GD675 3eo

SEN01775-04
MOTOR GRADER
GD655-3E0
GD675-3E0
GD655- 51501
SERIAL NUMBERS and up
GD675- 51301
SEN01777-04
MOTOR GRADER 1SHOP MANUAL
GD655-3E0,
GD675-3E0
Machine model Serial number

GD655-3E0 51501 and up
GD675-3E0 51301 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
GD655-3E0, GD675-3E0 1
SEN01777-04 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them
accordingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01775-04
00 Index and foreword SEN01776-04

Index SEN01777-04 q
Foreword and general information SEN01778-01
01 Specification SEN01779-00
Specification and technical data SEN01780-00
10 Structure, function and maintenance standard SEN01781-00

Engine and cooling system SEN01782-00
Power train SEN01783-00
Steering system SEN01784-00
Brake system SEN01785-00
Undercarriage and frame SEN01786-00
Hydraulic system SEN01787-00
Work equipment SEN01788-00
Cab and its attachments SEN01789-00
Electrical system SEN01790-00
20 Standard value table SEN01791-00

Standard service value table SEN01834-00
30 Testing and adjusting SEN01792-01

Testing and adjusting, Part 1 SEN01835-01
40 Troubleshooting SEN01793-01
Failure code table and fuse locations SEN01837-01
General information on troubleshooting SEN01838-01
Troubleshooting by failure code, Part 1 SEN01839-00
Troubleshooting of electrical system (E-mode) SEN01841-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01842-00
Troubleshooting of engine (S-mode) SEN01843-00
2 GD655-3E0, GD675-3E0
50 Disassembly and assembly SEN01794-02

General information on disassembly and assembly SEN01914-01
Engine and cooling system SEN01915-01 q
Power train, Part 1 SEN01916-00
90 Diagrams and drawings SEN01795-01

Hydraulic diagrams and drawings SEN01796-00
Electrical diagrams and drawings SEN01797-01
GD655-3E0, GD675-3E0 3
Table of contents 1
00 Index and foreword
Index SEN01777-04
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN01778-01
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling electric equipment and hydraulic component ........................................................... 11
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN01780-00
Specification and technical data .................................................................................................. 2
General assembly drawing ...................................................................................................... 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 11
Fuel, coolant, and lubricant selection ...................................................................................... 12
10 Structure, function and maintenance standard

Engine and cooling system ......................................................................................................... 2
Cooling line .............................................................................................................................. 2
Fan drive.................................................................................................................................. 3
Power train SEN01783-00
Power train .................................................................................................................................. 2
Power train diagram................................................................................................................. 2
Transmission hydraulic piping.................................................................................................. 3
Transmission control................................................................................................................ 4
Torque converter...................................................................................................................... 5
Torque converter control valve................................................................................................. 10
Transmission............................................................................................................................ 11
Transmission control valve ...................................................................................................... 32
ECMV ...................................................................................................................................... 34
Main relief valve and torque converter relief valve .................................................................. 40
Final drive ................................................................................................................................ 42
Steering system........................................................................................................................... 2
Steering hydraulic piping drawing ............................................................................................ 2
Steering valve (Q/Amp manual Orbit-roll type) ........................................................................ 3
Priority valve ............................................................................................................................ 10
Accumulator pressure governor valve ..................................................................................... 18
Front axle................................................................................................................................. 20
Brake system SEN01785-00
Brake system............................................................................................................................... 2
Blake hydraulic piping.............................................................................................................. 2
Brake valve .............................................................................................................................. 4
Wheel brake............................................................................................................................. 8
Slack adjuster .......................................................................................................................... 9
Accumulator............................................................................................................................. 11
4 GD655-3E0, GD675-3E0
Parking brake .......................................................................................................................... 12

