2
790-201-1570 q Plate 2
790-201-1580 q Plate 2
6 790-720-1000 Expander q 2
796-720-1620 Ring q 2
07281-00609 Clamp q 2
796-720-1640 Ring q 2
07281-00909 Clamp q 2
7
796-720-1650 Ring q 2
07281-01029 Clamp q 2
796-720-1670 Ring q 2
07281-01279 Clamp q 2
a For the cylinders which need tools, see "Special
tool list".

GD555-5,GD655-5,GD675-5 50-221
(02)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Blade lift cylinder 3. Cylinder head assembly

Insert dust seal (5A) and press-fit bushing (5).
1) Using tool U4, press-fit bushing (10) in the
cylinder head.
2) Using tool U5, press-fit dust seal (11).
a The figure shows the leaning cylinder as
an example.

2. Piston rod
Power tilt cylinder
Press-fit bushing (6) and install snap ring (7).

3) Install snap ring (12).

4) Install rod packing (14).
5) Install O-rings (15) and (16), and backup ring
(17).
a Do not insert the backup ring forcibly but
warm it in water of approximately 50 to
60 °C then insert.
Steering cylinder

Leaning cylinder articulate cylinder, scarifier

cylinder, and ripper cylinder
Press fit bushing (8) and dust seal (9).
a The figure shows the leaning cylinder as an
example.

50-222 GD555-5,GD655-5,GD675-5
(02)
 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Cylinder other than steering cylinder 2) Remove piston ring (21) from tool U6, and
install it to piston (22).
3) Using tool U7, compress piston ring (21).
4) Install wear ring (23).

6) Install cylinder head assembly (18) to piston

rod (19).

5) Install piston assembly (24) and nut (25) to

piston rod (19).

4. Piston assembly
1) Set piston ring (21) to tool U6 and rotate the
handle 8 to 10 turns to expand the piston
ring.
6) Set piston rod assembly (26) to tool U1.
7) Using tool U3, tighten nut (25) by directing its
machined side toward piston (22).
a Width across flats of piston nut:
q Steering cylinder: 30 mm
q Blade lift cylinder (right and left ): 41
mm
q Blade side shift cylinder: 41 mm
q Drawbar shift cylinder: 41 mm
q Leaning cylinder: 36 mm
(GD555-5)
q Leaning cylinder: 41 mm
(GD655,675-5)
q Power tilt cylinder: 41 mm
(machine equipped with power tilt)
q Scarifier cylinder: 46 mm
(machine equipped with scarifier)
q Articulate cylinder: 50 mm
q Ripper cylinder: 60 mm
(machine equipped with ripper)

GD555-5,GD655-5,GD675-5 50-223
(02)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

2 Piston nut: Adhesive 5. Piston rod assembly

(Loctite 262 or equivalent) 1) Remove piston rod assembly (26) from tool
3 Piston nut U1 and install it to cylinder (27).
q Steering cylinder:
245 ± 24.5 Nm {25 ± 2.5 kgm}
q Blade lift cylinder (right and left):
618 ± 62 Nm {63±6.3 kgm}
q Blade side shift cylinder:
618 ± 62 Nm {63 ± 6.3 kgm}
q Drawbar shift cylinder:
618 ± 62 Nm {63 ± 6.3 kgm}
q Leaning cylinder:
412 ± 41 Nm {42 ± 4.2 kgm}
(GD555-5)
q Leaning cylinder:
618 ± 62 Nm {63 ± 6.3 kgm}
(GD655,675-5)
q Power tilt cylinder:
647 ± 64.5 Nm { 66 ± 6.6 kgm}
(machine equipped with power tilt)
q Scarifier cylinder:
785 ± 78.5 Nm {80 ± 8.0 kgm}
(machine equipped with scarifier)
q Articulate cylinder:
1,080 ± 108 Nm {110 ± 11.0 kgm}
q Ripper cylinder:
1,770 ± 177 Nm {180 ± 18.0 kgm}
(machine equipped with ripper)

50-224 GD555-5,GD655-5,GD675-5
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 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

2) Set cylinder assembly (28) to tool U1.

3) Using tool U2, tighten the cylinder head.
3 Cylinder head
q Steering cylinder:
392 ± 39.0 Nm {40 ± 4.0 kgm}
q Blade lift cylinder (right and left):
588 ± 59.0 Nm {60 ± 6.0 kgm}
q Blade side shift cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
q Drawbar shift cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
q Leaning cylinder:
539 ± 54.0 Nm {55 ± 5.5 kgm}
(GD555-5)
q Leaning cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
(GD655,675-5)
q Power tilt cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
(machine equipped with power tilt)
q Scarifier cylinder:
677 ± 67.5 Nm {69 ± 6.9 kgm}
(machine equipped with scarifier))
q Articulate cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
q Ripper cylinder:
981 ± 98.0 Nm {100 ± 10 kgm}
(machine equipped with ripper)

GD555-5,GD655-5,GD675-5 50-225
(02)
Work equipment
Removal and installation of blade assembly

Work equipment 50-2 6

Removal and installation of blade assembly 50-2 6
4. Sling blade assembly (1), and remove the blade
Removal 50-2 6 while pushing it leftward. [*2]
k Park the machine on level ground, and lower a Remove the blade while shifting the blade lift-
the work equipment to the ground by operat- ing position to the blade center.
ing the gear shift lever to the P position. 4 Blade assembly:
k Chock the wheels. 760 kg

1. Raise the blade 100 mm or so by operating the

blade lift control lever, then place block [1] under
the circle to support the blade securely.
2. Move blade (1) to the leftmost position by oper-
ating the blade side shift control lever and stop
the engine.
3. Sling rod (2) of the blade side shift cylinder,
remove four mounting bolts (3) and remove rod
(2) from blade (1) along with plate (4).
[*1]
a After removing the cylinder rod, support the
cylinder with a block, etc.

50-226 GD555-5,GD655-5,GD675-5
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 Work equipment
Removal and installation of blade assembly

Installation 50-2 7
q Perform installation in the reverse order to re-
moval.

[*1]
3 Mounting bolt (3):
230.5 – 308.9 Nm {23.5 – 31.5 kgm}
2 Cylinder rod pin hole:
(When cylinder rod pin is removed)

[*2]
a Install the cylinder blade assembly according to
the following procedures.
1) Lift the center of blade assembly (1), and
install the right end of the blade to adjuster
(5).
2) Operate the blade side shift control lever to
extend rod (2) of the blade side shift cylinder
to the maximum.
3) While moving blade (1) lifting position, push
blade (1) in to the position where cylinder rod
(2) mounting plate (4) can be installed.
a Do not apply grease to the rail behind the
blade.
4) Fasten plate (4) with mounting bolt (3).
3 Mounting bolt (3):
230.5 – 308.9 Nm {23.5 – 31.5 kgm}

GD555-5,GD655-5,GD675-5 50-227
(02)
Work equipment
Removal and installation of circle drawbar assembly

Removal and installation of circle drawbar assembly 50-2 8

6. Remove cap (7) on both sides and disconnect
Removal 50-2 8 rod (8) of blade lift cylinder from drawbar (6).
k Park the machine on level ground, and lower [*2]
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Chock the wheels.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.
1. Remove the blade assembly. For details see
"Removal and installation of blade assembly".
2. Set the drawbar at the center by operating the
drawbar side shift control lever.
3. Set the drawbar to a level by operating the blade
lift control lever and support the adjuster and
bracket at the bottom of the circle with blocks,
etc.
k Stop the engine and release remaining
7. Remove top cover (9) of the front frame and
remove side cover (10) on both sides.
pressure in the piping by operating the
drawbar side shift control lever and circle
rotation control lever.
4. Remove clamp (1) and disconnect hoses (2) and
(3) from drawbar side shift cylinder (4).
5. Remove cap (5) and disconnect drawbar side
shift cylinder (4) from drawbar (6).
[*1]
a Fix the drawbar side shift cylinder to the
frame with lever blocks, etc.

8. Disconnect two hoses (11) and (12) on the right

side of the front frame.
q Tape color of hose (11): Green
q Tape color of hose (12): Brown

50-228 GD555-5,GD655-5,GD675-5
(02)

9. Disconnect six hoses (13), (14), (15), (16), (17)
and (18) on the right side of the front frame.
q Tape color of hose (13): Red
q Tape color of hose (14): White
q Tape color of hose (15): Blue
q Tape color of hose (16): Yellow
q Tape color of hose (17): Orange
q Tape color of hose (18): Gray
10. Sling the circle drawbar assembly.
11. Remove four nuts (19) and remove holder (20)
and shims (21).
[*3]
a Check and record the number of shims.
12. Disconnect ball joint (22) from the front frame
and lift off circle drawbar assembly (23).
[*4]
4 Circle drawbar assembly:
1,250 kg
GD555-5,GD655-5,GD675-5
(02)
Work equipment
Removal and installation of circle drawbar assembly
Installation 50-2 9
q Perform installation in the reverse order to re-
moval.
[*1]
2 Ball joint portion of drawbar side shift cyl-
inder:
Grease (G2-LI)
[*2]
2 Ball joint portion of blade lift cylinder:
Molybdenum disulphide lubricant (LM-P)
[*3] [*4]
a Adjustment procedure with shims for play of ball
joint in the axial direction
1) Install ball joint (22) and holder (20) to the
frame without shims and tighten four nuts
(19) partially.
q Don't apply grease to the ball joint.
3 Nut (19):
58.8 – 73.6 Nm {6 – 7.5 kgm}
2) Measure clearance (a) at four places near to
the location where holder (20) is fastened to
the front frame and calculate the mean of
clearances.
3) Select the shim having the same thickness
as the sum of the mean of clearances (a) and
two shims (0.29 x 2 = 0.58 mm).
q Type of shim thickness: 0.29 mm
q Standard shim thickness: 4 - 4.64 mm
4) Insert selected shim (21) and tighten nut (19)
to the specified torque.
2 Ball joint portion:
Molybdenum disulphide lubricant
(LM-P)
3 Nut (19):
588 – 1,030 Nm {60 – 105 kgm}
a Check that the ball joint moves smoothly
without generating abnormal noises due
to play.
50-229
Work equipment
Removal and installation of circle drawbar assembly

q Refilling of oil (hydraulic tank)

Refill the hydraulic tank with hydraulic oil through
the oil filler port to the specified level. Let the oil
circulate in the hydraulic system by running the
engine. Then check the oil level again.
5 Hydraulic oil:
69 l

q Air bleeding (work equipment circuit)

Bleed air from the work equipment circuit. For
details, see Testing and adjusting, "Bleeding air
from work equipment circuit".

50-230 GD555-5,GD655-5,GD675-5
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 Work equipment
Removal and installation of circle rotation gear assembly

Removal and installation of circle rotation gear assembly 50-231

Removal 50-231
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k After stopping the engine, release remaining
pressure in the piping by operating the circle
rotation control lever.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.

1. Disconnect two hoses (1) from circle motor (2).
4. Flatten out lock plate (5), loosen two mounting
bolts (6) to remove holder (7) and shim (8), then
pinion gear (9).
[*2]
k When removing the mounting bolts, sup-
port the pinion gear with your hand to pre-
vent it from falling.
a Check and record the number and thickness
of shims.

2. Drive two dowel pins (3) out from the bottom.

3. Remove four mounting bolts (4) of circle rotation
gear from the bottom.
[*1]

GD555-5,GD655-5,GD675-5 50-231
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Work equipment
Removal and installation of circle rotation gear assembly
5. Using the eyebolt, lift off circle rotation gear
assembly (10).
4 Circle rotation gear assembly:
190 kg
Installation 50-232
q Perform installation in the reverse order to re-
moval.
[*1]
3 Mounting bolt:
911 – 1,029 Nm {93 – 105 kgm}
[*2]
a Adjust the shim according to the following proce-
dures.
1) Install pinion gear (9) and install holder (7)
temporarily.
a Push up pinion gear (9) until it is closely
contacted with plate (12).
2) Measure clearance "b" between the end
faces of shaft (11) and pinion gear (9), then
select a shim thicker than clearance "b" by
0.1 to 0.5 mm.
q Standard shim thickness: 3 mm
q Type of shim thickness: 0.2 mm, 0.5 mm
and 1.0 mm
a Above thickness is necessary to provide
clearance "a" of the same measure be-
tween plate (12) and pinion gear (9).
q Clearance "a": 0.1 - 0.5 mm
50-232
1. Install pinion gear (9), selected shim (8) and
holder (7) in this order, then tighten mounting
bolts (6) and bend lock plate (5) securely.
2 Contact surface "c" of plate (12) and
pinion gear (9):
Molybdenum disulphide lubricant
(LM-P)
2 Upper side "d" of pinion gear (9):
Fill with molybdenum disulphide
grease (LM-P)
Adjustment of slip clutch
q Adjust the slip clutch. For details, see Testing
and adjusting, "Testing and adjusting of slip
clutch type rotating machine".
q Refilling of oil (hydraulic tank)
Refill the hydraulic tank with hydraulic oil through
the oil filler port to the specified level. Let the oil
circulate in the hydraulic system by running the
engine. Then check the oil level again.
5 Hydraulic oil:
69 l
q Air bleeding (work equipment circuit)
Bleed air from the work equipment circuit. For
details, see Testing and adjusting, "Bleeding air
from work equipment circuit".
GD555-5,GD655-5,GD675-5
(02)
 Work equipment
Disassembly and assembly of circle rotation gear assembly

Disassembly and assembly of circle rotation gear assembly 50-23

6. Remove four mounting bolts, cover (8), and shim
Disassembly 50-23 (9).
1. Remove the drain plug to drain the oil in the a Check the thickness and the number of the
circle rotation gear case. shims.
6 Circle rotation gear case:
7l

2. Remove four mounting bolts and remove circle

motor assembly (1).

3. Remove eight mounting bolts from case (2) and

remove cover (3).
a When removing cover (3), check the installed
direction of the oil filler plug.

7. Using the eyebolts, lift off worm wheel (10) and

shaft (11) assembly.

8. Remove belleville spring (12) and spacer (13).

4. Remove eight mounting bolts of cover (4) and

remove cover (4) by using two forcing screws [1].
a When removing cover (4), check the position
of the oblong hole under the oil filler plug.

9. Remove six discs (14) and five plates (15) from

worm wheel (10).

5. Remove three bolts from the worm wheel shaft

and remove plate (5), shim (6), and collar (7).
a Check the thickness and the number of the
shims.

GD555-5,GD655-5,GD675-5 50-233
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Work equipment
Disassembly and assembly of circle rotation gear assembly

10. Remove shaft (11) from worm wheel (10). Assembly 50-234
1. Press-fit bushing (20) to case (2).
11. Remove spacer (16) from shaft (11). 2 Inside surface of bushing:
Molybdenum disulphide lubricant
(LM-P)

2. Reverse the case and press-fit oil seal (19).

2 Sliding surface of oil seal shaft:
Grease (G2-LI)

12. Remove worm gear (17) from case (2).

13. Remove two bearings (18) from worm gear (17).

14. Reverse the case and remove oil seal (19) and
bushing (20).
3. Assemble worm wheel (10), shaft (11), and
spacer (16).

50-234 GD555-5,GD655-5,GD675-5
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 Work equipment
Disassembly and assembly of circle rotation gear assembly

4. Insert a spacer in worm wheel (10) and install 7. Install cover (8) to case (2).
five plates (15) and six discs (14) alternately.
a Before assembling, apply oil all over the
discs.
2 Disc (both sides):
Gear oil (GO90)

8. Adjust the preload on the bearing.

a Adjust while the worm wheel is not installed.
1) Install nuts (21) to the mounting bolts of cover
(8), insert shims (9), and tighten nuts (21).
2) Measure the rotating torque of the worm
5. Press-fit two bearings (18) to worm gear (17). gear. If it is out of the standard value, adjust
it by increasing or decreasing the shim.
q Standard rotating torque :
2.94 - 7.85 Nm {0.3 - 0.8 kgm}
q Shim thickness:
0.05 mm, 0.1 mm, 0.2 mm and 1.0 mm
q Standard thickness of shims (reference):
1.65 mm

6. Install worm gear (17) to case (2).

GD555-5,GD655-5,GD675-5 50-235
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Work equipment
Disassembly and assembly of circle rotation gear assembly

9. Install plate (13) and belleville spring (12) to

worm wheel (10).

10. Using the eyebolts, sling worm wheel (10) and

shaft (11) assembly and install it to case (2).

11. Using the guide bolt, install cover (4) to case (2)
and tighten the mounting bolts partially.
a Install cover (4) so that its oblong hole (a)
comes just under the oil filler plug. (See step
15.)

14. Install plate (5) and tighten three bolts.

15. Install cover (3) and tighten eight bolts.

12. Install collar (7) and tighten the bolts of cover (4).
2 Only two mounting bolts (22) of cover
(4) (Through tap hole of case (b)):
Adhesive (LT-2)

13. Install shims (6).

a Install the shims of 3.0 mm in total thickness.
a Install oil filler plug (22) to cover (3) as shown
q Type of shim thickness: 0.2 mm, 0.5 mm
in the figure.
a After installing the circle rotation gear assem-
a Check that the oil filler plug matches with the
bly to the machine, adjust the slip clutch. For
oblong hole of cover (4) shown in step 11. If
details, see Testing and adjusting, "Testing
it does not match, change the position of cov-
and adjusting of slip clutch type rotating ma-
er (4).
chine".

50-236 GD555-5,GD655-5,GD675-5
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 Work equipment
Disassembly and assembly of circle rotation gear assembly

16. Install circle motor assembly (1) to the worm

gear and tighten four bolts.

17. Tighten the drain plug.

3 Drain plug:
32.4 – 44.1 Nm {3.3 – 4.5 kgm}

18. Fill the gear case with oil through the oil filler
port.
5 Circle rotation gear case:
7 l (GO90 Gear oil)
3 Oil filler port plug:
73.5 – 122.6 Nm {7.5 – 12.5 kgm}

19. After installing the circle rotation gear assembly

to the machine, adjust the slip clutch. For details,
see Testing and adjusting, "Testing and
adjusting of slip clutch type rotating machine".

GD555-5,GD655-5,GD675-5 50-237
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Work equipment
Removal and installation of ripper assembly

Removal and installation of ripper assembly 50-238

(machine equipped with ripper) 3. Disconnect two ripper hoses (3).

Removal 50-238
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Loosen the hydraulic tank cap to release the
pressure inside the hydraulic tank.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.

1. Set lock pin (1) to the frame.

4. Sling the ripper assembly, then remove the bolt
and remove upper pin on the left (4) and right (5).
[*1]
k Care must be taken in this operation be-
cause removing the pins allows the ripper
assembly to move.

2. Remove right and left steps (2) in the rear.

5. Remove the bolt, then remove lower pin on the

left (6) and right (7).
[*2]
k Check that the ripper assembly is secure-
ly slung.

50-238 GD555-5,GD655-5,GD675-5
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 Work equipment
Removal and installation of ripper assembly

6. Lift off ripper assembly (8). 8. Remove two mounting bolts (11) of ripper
4 Ripper assembly: bracket (10) each on the right and left.
850 kg [*4]

7. Through the bottom, remove five mounting bolts
(9) of ripper bracket each on the right and left.
[*3]
9. Sling ripper bracket (10) and remove four
mounting bolts (12).
[*5]
k Check that the ripper bracket is securely
slung since removing the bolts allows de-
tachment of the ripper bracket.

10. Lift off ripper bracket (10).

[*6]
4 Ripper bracket:
170 kg

GD555-5,GD655-5,GD675-5 50-239
(02)
Work equipment
Removal and installation of ripper assembly

Installation 50-240
q Perform installation in the reverse order to re-
moval.

[*1]
2 Pin:
Grease (G2-LI)
[*2]
2 Pin:
Grease (G2-LI)
[*3]
3 Mounting bolt (9):
588 – 1,030 Nm {60 – 105 kgm}
[*4]
3 Mounting bolt (11): q Refilling of oil (hydraulic tank)
588–1,030 Nm {60–105 kgm} Refill the hydraulic tank with hydraulic oil through
[*5]
3
the oil filler port to the specified level. Let the oil
Mounting bolt (12): circulate in the hydraulic system by running the
319–608 Nm {32.5–62 kgm} engine. Then check the oil level again.
5 Hydraulic oil:
[*6]
a Adjust the shim according to the following proce- 69 l
dures.
1) Push ripper bracket (10) against the rear
surface of the rear frame until it is closely
contacted.
2) Install mounting bolts (9), (11) and (12) with
washers to bracket (10) and tighten all the
bolts partially.
3 Mounting bolt (9):
147–309 Nm {15–31.5 kgm}
3 Mounting bolt (12):
147–309 Nm {15–31.5 kgm}
3) Check clearance (a) (at two places indicated
with A), then adjust the clearance to 0.5 mm
maximum using the shim.
q Shim thickness: 0.5 mm
4) Tighten mounting bolts (9), (11) and (12) to
the specified torque.

50-240 GD555-5,GD655-5,GD675-5
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 Cab and its attachments
Removal and installation of operator cab assembly

Cab and its attachments 50-241

Removal and installation of operator cab assembly 50-241
2. Set lock pin (3) to the frame.
Removal 50-241
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut OFF
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker, and fix it after the rotation.
3. Drain the coolant through coolant drain valve (4).
6 Coolant:
39.5 l

k If you drain the coolant or disconnect the

heater hose when the coolant temperature is
high, you may be scalded. Wait until the cool-
ant temperature lowers and then drain the 4. Remove mat (5).
coolant or disconnect the heater hose. 5. Remove two covers (6) and (7) under the oper-
1. Collect the refrigerant (R134a) from the air ator seat.
conditioner circuit.
a Ask a qualified distributor for collection
and charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a)
into the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves
and long sleeved work clothes when col-
lecting or charging the refrigerant.
q Amount of air conditioner refrigerant (R134a)
to be collected:
1,050 ± 50g

GD555-5,GD655-5,GD675-5 50-241
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Cab and its attachments
Removal and installation of operator cab assembly

6. Remove magazine box (8) on the left side of the 9. Remove two connectors CN-TEL (12) and
operator cab. CN-AC1 (13) from the clamp of cover (11).
a Disconnect connector CN-TEL (12).
10. Remove four bolts and cover (11).