Parking brake and bank control valve ..................................................................................... 13
Undercarriage and frame SEN01786-00
Undercarriage and frame ............................................................................................................ 2
Tandem drive ........................................................................................................................... 2
Main frame............................................................................................................................... 5
Hydraulic system......................................................................................................................... 2
Work equipment hydraulic piping drawing ............................................................................... 2
Hydraulic pump........................................................................................................................ 10
Main control valve.................................................................................................................... 33
CLSS ....................................................................................................................................... 44
Work equipment .......................................................................................................................... 4
Work equipment control........................................................................................................... 4
Hydraulic system ..................................................................................................................... 6
Hydraulic tank.......................................................................................................................... 9
Swivel joint............................................................................................................................... 10
Pilot check valve...................................................................................................................... 11
Blade accumulator, float valve................................................................................................. 15
Blade float device .................................................................................................................... 18
Circle rotation motor ................................................................................................................ 20
Hydraulic cylinder .................................................................................................................... 22
Circle, drawbar ........................................................................................................................ 24
Blade ....................................................................................................................................... 26
Circle rotation gear .................................................................................................................. 28
Scarifier ................................................................................................................................... 32
Ripper ...................................................................................................................................... 34
Cab and its attachments.............................................................................................................. 2
Air conditioner (If equipped) .................................................................................................... 2
Electrical system ......................................................................................................................... 2
Engine starting circuit .............................................................................................................. 2
Engine stop circuit ................................................................................................................... 4
Preheat circuit.......................................................................................................................... 5
Automatic shift control system ................................................................................................. 6
Transmission controller............................................................................................................ 8
Monitor..................................................................................................................................... 14
Sensors ................................................................................................................................... 17
Communication controller........................................................................................................ 23
KOMTRAX terminal system (if equipped)................................................................................ 24
20 Standard value table

Standard service value table SEN01834-00
Standard service value table ....................................................................................................... 2
Standard value table for engine ............................................................................................... 2
Standard value table for chassis.............................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1....................................................................................................... 3
Tools for testing, adjusting and troubleshooting ...................................................................... 3
Measuring exhaust color ......................................................................................................... 6
Measuring exhaust temperature.............................................................................................. 7
GD655-3E0, GD675-3E0 5
Measuring intake air pressure (boost pressure) ...................................................................... 9

Measuring blowby pressure..................................................................................................... 11
Measuring engine oil pressure................................................................................................. 12
Measuring engine speed ......................................................................................................... 13
Testing fan belt tension ............................................................................................................ 13
Testing air conditioner compressor belt tension....................................................................... 14
Measuring torque converter stall speed................................................................................... 15
Checking clutch oil pressure.................................................................................................... 16
Checking torque converter oil pressure ................................................................................... 17
Adjusting speed sensor ........................................................................................................... 18
Flushing torque converter and transmission circuit ................................................................. 20
Testing brake disc .................................................................................................................... 21
Testing and adjusting parking brake ........................................................................................ 22
Method for emergency release of parking brake ..................................................................... 24
Testing and adjusting parking brake pad clearance................................................................. 25
Testing accumulator charge pressure...................................................................................... 26
Testing and adjusting work equipment oil pressure ................................................................. 27
Testing and adjusting LS differential pressure ......................................................................... 28
Adjusting PC valve................................................................................................................... 30
Bleeding air from hydraulic circuit............................................................................................ 31
Measuring internal cylinder leakage ........................................................................................ 32
Testing and adjusting differential lock oil pressure [Differential lock specification] .................. 34
Measuring steering and brake oil pressure.............................................................................. 36
Bleeding air from brake piping ................................................................................................. 37
Charging nitrogen gas for brake, work equipment accumulator .............................................. 38
Testing and adjusting circle guide clearance ........................................................................... 40
Testing and adjusting slip clutch type rotary device................................................................. 42
Memorizing idle and full position procedure ............................................................................ 44
Initial learning method for transmission controller ................................................................... 45
Inspection procedure of diode ................................................................................................. 47
Testing and adjusting, Part 2 ....................................................................................................... 2
Special functions of machine monitor (EMMS) ........................................................................ 2
Self-diagnosis display of gear shift lever ................................................................................. 27
Handling of high-voltage circuit of engine controller ................................................................ 28
Preparatory work for troubleshooting for electrical equipment system .................................... 29
Moving machine when transmission valve fails ....................................................................... 30
Adjusting cab stopper bolt ....................................................................................................... 32
How to start operation of KOMTRAX terminal ......................................................................... 34
Lamp display of KOMTRAX terminal ....................................................................................... 37
Pm-clinic .................................................................................................................................. 40
40 Troubleshooting
Failure code table and fuse locations SEN01837-01
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Fuse locations.......................................................................................................................... 6
General information on troubleshooting SEN01838-01
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Testing before troubleshooting................................................................................................. 4
Classification and procedures of troubleshooting .................................................................... 5
Connection table for connector pin numbers ........................................................................... 6
T- branch box and T- branch adapter table.............................................................................. 42
6 GD655-3E0, GD675-3E0