7. Remove four bolts and cover (9).

8. Remove four bolts and remove KOMTRAX 11. Remove cover (14).
terminal assembly (10). 12. Remove two upper bolts and remove air condi-
tioner duct (15).

50-242 GD555-5,GD655-5,GD675-5
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13. Remove the clamp. Using a hexagon wrench (4
mm), disconnect three connectors CN-TM39
(17), CN-TM40 (18) and CN-TM41 (19) from
transmission controller (16).
14. Remove four bolts and remove transmission
controller (16).
15. Remove upper cover mounting bracket (21) and
mounting bracket (22) for washer vinyl tube from
cover (20).
GD555-5,GD655-5,GD675-5
(02)
Cab and its attachments
Removal and installation of operator cab assembly
16. Disconnect three vinyl tubes from mounting
bracket (22) for washer vinyl tubes.
q Tape color of tube (23): Gray (for front)
q Tape color of tube (24): Orange (for door)
q Tape color of tube (25): White (for rear)
17. Remove the clamp from cover (20), and discon-
nect connectors CN-AC3 (26) and CN-AC4 (27).
18. Disconnect three connectors CN-AC1 (13),
CN-AC3 (26), and CN-AC4(27) which were
removed in step 9.
19. Remove three bolts and remove cover (20).
50-243
Cab and its attachments
Removal and installation of operator cab assembly

20. Remove four bolts and remove operator seat 23. Remove cover (34).
assembly (28).
4 Operator seat assembly:
50 kg

24. Remove the clamp and remove duct hose (35).

21. Remove covers (29) and (30) on the right side of
the operator cab.
22. Remove air conditioner duct (31) and duct hoses
(32) and (33).
25. Remove connector CN-B19 (36) from frame
(37).
26. Remove the clamp and remove wiring harness
(38) from frame (37).

27. Disconnect two connectors CN-C1 (39) and

CN-C2 (40) on the left side of the operator cab.

50-244 GD555-5,GD655-5,GD675-5
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28. Remove two clamps and release wiring harness
(41) from frame (37).
29. Remove eight bolts and remove operator seat
mounting frame (37).
30. Remove air conditioner duct hose (42) in the
right rear of the operator cab.
GD555-5,GD655-5,GD675-5
(02)
Cab and its attachments
Removal and installation of operator cab assembly
31. Disconnect two heater hoses (43) and (44) from
the bottom of the floor frame.
[*1]
a Plug the heater hoses to prevent entry of dirt,
dust, etc. after disconnection.
32. Disconnect two air conditioner hoses (45) and
(46) from the bottom of the floor frame.
[*2]
a Plug the air conditioner hoses to prevent en-
try of dirt, dust, etc. after disconnection.
33. Disconnect two drain hoses (47) and (48) for air
conditioner from the bottom of the floor frame.
50-245
Cab and its attachments
Removal and installation of operator cab assembly

34. Disconnect connector (49) on the floor frame. 38. Remove cover (55) in the right rear of the oper-
35. Remove two bolts (50) and disconnect air condi- ator cab.
tioner intermediate tubes (51).
[*3]
a Plug the air conditioner intermediate tubes to
prevent entry of dirt, dust, etc. after discon-
nection.

39. Remove air conditioner duct hose (56) in the rear

of the operator cab.

36. Disconnect two heater hoses (52) and (53).

40. Remove two front-side mounting bolts (58) and

two rear-side mounting bolts (59) of air condi-
tioner unit (57).

37. Remove stay (54) in the right rear of the operator

cab.

50-246 GD555-5,GD655-5,GD675-5
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 Cab and its attachments
Removal and installation of operator cab assembly

2) Remove mounting bracket (62) for cover

(61).

41. Remove duct (60) of air conditioner unit (57).

a Pull the air conditioner unit toward you, and
pull out the duct. 3) Remove step (63) and covers (64) and (65).

42. Remove the following parts on the right side 4) Remove step mounting bracket (66).
under the operator cab.
1) Remove cover (61) under the operator cab.

GD555-5,GD655-5,GD675-5 50-247
(02)
Cab and its attachments
Removal and installation of operator cab assembly

43. Remove the following parts on the bottom left 6) Remove three clamps and remove vinyl tube
side under the operator cab. (72).
1) Open the washer tank cover, and disconnect 7) Remove four bolts, then remove mounting
three connectors CN-B17 (67), CN-B16 (68), bracket (74) for washer tank cover.
and CN-B15 (69).
2) Remove three clamps and remove wiring
harness (70) from the cover.
3) Remove stopper (71).

8) Remove step (75) and covers (76) and (77).

4) Disconnect three vinyl tubes (72) from the

washer tank.
a Record the currently installed position by
the vinyl tape color so that it is not in-
stalled in wrong position.

9) Remove step mounting bracket (78).

5) Remove washer tank covers (73) together

with the washer tank.

50-248 GD555-5,GD655-5,GD675-5
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 Cab and its attachments
Removal and installation of operator cab assembly

44. Remove the cover of control valve assembly 4) Remove cover (84).
according to the following procedures. [*4]
1) Remove right and left rubber covers (79),
and remove plate (80).

45. Remove left stay (85) and right stay (86) which
are used to get on and off the operator cab.
2) Remove cover (81).

46. Depress tilt pedal (87) to cause the maximum tilt

3) Remove upper cover (82) and remove right of steering column (88) in the arrow direction.
and left covers (83).

GD555-5,GD655-5,GD675-5 50-249
(02)
Cab and its attachments
Removal and installation of operator cab assembly

51. Through the bottom, remove four operator cab

mounting bolts (93) each on the right and left.
[*5]

47. Remove three bolts and move inching pedal (89)

inward.
48. Remove two mounting bolts (90) on the left side
of the operator cab. 52. Remove plate (94), collars (95), rubber collars
(96), and mounting rubbers (97).
[*6]

49. Remove three bolts and move accelerator pedal

(91) inward.
50. Remove two mounting bolts (92) on the right
side of the operator cab.

50-250 GD555-5,GD655-5,GD675-5
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 Cab and its attachments
Removal and installation of operator cab assembly

53. Lift off operator cab assembly (98). Installation 50-251

a Check that all the wirings and pipings are dis-
connected before lifting off the operator cab
assembly.
4 Operator cab assembly:
780 kg
q Perform installation in the reverse order to re-
moval.
[*1]
2 Connecting part of heater hose and joint:
Liquid gasket (LG-7)
[*2] [*3]
a When installing the air conditioner hoses and
tubes, take care that dirt, dust, water, etc. do not
enter them.
a When installing the air conditioner hoses and
tubes, check that O-ring (99) is fitted to each of
their fittings.
Note: The size of O-ring (99) depends on the
fitting location.
a Check that O-ring (99) is free from flaw and de-
terioration.
a When connecting the refrigerant hose, apply
compressor oil for refrigerant (R134a) (DENSO:
ND-OIL8 or VALEO THERMAL SYSTEMS:
ZXL100PG (equivalent to PAG 46)) to O-ring
(99).
a Secure by using two wrenches. (Hold the device
side securely with one wrench and turn the flare
nut of the hose with another wrench.)
3 Air conditioner hose flare nut (45):
12 – 15 Nm {1.2 – 1.5 kgm}
3 Air conditioner hose flare nut (46):
30 – 35 Nm {3.0 – 3.5 kgm}
3 Mounting bolt (50) of air conditioner inter-
mediate tube (51):
8 – 12 Nm 0.8 – 1.2 kgm}

GD555-5,GD655-5,GD675-5 50-251
(02)
Cab and its attachments
Removal and installation of operator cab assembly

[*5] [*6]
a Install according to the following procedures.
1) Insert collars (95) and rubber collars (96) in
the frame.

2) Insert collar (95) in mounting rubber (97),

install plate (94) , and fasten with mounting
bolt (93).
a Check that the mounting rubber (97) con-
tacts uniformly.

[*4]
a Check that sponge (100) is adhered securely
while installing cover (84).

q Charging of refrigerant (R134a)

Charge the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,050 ± 50 kg

50-252 GD555-5,GD655-5,GD675-5
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 Cab and its attachments
Removal and installation of floor frame assembly

Removal and installation of floor frame assembly 50-253

1. Set lock pin (3) on the frame.
Removal 50-253
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker, and fix it after rotation.
2. Remove the operator cab assembly. For details,
see "Removal and installation of operator cab
assembly."
3. Remove the following parts from the right side of
the floor frame.
1) Disconnect three hoses (4), (5) and (6), and
remove block (7).
q Tape color of hose (4): Orange
q Tape color of hose (5): White
q Tape color of hose (6): Gray

k Loosen the hydraulic tank cap to release the

pressure inside the hydraulic tank.
a Record the currently installed positions of the
hoses and wires so that they are not installed in
wrong positions.
a Prepare an oil container since oil flows out when
the hydraulic hose and tube are disconnected.
a Plug the disconnected hose and tube to prevent
oil from flowing out.

2) Disconnect five hoses; PB port hose (9), PA

port hose (10), B port hose (11), A port hose
(12) and TA port hose (13) from brake valve
(8).
q Tape color of hose (9): White
q Tape color of hose (10): Red
q Tape color of hose (11): Blue
q Tape color of hose (12): Yellow
q Tape color of hose (13): Black

GD555-5,GD655-5,GD675-5 50-253
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Cab and its attachments
Removal and installation of floor frame assembly

5) Remove clamp (19) for air conditioner drain

hose (18) from the floor frame.

3) Disconnect three connectors CN-FP11 (14),

CN-FP10 (15) and CN-FL 17 (16).
4. Remove the following parts from the left side of
the floor frame.
1) Remove the clamp and disconnect articulate
sensor connector B11 (20).

4) Disconnect connector CN-FP13 (17).

2) Disconnect connector CN-R1 (21) and

remove plate (22).
3) Disconnect ground terminal CN-FT12 (23).

50-254 GD555-5,GD655-5,GD675-5
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4) Disconnect three connectors CN-R6 (24),
CN-R-5 (25) and CN-R7 (26).
5) Remove clamp (28) for air conditioner heater
hose (27) from the floor frame.
6) Remove clamp (29) and disconnect ground
terminal CN-FT11 (30).
GD555-5,GD655-5,GD675-5
(02)
Cab and its attachments
Removal and installation of floor frame assembly
7) Remove two bolts on the floor frame and pull
out three washer tank vinyl tubes through the
bottom.
a Remove the vinyl tubes along with the
clamp to be described in the next step.
q Tape color of tube (31): Gray (for front)
q Tape color of tube (32): Orange (for door)
q Tape color of tube (33): White (for rear)
8) Remove the bolt from the bottom of the floor
frame, and remove mounting clamp (34) for
washer tank vinyl tube.
9) Disconnect hose (35) for the steering valve
LS port.
50-255
Cab and its attachments
Removal and installation of floor frame assembly

10)Disconnect hose (37) for the steering valve P
port from valve (36).
7. Lift off floor frame assembly (41).
a Check that all the wirings and pipings are dis-
connected before lifting off the operator cab
assembly.
4 Floor frame assembly:
230 kg

5. Disconnect every linkage (38) of the control

valve. [*1]
a Record the dimension of every linkage.

Installation 50-256
q Perform installation in the reverse order to re-
moval.

[*1]
a Installation must be done according to the di-
mensions recorded in removal.
a Check that notch (43) comes to the correct posi-
tion when the right and left work equipment lock
levers (42) are set to the LOCK position. (EV
specification)

6. Remove a floor frame mounting bolt on the left

(39) and right (40).

q Air bleeding (brake circuit)

Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".

50-256 GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

Removal and installation of operator cab glass (adhered glass) 50-257

a In this section, the procedures for replacing the (a): Sticking surface of finisher
adhered window glass are explained. (b): Apply GE Toshiba Silicon tosprum D to glass
(1): Front window glass (adhered glass) and plate surfaces and seal them with GE Toshi-
(2): Finisher ba Silicon tosseal 381. (No extrusion shall not re-
(3): Rear window glass (adhered glass) main on the glass front surface.) (on both right
(4): Finisher and left sides)
(5): Finisher
(6): Dam rubber

GD555-5,GD655-5,GD675-5 50-257
(02)
Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

(6): Dam rubber

(7): Right upper side window glass (adhered glass)
(8): Right center side sash assembly (adhered)
(9): Right lower side window glass (adhered glass)

50-258 GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

(1): Front window glass (adhered glass)

(6): Dam rubber
(10): Left door window glass (adhered glass)
(11): Left side window glass (adhered window glass)
(*1): Step dimension between door and cab body
(*2): Difference dimension between door body face
and cab body face
(A): Adjust the right door in the same manner.

GD555-5,GD655-5,GD675-5 50-259
(02)
Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

Special tools 50-260 (The figure shows the operator cab of a

wheel loader.)

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

Lifter (Suction
1 793–498–1210 t 3
X cup)
2 20Y-54-13180 Stopper rubber t 3

Removal 50-260
a Remove the window glass to be replaced ac-
cording to the following procedure.
1. Use seal cutter [1] to cut the adhesive between
broken window glass (7) and operator cab
(metal sheet) (8).
a If the window glass is broken in small pieces,
it may be removed with knife [4] and a
flat-head screwdriver.
a Widening the cut with a flat-head screw-
driver, cut the adhesive and dam rubber with
knife [4].

(The figure shows the operator cab of a wheel

loader.)

a If a seal cutter is not available, make holes on

the adhesive and dam rubber with a drill and
pass a fine wire (piano wire, etc.) [2] through
the holes. Grip the both ends of the wire with
pliers [3], etc. (or hold them by winding them
onto pliers) and move the wire to the right
and left to cut the adhesive and dam rubber.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
2. Remove the window glass.
Since the wire may be broken by the frictional
heat, apply lubricant to it.

50-260 GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

Installation 50-261 3. When the adhesive is removed with the scraper,

1. Use scraper [5] to clean off adhesive remaining if any paint is flaked off, coat the bare part with
on the adhered surface. paint.
a Dot not scratch the paint a If a glass, from which paint is partly peeled, is
installed as it is, rust will appear at the peeled
portions.
a Do not apply to a part which will be coated
with primer.

2. Remove oil, dust, dirt, etc. from the adhering

surfaces of cab (2) and window glass (3) with
white gasoline.
a If the adhering surfaces are not cleaned well,
the glass may not be adhered perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhering surfaces, leave
them for at lease five minutes to dry.

GD555-5,GD655-5,GD675-5 50-261
(02)
Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

Applying primer 3) Evenly apply paint primer to the whole

4. Apply primer (10). painting area of operator cab (8).
a The primer is effective in performance for (a): Whole range of 30 mm
four months after the date of manufacture. 2 Primer for paint for cab:
Do not use the primer after the expiration Sun Star 435-95
date. a Do not apply the primer more than two
a Use the primer within two hours after opening times.
it. (If it is applied more than two times, its
a Even if the primer container is closed again performance will be lowered.)
just after it is opened, use it within twenty-four a Never apply the wrong primer.
hours after it is opened for the first time. If the glass primer, etc. is applied by
(Discard the primer in twenty-four hours after mistake, wipe it off with white gasoline.
it is opened.) a After applying the primer, leave it for at
1) Mix the primers for painted surface and glass least 5 minutes in air to dry and stick the
sufficiently before using them. dam rubber within 24 hours.
a If the primer is stored in a refrigerator, (The figure shows the operator's cab of a
leave it at the room temperature for at hydraulic excavator.)
least half a day before stirring it.
(If the primer container is opened just
after taken out of the refrigerator, water
will be condensed. Accordingly, leave the
primer at the room temperature for a suffi-
cient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again for
dirt and contaminant.
a Prepare respective brushes for the paint
primer and glass primer.

a (8) : Cab

50-262 GD555-5,GD655-5,GD675-5
(02)

Removal and installation of operator cab glass (adhered glass)
4) Apply the primer for glass to the whole
surface coated in black on window glass (9)
(a): Whole range of 30 mm
2 Primer for glass:
Sun Star 435-40
a Black coating on glass is for protection
against optical degradation.
a Do not apply the primer more than two
times.
(Applying primer more than twice will
degrade the performance.)
a (9): Glass
a Never apply the wrong primer.
If you have applied the primer for painted
surface, etc. by mistake, wipe it off with
white gasoline.
GD555-5,GD655-5,GD675-5
(02)
Cab and its attachments
Adhering dam rubber
5. Adhere dam rubber (6) along the edge of cab (8).
a Do not remove the release tape of dam rub-
ber on the glass adhering side before adher-
ing the glass.
a When sticking the dam rubber, do not touch
the cleaned surface to the utmost.
a Care should be taken not to float the dam
rubber in each adhering corner.
a When adhering dam rubber (6) goes around,
mind not to overlap dam rubber at the both
ends. Or, provide a clearance of approxi-
mately 5 mm at the mating portion (e).
1) Adhere dam rubber (6) for the right side
window glass to the position shown in the
figure.
a (The figure shows the operator cab of a
hydraulic excavator.)
50-263
Cab and its attachments
Removal and installation of operator cab glass (adhered glass)
Positioning window glass
6. Position the new window glass.
1) Check the clearances between the window
glass and the operator cab on the right, left,
upper, and lower sides, and then position the
window glass with the clearance evenly.
2) Stick tape [6] onto through window glass (9)
and operator cab (8), and draw positioning
line (n) on the tape.
a Stick tapes [6] for positioning at three
places of the right, left and lower sides of
the glass, and position them surely.
3) Cut the tape between window glass (9) and
operator cab (8) with a knife, etc. and then
remove the window glass.
a Do not remove the release tape of the
dam rubber on the glass adhering side
before adhering the glass.
(The figure shows the operator cab of a
hydraulic excavator.)
50-264
Applying adhesive
7. Preparation for applying the adhesive.
q Adhesive:
Sun Star Penguin Seal 580 Super
a The adhesive is effective in performance for
four months after the date of manufacture.
Do not use the adhesive after the expiration
date.
a Keep the adhesive in a dark place where the
temperature is below 25 °C.
a Never warm the adhesive higher than 30 °C.
a When starting using the adhesive, remove
the all hardened part form the nozzle tip.
1) Set adhesive cartridge (12) to caulking gun
[7].
a An electric caulking gun is more efficient.
2) Cut the tip of the adhesive nozzle (14) so that
dimensions (q) and (r) are as follows.
q Dimension (q): 10 mm
q Dimension (r): 15 mm
3) Remove the release tape of the dam rubber
on the glass adhesive side.
GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

8. Apply adhesive. Installation of window glass

a Apply adhesive (15) to dam rubber (6) of op-
erator cab (8) in the (s) and (t) dimensions
shown in the figure.
q Dimension (s): 10 mm
q Dimension (t): 15 mm
2 Adhesive:
Sun Star Penguin Seal 580 Super
a Apply adhesive (15) thicker than dam rubber
(6).
a Apply the adhesive evenly in height.
a (a): Applying range of primer (mentioned
above)
a Install window glass within 5 minutes after
applying the adhesive.
9. Install the window glass.
1) Install window glass (9), with the lines on the
positioning tapes drawn in step 6 above
aligned.
a Since the window glass cannot be re-
moved and adhered again, adhere it with
utmost care.
2) After adhering window glass (9), press the
glass at the whole edges through until the
glass adheres to the dam rubber.
a Press the corners of the window glass
firmly.
(The figure shows the operator cab of a
hydraulic excavator.)

a After applying adhesive

a You can perform this work efficiently by
pulling window glass (9) from the inside of
the operator cab with suction cup X1.

a Wipe off the squeezed adhesive.

GD555-5,GD655-5,GD675-5 50-265
(02)
Cab and its attachments
Removal and installation of operator cab glass (adhered glass)

10. Fix window glass.
1) After installing right window glass (1) to the
operator cab, insert stopper rubbers X2 in
two places (v) on the lower side of the glass
and fix it.
(The figure shows the operator cab of a
hydraulic excavator.)
11. After installing the window glass, remove any
excess of the primer and adhesive on the oper-
ator cab and window glass.
a By using white gasoline, wipe off the adhe-
sive before it dries off.
a When cleaning the glass, do not give an im-
pact on it.
a Only for the front glass and the front side
glass

2) In order to adhere the window glass and the

dam rubber perfectly, use styrene foam [9]
and rubber bands [10] to fix and cure them for
more than 10 hours.
(The figure shows the operator cab of a
hydraulic excavator.)

50-266 GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

Removal and installation of air conditioner unit assembly 50-267

2. Set lock pin (3) on the frame.
Removal 50-267
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker, and fix it after rotation.
3. Drain the coolant through coolant drain valve (4).
6 Coolant:
39.5 l

k If you drain the coolant or disconnect the

heater hose when the coolant temperature is
high, you may be scalded. Wait until the cool-
ant temperature lowers and then drain the 4. Remove mat (5).
coolant or disconnect the heater hose. 5. Remove two covers (6) and (7) under the oper-
1. Collect the refrigerant (R134a) from the air ator seat.
conditioner circuit.
a Ask a qualified distributor for collection
and charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a)
into the atmosphere.
a If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves
and long sleeved work clothes when col-
lecting or charging the refrigerant.
q Amount of air conditioner refrigerant (R134a)
to be collected:
1,050 ± 50 g

GD555-5,GD655-5,GD675-5 50-267
(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly

6. Remove magazine box (8) on the left side of the 9. Release two connectors CN-TEL (12) and
operator cab. CN-AC1 (13) from the clamp of cover (11).
10. Remove four bolts and cover (11).

7. Remove four bolts and cover (9).

11. Remove cover (14).

8. Remove four bolts and remove KOMTRAX 12. Remove two upper bolts and remove air condi-
terminal assembly (10). tioner duct (15).

50-268 GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

13. Remove the clamp. Using a hexagon wrench (4 18. Remove three bolts and remove cover (20).
mm), disconnect three connectors CN-TM39
(17), CN-TM40 (18) and CN-TM41 (19) from
transmission controller (16).
14. Remove four bolts and remove transmission
controller (16).

19. Remove four bolts and remove operator seat

assembly (25).
4 Operator seat assembly:
50 kg

15. Remove upper cover mounting bracket (21) and

mounting bracket (22) for washer vinyl tube from
cover (20).

20. Remove cover (26).

16. Remove the clamp from cover (20), and discon-

nect connectors CN-AC3 (23) and CN-AC4 (24).
17. Disconnect connector CN-AC1 (13) which was
disconnected at step 9., from connectors
CN-AC3 (23) and CN-AC4 (24).

GD555-5,GD655-5,GD675-5 50-269
(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly
21. Remove the clamp and remove duct hose (27).
22. Disconnect connector CN-B19 (28) from frame
(29).
23. Remove the clamp and release wiring harness
(30) from frame (29).
24. Remove two clamps and release wiring harness
(31) from frame (29).
25. Remove eight bolts and remove operator seat
mounting frame (29).
50-270
26. Disconnect two heater hoses (32) and (33) from
the bottom of the floor frame.
[*1]
a Plug the heater hose to prevent entry of dirt,
dust, etc. after disconnection.
27. Disconnect two air conditioner hoses (34) and
(35) from the bottom of the floor frame.
[*2]
a Plug the air conditioner hose to prevent entry
of dirt, dust, etc. after disconnection.
28. Disconnect two drain hoses (36) and (37) for air
conditioner from the bottom of the floor frame.
GD555-5,GD655-5,GD675-5
(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

29. Disconnect connector (38) on the floor frame.

30. Remove two bolts (39) and disconnect air condi-
tioner intermediate tube (40).
[*3]
a Plug the air conditioner intermediate tube to
prevent entry of dirt, dust, etc. after discon-
nection.

33. Remove air conditioner unit assembly (43).

31. Disconnect two heater hoses (41) and (42).

32. Remove two front-side mounting bolts (44) and

two rear-side mounting bolts (45) of air condi-
tioner unit (43).

GD555-5,GD655-5,GD675-5 50-271
(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly

Installation 50-272
q Perform installation in the reverse order to re-
moval.

[*1]
2 Connection between heater hose and
joint:
Liquid gasket (LG-7)
[*2] [*3]
a When installing the air conditioner hoses and
tubes, take care that dirt, dust, water, etc. do not
enter them.
a When installing the air conditioner hoses and
tubes, check that O-ring (46) is fitted to each of
their fittings.
Note: The size of O-ring (46) depends on the
fitting location.
a Check that O-ring (46) is free from flaw and de-
terioration.
a When connecting the refrigerant piping, apply
compressor oil for refrigerant (R134a) (DENSO:
ND-OIL8 or VALEO THERMAL SYSTEMS:
ZXL100PG (equivalent to PAG46)) to O-ring
(46).
a Secure by using two wrenches. (Hold the device
side with one wrench and turn the flare nut of the
hose with another wrench.)
3 Air conditioner hose flare nut (34):
12 – 15 Nm {1.2 – 1.5 kgm}
3 Air conditioner hose flare nut (35):
q Charging of refrigerant (R134a)
30 – 35 Nm {3.0 – 3.5 kgm} Charge the air conditioner circuit with refrigerant
3 Mounting bolt (39) of air conditioner inter-
(R134a).
mediate tube (40): a Quantity of refrigerant: 1,050 ± 50 g
8 – 12 Nm 0.8 – 1.2 kgm}

50-272 GD555-5,GD655-5,GD675-5
(02)
 Electrical system
Removal and installation of engine controller assembly

Electrical system 50-273

Removal and installation of engine controller assembly 50-273
2. Open side covers (4) and (5) on the right side of
Removal 50-273 the engine.
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker and fix it after rotation.

3. Disconnect connectors CN-EC2 (7), CN-EC1

(8), and CN-EC3 (9) from engine controller (6).
a Use a hexagonal wrench (4 mm) to remove
connectors CN-EC2 (7) and CN-EC1 (8).

1. Set lock pin (3) on the frame.

4. Remove two upper nuts (10) and remove the

clamp.

GD555-5,GD655-5,GD675-5 50-273
(02)
Electrical system
Removal and installation of engine controller assembly

5. Remove two stud bolts (11). 8. Remove two lower mounting bolts (14). [*1]

6. Remove nut (12) on the right and remove the 9. Remove engine controller assembly (6).
clamp.

Installation 50-274
7. Remove stud bolt (13). q Rerform installation in the reverse order to re-
moval.

[*1]
a Tighten left bolt (14) together with ground termi-
nal (15).

50-274 GD555-5,GD655-5,GD675-5
(02)
 Electrical system
Removal and installation of machine monitor assembly

Removal and installation of machine monitor assembly 50-275

2. Remove four bolts and remove cover (4) of the
Removal 50-275 machine monitor.
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker and fix it after rotation.

3. Disconnect connector CN-FP3 (5).

1. Set lock pin (3) on the frame.

4. Disconnect three connectors CN-FP1 (6),

CN-FP2 (7) and CN-FP 12 (8).
5. Remove machine monitor assembly (9).

GD555-5,GD655-5,GD675-5 50-275
(02)
Electrical system
Removal and installation of machine monitor assembly

Installation 50-276
q Rerform installation in the reverse order to re-
moval.

50-276 GD555-5,GD655-5,GD675-5
(02)
 Electrical system
Removal and installation of transmission controller assembly

Removal and installation of transmission controller assembly 50-27

2. Remove magazine box (4) on the left side of the
Removal 50-27 operator cab.
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off
when the lever is removed. And it is
closed if you attach and rotate the lever of
circuit breaker and fix it after rotation.

3. Remove four bolts and cover (5).

1. Set lock pin (3) on the frame.

4. Disconnect connector CN-L80 (7) from

KOMTRAX terminal assembly (6).
a Use a hexagonal wrench (4 mm) to remove
the connector.
5. Disconnect GPS antenna connector (8) and
ORBCOMM antenna connector (9) from
KOMTRAX terminal assembly (6).

GD555-5,GD655-5,GD675-5 50-277
(02)
Electrical system
Removal and installation of transmission controller assembly

6. Remove four bolts and remove KOMTRAX 9. Remove the clamp. Using a hexagon wrench (4
terminal assembly (6). mm), disconnect three connectors CN-TM39
(14), CN-TM40 (15) and CN-TM41 (16) from
transmission controller (13).

7. Disconnect two connectors CN-TEL (11) and

CN-AC1 (12) from the clamp of cover (10).
8. Remove four bolts and cover (10). 10. Remove four bolts and remove transmission
controller assembly (13).

Installation 50-278
q Perform installation in the reverse order to re-
moval.

50-278 GD555-5,GD655-5,GD675-5
(02)
 Electrical system
Removal and installation of KOMTRAX terminal assembly

Removal and installation of KOMTRAX terminal assembly 50-279

2. Remove magazine box (4) on the left side of the
Removal 50-279 operator cab.
k Park the machine on level ground, and lower
the work equipment to the ground by operat-
ing the gear shift lever to the P position.
k Stop the engine and chock the wheels.
k Shut off the battery (negative) circuit by turn-
ing and removing lever (2) of disconnect
switch (1) (front left side of the engine room)
being installed on the battery and hydraulic
tank mounting frame.
a The battery (negative) circuit is shut off when
the lever is removed. And it is closed if you
attach and rotate the lever of circuit breaker
and fix it after rotation.

3. Remove four bolts and cover (5).

1. Set lock pin (3) on the frame.

4. Disconnect connector CN-L80 (7) from

KOMTRAX terminal assembly (6).
a Use a hexagonal wrench (4 mm) to remove
the connector.
5. Disconnect GPS antenna connector (8) and
ORBCOMM antenna connector (9) from
KOMTRAX terminal assembly (6).

GD555-5,GD655-5,GD675-5 50-279
(02)
Electrical system
Removal and installation of KOMTRAX terminal assembly

6. Remove four bolts and remove KOMTRAX

terminal assembly (6).

Installation 50-280
q Perform installation in the reverse order to re-
moval.

50-280 GD555-5,GD655-5,GD675-5
(02)
 DRAFT

GD555-5,GD655-5,GD675-5
SEN0521520-00

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

60 Maintenance standard
4

GD555-5,GD655-5,GD675-5 60-1
 DRAFT

Contents

Contents
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

60-2 GD555-5,GD655-5,GD675-5
 DRAFT

Contents

GD555-5,GD655-5,GD675-5 60-3
 DRAFT
Engine and Cooling
Engine mount and transmission mount

Engine and Cooling

Engine mount and transmission mount

60-4 GD555-5,GD655-5,GD675-5
 DRAFT
Engine and Cooling
Engine mount and transmission mount

GD555-5,GD655-5,GD675-5 60-5
 DRAFT
Engine and Cooling
Cooling system

Cooling system

60-6 GD555-5,GD655-5,GD675-5
 DRAFT
Engine and Cooling
Cooling system

GD555-5,GD655-5,GD675-5 60-7
 DRAFT
Engine and Cooling
Cooling fan motor

Cooling fan motor

Type: LMF16

60-8 GD555-5,GD655-5,GD675-5
 DRAFT
Engine and Cooling
Cooling fan motor

GD555-5,GD655-5,GD675-5 60-9
 DRAFT
Engine and Cooling
Cooling fan motor

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable limit
Free length x
Installed Installed Installed
1 Spool return spring Outside diame- Free length If sping is damaged
length force force
ter or deformed,
58.8 N 47.1 N
44.84 x 12 33 ― replace it.
{6 kg} {4.8 kg}
32.2 x (8.5 ± 56.6 N 35.3 N
2 Spool return spring 34 ―
0.2) {5.78 kg} {3.6 kg}

60-10 GD555-5,GD655-5,GD675-5
 DRAFT
Engine and Cooling
Cooling fan motor

GD555-5,GD655-5,GD675-5 60-11
 DRAFT
Power train system
Transmission control

Power train system

Transmission control

60-12 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Transmission control

GD555-5,GD655-5,GD675-5 60-13
 DRAFT
Power train system
Torque converter

Torque converter

60-14 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Torque converter

Unit: mm

No. Item Criteria Remedy

Standard size Tolerance Repair limit
1 Outside diameter of pilot -0.010
71.954 71.9 Apply hard chrome
-0.040
plating or replace
Inside diameter of pilot seal ring +0.025
2 35 35.5
contact surface 0
Inside diameter of PTO drive gear +0.040
3 125 125.5
seal ring contact surface 0 Apply hard chrome
Inside diameter of stator shaft seal +0.030 plating or replace
4 55 55.5
ring contact surface 0
Inside diameter of free wheel +0.005
5 88.882 88.912
transfer surface of race -0.008
Outside diameter of free wheel +0.008
6 72.217 72.187
transfer surface of stator shaft -0.005
Inside diameter of bushing sliding 0.015
7 72.32 72.4
part 0
0
8 Thickness of bushing sliding part 5 4.5
-0.1 Replace
9 Thickness of clutch disc 5 ±0.1 4.5
Backlash between PTO drive gear
10 0.160 – 0.418
and PTO idler gear
Standard size Repair limit
Wear of the stator shaft
11 Width 3.95 3.55
seal ring
Thickness 4.8 4.32

GD555-5,GD655-5,GD675-5 60-15
 DRAFT
Power train system
Transmission

Transmission

60-16 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Transmission

GD555-5,GD655-5,GD675-5 60-17
 DRAFT
Power train system
Transmission

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Allowable Allowable
Clearance between input shaft sion Shaft Hole limit clearance
1
bearing and rear case 0 +0.030
150 0 – 0.048 ―
-0.018 0
Clearance between input shaft 0 +0.022 -0.013 –
2 100 ―
bearing and front case -0.015 -0.013 0.037
Clearance between upper shaft 0 +0.030
3 100 0 – 0.045 ―
bearing and rear case -0.015 0
Clearance between upper shaft 0 +0.022 -0.013 –
110 ―
bearing and front case -0.015 -0.013 0.037
4
Clearance between upper shaft +0.034 0 -0.049 –
60 ―
bearing and upper shaft +0.021 -0.015 -0.021
Clearance between lower shaft 0 +0.026 -0.014 –
5 140 ―
bearing and rear case -0.018 -0.014 0.044
Clearance between lower shaft 0 +0.026 -0.014 –
6 130 ―
bearing and front case -0.018 -0.014 0.044
Clearance between output shaft 0 +0.026 -0.014 –
7 140 ―
bearing and rear case -0.018 -0.014 0.044
Clearance between output shaft 0 +0.040
8 160 0 – 0.065 ―
bearing and front case -0.025 0
Clearance between PTO idler gear 0 +0.004 -0.018 –
90 ―
A bearing and rear case -0.018 -0.018 0.022
9 Replace
Clearance between PTO idler gear +0.018 0 -0.030 –
50 ―
A bearing and PTO idler gear A +0.002 -0.012 -0.002
Clearance between PTO gear A 0 +0.004 -0.015 –
80 ―
shaft bearing and rear case -0.012 -0.015 0.016
10
Clearance between PTO gear A +0.018 0 -0.030 –
50 ―
shaft bearing and PTO gear A shaft +0.002 -0.012 -0.002
Basic dimension Allowance Allowable limit
Width of input shaft seal ring groove
11 +0.18
(rear) 2.5 2.7
+0.10
Width of input shaft seal ring groove +0.076
12 3.2 3.5
(center) 0
Inside diameter of case seal ring
+0.05
contact surface (lower shaft, output 50 50.1
0
13 shaft)
Width of seal ring groove (lower +0.076
3.2 3.5
shaft, output shaft) 0
Outer diameter of output coupling 0
14 80 79.8
oil seal contact surface -0.074
Inside diameter of case seal ring
+0.05
contact surface (input shaft, upper 55 55.1
0
15 shaft)
Width of seal ring groove (input 0.076
3.2 3.5
shaft, upper shaft) 0

60-18 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Transmission

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between PTO idler gear sion Shaft Hole clearance clearance
1 B bearing and rear case 0 +0.004 -0.018 –
90 ―
-0.018 -0.018 0.022
Clearance between PTO idler gear +0.018 0 -0.030 –
50 ―
B bearing and PTO idler gear B +0.002 -0.012 -0.002
Clearance between PTO gear B 0 +0.004 -0.015 – Replace
80 ―
shaft bearing and rear case -0.012 -0.015 0.016
2
Clearance between PTO gear B +0.018 0 -0.030 –
50 ―
shaft bearing and PTO gear B shaft +0.002 -0.012 -0.002
Clearance between R idler gear 0 -0.049 -0.073 –
100 ―
bearing and R idler gear -0.015 -0.073 -0.034
3
Clearance between R idler gear +0.032 0 -0.047 –
70 ―
bearing and front case +0.002 -0.015 -0.002

GD555-5,GD655-5,GD675-5 60-19
 DRAFT
Power train system
Transmission

FL and R clutches

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between input shaft sion Shaft Hole clearance clearance
1
bearing and input shaft (rear) +0.030 0 -0.045 –
60 ―
+0.011 -0.015 -0.011
Clearance between input shaft +0.034 0 -0.049 –
2 55 ―
bearing and input shaft (front) +0.021 -0.015 -0.021
Basic dimension Allowance Allowable limit

3 Clutch plate Thickness 1.7 ±0.05 1.53

Distortion ― 0.05 0.15

Replace
Thickness 2.2 ±0.08 1.82
4 Clutch disc
Distortion ― 0.1 0.25
Force of wave spring 1,010 N ±101 N 859 N
5 {±10.3 kg} {87.6 kg}
[Test height: 2.2 mm] {103 kg}
6 Thickness of thrust washer 3 ±0.1 2.7

7 End play of R clutch gear 0.11 – 0.99

8 End play of FL clutch gear 0.06 – 1.24

60-20 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Transmission

FH and 1st clutchs

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between upper shaft sion Shaft Hole clearance clearance
1
bearing and upper shaft (rear) +0.034 0 -0.049 –
55 ―
+0.021 -0.015 -0.021
Basic dimension Allowance Allowable limit
Thickness 1.7 ±0.05 1.53
2 Clutch plate
Distortion ― 0.05 0.15

Thickness 2.2 ±0.08 1.82 Replace

3 Clutch disc
Distortion ― 0.1 0.25
Force of wave spring 1,010 N ±101 N 859 N
4 {±10.3 kg} {87.6 kg}
[Test height: 2.2 mm] {103 kg}
5 Thickness of thrust washer 3 ±0.1 2.7

6 End play of 1st clutch gear 0.02 – 1.18

7 End play of FH clutch gear 0.11 – 0.99

GD555-5,GD655-5,GD675-5 60-21
 DRAFT
Power train system
Transmission

2nd and 3rd clutches

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between lower shaft sion Shaft Hole clearance clearance
1
bearing and lower shaft (rear) +0.030 0 -0.045 –
65 ―
+0.011 -0.015 -0.011
Clearance between lower shaft +0.054 0 -0.069 –
2 60 ―
bearing and lower shaft (front) +0.044 -0.015 -0.044
Basic dimension Allowance Allowable limit

Thickness 1.7 ±0.05 1.53

3 Clutch plate
Distortion ― 0.05 0.15
Replace
Thickness 2.2 ±0.08 1.82
4 Clutch disc
Distortion ― 0.1 0.25
Force of wave spring 1,010 N ±101 N 859 N
5 {±10.3 kg} {87.6 kg}
[Test height: 2.2 mm] {103 kg}
6 Thickness of thrust washer 3 ±0.1 2.7

7 End play of 2nd clutch gear 0.01 – 1.19

8 End play of 3rd clutch gear 0.17 – 1.03

60-22 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Transmission

4th clutch

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between output shaft sion Shaft Hole clearance clearance
1
bearing and output shaft (rear) +0.030 0 -0.045 –
65 ―
+0.011 -0.015 -0.011
Clearance between output shaft +0.030 0 -0.045 –
2 75 ―
bearing and output shaft (front) +0.011 -0.015 -0.011
Basic dimension Allowance Allowable limit

Thickness 1.7 ±0.05 1.53

3 Clutch plate
Distortion ― 0.05 0.15

Thickness 2.2 ±0.08 1.82 Replace

4 Clutch disc
Distortion ― 0.1 0.25
Force of wave spring 1,010 N ±101 N 859 N
5 {±10.3 kg} {87.6 kg}
[Test height: 2.2 mm] {103 kg}
6 Thickness of thrust washer 3 ±0.1 2.7
Inside diameter of cylinder seal ring +0.030
70 70.1
contact surface 0
7
Width of output shaft seal ring +0.076
3.2 3.5
groove 0
8 End play of 4th clutch gear 0.10 – 0.90

GD555-5,GD655-5,GD675-5 60-23
 DRAFT
Power train system
Main relief valve and torque converter relief valve

Main relief valve and torque converter relief valve

Unit: mm

No. Item Criteria Remedy

Basic Allowance Standard Allowable
Clearance between main relief dimension Shaft Hole clearance clearance
1
valve and valve body -0.035 +0.013 0.035 –
28 0.078
-0.045 0 0.058
Clearance between torque con- -0.035 +0.013 0.035 –
2 22 0.078
verter relief valve and valve body -0.045 0 0.058
Basic dimension Allowable limit
Installed Replace
Free length Installed force Free length Installed force
3 Main relief valve spring (outside) length
275 N 261 N
108 79.5 104.8
{28.0 kg} {26.6 kg}
325 N 309 N
4 Main relief valve spring (inside) 108 79.5 104.8
{33.2 kg} {31.5 kg}
162 N 154 N
5 Torque converter relief valve spring 50 41.5 48.5
{16.5 kg} {15.7 kg}

60-24 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Main relief valve and torque converter relief valve

GD555-5,GD655-5,GD675-5 60-25
 DRAFT
Power train system
Front axle

Front axle

60-26 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Front axle

GD555-5
Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between center pin and sion Shaft Hole clearance clearance
1
bearing -0.030 +0.174 0.130 –
55 3.0
-0.076 +0.100 0.250
Clearance between kingpin and -0.025 +0.164 0.145 – Replace bushing
2 45 2.0
bushing -0.064 +0.120 0.228
Clearance between front axle pin -0.025 +0.164 0.145 –
3 40 2.0
and bushing -0.064 +0.120 0.228
Clearance between ball joint and -0.060 +0.020 0.060 –
4 55 1.0
bushing -0.090 0 0.110
6 Amount of pre-load of hub bearing Starting torque: 78.5 – 117.7 Nm {8 – 12 kgm} Adjust

GD555-5,GD655-5,GD675-5 60-27
 DRAFT
Power train system
Front axle

GD655-5 and GD675-5

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between center pin and sion Shaft Hole clearance clearance
1
bearing -0.030 +0.174 0.130 –
55 3.0
-0.076 +0.100 0.250
Clearance between kingpin and -0.025 +0.164 0.145 – Replace bushing
2 45 2.0
bushing -0.064 +0.120 0.228
Clearance between front axle pin -0.025 +0.164 0.145 –
3 45 2.0
and bushing -0.064 +0.120 0.228
Clearance between ball joint and -0.060 +0.020 0.060 –
4 55 1.0
bushing -0.090 0 0.110
5 Amount of pre-load of hub bearing Starting torque: 78.5 – 117.7 Nm {8 – 12 kgm} Adjust

60-28 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Front axle

GD555-5,GD655-5,GD675-5 60-29
 DRAFT
Power train system
Final drive (no differential specification)

Final drive (no differential specification)

60-30 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Final drive (no differential specification)

Unit: mm

No. Item Criteria Remedy

Amount of pre-load of bevel pinion
1 Starting torque: 1.1 – 4.7 Nm {0.11 – 0.48 kgm}
and bearing
Amount of pre-load of bevel gear Starting torque: Item No.1 + 0.7 – 1.5 Nm {0.07 – 0.15 kgm}
2
and bearing (Measured at the pinion shaft after running-in.)
Basic dimension
Backlash between bevel pinion and
3 Adjust
bevel gear 0.25 – 0.33
Amount of pre-load of shaft and
4 Rotation starting torque: 5.2 - 13.0 Nm {0.50 - 1.30 kgm}
bearing
5 End play of flange 0 – 0.10