Troubleshooting by failure code, Part 1....................................................................................... 3
Failure code [(DF1000)] Neutral safety ................................................................................... 3
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front).................................... 4
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear) .................................... 5
Failure code [AB00L6] Signal of alternator disagrees with operating state of engine ............. 6
Failure code [AB00MA] Malfunction of alternator .................................................................... 8
Failure code [B@BAZG] Engine oil pressure too low.............................................................. 10
Failure code [B@BCNS] Engine overheat............................................................................... 11
Failure code [B@CENS] Torque converter oil temperature too high ....................................... 12
Failure code [B@CKNS] Differential oil overheat .................................................................... 13
Failure code [CA111] Abnormality in controller........................................................................ 14
Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors ............................. 15
Failure code [CA122] Charge pressure sensor too high ......................................................... 16
Failure code [CA123] Charge pressure sensor too low........................................................... 18
Failure code [CA131] Throttle sensor too high ........................................................................ 20
Failure code [CA132] Throttle sensor too low ......................................................................... 22
Failure code [CA144] Coolant temperature sensor too high ................................................... 24
Failure code [CA145] Coolant temperature sensor too low..................................................... 26
Failure code [CA153] Charge temperature sensor too high .................................................... 28
Failure code [CA154] Charge temperature sensor too low ..................................................... 30
Failure code [CA155] Charge temperature too high and engine speed derated ..................... 32
Failure code [CA187] Sensor power source 2 too low ............................................................ 34
Failure code [CA221] Atmospheric pressure sensor too high ................................................. 36
Failure code [CA222] Atmospheric pressure sensor too low................................................... 38
Failure code [CA227] Sensor power source 2 too high ........................................................... 40
Failure code [CA234] Engine over speed................................................................................ 42
Failure code [CA238] Abnormal power source for Ne speed sensor ...................................... 43
Failure code [CA271] Short circuit in fuel pump actuator ........................................................ 44
Failure code [CA272] Disconnection in fuel pump actuator..................................................... 46
Failure code [CA281] Abnormal supply pump pressure balance ............................................ 48
Failure code [CA322] Disconnection or short circuit in injector No.1....................................... 50
Failure code [CA342] Abnormality in engine controller data consistency................................ 3
Failure code [CA351] Abnormality in injector drive circuit ....................................................... 4
Failure code [CA352] Sensor power source 1 too low ............................................................ 6
Failure code [CA386] Sensor power source 1 too high ........................................................... 8
Failure code [CA428] Water detection sensor too high ........................................................... 10
Failure code [CA429] Water detection sensor too low............................................................. 12
Failure code [CA435] Abnormality in engine oil pressure switch............................................. 14
Failure code [CA441] Power supply voltage too low ............................................................... 16
Failure code [CA442] Power supply voltage too high .............................................................. 18
Failure code [CA449] Common rail pressure too high (2) ....................................................... 20
Failure code [CA451] Common rail pressure sensor too high................................................. 24
Failure code [CA452] Common rail pressure sensor too low .................................................. 26
Failure code [CA488] Charge temperature too high and torque derated ................................ 28
Failure code [CA553] Common rail pressure too high (1) ....................................................... 29
Failure code [CA559] Supply pump no pressure (1) ............................................................... 30
Failure code [CA689] Abnormality in engine Ne speed sensor ............................................... 32
Failure code [CA731] Abnormality in engine Bkup speed sensor phase................................. 34
Failure code [CA757] Loss of all engine controller data .......................................................... 36
Failure code [CA778] Abnormality in engine Bkup speed sensor ........................................... 38
GD655-3E0, GD675-3E0 7
Failure code [CA1633] Abnormality in KOMNET..................................................................... 40

Failure code [CA2185] Accelerator pedal sensor power source too high................................ 42
Failure code [CA2186] Accelerator pedal sensor power source too low ................................. 44
Failure code [CA2249] Supply pump no pressure (2).............................................................. 46
Failure code [CA2265] Disconnection in electric lift pump....................................................... 48
Failure code [CA2266] Short circuit in electric lift pump .......................................................... 50
Failure code [CA2311] Abnormal resistance in IMV solenoid .................................................. 52
Failure code [CA2555] Disconnection in air intake heater relay .............................................. 54
Failure code [CA2556] Short circuit in air intake heater relay.................................................. 56
Failure code [D19CKZ] Disconnection or short circuit in differential control relay ................... 4
Failure code [D19KKZ] Differential lock-up relay : Disconnection ........................................... 6
Failure code [DAQ0KK] Power source voltage of transmission controller too low .................. 10
Failure code [DAQSKR] Communication controller cannot recognize S-NET......................... 11
Failure code [DB2RKR] Communication lost engine controller ............................................... 12
Failure code [DBF0KK] Power source voltage of communication controller too low ............... 14
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low ..................... 16
Failure code [DBFRKR] Communication lost communication controller.................................. 18
Failure code [DD1PKB] Power supply line short in RPM set switch........................................ 20
Failure code [DD1QKB] Short circuit in RPM set mode switch................................................ 22
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch ......................................... 24
Failure code [DDTGKB] Fill signal is ON when command current is OFF
(lock-up clutch fill switch).................................................................................... 25
Failure code [DDTHKA] Disconnection in FH clutch fill switch ................................................ 26
Failure code [DDTHKB] Fill signal is ON when command current is OFF
(FH clutch fill switch)........................................................................................... 27
Failure code [DDTJKA] Disconnection in FL clutch fill switch.................................................. 28
Failure code [DDTJKB] Fill signal is ON when command current is OFF
(FL clutch fill switch) ........................................................................................... 29
Failure code [DDTKKA] Disconnection in 1st clutch fill switch ................................................ 30
Failure code [DDTKKB] Fill signal is ON when command current is OFF
(1st clutch fill switch)........................................................................................... 32
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch................................................ 34
Failure code [DDTLKB] Fill signal is ON when command current is OFF
(2nd clutch fill switch) ......................................................................................... 36
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch ............................................... 38
Failure code [DDTMKB] Fill signal is ON when command current is OFF
(3rd clutch fill switch) .......................................................................................... 40
Failure code [DDTNKA] Disconnection in R clutch fill switch .................................................. 42
Failure code [DDTNKB] Fill signal is ON when command current is OFF
(R clutch fill switch) ............................................................................................. 43
Failure code [DDTPKA] Disconnection in 4th clutch fill switch ................................................ 44
Failure code [DDTPKB] Fill signal is ON when command current is OFF
(4th clutch fill switch) .......................................................................................... 46
Failure code [DF10KA] Disconnection in transmission shift lever switch ................................ 48
Failure code [DF10KB] Short circuit in transmission shift lever switch .................................... 52
Failure code [DGF1KX] Transmission oil temperature out of range ........................................ 56
Failure code [DGT1KX] Torque converter oil temperature out of range................................... 58
Failure code [DJF1KA] Disconnection in fuel level sensor ...................................................... 60
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range ........... 62
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range.................. 64
Failure code [DKD0KA] Disconnection in articulate sensor..................................................... 66
Failure code [DLE2KA] Disconnection in engine speed sensor .............................................. 68
Failure code [DLF1KA] Disconnection in transmission input speed sensor ............................ 69
Failure code [DLT3KA] Disconnection in transmission output speed sensor .......................... 70
Failure code [DV00KB] Short circuit in caution buzzer ............................................................ 71
Failure code [DW4BKA] Disconnection in parking brake relay ................................................ 72
8 GD655-3E0, GD675-3E0
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid.......................................... 74

Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid ........................... 75
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid ...................................... 76
Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid ....................... 78
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid....................................... 80
Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid ........................ 82
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid ...................................... 84
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid ................ 85
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid ..................................... 86
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid ............... 87
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid...................................... 88
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid ........................................ 89
Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid.......................... 90
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid ..................................... 92
Troubleshooting of electrical system (E-mode) SEN01841-00
Troubleshooting of electrical system (E-mode) ........................................................................... 3
Contents of troubleshooting table ............................................................................................ 3
E-1 Engine does not start at all or does not start easily .......................................................... 4
E-2 Transmission mode does not change ............................................................................... 12
E-3 Differential lock function does not work or is not reset [Differential lock specification] ..... 14
E-4 Wheel brake does not work normally................................................................................ 18
E-5 Parking brake does not work or is not reset...................................................................... 20
E-6 Lift arm lock pin is not locked or reset [Lift arm specification] ........................................... 22
E-7 Blade accumulator function does not work or is not reset
[Blade accumulator and float specification] ...................................................................... 25
E-8 Blade float function does not work or is not reset
[Blade accumulator and float specification] ...................................................................... 28
E-9 When starting switch is turned ON, machine monitor does not operate normally............. 36
E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display .... 38
E-11 When starting switch is turned ON, caution item lights up .............................................. 39
E-12 While engine is running, emergency stop item lights up ................................................. 40
E-13 Indication of speedometer and engine tachometer is abnormal ..................................... 49
E-14 Indication of engine coolant temperature gauge is abnormal ......................................... 50
E-15 Indication of articulate gauge is abnormal ...................................................................... 52
E-16 Indication of torque converter oil temperature gauge is abnormal.................................. 53
E-17 Indication of fuel level gauge is abnormal....................................................................... 54
E-18 Display of character display is abnormal ........................................................................ 56
E-19 Centralized warning lamp does not light up or go off ...................................................... 57
E-20 Alarm buzzer does not sound or stop ............................................................................. 58
E-21 Machine monitor mode selector switch does not function .............................................. 60
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off .................................. 63
E-23 Working lamp does not light up or go off......................................................................... 68
E-24 Turn signal lamp and hazard lamp do not blink or go off ................................................ 72
E-25 Brake lamp does not light up or go off ............................................................................ 78
E-26 Backup lamp does not light up or go off.......................................................................... 80
E-27 Backup buzzer does not sound or stop........................................................................... 81
E-28 Air conditioner does not work or stop.............................................................................. 82
E-29 KOMTRAX system does not operate normally ............................................................... 86
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01842-00
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 3
Contents of troubleshooting table ............................................................................................ 3
H-1 Excessive drop in engine speed, or engine stalls ............................................................. 4
H-2 Machine does not move in either forward or reverse direction ......................................... 5
H-3 Transmission does not shift up or shift down .................................................................... 6
H-4 Machine is slow or lacks power when traveling ................................................................ 7
H-5 Torque converter lockup function cannot be actuated or canceled................................... 9
H-6 Excessive time lag when starting or shifting gear ............................................................. 10
GD655-3E0, GD675-3E0 9
H-7 Torque converter oil temperature is high........................................................................... 11