GD555-5,GD655-5,GD675-5 60-31
 DRAFT
Power train system
Final drive (differential/ differential lock specification)

Final drive (differential/ differential lock specification)

60-32 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Final drive (differential/ differential lock specification)

Unit: mm

No. Item Criteria Remedy

Amount of pre-load of bevel pinion
1 Rotation starting torque: 1.1 – 4.7 Nm {0.11 – 0.48 kgm}
and bearing
Amount of pre-load of bevel gear Starting torque: Item No.1 + 0.7 – 1.5 Nm {0.07 – 0.15 kgm}
2
and bearing (Measured at the pinion shaft after running-in.)
Adjust
Backlash between bevel pinion and
3 0.25 – 0.33
bevel gear
Amount of pre-load of shaft and
4 Rotation starting torque: 5.2 – 13.0 Nm {0.50 – 1.30 kgm}
bearing
Basic dimension Allowance Allowable limit
Thickness of disc
2.8 ±0.1 2.65
5
Depth of flute of lining 0.15 (minimum) ±0.1 1.8 Replace

Basic dimension Allowance Allowable limit

6 Thickness of plate
1.8 ±0.05 1.65

7 End play of flange 0 – 0.1 Adjust

8 Thickness of pinion gear washer 2 ±0.13 1.8 Replace

-0.02
9 Thickness of side gear washer 4 3.8 Replace
-0.05

GD555-5,GD655-5,GD675-5 60-33
 DRAFT
Power train system
Differential lock solenoid valve

Differential lock solenoid valve

With differential lock
(if equipped)

Unit: MPa {kg/cm2}

No. Item Criteria Remedy

Differential oil pressure Standard oil pressure Allowable limit
(Differential oil temperature
1 50 ± 5°C, range from engine low 2.7 – 3.09 Max. 2.7 Adjust
idle (800 ± 50 rpm) to high idle {27.5 – 31.5} {Max. 27.5}
(2,225 ± 50 rpm))

60-34 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Differential lock solenoid valve

GD555-5,GD655-5,GD675-5 60-35
 DRAFT
Power train system
Tandem drive

Tandem drive

Unit: mm

No. Item Criteria Remedy

Starting torque: 11 – 16 Nm {1.15 – 1.65 kgm}
1 Amount of pre-load of hub bearing Adjust
(Torque which is added to dragging torque)
Basic dimension Allowable limit
Elongation of chain
2 Replace
(for ten links) 508.0 515.62

60-36 GD555-5,GD655-5,GD675-5
 DRAFT
Power train system
Tandem drive

GD555-5,GD655-5,GD675-5 60-37
 DRAFT
Brake system
Slack adjuster

Brake system
Slack adjuster

Unit: mm

No. Item Criteria Remedy

Basic Allowance Standard Allowable
Clearance between body and pis- dimension Shaft Hole clearance clearance
1
ton -0.030 +0.074 0.030 –
55 0.25
-0.076 0 0.150
Basic dimension Allowable limit Replace
Installed
Free length Installed force Free length Installed force
2 Slack adjuster spring height
43.2 N
198 38 ― ―
{4.4 kg}
66.7 N
3 Spring 38.8 33 ― ―
{6.8 kg}

60-38 GD555-5,GD655-5,GD675-5
 DRAFT
Brake system
Slack adjuster

GD555-5,GD655-5,GD675-5 60-39
 DRAFT
Brake system
Wheel brake

Wheel brake

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable limit
1 Thickness of disc
3.8 ± 0.1 3.3 ± 0.1

2 Thickness of plate 2.3 ± 0.08 ―

Replace
Allowable
Basic dimension
limit
3 Spring Installed height Installed force Installed force
735 N 662 N
60.5
{75 kg} {67.5 kg}

60-40 GD555-5,GD655-5,GD675-5
 DRAFT
Brake system
Wheel brake

GD555-5,GD655-5,GD675-5 60-41
 DRAFT
Brake system
Parking brake

Parking brake

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable limit
1 Thickness of brake disc
10.4 9.4
Replace

2 Thickness of brake pad 12.5 9.5

60-42 GD555-5,GD655-5,GD675-5
 DRAFT
Brake system
Parking brake

GD555-5,GD655-5,GD675-5 60-43
 DRAFT
Hydraulic system
Power train pump

Hydraulic system
Power train pump
Single pump type
SAR (2) 63

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable clearance

1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bearing
2 inside diameter and gear shaft out- 0.067 – 0.125 0.20
side diameter
Basic dimension Allowance
Replace
3 Press-fitting length of pin 0
12
-0.5
4 Torque of splined shaft 2.9 – 6.9 Nm {0.3 – 0.7 kgm}

Discharge Allowable
Basic discharge
Engine speed pressure discharge
Discharge amount amount
(rpm) amount
― Oil: EO10-CD (MPa {kg/cm2}) (l/min)
(l/min)
Temperature: 45 – 55°C
2300 15.2 {155} 137 124 ―

60-44 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Power train pump

Double pump type

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

Unit: mm

No. Item Criteria Remedy

Type Basic dimension Allowable clearance
SAR (2)
0.10 – 0.15 0.19
1 Side clearance 63
SBR (1)
0.10 – 0.15 0.19
10
Clearance between plain SAR (2)
0.067 – 0.125 0.20
bearing inside diameter 63
2 Replace
and gear shaft outside SBR (1)
0.064 – 0.119 0.20
diameter 10
Type Basic dimension Allowance Allowable limit
SAR (2)
12
3 Press-fitting length of pin 63 0
―
SBR (1) -0.5
10
10
4 Torque of splined shaft 4.9 – 11.8 Nm {0.5 – 1.2 kgm}

Discharge Allowable
Basic discharge
Engine speed pressure discharge
Type amount
(rpm) amount
Discharge amount (MPa {kg/cm2}) (l/min) ―
(l/min)
― Oil: EO10-CD SAR (2)
Temperature: 45 – 55°C 2300 2.9 {30} 140.2 124
63
SBR (1)
2300 2.9 {30} 22.6 18
10

GD555-5,GD655-5,GD675-5 60-45
 DRAFT
Hydraulic system
Control valve

Control valve
9-spool valve
General view

60-46 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Control valve

10-spool valve
General view

GD555-5,GD655-5,GD675-5 60-47
 DRAFT
Hydraulic system
Control valve

Sectional view

Unit: mm

No. Item Criteria Remedy

Spool return spring Basic dimension Allowable range
(q if equipped) Free length x
(q Blade shift) Installed
Outside diam- Installed force Free length Installed force
1 (q Power tilt) length If sping is dam-
eter
(q Articulate) aged or deformed,
34.8 N 27.9 Nm
(q Drawbar shift) 56.27 x 20.1 25.4 ― replace it.
{3.55 kg} {2.84 kg}
(q Leaning)
Spool return spring 34.8 N 27.9 Nm
2 87.7 x 19.7 25.4 ―
(circle) {3.55 kg} {2.84 kg}

60-48 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Control valve

Sectional view

GD555-5,GD655-5,GD675-5 60-49
 DRAFT
Hydraulic system
Control valve

Sectional view

60-50 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Control valve

Sectional view

GD555-5,GD655-5,GD675-5 60-51
 DRAFT
Hydraulic system
Control valve

Sectional view

60-52 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Control valve

Sectional view

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable range
Free length x
Installed
Pressure compensation valve Outside diam- Installed force Free length Installed force
3 length
spring eter
34.8 N 27.9 Nm
56.27 x 20.1 25.4 ―
{3.55 kg} {2.84 kg}
Pressure compensation valve 34.8 N 27.9 Nm
4 87.7 x 19.7 25.4 ―
spring {3.55 kg} {2.84 kg}
Pressure compensation valve 134 N 107 Nm
5 35.25 x 19 20.9 ―
spring {13.63 kg} {10.9 kg}
Pressure compensation valve 157 N 12.6 Nm
6 18.31 x 9.4 14.5 ―
spring {1.6 kg} {1.28 kg}

GD555-5,GD655-5,GD675-5 60-53
 DRAFT
Hydraulic system
Hydraulic cylinder

Hydraulic cylinder

Unit: mm

No. Item Criteria Remedy

Cylinder Basic dimen- Allowance Standard Allowable
name sion Shaft Hole clearance clearance
-0.025 +0.132 0.031 –
Steering 35 0.519
-0.087 +0.006 0.219
-0.025 +0.132 0.031 –
Leaning 35 0.519
-0.087 +0.006 0.219
-0.025 +0.152 0.032 –
Clearance between Articulate 45 0.539
1 -0.087 +0.007 0.239
piston rod and bushing -0.025 +0.164 0.032 –
Blade lift 50 0.528
-0.064 +0.007 0.228
Drawbar -0.025 +0.152 0.032 –
shift
45 0.516
-0.064 +0.007 0.216
Blade side -0.025 +0.164 0.032 –
shift
50 0.528
-0.064 +0.007 0.228
-0.025 +0.132 0.031 –
Power tilt 40 0.519 Replace bushing
-0.087 +0.006 0.219
Steering +0.015 +0.030 -0.015 –
62 1.0
-0.010 0 0.040
-0.025 +0.142 0.105 –
Leaning 45 1.0
-0.064 +0.080 0.206
Articulate -0.030 +0.142 0.105 –
50 1.0
-0.076 +0.080 0.206
Clearance between
2 Blade lift -0.050 +0.100 0.050 –
piston rod support shaft 80 1.0
-0.150 0 0.250
and bushing
Drawbar -0.050 +0.100 0.050 –
80 1.0
shift -0.150 0 0.250
Blade -0.025 +0.142 0.105 –
40 1.0
side shift -0.064 +0.080 0.206
Power tilt 0 +0 -0.012 –
40 1.0
-0.019 -0.012 0.019

60-54 GD555-5,GD655-5,GD675-5
 DRAFT
Hydraulic system
Hydraulic cylinder

Unit: mm

No. Item Criteria Remedy

Cylinder Basic dimen- Allowance Standard Allowable
name sion Shaft Hole clearance clearance
-0.025 0 0.013 –
Steering 35 1.0
-0.064 -0.012 0.064
-0.025 +0.142 -0.015 –
Leaning 40 1.0
-0.064 +0.080 0.022
Clearance between -0.030 +0.142 0.140 –
cylinder bottom sup- Articulate 50 1.0
-0.076 +0.080 0.218
3 Replace bushing
port shaft and bush- -0.080 +0.117 0.167 –
Blade lift 45 1.0
ing -0.142 +0.087 0.259
Drawbar -0.050 +0.100 0.050 –
shift
80 1.0
-0.150 0 0.250
Blade side -0.025 +0.142 -0.015 –
shift
40 1.0
-0.064 +0.080 0.022
-0.100 +0 0.088 –
Power tilt 40 1.0
-0.174 -0.012 0.174
Steering 245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)

Leaning 412 ± 41.0 Nm {42 ± 4.2 kgm} (width across flats: 36)

Articulate 1,080 ± 110 Nm {110 ± 11 kgm} (width across flats: 50)

Piston nut tightening
4 Blade lift 618 ± 62 Nm {63 ± 6.3 kgm} (width across flats: 41)
torque
Drawbar
shift
618 ± 62 Nm {63 ± 6.3 kgm} (width across flats: 41)

Blade side
shift
618 ± 62 Nm {63 ± 6.3 kgm} (width across flats: 41)

Power tilt 647 ± 64.5 Nm {66 ± 6.6 kgm} (width across flats: 41)
Retighten
Steering 392 ± 39.0 Nm {40 ± 4.0 kgm}

Leaning 539 ± 54.0 Nm {55 ± 5.5 kgm}

Articulate 588 ± 59.0 Nm {60 ± 6.0 kgm}

Cylinder head tighten-
5 Blade lift 588 ± 59.0 Nm {60 ± 6.0 kgm}
ing torque
Drawbar
shift
588 ± 59.0 Nm {60 ± 6.0 kgm}

Blade side
shift
588 ± 59.0 Nm {60 ± 6.0 kgm}

Power tilt 588 ± 59.0 Nm {60 ± 6.0 kgm}

GD555-5,GD655-5,GD675-5 60-55
 DRAFT
Work equipment
Circle and drawbar

Work equipment
Circle and drawbar

60-56 GD555-5,GD655-5,GD675-5
 DRAFT
Work equipment
Circle and drawbar

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable If shim adjustment
Clearance of ball stud sphere por- sion Shaft Hole clearance clearance is impossible,
1
tion -0.050 +0.100 0.050 – replace joint or ball
S150 – stud.
-0.100 0 0.200
Basic dimension Allowable dimension If shim adjustment
Clearance between circle and draw-
2 is impossible,
bar 1.0 – 2.0 1.0 – 2.0
replace circle guide.

3a If replacement or
Wear of guide bushing 8 3 shim adjustment is
3b impossible, replace
guide bushing or
4 Wear of guide plate 6 2 guide plate.
If shim adjustment
is impossible,
5 Axial play of drawbar 0.65 – 0.95
replace joint or ball
stud.
Standard shim thickness for ball
6 4 – 4.6
joint portion
Adjust shim
Standard shim thickness for guide
7 7
mount portion

GD555-5,GD655-5,GD675-5 60-57
 DRAFT
Work equipment
Blade

Blade

60-58 GD555-5,GD655-5,GD675-5
 DRAFT
Work equipment
Blade

Unit: mm

No. Item Criteria Remedy

Basic dimension Allowable limit
1 Wear of cutting edge
From blade base: 74 From blade base: 10

2 Wear of side edge From blade base: 44 From blade base: 25

3a Height 368 364 Replace

Wear of blade rail
3b Thickness 22 21

4a Height 8 5
Wear of blade rail
guide Width of
4b groove
25 33

GD555-5,GD655-5,GD675-5 60-59
 DRAFT
Work equipment
Lifter

Lifter

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between yoke and bush- sion Shaft Hole clearance clearance
1 Replace bushing
ing -0.3 +0.174
75 0.3 - 0.8 0.6
-0.6 +0.100

60-60 GD555-5,GD655-5,GD675-5
 DRAFT
Work equipment
Lifter

GD555-5,GD655-5,GD675-5 60-61
 DRAFT
Work equipment
Circle rotation gear

Circle rotation gear

60-62 GD555-5,GD655-5,GD675-5
 DRAFT
Work equipment
Circle rotation gear

Unit: mm

No. Item Criteria Remedy

Basic dimen- Allowance Standard Allowable
Clearance between shaft and bush- sion Shaft Hole clearance clearance
1 Replace bushing
ing -0.030 +0.057 0.040 –
75 0.4
-0.060 +0.010 0.117
Clearance between collar and +0.035 +0.270 0.026 –
2 90 0.6 Replace bushing
bushing 0.000 +0.061 0.270
Standard clearance Allowable clearance
Backlash between worm and worm
3 Replace
wheel 0.3 – 0.4 2.0
Clearance between case under sur-
4 0.1 – 0.5 0.6 Adjust shim
face plate and pinion
Basic dimension Allowable limit
5 Wear of pinion Replace
25 20
Starting torque: 2.9 - 7.8 Nm {0.3 - 0.8 kgm}
6 Amount of pre-load of bearing Adjust
When worm is not engaged with worm wheel
Standard shim thickness of shaft
7 3
(upper)
―
Standard shim thickness of shaft
8 3
(lower)

GD555-5,GD655-5,GD675-5 60-63
 DRAFT
Work equipment
Circle rotation gear

60-64 GD555-5,GD655-5,GD675-5
GD555-5,GD655-5,GD675-5
SEN0521531-00 80-1

MOTOR GRADER
Shop Manual 80-1

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

80 Appendix 80-1

GD555-5,GD655-5,GD675-5 80-1
(01)
Table of contents

Table of contents 80-2

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
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

80-2 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Precautions for refrigerant

Air conditioner 80-3

Precautions for refrigerant 80-3
k Collect the air conditioner refrigerant (R134a)
from the air conditioner circuit before dis-
connecting the air conditioner hoses to re-
place the air conditioner unit, air conditioner
compressor or receiver drier and so on.
a Ask a qualified shop for collecting, adding and fill-
ing operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmo-
sphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on the protective goggles,
gloves and working suits with long sleeves
while you are collecting the refrigerant
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be performed by a qualified
person.

GD555-5,GD655-5,GD675-5 80-3
(01)
Air conditioner
Air Conditioner Components

Air Conditioner Components 80-4

80-4 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Air Conditioner Components

1. Air conditioner control panel Specifications 80-5

2. Air conditioner unit Refrigerant R134a
3. Hot water return hose Refrigerant refilling quantity (g) 1,000 ± 50
4. Hot water supply hose
5. Recirculation air filter
6. Dual pressure switch A: Front window glass warm/cool air outlet
7. Refrigerant hose B: Rear warm/cool air outlet
8. Receiver drier C: Side warm/cool air outlet
9. Condenser D: Front warm/cool air outlet
10. Compressor E: Recirculation air inlet
11. Fresh air filter F: Fresh air inlet
12. Sight glass

GD555-5,GD655-5,GD675-5 80-5
(01)
Air conditioner
Structure and Function of Refrigeration System

Structure and Function of Refrigeration System 80-6

Step Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Location Engine compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates refrigerant
gas and increases its Uses throttle to lower tem- Evaporates refrigerant to
Condenses refrigerant
temperature and pres- perature and pressure of absorb heat from air
to discharge heat
sure so that it can be refrigerant liquid and gas around evaporator to
Function absorbed in evaporator.
liquefied easily in con- for easy evaporation. Also cool.
(Condensation of refrig-
denser. controls flow rate. (Evaporation of refriger-
erant)
(Compression of (Throttling of refrigerant) ant)
refrigerant)
GasoGas
GasoLiquid LiquidoLiquid and gas Liquid and gas oGas
Condition of
refrigerant Adiabatic compres-
Isobaric change Adiabatic expansion Isobaric change
sion

80-6 GD555-5,GD655-5,GD675-5
(01)

Overview of Refrigeration System
The refrigeration system consists of four steps. The refrigerant is circulated while repeatedly switching be-
tween liquid o gas o liquid condition.
1. Compression (Compressor)
The compressor sucks in the refrigerant that has
been vaporized in the evaporator and
compresses it into a state in which it can be
easily liquefied at the ambient temperature.
The gaseous refrigerant sucked into the
compressor cylinder is compressed to a temper-
ature and pressure at which it can be easily
liquefied when cooled to the ambient tempera-
ture.
2. Condensation (Condenser)
The condenser cools and liquefies the
high-pressure, high-temperature gaseous refrig-
erant sent from the compressor.
The heat released to the outside from the
condenser is called condensation heat.
The amount of condensation heat is the sum
total of the heat absorbed by the evaporator from
the air in the cab and the amount of work done
(converted into a heat quantity) through
compression by the compressor.
The refrigerant liquefied in the condenser is sent
to the receiver drier, where moisture is removed.
In the compression stage, gaseous and liquid
refrigerant coexist.
The temperature (i.e., condensation tempera-
ture) and the pressure (i.e., condensation pres-
sure) at which the gaseous refrigerant is
liquefied are proportional to each other.
Reference: The pressure varies depending on
the condensation temperature of the refrigerant.
3. Expansion (Expansion valve)
Through throttle action (*1), the expansion valve
reduces the liquid refrigerant's pressure to a
level at which it can be easily evaporated.
The action of reducing the liquid refrigerant pres-
sure to a level where it can be easily evaporated
before it is sent to the evaporator is called
expansion.
The expansion valve, which reduces the refrig-
erant pressure, and adjusts the refrigerant flow
rate simultaneously.
The quantity of the liquid refrigerant that can be
evaporated in the evaporator depends on the
amount of heat (i.e., the refrigeration load) to be
removed under the specific evaporation temper-
ature and pressure .
The expansion valve controls the refrigerant
feed rate so that the optimum quantity of liquid
refrigerant is supplied to the evaporator.
GD555-5,GD655-5,GD675-5
(01)
Air conditioner
Overview of Refrigeration System
80-7
(*1) Throttle action
If there is a narrow section in the passage
through which liquid flows at a constant rate, a
resistance to the flow will be generated.
The liquid expands when it passes through the
narrow section and rushes into the passage
where the sectional area is larger, and conse-
quently, its pressure and temperature are
reduced.
No heat is transferred from or to the outside
during the throttle action.
4. Evaporation (Evaporator)
The evaporator evaporates the liquid refrigerant
(to a superheated vapor).
As the refrigerant evaporates, it absorbs the
heat necessary for evaporation (i.e., latent evap-
oration heat) from the air around the cooling fins
(i.e., the air in the cab).
After the heat has been removed, the cooled air
is sent into the cab by the blower fan, reducing
the temperature inside the cab.
The mist refrigerant that has been sent from the
expansion valve and the evaporated refrigerant
coexist in the evaporator.
The evaporation temperature and the evapora-
tion pressure at which the liquid refrigerant is
evaporated are proportional to each other.
The compressor draws in the evaporated refrig-
erant in order to keep the pressure level in the
evaporator as low as possible so that the liquid
refrigerant can be evaporated at a much lower
temperature.
Relation between refrigerant and defective air
conditioning 80-7
q As refrigerant circulates through the refrigeration
circuit, it repeats the refrigeration cycle in order
to expel the heat inside the cab.
q If there is an insufficient quantity of refrigerant, it
will all be evaporated while passing through the
evaporator. This causes evaporator efficiency to
deteriorate, which will result in defective air con-
ditioning.
q If there is excessive refrigerant, not all of it will be
evaporated and the remainder will be sucked
into the compressor in liquid form, which will
cause the compressor to compress liquid and
may result in component damage.
q If water gets into the refrigeration circuit, it will
freeze at the small hole in the expansion valve
and reduce the refrigerant flow, and may result in
defective air conditioning.
80-7
Air conditioner
Air Conditioner Unit

Air Conditioner Unit 80-8

80-8 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Air Conditioner Unit

A: Refrigerant outlet (to compressor) Outline 80-9

B: Refrigerant inlet (from receiver) q The air conditioner unit consists of evaporator
C: Hot water inlet (1) and heater core (2), and is used to cool down
D: Hot water outlet or warm up the air in the cab.

1: Evaporator Temperature control 80-9

2: Heater core
3: Air mix damper (upper)
4: Air mix damper (lower)
5: Expansion valve
6: Blower amp
7: Compressor relay
8: blower off relay
9: Air mix actuator
10: Evaporator temperature sensor
11: Blower motor and fan assembly
12: FRESH/RECIRC air changeover actuator
13: FRESH/RECIRC air changeover damper
14: Recirculation air filter
a A damper is essentially a door.
q When the temperature control switch on the air
conditioner control panel is operated, the air
conditioner control panel controls air mix actua-
tor (9) which changes the angles of air mix
dampers (3) and (4) to adjust the temperature.
Overcooling (freezing) prevention 80-9
q The resistance of evaporator temperature sen-
sor (10) changes in response to temperature.
q The air conditioner control panel converts the
variation in resistance of evaporator temperature
sensor (10) into voltage and uses this voltage for
detecting evaporator (1) temperature.
q The air conditioner control panel activates com-
pressor relay (8) to stop the compressor and to
prevent evaporator (1) from freezing.

Air flow control 80-9

q When the air flow control switch on the air condi-
tioner control panel is operated, the air condi-
tioner control panel controls blower motor and
fan assembly (11) via blower amp (6) and blower
off relay (7) to adjust the air flow.

Functions of major components 80-9

Evaporator 80-9
q The evaporator (1) is cooled by the low-pres-
sure, low-temperature refrigerant gas sent from
expansion valve (5). Air from blower motor and
fan assembly (11) is cooled and dehumidified
when passing through the evaporator fins.

Heater core 80-9

q Heater core (2) is warmed by the hot water (en-
gine coolant) sent from the engine. Air from
blower motor and fan assembly (11) is warmed
when passing through the heater core fins.

Expansion valve 80-9

q Expansion valve (5) converts high pressure and
high temperature liquid refrigerant from the re-
ceiver drier to a mist of low pressure, low tem-
perature refrigerant through throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in evaporator (1).

GD555-5,GD655-5,GD675-5 80-9
(01)
Air conditioner
Air Conditioner Unit

Air mix actuator 80-10 Dual pressure switch 80-10

q When the switch on the air conditioner control a The dual pressure switch is located before the
panel is operated, the motor drive power (at 24 relay on the air conditioner piping.
V) is supplied to the actuator terminals. q The dual pressure switch turns "OFF" when the
q The rotating direction of the motor changes ac- refrigerant circuit pressure becomes abnormally
cording to the polarity of the received power. low or abnormally high.
q A variable resistor is built into the actuator, and q Turning the dual pressure switch "OFF" causes
its resistance changes as the motor rotates. the compressor relay to turn off. Then the mag-
q A voltage of 5 V is supplied to both ends of the netic clutch of the compressor is released in or-
variable resistor from the air conditioner control der to protect the air conditioner components.
panel, and the air conditioner control panel de-
tects the motor rotation angle based on the vari-
able resistor's voltage.
q When a target temperature is set using the tem-
perature control switch on the air conditioner
control panel, the control panel determines the
motor's rotating direction by reading the voltage
of the variable resistor.
q When the air mix damper reaches the position
specified by the air conditioner control panel, the
air conditioner control panel stops the current
output to the actuator to stop the damper.
q Rotation of the motor also stops when the limiter
moving in unison with it is detached.
a LA or lower: Abnormally low pressure
Blower motor and fan assembly 80-10 a HA or higher: Abnormally high pressure
q Blower motor and fan assembly (11) rotates the
blower fan to draw in air and send it to the evap- LA: 0.20 MPa {2 kg/cm2}
orator and heater core. LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
FRESH/RECIRC air changeover actuator 80-10 HB: 0.59 MPa {6 kg/cm2}
q FRESH/RECIRC air changeover actuator (12)
receives the drive current from the air condition-
er control panel and opens or closes the
FRESH/RECIRC air changeover damper to
make a switch between the fresh air and recircu-
lated-air settings.
q When the switch on the air conditioner control
panel is operated, the motor drive power (at 24
V) is supplied to the actuator terminals.
q The rotating direction of the motor changes ac-
cording to the polarity of the received power.
q The direction of rotation of the motor is deter-
mined based on the operation of the
FRESH/RECIRC air changeover switch on the
air conditioner control panel.
q The rotation of the motor stops when the limiter
moving in unison with it is detached or when the
drive current from the air conditioner control pan-
el is turned off.

Evaporator temperature sensor 80-10

q To prevent the evaporator from freezing, evapo-
rator temperature sensor (10) varies its electrical
resistance with the evaporator temperature, and
the temperature is monitored on the air condi-
tioner control panel.

80-10 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Compressor

Compressor 80-1

A: Refrigerant inlet (from air conditioner unit) Function 80-1

B: Refrigerant outlet (to condenser)
q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
evaporator into a misty refrigerant at high pres-
sure and high temperature so that it will be easily
regenerated (liquefied) at the normal tempera-
ture.
q Its built-in magnetic clutch is engaged or disen-
gaged according to the evaporator temperature
and refrigerant pressure.
q When the clutch is engaged, the power of the en-
gine rotates the compressor shaft to drive the
compressor.

Specifications 80-1
Number of cylinder - Bore x
Stroke 7 - 29.3x32.8
(mm)
Piston capacity
154.9
(cc/rev)
Allowable maximum speed
4,000
(rpm)
Sanden:
Compressor oil
SP-10 (for R134a)
Compressor oil refill capacity
240
(cc)

GD555-5,GD655-5,GD675-5 80-11
(01)
Air conditioner
Condenser

Condenser 80-12

A: Refrigerant inlet (from compressor) Specifications 80-12

B: Refrigerant outlet (to receiver drier) Fin pitch (mm) 1.5
Total heat dissipation area
6.55
Function 80-12 (m2)
q The condenser cools and liquefies the Maximum operating pressure
3.6 {36}
high-pressure and high-temperature misty refrig- (MPa {kg/cm2})
erant sent from the compressor.

a If the fins are crushed or are clogged with dust,

heat exchange efficiency is reduced and com-
plete liquefaction of refrigerant becomes impos-
sible.
If the heat exchange efficiency is reduced, pres-
sure in the refrigerant circulation circuit will be
increased, applying extra load to the engine or
reducing the cooling effect. Take care not to
crush or damage the fins when handling and
performing daily inspection.

80-12 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Receiver drier

Receiver drier 80-13

Function 80-13
q The receiver drier temporarily stores the
high-pressure and high-temperature liquid refrig-
erant from the condenser so that it can be sup-
plied to the evaporator according to the cooling
demand.
q It sends the stored refrigerant from its bottom to
the evaporator, allowing the refrigerant to be liq-
uefied completely even when it contains bubbles
due to the lowered heat dissipation of the con-
denser.
q The built-in filter and desiccating agent eliminate
foreign substances in the circulation circuit and
water in the refrigerant.
q Sight glass (1) allows the flow of refrigerant to be
checked.

Specifications 80-13
Effective volume (cm3) 578
Weight of desiccating agent 300
(g)

A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
1. Sight glass

GD555-5,GD655-5,GD675-5 80-13
(01)
Air conditioner
Air conditioner control panel

Air conditioner control panel 80-14

Switches 80-14
No. Name Function Operation
RECIRC
FRESH/RECIRC selector
1 Switch to select recirculated or fresh air IO
switch
FRESH
Switch to turn cooling, drying, and heating function on or
2 Air conditioner switch OFFioION
off.
3 Main power switch Switch to turn the air conditioner's main power on or off. OFFioON
Switch for adjusting the output air temperature Low temperatureio
4 Temperature control switch
(eight level settings) High temperature
Switch to adjust the fan speed
6 Fan switch LoioHI
(five level settings - LO, M1, M2, M3, and HI)

Outline 80-14
q The air conditioner control panel contains a CPU
(Central Processing Unit) that processes the in-
put signals from each sensor and the control sig-
nals from each switch, and displays the signals
on the panel and outputs them to the actuators
and relays.
a See "System Diagrams" for details regarding in-
put/output signals and operation.

80-14 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Air conditioner control panel

GD555-5,GD655-5,GD675-5 80-15
(01)
Air conditioner
Procedure for check and troubleshooting

Procedure for check and troubleshooting 80-16

The air conditioner is provided with self-diagnosis function in order to check its main components. Specifically,
the operation of sensors and actuators can be checked.
If a section which has a problem is found, every part of the section must be checked.

1. After basic check, narrow down the sections which may have a failure according to the problem of the air
conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
However, if the air conditioner unit does not operate at all, check to see whether power is being supplied
to the air conditioner control panel normally.
If any part of the air conditioner unit is operating, it will indicate that power is being supplied normally to
the air conditioner control panel.
3. After narrowing down to the section, check the component parts in that section and repair the failure.

Basic check and troubleshooting sequence

80-16 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Procedure for check and troubleshooting

*1 Error display on air conditioner control panel

A) Flashing of set-temperature display LED
B) Flashing of Recirc/Fresh air LED
C) Flashing of air conditioner logo (A/C)
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the checking.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.

S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant

*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."

*4: Start the engine and perform the check with the air conditioner switch set to ON.

GD555-5,GD655-5,GD675-5 80-17
(01)
Air conditioner
Circuit diagram and layout of connector pins

Circuit diagram and layout of connector pins 80-18

80-18 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Circuit diagram and layout of connector pins

GD555-5,GD655-5,GD675-5 80-19
(01)
Air conditioner
System diagram

System diagram 80-20

a This air conditioner has manual temperature control only. (It is not an automatic air conditioner)

80-20 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
System diagram

Input/output signals of control panel 80-21 Operation of control panel 80-21

AC5 Control panel connector: 1. The control panel controls the air conditioner
JAE IL-AG5-22P based on switch input.
Harness connector: JAE IL-AG5-22S-D3C1 2. The control panel adjusts the temperature (AIR
Pin Input/out MIX) by controlling the air mix actuator (A/MA).
Symbol Signal name
No. put
FRESH/RECIRC air
3. The control panel changes over the recirculated
1 R/F limit changeover damper Input air and fresh air by controlling the
actuator limiter FRESH/RECIRC air changeover actuator
Air mix damper (R/FA).
2 Am limit Input
actuator limiter 4. The control panel turns the fan to blow air by
3–5 NC – turning on the blower off relay and driving the
Evaporator temperature blower motor.
6 EVA2 Input
sensor 2 5. The control panel controls the air flow using the
7–11 NC –
blower amp.
FRESH/RECIRC air
a The blower amp contains an over-current
12 R/F out1 changeover damper Output
prevention fuse.
actuator output 1
FRESH/RECIRC air 6. The control panel senses the evaporator
13 R/F out2 changeover damper Output temperature with the evaporator temperature
actuator output 2 sensor.
14 NC – 7. The control panel turns the compressor relay
Air mix damper ON/OFF to control the compressor so that the
15 Am out2 Output
actuator output 2 evaporator does not freeze.
Air mix damper a If the dual pressure switch detects abnormal
16 Am out1 Output
actuator output 1
pressure, it is turned OFF, then the compres-
17 NC –
sor relay is turned OFF and the compressor
18 COMP RL Compressor relay Output
stops.
19 BL OFF RL blower off relay Output
8. The control panel performs self-diagnosis on the
20 NC – air mix actuator, the FRESH/RECIRC air
21 Pot GND Potentiometer ground Input changeover actuator, and the evaporator
Air mix temperature sensor, and if a failure is found, it
22 Am pot Input
potentiometer voltage
provides notification (using flashing lights). (See
AC6 Control panel connector: "Checkng with self-diagnosis function".)
JAE IL-AG5-14P
Harness connector:
JAE IL-AG5-14S-D3C1-A
Pin Input/out
Symbol Signal name
No. put
Air mix
1 Pot 5 V potentiometer 5 V power Output
supply
2 Blow F/B Blower amp feedback Input
3 Blow gate Blower amp gate Output
4–7 NC –
Evaporator temperature
7 EVA1 Input
sensor 1
9 NC –
10 NC –
11 NC –
12 GND GND Input
13 DC24 V 24 V power supply Input
14 NC –
q R/F: Recirculation/Fresh
q Am: Air mix
q F/B: Feedback
q NC: No connection

GD555-5,GD655-5,GD675-5 80-21
(01)
Air conditioner
Detail of air conditioner unit

Detail of air conditioner unit 80-2

80-22 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Detail of air conditioner unit

1. Air mix damper (or door) AC1: Power-supply compressor connector

2. FRESH/RECIRC air changeover damper (or AC3, AC4: Control panel intermediate connector
door) [3]: Evaporator temperature sensor connector
3. Recirculation air filter [4]: Temperature adjustment (air mix) servomotor
4. Expansion valve connector
5. Air mix actuator [5]: Compressor relay connector
6. FRESH/RECIRC air changeover actuator [6]: FRESH/RECIRC air changeover servomotor
7. Compressor relay connector
8. blower off relay [8]: blower off relay connector
9. Blower amp [12]: Blower amp connector
A: Recirculation air port a See "Parts and connectors layout" regarding [7]
B: Fresh air port and [11].

q Evaporator temperature sensor mounting

position

TS: Evaporator temperature sensor

H: Holder
X: Tip of evaporator temperature sensor is in the 10th row.

GD555-5,GD655-5,GD675-5 80-23
(01)
Air conditioner
Parts and connectors layout

Parts and connectors layout 80-24

a There are three fuses in the fuse box. a The condition with the cover removed is
a The air conditioner unit is located below the op- shown.
erator's seat. q BL OFF RL: blower off relay
1. Remove cover (1). q COMP RL: Compressor relay
a Right figure shows the condition with cover q A/MA: Air mix actuator
(1) removed. q BL AMP: Blower amp
q No. 1, 20A in fuse box FB2: q PRSW: Dual pressure switch
For blower motor power q [3]: Evaporator temperature sensor con-
q No. 8, 5A in fuse box FB2: nector
For air conditioner compressor power q [5]: Compressor relay connector
q No. 11, 5A in fuse box FB2: q [6]: Air mix servomotor connector
For primary power for air conditioner control q [7]: Dual pressure switch connector
panel and relays q [8]: blower off relay connector
q Fuse Part No. q [12]: Blower amp connector
20A: 08041-02000
5A: 08041-00500

3. Remove covers (3) and (4).

2. Remove cover (2).

80-24 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Parts and connectors layout

a The condition with the cover removed is 6. Remove cover (5).

shown. 7. Pull the air conditioner control panel (6) and
q AC1: Air conditioner unit connector for 24 V disconnect the connectors.
power and compressor
q AC3, AC4: Connector for air conditioner unit
and control panel

a The condition with air conditioner control

panel disconnected is shown.
q AC5, AC6: Air conditioner control panel
4. Remove the seat. connectors
q R/FA: FRESH/RECIRC air changeover actu-
ator
[6]: Connector for FRESH/RECIRC air change-
over actuator

5. Remove the recirculated air filter.

a The condition with the recirculated air filter
removed
[11]: Blower motor connector

GD555-5,GD655-5,GD675-5 80-25
(01)
Air conditioner
Testing air leakage (ducts)

Testing air leakage (ducts) 80-26

1. Remove seat (1). 5. Remove bar (10) at the left and right.
2. Remove floor mat (2). 6. Remove rear cover (11).
3. Remove covers (3) and (4).

7. Check the following ducts for disconnection.

4. Check the following ducts for disconnection. 1) Rear duct (12)
1) Face ducts (5), (6) 2) Outside air duct (13)
2) Foot duct (7)
3) Defroster duct (8)

3) Defroster duct (14)

4) Foot duct (9)

80-26 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Check with self-diagnosis (control panel display)

Check with self-diagnosis (control panel display) 80-27

Outline 80-27 Stop of output to the FRESH/RECIRC air

When the following three self-diagnoses are per-
formed, problems are identified and notified through
flashing of the LEDs or the pilot lamps on air condi-
tioner control panel (1).
a Even if the cause of the detected problem is re-
moved to normal, the self-diagnosis failure con-
dition will not automatically be reset. To reset the
failure condition (to stop LED flashing), the start-
er switch must be set to OFF position.
1. Failure in potentiometer circuit for air mix actu-
ator controlling temperature (i.e., open circuit or
short circuit) or failure of actuator not to reach
target opening position (i.e., the potentiometer
input voltage is low or damper lock is detected
based on the absence of limiter input)
q Flashing of set-temperature display LED
(i.e., flashing of one of the LEDs (2))
a Control panel action:
Stop of output to the air mix actuator
a Symptom: Temperature control switch (4)
does not work.
a Even in the situation where the link is discon-
nected and the damper does not rotate, the
self-diagnosis will identify the condition as
being normal if the air mix actuator rotates
correctly.
a See "Checking temperature control"
changeover actuator
a Symptom: FRESH/RECIRC selector switch
(5) does not work.
a Even in the situation where the lever is dis-
connected and the damper does not rotate,
the self-diagnosis will identify the condition
as being normal if the FRESH/RECIRC air
changeover actuator rotates correctly.
a See "Checking FRESH/RECIRC air change-
over"
3. Failure in input circuit for evaporator tempera-
ture sensor (i.e., open circuit or short circuit)
q Flashing of A/C logo (3)
a Symptom: The air conditioner does not work.
a See "Electrical testing of evaporator sensor".
a Control panel reset:
Turn the starting switch to OFF position.

2. Failure of the FRESH/RECIRC air changeover

damper not to reach the target opening position
(i.e., damper lock is detected based on the
absence of limiter input)
q Flashing of fresh air LED (6)
a Control panel action:

GD555-5,GD655-5,GD675-5 80-27
(01)
Air conditioner
Testing temperature control

Testing temperature control 80-28

Outline 80-28 4. Start the engine and turn the air conditioner ON.
The angle of the door (or damper) in the air condi- Set the temperature to the maximum HOT MAX
tioner unit is adjusted by the air mix actuator so that and minimum COOL MAX on the control panel
the temperature can be controlled by changing the and check visually that levers (L1), (L2) move
mixing ratio of hot air from the heater and cold air smoothly between C1 and H1, and between C2
from the evaporator. The levers and the bar can be and H2, respectively, as shown in the figures.
seen from the outside.
a The starter switch must be turned off in order to
deactivate the self-diagnosis function (to stop
LED flashing). (When the LED is flashing, noth-
ing is output to the air mix actuator due to the de-
tection of a failure by self-diagnosis.)

1. Remove cover (1).

2. Check levers (L1) and (L2), and bar (2) for

disconnection.
3. Check contact of connector [4] of the air mix
actuator. (Check whether the connector is
partially disconnected.)

a In the case of electrical failure, see "Trouble-

shooting for temperature control".

80-28 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Testing Fresh/Recirc air changeover

Testing Fresh/Recirc air changeover 80-29

Outline 80-29
The FRESH/RECIRC air changeover actuator
changes the angle of the FRESH/RECIRC air
changeover door (damper) through the lever and
bar to change over the recirculated air and fresh air.
Visually check the operation of the lever.
a Self-diagnosis diagnoses only motor locking.
(It does not check for open circuit and short
circuit.)
a The starter switch must be turned off in order to
deactivate the self-diagnosis function (to stop
LED flashing). (When the LED is flashing, noth-
ing is output to the FRESH/RECIRC air change-
over actuator due to the detection of a failure by a In the case of electrical trouble, see "Trouble-
self-diagnosis.) shooting for FRESH/RECIRC air change-
over".
1. Remove the seat.
2. Check the condition of contact at connector [6]
for FRESH/RECIRC air changeover actuator (1).
3. Check levers (L1) and (L2), and bar (2) for
disconnection.

4. Start the engine and turn the air conditioner ON.

5. Press the FRESH/RECIRC selector switch on
the control panel and visually check whether
levers (L1) and (L2) move between FRESH and
RECIRC as shown in the figures.
F1, F2: FRESH positions
R1, F2: RECIRC positions
B: Fresh air inlet

GD555-5,GD655-5,GD675-5 80-29
(01)
Air conditioner
Testing evaporator temperature sensor

Testing evaporator temperature sensor 80-30

q If a failure is identified, remove the air condi-
q Perform inspection if an error is shown by self-di- tioner unit (see "Removing the air conditioner
agnosis. unit") and replace the evaporator tempera-
q To reset the self-diagnosis system (detection of ture sensor. See the figure of the disassem-
failure), the starting switch must be turned OFF. bly in "Air conditioner unit".
a Precautions for the replacement of the evap-
1. Remove cover (1). orator temperature sensor
See "Detail of air conditioner unit" for more
information regarding the mounting position
of the evaporator temperature sensor.
a If an error is notified by self-diagnosis and the
evaporator temperature sensor is operating
properly, it indicates that either the control
panel or the wiring harness is defective.