H-8 Differential lock function is not operated or reset [Differential lock specification].............. 13
H-9 Machine is slow or lacks power when steering ................................................................. 14
H-10 Wheel brake does not work normally.............................................................................. 15
H-11 Parking brake is not applied or released ......................................................................... 16
H-12 All work equipment is slow or lacks power...................................................................... 17
H-13 No work equipment moves ............................................................................................. 18
H-14 Abnormal noise generated around pump........................................................................ 19
H-15 Blade is slow or lacks power in lifting.............................................................................. 20
H-16 Excessive blade drift ....................................................................................................... 21
H-17 Drawbar side shift operation is slow or lacks power ....................................................... 22
H-18 Blade side shift operation is slow or lacks power............................................................ 23
H-19 Power tilt operation is slow or lacks power ..................................................................... 24
H-20 Articulate operation is slow or lacks power ..................................................................... 25
H-21 Leaning operation is slow or lacks power ....................................................................... 26
H-22 Excessive drift of leaning ................................................................................................ 27
H-23 Blade does not rotate...................................................................................................... 28
H-24 Lift arm lock pin is not locked or reset [Lift arm specification] ......................................... 29
H-25 Blade accumulator function is not operated or reset
[Blade accumulator and float specification] .................................................................... 30
H-26 Blade float function is not operated or reset [Blade accumulator and float specification] 31
Troubleshooting of engine (S-mode) SEN01843-00
Troubleshooting of engine (S-mode) ........................................................................................... 3
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor. ............................................................................................ 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations......................................................................................... 11
S-5 Engine does not rotate smoothly....................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15
S-9 Oil becomes contaminated quickly.................................................................................... 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ............................. 18
S-12 Oil pressure drops........................................................................................................... 19
S-13 Oil level rises (water, fuel in oil)....................................................................................... 20
S-14 Coolant temperature becomes too high (overheating).................................................... 21
S-15 Abnormal noise is made.................................................................................................. 22
S-16 Vibration is excessive...................................................................................................... 23
50 Disassembly and assembly

General information on disassembly and assembly SEN01914-01
How to read this manual.............................................................................................................. 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tool list ......................................................................................................................... 7
Sketches of special tools ......................................................................................................... 12
Engine and cooling system ......................................................................................................... 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of fuel injector assembly .................................................................. 5
Removal and installation of cylinder head assembly ............................................................... 10
Removal and installation of engine front seal .......................................................................... 22
Removal and installation of engine rear seal........................................................................... 26
Removal and installation of engine assembly.......................................................................... 32
Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly............. 36
10 GD655-3E0, GD675-3E0
Removal and installation of air conditioner condenser ............................................................ 40