5. Turn off the starter switch and disconnect

connectors AC5 and AC6 (see "Circuit diagram"
and "Connectors layout") from the control panel.
Between (6) (R/8) of connector AC5 and (8)
(Lg/R) of connector AC6:
Standard value: 7.2 kz (at 0°C)
2.2 kz (at 25°C)
2. Check the condition of contact of connector [3].
a If step 5 indicates a normal condition, the
(Check whether the connector is partially discon-
control panel is defective. If it indicates an ab-
nected.)
normal condition, the wiring harness is defec-
3. Turn the starting switch to OFF position and tive.
disconnect connector [3].
4. Measure the resistance between the terminals of
connector [3] (on the evaporator temperature
sensor side).
Standard value: 7.2 kz(at 0°C)
2.2 kz(at 25°C)

80-30 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Testing relays

Testing relays 80-31

a If the air conditioner compressor is normal and
air is being discharged, this test can be omitted.
a Listen closely to the relay to check the operation
sound.
There are two relays.
q blower off relay: Used to turn the fan motor
ON/OFF.
q Compressor relay: Used to turn the air condition-
er compressor (clutch) ON/OFF.
1. Remove cover (1).
4. If you suspect that one of the relays is defective,
proceed as follows to investigate.
1) Turn the main air conditioner power off
temporarily and disconnect the ground cable
from the battery.
2) Remove the relays' mounting screws and
replace the blower off relay and compressor
relay.
3) Connect the ground cable to the battery,
repeat steps 2 and 3 above, and check
whether the symptom is reversed.
q COMP RL: Compressor relay
q BL OFF RL: blower off relay
[5]: Compressor relay connector
[8]: blower off relay connector

2. Turn the starting switch ON (do not start the

engine) and turn the main power of the air condi-
tioner ON. If the blower off relay is normal, it is
turned ON. Check its click.
3. If the air conditioner switch is turned ON at this q Checking relay unit
time, the compressor relay is turned ON if the 1) The coil resistance between the terminals (1)
switch is normal. Check its click. and (2) is approximately 320 z.
a The control panel will not turn on the com- 2) While no voltage (20 to 30 V DC, normally) is
pressor relay in the following cases. present between the terminals (1) and (2),
1) When the evaporator temperature is 5°C or terminals (3) and (4) are disconnected.
below (depending on the input voltage from 3) While voltage (20 to 30 V DC) is present
the evaporator temperature sensor). between the terminals (1) and (2), terminals
2) When the dual pressure switch detects a (3) and (4) are connected
failure (i.e., it is OFF).
a If the fan sound is so large that you cannot
hear the operation sound of the compressor
relay, proceed as follows.
1) Turn the main air conditioner power off
temporarily and disconnect the ground cable
from the battery.
2) Disconnect connector [8].
3) Perform after connecting the ground cable to
the battery.

GD555-5,GD655-5,GD675-5 80-31
(01)
Air conditioner
Testing blower amp

Testing blower amp 80-32

a If air is discharged when the main air conditioner
power is turned on, it will indicate that the fuse is
normal, and therefore, this test can be omitted.
a As internal electronic circuitry cannot be diag-
nosed, replace the blower amp with a new one if
air is discharged but its volume cannot be con-
trolled.
1. Remove cover (1).
q Checking the blower amp unit (fuse and diodes
only)
1) The resistance between the terminals (1) and
(3) is approximately 4.7 kz.
2) Set a multimeter to the diode range.
3) Continuity between terminals (1) (+) and (2)
(-) (sound produced)
4) Continuity between terminals (1) (-) and (2)
(+) (no sound produced)

2. Check the condition of contact of the connector

[12].
3. Turn starting switch to OFF position and discon-
nect connector [12].
q BL AMP: Blower amp

80-32 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting Chart 1

Troubleshooting Chart 1 80-3

The numbers in the T correspond to item numbers in the troubleshooting table.

1. Cooling trouble 80-3

GD555-5,GD655-5,GD675-5 80-33
(01)
Air conditioner
Troubleshooting Chart 1

2. Heating trouble 80-34

80-34 GD555-5,GD655-5,GD675-5
(01)

Troubleshooting Chart 2
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause
Defective blower off relay
Disconnection of wire or defec-
tive connection
Defective blower fan motor
Defective blower amp
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause
Large duct resistance
Air leakage through duct joints
Obstacle on evaporator suctiion
side
Defective evaporator tempera-
ture sensor
Defective expansion valve*
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure problem (high-pressure / low-pressure) during cooling.
Probable cause
Insufficient refrigerant
Overcharged refrigerant
Judgment by pressure at
inlet/outlet of compressor
GD555-5,GD655-5,GD675-5
(01)
Air conditioner
Troubleshooting Chart 2
80-35
Check method Remedy
See "Testing relay" Replace
Check connector of blower fan motor for disconnection. Repair broken parts
See "Detail of air conditioner unit" and "Parts and connectors and connect cor-
layout." rectly
See "Troubleshooting for blower motor system" and "Parts and
Replace
connectors layout".
Activate fan switches in order and check fan speed.
See "Testing the blower amp" and "Troubleshooting for the Replace
blower motor system",
Check method Remedy
Check duct for crushing and clogging and filter for clogging Repair
Check duct joints.
Repair
Check for defective duct seal and disconnection of duct
Remove obstruc-
Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Check sensor fixing clip, and sensor for contamination
Check the air conditioner hose around the pressure switch for Repair or replace
frost.
(when freezing has advanced even further)
Check method Remedy
Repair leaking part,
then charge with
proper quantity of
Check refrigerant volume through sight glass.
refrigerant again
To be accurate, perform checking with the gauge manifold con-
Collect refrigerant,
nected.
then fill up with
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approximately 0.13 to 0.2 MPa {1.3 to 2.0
See Troubleshoot-
kg/cm2}
ing with gauge pres-
High-pressure: Approximately 1.5 to 1.7 MPa {15 to 17 kg/cm2} sure
Cab internal temperature: 30 to 35°C, Engine speed: Approxi-
mately 1,500 rpm
80-35
Air conditioner
Troubleshooting Chart 2

4. During cooling, the compressor does not operate easily or at all.

a See "Troubleshooting for compressor system (Air is not cooled)".
Failed part Probable cause Check method Remedy
Compressor
Loose compressor belt Check for excessive deflection of belt. Adjust tension
belt
Failure in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling com-
Overheating of compressor
Compressor seizure pressor oil".
Low battery voltage Slip of clutch Charge battery
Inspect with multimeter (10 to 20 z)
Open circuit or short circuit in coil Replace
Magnet clutch Check ground wire and connections
Open circuit in wiring or defective
See "Troubleshooting for compressor and Repair
connection of ground cable
refrigerant system".
Relay Defective compressor clutch relay See "Testing relays" Replace
Refrigerant Improper pressure (Operation of See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure pressure switch) with gauge pressure".
Pressure See "Troubleshooting for compressor and
Defective pressure switch Replace
switch refrigerant system".

5. During cooling, the blower fan motor is normal and the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check duct for crushing and clogging, and filter for clogging. Repair
Check duct joints for defective duct seal and disconnection of
Air leakage through duct joints Repair
duct
Clogging of heater core fins Check heater core fins for clogging Clean

6. Improper engine coolant temperature or volume during heating or cooling

Probable cause
Low engine coolant tempera-
ture
Low engine coolant level
Insufficient circulation of engine
coolant
Contrary connection of IN and
OUT heater hoses
Check method Remedy
Warm up engine, and then check engine coolant temperature Find out cause
Check coolant level in radiator Add coolant
Check engine coolant piping for clogging
Bleed air and repair
(Hose, pipe, and core)
Check the destination of heater hoses Repair

7. Improper fan speed abnormalities during cooling

Probable cause Check method Remedy
See “Testing and adjusting” from Chapter 30 of the shop
Fan rotation speed is low manual. "Checking speed of hydraulic drive fans" in "Adjusting" Repair
in "Special functions of machine monitor (EMMS)"

8. Other failures
Probable cause
Temperature cannot be con-
trolled
Recirc/Fresh cannot be
changed over
Excessive compressor oil
Water leakage into cab
Check method Remarks
See "Testing temperature control" and "Troubleshooting for
temperature control" Common to cooling and
See "Testing FRESH/RECIRC air changeover" and "Trouble- heating
shooting for FRESH/RECIRC air changeover"
See "Handling compressor oil".
Cooling only
Clogging of drain hole

80-36 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Information in troubleshooting table

Information in troubleshooting table 80-37

Information in troubleshooting table 80-37
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand the information fully.
Failure Problem on machine
Related information Information related to detected failure or troubleshooting

Cause Procedure, measuring location, criteria and remarks

Details:
q Procedure
q Measuring location
1 a "Between A and B" means the measurement of voltage, resistance or others between ter-
minals A and B.
Assumed causes for
q Standard value required for judgement
trouble
q Remarks requiredfor judgement
(Perform trouble-
shooting in order.)
Precautions for troubleshooting:
2 (1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless other-
wise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus(–) lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple places
a Normal in 1 but abnormal in 2
3 Defective (part) In that occasion the description is made as “Defective (part)” as shown on the left

a If a wiring harness is burnt, replace it.

Failures in wiring harness:
q Open circuit
The connector connection is defective or wiring harness is disconnected.
q Ground fault
A wiring harness not to be connected to the ground circuit is in contact with the ground circuit or chassis.
q Hot short
A wiring harness not to be connected to the power (24 V) circuit is in contact with the power (24 V) circuit.
q Short circuit
An independent wire in the wiring harness is in contact with one of other wires. (Defective insulation in
connector or others)

Related circuit diagram 80-37

This is the excerpted circuit diagram related to the troubleshooting
q Connector numbers and pin numbers are shown.
q See "Circuit diagram and layout of connector pins" and "Parts and connector locations" for connector location.
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], ... are numbers of unlabeled connectors.
q Arrow (io): Roughly indicates their mounting place on the machine.

GD555-5,GD655-5,GD675-5 80-37
(01)
Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)

Troubleshooting for power supply system (Air conditioner does not

operate) 80-38
Failure Air conditioner does not operate due to power supply system failure.
Problem on
q When the control panel is operated, the related LED does not light up.
machine
qAir conditioner ground is housed in the machine wiring harness together with those of electric
equipment installed on the machine and connected to the machine ground.
q For connectors etc., see "Parts and connector locations".
Related informa- q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC4: 799-601-7050
tion a T-adapter is not available for connectors of types other than SWP and M.
q Turn starting switch to ON position and turn air conditioner main switch ON. At this time, if LED
above control panel lights up for a moment and the fuse is blown immediately, see "Trouble-
shooting for compressor and refrigerant system" and "Troubleshooting for blower motor system".

Cause Procedure, measuring location, criteria and remarks

Defective fuses FB2-8,
1 When a fuse is blown, a ground fault likely occurred in the circuit.
FB2-11
Defective wiring harness
2
(ground)
3 Defective wiring harness
Open circuit in wiring har-
4 ness
(on control panel side)
5 Defective control panel
1. Turn starting switch to OFF position.
2. Disconnect connector AC6 from control panel.
3. Insert T-adapter into connector AC1.
Between AC1(4) and chassis ground Resistance Max. 1 z
a If the fuse has blown, replace it first.
1. Turn starting switch to OFF position.
2. Disconnect connector AC6 from control panel.
3. Insert T-adapter into connector AC1.
4. Turn starting switch to ON position.
Between AC1(10) and (4) Voltage 20 to 30 V A
a Perform the following when the test result "A" above is abnormal
a If the fuse has blown, replace it first.
1. Turn starting switch to OFF position.
2. Disconnect connector AC1 and connect T-adapter to female side.
3. Turn starting switch to ON position.
a If the fuse is blown again or the test result "B" or "C" below is abnormal, wiring
harness on machine body side is defective.
Between AC1(10) and (4) Voltage 20 to 30 V B
Between AC1(1) and (4) Voltage 20 to 30 V C
a Perform the following when the fuse is blown during test "A" above and the test
results "B" and "C" above are normal.
a If the fuse has blown, replace it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC5, AC6 from control panel.
3. Insert T-adapter into connector AC1.
4. Disconnect connectors [7], [8], [12]
5. Turn starting switch to ON position.
Between AC1(10) and (4) Voltage 20 to 30 V D
a If the test result "D" above is abnormal, air conditioner wiring harness is defective.
a If the fuse is blown during test "D" above, disconnect male side of connectors
AC3, AC4 and perform test again to see on which side wiring harness is defec-
tive, control panel side or air conditioner unit side.
a If the test result "A" is abnormal and test result "D" is normal, see "Troubleshoot-
ing for compressor and refrigerant system" and "Troubleshooting for blower mo-
tor system".
a If the fuse is not blown, check with circuit diagram.
If cause is not found by above checks, control panel may be defective.

80-38 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)

Electrical circuit diagram for main power system 80-39

GD555-5,GD655-5,GD675-5 80-39
(01)
Air conditioner
Troubleshooting of compressor and refrigerant system (Air is not cooled)

Troubleshooting of compressor and refrigerant system (Air is not

cooled) 80-40
Failure Air is not cooled due to compressor or refrigerant system failure.
Problem on qWhen engine is started and A/C switch is pressed, air is not cooled.
machine qAir conditioner compressor does not operate.
q If refrigerant pressure is abnormal, air is not cooled because the compressor is not turned ON.
a An abnormal refrigerant pressure indicates that the dual pressure switch is turned off.
q When temperature is 5°C or lower, control panel does not turn compressor relay ON in order to
prevent evaporator from freezing (normal condition).
Related infor-
q For connectors and other parts, see "Parts and connectors layout".
mation
q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC3: 799-601-7070,
T-adapter for connector AC4: 799-601-7050
a T-adapter is not available for connectors other than the above and for DT type connectors. Accord-
ingly, perform troubleshooting by using connectors for which T-adapter is available.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuses FB2-8, FB2-11 When a fuse is blown, a ground fault likely occurred in the circuit.
1. Turn starting switch to OFF position.
2. Disconnect connector ET88 from air conditioner compressor and connect
2 Defective compressor T-adapter to male side.

Between ET88(1) and (2) (air conditioner com- Resis-

Open circuit in wiring harness
3
(on machine side)
Ground fault in wiring harness
4 (Contact with ground circuit)
(on machine side)
Defective compressor relay
5
(Does not turn ON)
Defective evaporator temperature
6 Check while referring to "Testing the evaporator temperature sensor"
sensor
Approx. 15 z
pressor coil resistance) tance
1. Turn starting switch to OFF position.
2. Disconnect connector AC1 and connect T-adapter to female side.
Between AC1 (female) (8) and ground Resis-
Approx. 15 z
(air conditioner compressor coil resistance) tance
a If the fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector ET88.
3. Insert T-adapter into connector AC1.
Resis-
Between AC1 (female) (8) and ground Min. 1 Mz
tance
Resis-
Between AC1 (female) (8) and (4) Min. 1 Mz
tance
q Referring to "Testing relays", check sound Click is
A
made when compressor relay is turned ON. heard.
a If the test result "A" above is normal, this check is not required.
a Check in advance that air is being blown out.
1. Turn starting switch to OFF position.
2. Replace the compressor relay with the blower off relay.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
If compressor operates (air is cooled), original compressor relay is defective.

80-40 GD555-5,GD655-5,GD675-5
(01)

Cause
7 Defective dual pressure switch
Voltage check
8 (Defective wiring harness or defec- 3. Turn starting switch to ON position.
tive control panel)
9 Short circuit in wiring harness
10 Open circuit in wiring harness
11 Defective control panel
GD555-5,GD655-5,GD675-5
(01)
Air conditioner
Troubleshooting of compressor and refrigerant system (Air is not cooled)
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors AC3 and AC4, and connect T-adapter to female
side.
a The dual pressure switch may be turned OFF normally. If the following is
abnormal (switch is turned OFF), install pressure gauge to low-pressure
side of air conditioner compressor and check refrigerant pressure. (See
"Troubleshooting with gauge pressure".)
Between AC3(9) and AC4(6) Resis-
Approx. 320 z
(compressor relay coil resistance) tance
k If the dual pressure switch is to be replaced, refrigerant must be col-
lected in advance.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connectors AC3 and AC4.
4. Turn air conditioner switch ON.
Between AC3(9) and AC4(5) Voltage Max. 1 V
a If no failure is found by check on cause 7, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC1, AC5, AC6, [5], [8] and [12]
3. Insert T-adapter into connectors AC3 and AC4.
a Check with circuit tester in continuity mode.
Between AC3 (9) and each pin other than (9) No continuity
Between AC4 (6) and each pin other than (6) No continuity
a Check with circuit diagram.
If check result for cause 8 is abnormal and check results for causes 9 and 10
are normal, control panel is defective.
80-41
Air conditioner
Troubleshooting of compressor and refrigerant system (Air is not cooled)

Electrical circuit diagram for compressor and refrigerant system 80-42

80-42 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting of compressor and refrigerant system (Air is not cooled)

GD555-5,GD655-5,GD675-5 80-43
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is improper)

Troubleshooting for blower motor system (Air does not come out or air
flow is improper) 80-4
Failure Air does not come out or air flow is improper because of failure in blower motor system.
Problem on
q Air does not come out or air flow is abnormal because of failure in blower motor system.
machine
q If, regardless of air flow setting, the actual air flow does not change, replace the blower amp.
q If air flow decreases (air does not come out) after a while in cooling mode, the evaporator may have
frozen. The probable causes for this failure are as follows.
1) Compressor relay is defective (stays on). (See "Troubleshooting for compressor and refrigerant
system", 5-A).
Related infor- 2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
mation conditioner unit.)
3) Expansion valve is defective (collect the refrigerant and replace the expansion valve)
q For connectors, relays, etc., see "Parts and connectors layout".
q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC3: 799-601-7070, T-adapter
for connector AC4: 799-601-7050
a T-adapter is not available for connectors of types other than the above and M.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuses FB2-8, FB2-11
2 Defective blower (fan) motor
Defective blower OFF relay
3
(Does not turn ON)
4 Defective blower amp
Voltage check
5 (Defective wiring harness or
defective control panel)
6 Short circuit in wiring harness
7 Open circuit in wiring harness
8 Defective control panel
When a fuse is blown, a ground fault likely occurred in the circuit.
1. Turn starting switch to OFF position.
2. Disconnect connector [12].
Between [12] (male) (1) and (2) Continuity
q Referring to test of relay, check turn-on sound of Click is
A
blower off relay heard.
a If the test result "A" above is normal, this check is not required.
1. Turn starting switch to OFF position.
2. Replace the blower off relay with the compressor relay.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
If air comes out, original blower off relay is defective.
Referring to "Testing the blower amp", check the blower amp.
q Output to primary side of relay from control panel
1. Turn starting switch to OFF position.
2. Insert T-adapter into connectors AC3 and AC4.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
Between AC3(10) and AC4(5) Voltage Max. 1 V
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, R1 to R4, and [5].
3. Insert T-adapter into connector AC3.
a Check with circuit tester in continuity mode.
Between AC3 (10) and each pin other than (10) No continuity
a Check with circuit diagram.
If check result for cause 3 is abnormal and check results for causes 4 to 7 are
normal, control panel is defective.

80-44 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is improper)

Electrical circuit diagram for blower motor system 80-45

GD555-5,GD655-5,GD675-5 80-45
(01)
Air conditioner
Troubleshooting for temperature control

Troubleshooting for temperature control 80-46

Failure q Temperature cannot be controlled
Problem on
q When temperature control switch is operated, temperature does not change.
machine
qTemperature control refers to the action of mixing warm air and cold air in the right proportion by
changing the angle of a damper (or door).
q When a failure has been detected by self-diagnosis function and the main power switch on the
control panel is turned on, the temperature setting LED on the panel will flash.
q Each time the main power switch on the control panel is turned on, self-diagnosis checks the air
mix actuator for open circuits and short circuits, and it also checks the contacts (or LIMIT termi-
nals) in the air mix actuator.
q Even when the link has been disconnected (see "Testing temperature control (air mix)"), self-di-
Related informa- agnosis will determine that the condition is normal if the air mix actuator rotates in response to
tion operation of the switch.
q Referring to "Testing temperature control", check connector [4] for defective contact and me-
chanical failure (disconnection of link, interference of lever, etc.).
q The link must be removed in order to replace the air mix actuator. (See "Air conditioner unit" or
parts book.)
q For each connector and other parts, see "Parts and connectors layout".
q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC3: 799-601-7070,
T-adapter for connector AC4: 799-601-7050
a T-adapter is not available for other connectors.

Cause Procedure, measuring location, criteria and remarks

1 Defective air mix actuator
As there is no T-adapter for the connector [4], use the connectors AC3 and AC4 for
check.
1. Turn starting switch to OFF position.
2. Disconnect connector AC3 and AC4 and connect a T-adapter to the male side (air
conditioner unit side).
Approx. 110 z
Resis-
Between connector AC3 (male) (2) and (6) (motor coil resis-
tance
tance)
Resis-
Between connector AC3 (male) (13) and AC4 (1) Approx. 4 kz
tance
Resis- Approx. 500 z to
Between connector AC3 (male) (13) and (14)
tance 3.5 kz
a Check of contact for input cannot be performed on assembled unit (see related
information).
a If no LED flashing results from self-diagnosis, output to the actuator is not
stopped. Then, the check can be made.
a If air mix actuator does not operate (the test result "C" below is abnormal) while
the test results "A" and "B" below are normal, air mix actuator is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connectors AC3 and AC4.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
Between AC4(1) and AC3(13) Voltage 5V A
1. Turn starting switch to OFF position.
2. Insert T-adapter into connectors AC3 and AC4.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
5. Press left triangle temperature control switch several times to set temperature to
the lowest in advance.
6. Perform troubleshooting while pressing triangle on the right side of temperature
control switch.
7. Press triangle on the right side of temperature control switch several times to set
temperature to the highest in advance.
8. Perform troubleshooting while pressing triangle on the left side of temperature
control switch.

80-46 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting for temperature control

Cause Procedure, measuring location, criteria and remarks

1 Defective air mix actuator
Open circuit in wiring har-
2
ness
Short circuit in wiring har-
3
ness
Open circuit in wiring har-
4 ness
(on control panel side)
5 Defective control panel
Between AC3(6) and (7)
a Voltage appears for only approximately 1 sec-
ond (only while door is moving) and polarity is
reversed when right triangle and left triangle on Voltage ± 24 V B
temperature control switch are pressed. When
right triangle switch (WARM side) is pressed,
polarity of pin 2 becomes positive.
Between AC3(14) and (13) Variable
a Voltage changes only while door is moving. Voltage at 5 V or C
(Voltage settles after the door stops.) lower
a If no failure is found by check on cause 1, this check is not required.
Check with circuit diagram.
a If no failure is found by check on cause 1, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC5, AC6, and [4].
3. Insert T-adapter into connector AC3.
a Check with circuit tester in continuity mode.
Between AC3 (2) and each pin other than (2) No continuity
Between AC3 (6) and each pin other than (6) No continuity
Between AC3 (7) and each pin other than (7) No continuity
Between AC3 (13) and each pin other than (13) No continuity
Between AC3 (14) and each pin other than (14) No continuity
Check with circuit diagram.
If check result for cause 1 is abnormal and check results for causes 2 to 4 are nor-
mal, control panel is defective.

Electrical circuit diagram for temperature adjustment 80-47

GD555-5,GD655-5,GD675-5 80-47
(01)
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Troubleshooting for FRESH/RECIRC air changeover 80-48

Failure qRecirc/Fresh cannot be changed over
q When FRESH/RECIRC air changeover switch on control panel is operated, the air does not switch
Problem on
between fresh and recirculated.
machine
(FRESH/RECIRC air changeover damper (door) does not rotate)
q When a failure is detected by self-diagnosis functionality and the main power switch on the control
panel is turned on, Recirc/Fresh mode LED on the panel will flash.
q Each time the main power switch on the control panel is turned on, self-diagnosis checks the contacts
(or LIMIT terminals) in the FRESH/RECIRC air changeover actuator.
a Self-diagnosis does not check for short circuits and open circuits in the FRESH/RECIRC air change-
over actuator, and therefore, flashing of the LED by self-diagnosis does not necessarily mean that all
the probable actuator failures are checked.
Related infor-
q The resistance (or potentiometer) inside the FRESH/RECIRC air changeover actuator is not used.
mation
q Referring to "Testing FRESH/RECIRC air changeover", operate FRESH/RECIRC air changeover
switch and check FRESH/RECIRC air changeover damper for mechanical failure (disconnection of
link, interference of lever, etc.)
q For connectors and other parts, see "Parts and connectors layout".
q T-adapter for connector AC1: 799-601-7310, T-adapter for connector AC3: 799-601-7070, T-adapter
for connector AC4: 799-601-7050
a T-adapter is not available for other connectors.

Cause Procedure, measuring location, criteria and remarks

As there is no T-adapter for connector [6], check with the connector AC3.
1. Turn starting switch to OFF position.
2. Disconnect connector AC3 and connect a T-adapter to male side (air condi-
tioner unit side).
Between connector AC3 (male) (1) and Approx. 110 z
Resistance
(5) (motor coil resistance)
Between connector AC3 (1) and (4)
Continuity on one side only
a Check the continuity in diode range.
(as one of internal switches
a Check both directions by changing polarity of
is turned off)
probes of multimeter.
a If FRESH/RECIRC air changeover actuator does not operate while following is
Defective FRESH/RECIRC air normal (See Testing FRESH/RECIRC air changeover), FRESH/RECIRC air
1
changeover actuator changeover actuator is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AC3.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
5. Perform troubleshooting while pressing RECIRC air switch and FRESH air
switch.
a Voltage appears only for approx. 3 seconds (only while door is moving to
FRESH or RECIRC position).
Between AC3(4) and (5)
Voltage ±24 V
a Polarity is reversed.
a If no failure is found by check on cause 1, this check is not required.
2 Open circuit in wiring harness
Check with circuit diagram.
a If no failure is found by check on cause 1, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC5, AC6, and [6].
3. Insert T-adapter into connector AC3.
3 Short circuit in wiring harness
a Check with circuit tester in continuity mode.
Between AC3 (1) and each pin other than (1) No continuity
Between AC3 (4) and each pin other than (4) No continuity
Between AC3 (5) and each pin other than (5) No continuity
Open circuit in wiring harness
4 Check with circuit diagram.
(on control panel side)
If check result for cause 1 is abnormal and check results for causes 2 to 4 are nor-
5 Defective control panel
mal, control panel is defective.

80-48 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Electrical circuit diagram for FRESH/RECIRC air changeover 80-49

GD555-5,GD655-5,GD675-5 80-49
(01)
Air conditioner
Troubleshooting with gauge pressure

Troubleshooting with gauge pressure 80-50

Referring to "Connection of service tool", perform <Measurement condition for pressure>
troubleshooting by reading the gauge pressures of Item Value as condition
the high-pressure and low-pressure lines in the re- Ambient temperature 25 to 50°C
frigeration system. Engine speed 1,500 rpm
a The gauge pressure varies largely with the Air conditioner switch ON
Fan switch HI
weather condition and operating condition of the
Set temperature Cool lowest
machine. Check the gauge pressure under the
pressure measurement conditions. q Dual pressure switch
q Excessive high-pressure: Approximately 2.5 a The switch is normally turned "ON" and is turned
MPa {25 kg/cm2} or higher "OFF" when it detects unusual pressure in com-
q Insufficient high-pressure: Approximately 1 MPa
pressor operation.
{10 kg/cm2} or lower
q Excessive low-pressure: Approximately 0.3 MPa

{3 kg/cm2} or higher
q Insufficient low-pressure: Approximately 0.05

MPa {0.5 kg/cm2} or lower

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-pressure line is abnormal.

LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

80-50 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Troubleshooting with gauge pressure

Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any failure (cooling failure), there is another cause.
Pressure is normal -
High-pressure: Approximately 1.5 to 1.7 MPa {15 to 17 kg/cm2}
2
Low-pressure: Approximately 0.13 to 0.2 MPa {1.3 to 2.0 kg/cm }
Collect refrigerant, then
fill up with proper quan-
Insufficient refrigerant Bubbles are seen through sight glass *3
tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosted.
Clean or replace
<Both high pres- Clogging of expansion valve Expansion valve is frosted
*2
sure and low pres-
Gas leakage at heat sensing tube of Replace
sure are too low> Low pressure gauge becomes vacuum
expansion valve *2
Repair or replace
Low pressure gauge
Evaporator is frozen. Replace receiver drier
indicates vacuum Defective evaporator temperature sensor
Air flow is decreased by freezing Collect refrigerant, then
or defective contact of sensor (removal of
(As setting to cool max. and HI speed of fill up with proper quan-
fixing clip)
fan, later it does not get cold.) tity of refrigerant again
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
indicates vacuum
Collect refrigerant, then
fill up with proper quan-
Overfilling of refrigerant Connect gauge manifold.
tity of refrigerant again
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of repair or replace con-
<Both high pres- Failure in cooling by condenser
fins, or defective rotation of cooling fan denser
sure and low pres-
*2
sure are too high>
Improper adjustment of expansion valve Replace
Bubbles are seen through sight glass *3
(Valve is opened too wide) *2
Evacuate and then fill up
with proper quantity of
Air in circuit Bubbles are seen through sight glass *3
refrigerant again
*2
<High pressure is
Clogged or crushed piping between com- There is a remarkable temperature differ- Clean piping or replace
too high and low
pressor and condenser ence around clogged part *2
pressure is too low>
Both high pressure and low pressure has
<High pressure is
little difference while compressor is in oper-
too low and low Defective compressor (Compression fail- Replace
ation.
pressure is too ure of compressor) *2
Compressor has seized and is extremely
high>
hot.
*1 If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2
k When replacing a cooling device parts, see "Caution about refrigerant" and collect refrigerant. Af-
ter replacing it, fill up the air conditioner system with refrigerant again.
*3 Sight glass is on the receiver drier .

GD555-5,GD655-5,GD675-5 80-51
(01)
Air conditioner
Connection of service tool

Connection of service tool 80-52

Connect the gauge manifold, hoses and other ser-
vice tools according to the following procedure.
Symbol Part No. Part name 1. Close the high-pressure valve (6) and low-pres-
sure valve (7) of gauge manifold (1).
X 799-703-1200 Service tool kit
2. Connect red charging hose (2) to the (HI) side
a Use the service tool kit for R134a. and blue charging hose (3) to the (LO) side of the
gauge manifold.
Service tool kit X 80-52
(1): Gauge manifold
3. Connect quick couplers (4) and (5) to each hose.
(2): Red high-pressure charging hose
(3): Blue low-pressure charging hose
4. Connect the quick couplers (4) and (5) to the
(4): Large quick coupler for HI side
service valves (8) and (9) of the high and
(5): Small quick coupler for LO side
low-pressure pipings.
(a): As the thread is coarse, care should be taken
with regard to loosening.

80-52 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Connection of service tool

GD555-5,GD655-5,GD675-5 80-53
(01)
Air conditioner
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting and connecting air conditioner piping
Precautions for disconnecting
k Collect the air conditioner refrigerant (R134a)
from the air conditioner circuit before dis-
connecting the air conditioner hoses to re-
place the air conditioner unit, air conditioner
compressor, or receiver drier and so on.
a Ask a gualified person for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles, gloves
and working suits with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be performed by a qualified person.
q When loosening the air conditioner hose nuts af-
ter collecting the refrigerant, be sure to use two
wrenches; use one wrench to fix and use the oth-
er one to loosen the nuts.
80-54
80-54
80-54 Precautions for connecting 80-54
q When connecting the piping, apply compressor
oil (SP-10) for R134a to the O-rings. (See item 4.
in "Handling of compressor oil".)
Do not apply oil to the threads of a bolt, nut or
union, however.
q Once an O-ring is used, it is deformed and dete-
riorated. Accordingly, do not reuse it. When re-
moving it, use a soft tool (such as a toothpick) so
that the piping will not be damaged.
q Push in each pipe to the stopper and tighten the
bolt or nut fully with your fingers.
q Be sure to use two wrenches to tighten each nut.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Precautions for disconnecting and connecting air conditioner piping

Table of tightening torques for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 to 12 {0.8 to 1.2}
M8 x 1.25 20 to 25 {2.0 to 2.6}
M8 Unit 9.8 to 12 {1.0 to 1.2}
M16 x 1.5 12 v 15 {1.2 to 1.5}
M22 x 1.5 20 to 25 {2.0 to 2.6}
M24 x 1.5 30 to 35 {3.1 to 3.6}

1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit

GD555-5,GD655-5,GD675-5 80-55
(01)
Air conditioner
Handling compressor oil

Handling compressor oil 80-56

1. Compressor oil management (Sanden: SP-10 2. Filling of compressor oil 80-56
for R134a) 80-56
k As refrigerant is dangerous and bad for the
Compressor oil does not need to be checked or add- environment, collect it before disconnecting
ed as frequently as engine oil. Insufficient or exces- the air conditioner hoses. See "Precautions
sive quantity of compressor oil can cause the for disconnecting and connecting air condi-
following problems. tioner piping".
Condition Description a If oil for CFC-12 (R-12) is used, lubrication prob-
Insufficient oil
Lubrication problem and seizure of lem will occur and the compressor may be bro-
compressor ken or seized.
Cooling problem Be sure to always use an oil suitable for R134a
Excessive of oil (Excessive oil sticks to parts and lowers (SP-10 from Sanden).
heat exchange performance)
a Oil for use with R134a is extremely hygroscopic,
and therefore, the cap must be immediately put
Accordingly, the compressor oil must be filled to the on after use to limit contact with air.
specified level, similarly to the refrigerant. Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow the oil for use with R134a to contact
with acrylic plastic or polystyrene surfaces
(except for baked painting) as it may dissolve
these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is failed and replaced.
q When a system part such as the air conditioner
unit, condenser, receiver drier, evaporator unit,
etc. is replaced.

q Quantity of oil to be added when the system part

is replaced
Quantity to be
Air conditioner part
added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (Compressor to Cab) Approx. 25
Hose (Compressor to Condenser) Approx. 10
Hose (cab to receiver drier) Approx. 15

80-56 GD555-5,GD655-5,GD675-5
(01)
 Air conditioner
Handling compressor oil

3. Replacement of compressor 80-57 4. Applying compressor oil to O-rings 80-57

q In case of compressor seizure or breakage. Whenever connecting pipes or hoses, the compres-
Metal chips will circulate through the air condi- sor oil (SP-10) must be applied to O-rings in order to
tioner circuit and contaminate the compressor oil prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (240 cc) filled in it.

q Other cases
a A new compressor has 240 cc compressor oil in
it. So drain excessive compressor oil before in-
stalling the new compressor as follows.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.

3) Drain the oil by the quantity descrited below

from the new compressor.
q Drain volume = 240 cc - Noted volume
Example: If 30 cc was drained from the
removed compressor, the amount to be
drained from the new compressor is 210
cc (i.e., 240 - 30 cc).

GD555-5,GD655-5,GD675-5 80-57
(01)
Air conditioner
Handling compressor oil

80-58 GD555-5,GD655-5,GD675-5
(01)
 DRAFT

GD555-5,GD655-5,GD675-5
SEN0521524-00

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

90 Diagrams and drawings

4

Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
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Symbols used in electric circuit diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
9
Electrical circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
12
Symbols used in hydraulic circuit diagrams- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
3
Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
5
Power train hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
7
Differential hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
8

GD555-5,GD655-5,GD675-5 90-1
 DRAFT

Contents

Contents
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

90-2 GD555-5,GD655-5,GD675-5
(01)
 DRAFT
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams

Hydraulic diagrams and drawings

Symbols used in hydraulic circuit diagrams

Symbol Substance

Main piping line

Pilot or drain line

Flexible pipe (hose, etc.)

Lines intersecting without joining

Lines joining (junction with a round black mark)

Direction of flow

Throttle in passage.

Variable

Electricity

Spring

Take-off port

Take-off port and pressure gauge

Check valves

Suction (with strainer)

Tank and return pipe

Filter

Oil cooler

Stop valve

Drive shaft䋨unidirectional䋩

Drive shaft䋨bidirectional䋩

GD555-5,GD655-5,GD675-5 90-3
 DRAFT
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams

Symbol Substance

Pump
Note : Black triangle shows outlet port䋩

Variable capacity hydraulic pump

Hydraulic motor (The figure shows bidirectional type.)

Note䋺Two black triangles in the figure show direction of oil entering hydraulic motor
㩷㩷㩷㩷㩷㩷㩷㩷㩷depending on the oil entry port, the direction of rotation is reversed.

Servo piston

PPC valve

Control valve

Single-acting solenoid

Hydraulic pilot valve

Hydraulic two-stage pilot valve

Lock valve

Drain valve

Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve

Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve

䋨When the figure shows air pressure, being released to atmosphere.䋩

Bypass valve

Accumulator

Cylinder

Component group

90-4 GD555-5,GD655-5,GD675-5
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-5

Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-6

90-7
(01)
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-9

90-7
(01)
Differential hydraulic circuit diagram Differential hydraulic circuit diagram
GD555, 655, 675-5 GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-11

90-8
(01)
 DRAFT
Electrical diagrams and drawings
Symbols used in electric circuit diagrams

Electrical diagrams and drawings

Symbols used in electric circuit diagrams

Symbol Substance

Electric wire

Electric wire 䋨Wires intersecting without connecting䋩

Electric wire 䋨Wires intersecting and connecting (junction) with a round

black mark 䋩

Electric wire (Bundled drawing style)

Terminal

Chassis ground

Chassis ground using terminal

Contact
Switch

Push-button type switch (N.O. type)

*N.O.: Normally Open

Push-button type switch (N.C. type)

*N.C.: Normally Close

Pull-button type switch (N.O. type)

*N.O.: Normally Open

Pull-button type switch (N.C. type)

*N.C.: Normally Close

Variable

Resistance (resistor)

Variable resistance (variable resistor)

GD555-5,GD655-5,GD675-5 90-13
(01)
 DRAFT
Electrical diagrams and drawings
Symbols used in electric circuit diagrams

Symbol Substance

Diode

Light emitting diode (LED)

Photo diode

Constant voltage diode (Zener diode)

Transistor (PNP type)

Transistor (NPN type)

Coil

Battery

Fuse

Connector
䋨Note䋩
䊶Convex side of connecting portion (right in figure): male
䊶Concave side of connecting portion (left in figure): female
*Figure shows a line disconnection status.

Plug and receptacle type connector (left: male, right: female)

Note: Figure shows a line connection status.

Solenoid

Motor

90-14 GD555-5,GD655-5,GD675-5
(01)
 DRAFT
Electrical diagrams and drawings
Symbols used in electric circuit diagrams

Symbol Substance

Lamp

Pressure switch (N.O. type)

*N.O.: Normally Open

Pressure switch (N.C. type)

*N.C.: Normally Close

Potentiometer

Fuel dial

Temperature sensor

Starting switch

Backup alarm

Horn

Buzzer

Antenna

GD555-5,GD655-5,GD675-5 90-15
(01)
 DRAFT
Electrical diagrams and drawings
Symbols used in electric circuit diagrams

90-16 GD555-5,GD655-5,GD675-5
(01)
Electrical circuit diagram (1/9) Electrical circuit diagram (1/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-17

(01)
Electrical circuit diagram (2/9) Electrical circuit diagram (2/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-19

90-18
(01)
Electrical circuit diagram (3/9) Electrical circuit diagram (3/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-21

90-19
(01)
Electrical circuit diagram (4/9) Electrical circuit diagram (4/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-23

90-20
(01)
Electrical circuit diagram (5/9) Electrical circuit diagram (5/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-25

90-21
(01)
Electrical circuit diagram (6/9) Electrical circuit diagram (6/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-27

90-22
(01)
Electrical circuit diagram (7/9) Electrical circuit diagram (7/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-29

90-23
(01)
Electrical circuit diagram (8/9) Electrical circuit diagram (8/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-31

90-24
(01)
Electrical circuit diagram (9/9) Electrical circuit diagram (9/9)
GD555, 655, 675-5
GD555, 655, 675-5
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.

GD555, 655, 675-5 90-33

90-25
(01)
Electrical circuit diagram (KOMTRAX HARNESS) Electrical circuit diagram
GD555, 655, 675-5
GD555, 655, 675-5
★ Chinese specification

GD555, 655, 675-5 90-35

(03)
 Index

Index
A Disassembly and assembly of engine and transmission/
Accumulator (for blade) 10-172 torque converter assembly 50- 87
Accumulator (for brake) 10-98 Disassembly and assembly of final drive assembly
Adjusting transmission speed sensor 30-56 50- 144
Adjusting valve clearance 30-18 Disassembly and assembly of hydraulic cylinder
Air Conditioner Components 80-4 assembly 50- 221
Air conditioner control panel 80-14 Disassembly and assembly of steering valve (orbit-roll)
Air Conditioner Unit 80-8 assembly 50- 169
Automatic shift control system 10-190 Disassembly and assembly of tandem drive assembly
50- 139
Disassembly and assembly of torque converter assembly
B
50- 89
Blade 10-176,60-58
Disassembly and assembly of transmission assembly
Bleeding air from brake circuit 30-79
50- 97
Bleeding air from fuel circuit 30-29
Disassembly and assembly of wheel brake assembly
Bleeding air from steering circuit 30-72
50- 180
Bleeding air from work equipment circuit 30-97
Brake hydraulic piping diagram 10-88
Brake valve 10-89 E
E-1 Engine does not start (starting motor does not turn)
40-366
C
E-2 Preheating does not work 40-372
Cab 10-184
E-3 When starting switch is turned to ON position,
Check with self-diagnosis (control panel display) 80-27
machine monitor displays nothing 40-377
Checking cylinder head and manifolds for looseness
E-4 When starting switch is turned to ON position,
30-36
machine monitor does not reach standard screen
Checking engine piping for damage and looseness 30-37
40-380
Checking fuel delivery, return rate and leakage 30-38
E-5 When starting switch is turned to ON position, caution
Checking muffler body and muffler stack for looseness
monitor flashes or lights up, or machine monitor does not
and damage 30-34
display correct screen 40-380
Checking muffler function 30-35
E-6 Emergency stop monitor lights up while engine is
Checks before troubleshooting 40-9
running 40-381
Charge valve 10-99
E-7 Speedometer or engine tachometer does not indicate
Circle and drawbar 10-174,60-56
correctly 40-385
Circle rotation gear 10-182,60-62
E-8 Engine coolant temperature gauge does not indicate
Circle rotation motor 10-180
correctly 40-386
Circuit diagram and layout of connector pins 80-18
E-9 Articulation angle indicator does not indicate correctly
Classification and procedures for troubleshooting 40-29
40-388
Clearance adjustment of drawbar ball joint 30-98
E-10 Torque converter oil temperature gauge does not
CLSS 10-146
indicate correctly 40-390
Coating materials list 50- 6
E-11 Fuel level gauge does not indicate correctly 40-392
Compressor 80-11
E-12 Character display does not display correctly 40-394
Condenser 80-12
E-13 Centralized warning lamp does not light up or does
Connector list and layout 40-43
not go off 40-396
Connection of service tool 80-52
E-14 Alarm buzzer does not sound or does not stop
Connection table for connector pin numbers 40-58
sounding 40-398
Control valve 10-136,60-46
E-15 Machine monitor mode selector switch does not
Conversion table 00-43
work 40-400
Cooling fan control function 10-228
E-16 Transmission mode does not switch 40-404
Cooling fan pump 10-6
E-17 Engine mode does not switch 40-406
Cooling fan motor 60-8
E-18 Differential lock function does not work or cannot be
Cooling system 10-4,60-6
reset [for machine with differential lock specification]
Cylinder cut-out test mode 30-31
40-408
E-19 Lift arm lock pin does not lock lift arm or does not
D unlock it [for machine with lift arm specification]
Detail of air conditioner unit 80-22 40-412
Differential hydraulic circuit diagram 90-11 E-20 Blade accumulator function does not work or is not
Differential lock solenoid valve 10-68,60-34 reset [for machine with blade accumulator specification]
Disassembly and assembly of circle rotation gear 40-414
assembly 50- 233 E-21 Horn does not sound or does not stop sounding
Disassembly and assembly of control valve assembly 40-418
50- 218

GD555-5,GD655-5,GD675-5 1
(05)
(03)
Index

E-22 Backup alarm does not sound or does not stop Failure code [15SFMA] ECMV 2nd clutch: Malfunction
sounding 40-420 40-124
E-23 Headlamp, clearance lamp and tail lamp do not light Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON
up or do not go off 40-423 when command signal is OFF 40-126
E-24 Working lamp does not light up or does not go off Failure code [15SGMA] ECMV 3rd clutch: Malfunction
40-430 40-128
E-25 Turn signal lamp and hazard lamp do not flash. Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON
40-436 when command signal is OFF 40-130
E-26 Stop lamp does not light up or does not go off Failure code [15SHMA] ECMV 4th clutch: Malfunction
40-442 40-132
E-27 Backup lamp does not light up or does not go off Failure code [15SJMA] ECMV lockup clutch: Malfunction
40-444 40-134
E-28 Windshield wiper does not operate 40-446 Failure code [15UONT] Inching clutch: Overheating
E-29 Window washer does not operate 40-454 40-134
E-30 KOMTRAX system does not operate correctly Failure code [2G42ZG] Front accumulater: Oil pressure
40-458 drop 40-135
ECMV 10-50 Failure code [2G43ZG] Rear accumulater: Pressure drop
Electrical circuit diagram 90-17 40-135
Emergency escape method in case of transmission valve Failure code [AA1ANX] Air cleaner: Clogging 40-136
failure 30-60 Failure code [AB00L6] Alternator; Engine start and stop
Emergency release method of parking brake 30-84 signals are not matched. 40-138
Engine controller 10-202 Failure code [AB00MA] Alternator: Malfunction 40-140
Engine mount and transmission mount 60-4 Failure code [B@BAZG] Derating in speed due to engine
Engine power mode select circuit 10-226 oil pressure drop 40-142
Explanation of terms for maintenance standard 00-12 Failure code [B@BCNS] Engine coolant overheat 40-142
Failure code [B@CENS] Torque converter oil overheat
F 40-143
Failure and troubleshooting numbers 40-37 Failure code [B@CKNS] Differential case: Overheat
Failure code [1500LO] TORQUEFLOW transmission: 40-144
Double engagement 40-99 Failure code [B@HANS] Hydraulic oil: Overheating
Failure code [15G0MW] Transmission R clutch: Slip 40-146
40-100 Failure code [CA111] Engine controller internal error
Failure code [15H0MW] Transmission FH clutch: Slip 40-148
40-101 Failure code [CA115] Engine Ne, Bkup speed sensor
Failure code [15J0MW] Transmission FL clutch: Slip error 40-149
40-101 Failure code [CA122] Charge pressure sensor high error
Failure code [15K0MW] Transmission 1st clutch: Slip 40-150
40-102 Failure code [CA123] Charge pressure sensor low error
Failure code [15L0MW] Transmission 2nd clutch: Slip 40-152
40-103 Failure code [CA131] Throttle sensor high error 40-154
Failure code [15M0MW] Transmission 3rd speed clutch: Failure code [CA132] Throttle sensor low error 40-156
Slip 40-104 Failure code [CA144] Coolant sensor high error 40-158
Failure code [15N0MW] Transmission 4th clutch: Slip Failure code [CA145] Coolant sensor low error 40-160
40-105 Failure code [CA153] Charge temperature sensor high
Failure code [15SBL1] ECMV R clutch: Fill signal is ON error 40-162
when command signal is OFF 40-106 Failure code [CA154] Charge temperature sensor low
Failure code [15SBMA] ECMV R clutch: Malfunction error 40-164
40-108 Failure code [CA155] Speed derating error by high charge
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON temperature 40-166
when command signal is OFF 40-110 Failure code [CA187] Sensor power supply 2 low error
Failure code [15SCMA] ECMV FH clutch: Malfunction 40-168
40-112 Failure code [CA221] Atmospheric pressure sensor high
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON error 40-170
when command signal is OFF 40-114 Failure code [CA222] Atmospheric pressure sensor low
Failure code [15SDMA] ECMV FL clutch: Malfunction error 40-172
40-116 Failure code [CA227] Sensor power supply 2 high error
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON 40-174
when command signal is OFF 40-118 Failure code [CA234] Engine overspeed 40-174
Failure code [15SEMA] ECMV 1st clutch: Malfunction Failure code [CA238] Ne speed sensor power supply
40-120 error 40-175
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON Failure code [CA271] IMV/IMA: Short circuit 40-176
when command signal is OFF 40-122 Failure code [CA272] IMV/IMA open circuit 40-178
Failure code [CA322] Injector #1 (L#1) open/short 40-180

2 GD555-5,GD655-5,GD675-5
(02)
 Index

Failure code [CA323] Injector #5 (L#5) open/short 40-182 Failure code [D19KKZ] Differential lock relay: Open
Failure code [CA324] Injector #3 (L#3) open/short 40-184 circuit, ground fault 40-242
Failure code [CA325] Injector #6 (L#6) open/short 40-186 Failure code [D5ZHL6] C terminal signal: Signal does not
Failure code [CA331] Injector #2 (L#2) open/short 40-188 match to actual engine state 40-244
Failure code [CA332] Injector #4 (L#4) open/short 40-190 Failure code [DAFRKR] CAN communication failure
Failure code [CA342] Data compatibility error in engine (monitor panel) 40-246
controller 40-192 Failure code [DAQ0KK] Transmission controller: Power
Failure code [CA351] Injector drive circuit error 40-193 supply voltage low error (input) 40-248
Failure code [CA352] Sensor power supply 1 low error Failure code [DAQOKT] Transmission controller:
40-194 Non-volatile memory error 40-250
Failure code [CA386] Sensor power supply 1 high error Failure code [DAQ2KK] Transmission controller load
40-195 power line: Power supply voltage drop (input) 40-252
Failure code [CA428] Water-in-fuel sensor high error Failure code [DAQ9KQ] Transmission controller model
40-196 selection: Model selection signal disagreement 40-254
Failure code [CA429] Water-in-fuel sensor low error Failure code [DAQRKR] Transmission controller CAN
40-198 communication: Communication error 40-256
Failure code [CA431] Idle validation switch error 40-200 Failure code [DAQRMA] Transmission controller option
Failure code [CA432] Idle validation action error 40-204 setting: Malfunction 40-260
Failure code [CA435] Engine oil pressure switch error Failure code [DB2RKR] Engine controller CAN
40-207 communication: Communication error 40-261
Failure code [CA441] Power supply voltage low error Failure code [DD1NLD] Fan reverse switch signal: Short
40-208 circuit 40-268
Failure code [CA442] Power supply voltage high error Failure code [DD1PKB] RPM set switch power supply
40-210 short circuit 40-270
Failure code [CA449] Common rail pressure high error Failure code [DD1QKB] RPM set mode switch short circuit
240-211 40-272
Failure code [CA451] Common rail pressure sensor high Failure code [DDB6L4] Transmission gearshift lever:
error 40-212 Parking brake signal error 40-274
Failure code [CA452] Common rail pressure sensor low Failure code [DDTHKA] Fill switch for FH clutch: Open
error 40-214 circuit 40-276
Failure code [CA488] Torque derating error by high Failure code [DDTJKA] Fill switch for FL clutch: Open
charge temperature 40-216 circuit 40-276
Failure code [CA553] Common rail pressure high error Failure code [DDTKKA] Fill switch for 1st clutch: Open
140-217 circuit 40-277
Failure code [CA559] Supply pump pressure low error Failure code [DDTLKA] Fill switch for 2nd clutch: Open
140-218 circuit 40-277
Failure code [CA689] Engine Ne speed sensor error Failure code [DDTMKA] Fill switch for 3rd clutch: Open
40-219 circuit 40-278
Failure code [CA731] Engine Bkup speed sensor phase Failure code [DDTNKA] Fill switch for R clutch: Open
error 40-221 circuit 40-279
Failure code [CA757] All continuous data lost error Failure code [DDTPKA] Fill switch for 4th clutch: Open
40-222 circuit 40-280
Failure code [CA778] Engine Bkup speed sensor error Failure code [DF10KA] Transmission gearshift lever: No
40-223 gear speed signal is input 40-281
Failure code [CA1633] KOMNET (CAN communication) Failure code [DF10L4] Transmission gearshift lever: Gear
error 40-226 speed/travel direction signal error 40-285
Failure code [CA2185] Throttle sensor power supply high Failure code [DGF1KX] Transmission oil temperature
error 40-228 sensor: Input signal out of range 40-288
Failure code [CA2186] Throttle sensor power supply low Failure code [DGH2KB] Hydraulic oil temperature sensor:
error 40-230 Ground fault 40-290
Failure code [CA2249] Supply pump pressure low error Failure code [DGT1KX] Torque converter oil temperature
240-232 sensor: Input signal out of range 40-292
Failure code [CA2311] Abnormality in IMV (IMA) solenoid Failure code [DGT7KB] Differential oil temperature
40-233 sensor: Ground fault 40-294
Failure code [CA2555] Intake heater relay open circuit Failure code [DJF1KA] Fuel level sensor: Open circuit
40-234 40-296
Failure code [CA2556] Intake heater relay short circuit Failure code [DK70KX] Inching pedal angle sensor: Input
40-236 signal out of range 40-298
Failure code [D160KA] Backup lamp relay: Open circuit, Failure code [DKD0KX] Articulation angle sensor: Input
hot short circuit in wiring harness 40-238 signal out of range 40-300
Failure code [D160KB] Backup lamp relay: Ground fault Failure code [DLF1KA] Transmission input shaft speed
40-240 sensor: Open circuit 40-302

GD555-5,GD655-5,GD675-5 3
(02)
Index

Failure code [DLF1LC] Transmission input shaft speed Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short
sensor: Speed signal does not match 40-303 circuit to power supply line 40-354
Failure code [DLF2KA] Transmission intermediate shaft Failure code [DXH7KA] R clutch ECMV solenoid: Open
speed sensor: Open circuit 40-304 circuit 40-356
Failure code [DLF2LC] Transmission intermediate shaft Failure code [DXH7KB] R clutch ECMV solenoid: Short
speed sensor: Speed signal does not match 40-305 circuit 40-357
Failure code [DLM3KA] Fan speed sensor: Open circuit Failure code [DXH7KY] R clutch ECMV solenoid: Short
40-306 circuit to power supply line 40-358
Failure code [DLM3LC] Fan speed sensor: Short circuit Failure code [DXHHKA] 4th clutch ECMV solenoid: Open
40-307 circuit 40-360
Failure code [DLT3KA] Transmission output shaft speed Failure code [DXHHKB] 4th clutch ECMV solenoid: Short
sensor: Open circuit 40-308 circuit 40-362
Failure code [DV00KB] Buzzer: Short circuit 40-310 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short
Failure code [DW4BKA] Parking brake solenoid valve: circuit to power supply line 40-364
Open circuit 40-312 Failure codes table 40-30
Failure code [DW4BKB] Parking brake solenoid valve: Filling gas into blade accumulator [machine with blade
Short circuit 40-314 accumulator] 30-103
Failure code [DW7BKA] Fan reverse solenoid: Open Filling gas into brake accumulator 30-86
circuit 40-315 Final drive (differential/ differential lock specification)
Failure code [DW7BKB] Fan reverse solenoid: Short 10-66,60-32
circuit 40-316 Final drive (no differential specification) 10-64,60-30
Failure code [DW7BKY] Fan reverse solenoid: Short Flushing torque converter and trasmission circuits 30-64
circuit to power supply line 40-318 Frame 10-106
Failure code [DX16KA] Fan motor EPC solenoid: Open Front axle 10-60,60-26
circuit 40-320 Functions and operation by valve 10-150
Failure code [DX16KB] Fan motor EPC solenoid: Short
circuit 40-321 H
Failure code [DX16KY] Fan motor EPC solenoid: Short H-1 Engine speed lowers significantly or engine stalls
circuit to power supply line 40-322 40-466
Failure code [DXH1KA] Lockup ECMV solenoid: Open H-2 Machine does not start 40-467
circuit 40-324 H-3 Gear is not shifted 40-468
Failure code [DXH1KB] Lockup ECMV solenoid: Short H-4 Travel lacks speed or power 40-469
circuit 40-325 H-5 Torque converter lockup does not work or is not
Failure code [DXH1KY] Lockup ECMV solenoid: Short released 40-474
circuit to power supply line 40-326 H-6 A large time lag results at start or in gear shift40-475
Failure code [DXH2KA] FH clutch ECMV solenoid: Open H-7 Oil temperature of torque converter is high 40-480
circuit 40-328 H-8 Differential lock-up function does not work or is not
Failure code [DXH2KB] FH clutch ECMV solenoid: Short released 40-485
circuit 40-329 H-9 Steering lacks speed or power 40-486
Failure code [DXH2KY] FH clutch ECMV solenoid: Short H-10 Steering wheel does not move 40-487
circuit to power supply line 40-330 H-11 Wheel brake does not work at all or sufficiently
Failure code [DXH3KA] FL clutch ECMV solenoid: Open 40-488
circuit 40-332 H-12 Wheel brake cannot be released or drags 40-489
Failure code [DXH3KB] FL clutch ECMV solenoid: Short H-13 Parking brake does not work at all or insufficiently
circuit 40-334 40-490
Failure code [DXH3KY] FL clutch ECMV solenoid: Short H-14 Parking brake (including emergency release
circuit to power supply line 40-336 system) cannot be released or drags 40-491
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open H-15 All work equipment operation lacks speed or power
circuit 40-338 40-492
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short H-16 Work equipment does not work at all 40-493
circuit 40-340 H-17 Unusual noise comes out from around hydraulic
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short pump 40-494
circuit to power supply line 40-342 H-18 Blade lift operation lacks speed or power 40-495
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open H-19 Hydraulic drift of blade lift cylinders is large 40-496
circuit 40-344 H-20 Drawbar side shift operation lacks speed or power
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short 40-497
circuit 40-346 H-21 Blade side shift operation lacks speed or power
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short 40-498
circuit to power supply line 40-348 H-22 Power tilt operation lacks speed or power 40-499
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open H-23 Articulate operation lacks speed or power 40-500
circuit 40-350 H-24 Leaning operation lacks speed or power 40-501
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short H-25 Hydraulic drift of leaning cylinders (leaning) is large
circuit 40-352 40-502

4 GD555-5,GD655-5,GD675-5
(02)
 Index

H-26 Blade does not rotate 40-503 Points to remember when troubleshooting 40-7
H-27 Lift arm lock pin does not lock lift arm or does not Power train hydraulic circuit diagram 90-9
unlock it (for machine with lift arm specification) 40-504 Power train piping drawing 10-16
H-28 Blade accumulator function does not work or cannot Power train pump 10-134,60-44
be released (for machine with blade accumulator float Power train system drawing 10-14
specification) 40-505 Precautions for disconnecting and connecting air
H-29 Blade float function does not work or cannot be conditioner piping 80-54
released 40-506 Precautions for refrigerant 80-3
H-30 Fan revolution is abnormal (Fan sound/vibration is Precautions when carrying out work 00-29
abnormally large or engine overheats) 40-507 Procedure for check and troubleshooting 80-16
Handling compressor oil 80-56 Preheating circuit 10-212
Handling fuel system device 30-26 Preparation work for troubleshooting of electrical system
Handling high voltage circuit of engine controller 30-154 30-164
Handling of connectors newly used for engines 00-23 Priority valve 10-74
Handling of electric equipment and hydraulic components Procedure for testing diodes 30-104
00-14
Handling voltage circuit of engine controller 30-33 R
How to read electric wire code 00-26 Receiver drier 80-13
How to read the shop manual 00-10 Releasing remaining pressure from brake circuit 30-78
How to read this manual 50-4 Releasing remaining pressure from fuel system 30-27
How to read troubleshooting matrix 40-460 Removal and installation of aftercooler assembly 50-68
How to start KOMTRAX terminal operations 30-156 Removal and installation of air conditioner unit assembly
Hydraulic circuit diagram 90-5 50-268
Hydraulic cylinder 10-160,60-54 Removal and installation of blade assembly 50-227
Hydraulic system 10-110 Removal and installation of center hinge pin 50-186
Hydraulic tank 10-120 Removal and installation of circle drawbar assembly
50-229
I Removal and installation of circle rotation gear assembly
Indicator lamps of KOMTRAX terminal 30-161 50-232
Information in troubleshooting table 40-39, 80-37 Removal and installation of control valve assembly
50-213
K Removal and installation of cooling fan and fan motor
KOMTRAX system 10-206 assembly 50-60
Removal and installation of cooling fan pump assembly
50-58
L Removal and installation of cylinder head assembly
Lifter 10-178,60-60 50-32
List of Abbreviation 00-39 Removal and installation of engine and
Locations of fuses 40-97 transmission/torque converter assembly 50-80
Removal and installation of engine controller assembly
M 50-274
Machine monitor 10-186 Removal and installation of engine front oil seal 50-50
Main pump 10-122 Removal and installation of engine hood assembly 50-78
Main relief and torque converter relief valve 10-58 Removal and installation of engine rear oil seal 50-53
Main relief valve and torque converter relief valve 60-24 Removal and installation of floor frame assembly 50-254
Method of disassembling and connecting push-pull type Removal and installation of fuel injector assembly 50-22
coupler 00-32 Removal and installation of fuel supply pump assembly
Method of using troubleshooting chart 40-508 50-17
Removal and installation of fuel tank assembly 50-74
N Removal and installation of hydraulic tank, battery and
frame assembly 50-199
No injection cranking 30-32
Removal and installation of hydraulic tank assembly
50-206
O Removal and installation of KOMTRAX terminal assembly
Overview of Refrigeration System 80-7 50-280
Removal and installation of machine monitor assembly
50-276
P Removal and installation of operator cab assembly
Parking brake 10-104,60-42 50-242
Parking brake and bank control valve 10-102 Removal and installation of operator cab glass (adhered
Parts and connectors layout 80-24 glass) 50-258
Pilot check valve 10-164 Removal and installation of power train oil cooler
Pm Clinic 30-166 assembly 50-71

GD555-5,GD655-5,GD675-5 5
(02)
Index

Removal and installation of radiator assembly 50- 63 Testing and adjusting differential lock-up oil pressure
Removal and installation of ripper assembly 50- 238 [machine with differential lock-up] 30-68
Removal and installation of steering valve (orbit-roll) Testing and adjusting parking brake 30-82
assembly 50- 163 Testing and adjusting pump LS differential pressure
Removal and installation of tandem drive and final drive 30-91
assembly 50- 135 Testing and adjusting slip clutch type circle rotator
Removal and installation of transmission controller 30-101
assembly 50- 277 Testing and adjusting steering oil pressure 30-70
Replacing alternator belt 30-41 Testing and adjusting toe-in 30-66
Testing and adjusting work equipment oil pressure 30-88
S Testing air leakage (ducts) 80-26
S-1 Startability is poor 40-512 Testing blowby pressure 30-23
S-2 Engine does not start 40-513 Testing blower amp 80-32
S-3 Engine does not pick up smoothly 40-516 Testing compression pressure 30-20
S-4 Engine stops during operation 40-517 Testing engine oil pressure 30-25
S-5 Engine runs rough or is unstable 40-518 Testing engine speed 30-10
S-6 Engine lacks power 40-519 Testing evaporator temperature sensor 80-30
S-7 Exhaust smoke is black (incomplete combustion) Testing exhaust gas color 30-16
40-520 Testing exhaust gas temperature 30-14
S-8 Oil consumption is excessive (or exhaust smoke is Testing Fresh/Recirc air changeover 80-29
blue) 40-521 Testing fuel circuit for leakage 30-30
S-9 Oil becomes contaminated early 40-522 Testing fuel pressure 30-28
S-10 Fuel consumption is excessive 40-523 Testing intake air pressure (boost pressure) 30-12
S-11 Oil is in coolant (or coolant spurts or coolant level Tire 10-108
goes down) 40-524 Testing lift arm lock cylinder circuit oil pressure [machine
S-12 Oil pressure drops 40-525 with bank cut] 30-93
S-13 Oil level rises (coolant or fuel in oil) 40-526 Testing power train oil pressure 30-44
S-14 Coolant temperature rises too high (overheating) Testing relays 80-31
40-527 Testing steering cylinder oil leakage 30-71
S-15 Unusual noise is made 40-528 Testing temperature control 80-28
S-16 Vibration is excessive 40-529 Testing wheel brake disc wear 30-80
Safety notice 00-5 Testing work equipment cylinder oil leakage amount
Sensor 10-214 30-94
Sequence of events in troubleshooting 40-8 Tools for testing, adjusting, and troubleshooting 30-4
Sketches of special tools 50- 13 Torque converter 10-20,60-14
Slack adjuster 10-96,60-38 Transmission 10-24,60-16
Special functions of machine monitor (EMMS) 30-105 Transmission control 10-18,60-12
Special tools list 50- 9 Transmission control valve 10-46
Specification drawing 01-3 Transmission controller 10-198
Specifications 01-4 Troubleshooting by failurecode 40-99
Standard tightening torque table 00-35 Troubleshooting Chart 1 80-33
Standard value table for engine 20-3 Troubleshooting Chart 2 80-35
Standard value table for machine 20-5 Troubleshooting for blower motor system (Air does not
Starting engine circuit 10-208 come out or air flow is improper) 80-44
Steering piping diagram 10-72 Troubleshooting for FRESH/RECIRC air changeover
Steering valve 10-80 80-48
Stopping engine circuit 10-210 Troubleshooting for power supply system (Air conditioner
Structure and Function of Refrigeration System 80-6 does not operate) 80-38
Swivel joint 10-162 Troubleshooting for temperature control 80-46
Symbols used in electric circuit diagrams 90-13 Troubleshooting method for open circuit in wiring harness
Symbols used in hydraulic circuit diagrams 90-3 of pressure sensor system 40-41
System diagram 80-20 Troubleshooting of compressor and refrigerant system
(Air is not cooled) 80-40
Troubleshooting with gauge pressure 80-50
T
T- branch box and T- branch adapter table 40-94
Table of contents 00-2
W
Table of fuel, coolant and lubricants 01-11 Weight table 01-10
Tandem drive 10-70,60-36 Wheel brake 10-100,60-40
Testing and adjusting air conditioner compressor belt Work equipment control 10-118
tension [machines with air conditioner] 30-42 Work equipment hydraulic piping diagram 10-114
Testing and adjusting brake oil pressure 30-74
Testing and adjusting circle guide clearance 30-99

6 GD555-5,GD655-5,GD675-5
(03)
GD555,655,675-5 MOTOR GRADER
Form Number : SEN05215-05

©2011 KOMATSU
All Rights Reserved
Printed in Japan 02-11