Removal and installation of oil cooler assembly ...................................................................... 43
Removal and installation of aftercooler assembly ................................................................... 45
Removal and installation of radiator assembly ........................................................................ 48
Removal and installation of engine hood................................................................................. 51
Power train, Part 1 ...................................................................................................................... 2
Removal and installation of engine and transmission assembly ............................................. 2
Removal and installation of transmission assembly ................................................................ 8
Disassembly and assembly of torque converter assembly...................................................... 14
Disassembly and assembly of transmission assembly............................................................ 21
Power train, Part 2 ...................................................................................................................... 2
Removal and installation of final drive assembly ..................................................................... 2
Disassembly and assembly of final drive assembly ................................................................ 7
Disassembly and assembly of final brake case assembly....................................................... 12
Disassembly and assembly of side case assembly (For standard final drive)......................... 16
Disassembly and assembly of bevel gear assembly ............................................................... 19
Disassembly and assembly of bevel gear shaft ...................................................................... 23
Disassembly and assembly of bevel pinion assembly............................................................. 25
Steering system........................................................................................................................... 2
Removal and installation of steering valve (Orbit-roll) ............................................................. 2
Disassembly and assembly of steering valve.......................................................................... 4
Hydraulic system......................................................................................................................... 2
Disassembly and assembly of work equipment control valve assembly ................................. 2
Disassembly and assembly of hydraulic cylinder assembly .................................................... 5
Work equipment .......................................................................................................................... 2
Removal and installation of blade assembly ........................................................................... 2
Removal and installation of circle drawbar assembly .............................................................. 3
Removal and installation of blade circle gear assembly .......................................................... 5
Removal and installation of blade circle rotation gear assembly (with shear pin) ................... 7
Disassembly and assembly of blade circle rotation gear assembly (with shear pin) ............... 9
Disassembly and assembly of circle rotation gear assembly (with slip clutch)........................ 13
Cab and its attachments.............................................................................................................. 2
Removal and installation of operator's cab assembly.............................................................. 2
Removal and installation of floor frame assembly ................................................................... 4
Disassembly and assembly of operator’s seat assembly ........................................................ 7
Removal and installation of operator's cab glass (stuck glass) ............................................... 16
Removal and installation of air conditioner unit assembly ....................................................... 22
Electrical system ......................................................................................................................... 2
Removal and installation of machine monitor assembly.......................................................... 2
Removal and installation of engine controller assembly.......................................................... 3
Removal and installation of transmission controller assembly ................................................ 4
Removal and installation of KOMTRAX controller assembly................................................... 5
Removal and installation of COMMUNICATION controller assembly...................................... 6
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01796-00
Hydraulic diagrams and drawings ............................................................................................... 2
Power train hydraulic circuit diagram....................................................................................... 2
GD655-3E0, GD675-3E0 11
Brake hydraulic circuit.............................................................................................................. 4

Hydraulic circuit diagram (1/2) ................................................................................................. 5
Hydraulic circuit diagram (2/2) ................................................................................................. 7
Electrical diagrams and drawings SEN01797-01
Electrical diagrams and drawings................................................................................................ 3
Electrical circuit diagram (1/6) ................................................................................................. 3
Connector arrangement diagram............................................................................................. 15
12 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 13
SEN01777-04
GD655-3E0, GD675-3E0 Motor grader

Form No. SEN01777-04
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
14
SEN01778-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
GD655-3E0, GD675-3E0 1
Safety notice 1 (Rev. 2006/09)

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
purpose.
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 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 GD655-3E0, GD675-3E0
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
GD655-3E0, GD675-3E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker 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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing 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 allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 GD655-3E0, GD675-3E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate 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)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up 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 immedi-
ately in an emergency.
GD655-3E0, GD675-3E0 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit 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 is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 GD655-3E0, GD675-3E0
How to read the shop manual 1
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 volume of the engine model mounted on the machine.
1. 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 explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
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 adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained 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
assembling 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.
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 reproducing, repairing, and replacing parts.
2. 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.
GD655-3E0, GD675-3E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. 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 stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque 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.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 GD655-3E0, GD675-3E0
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated 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 indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
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
GD655-3E0, GD675-3E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table 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)
between 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 “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

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 must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 GD655-3E0, GD675-3E0
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before 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
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
GD655-3E0, GD675-3E0 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), 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-cir-
cuited 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 sur-
face between 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 com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 GD655-3E0, GD675-3E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors 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
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction 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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
GD655-3E0, GD675-3E0 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 GD655-3E0, GD675-3E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally 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
GD655-3E0, GD675-3E0 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed 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 connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 GD655-3E0, GD675-3E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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
body, disconnect all wiring harness con-
nectors 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
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
GD655-3E0, GD675-3E0 17
Points to remember when handling hydraulic equipment

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 equipment, 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 equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 GD655-3E0, GD675-3E0
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 contaminants 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 equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
GD655-3E0, GD675-3E0 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 GD655-3E0, GD675-3E0
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
GD655-3E0, GD675-3E0 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the 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 har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 GD655-3E0, GD675-3E0
How to read electric wire code 1

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 sym-
bols. 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 nomi-
nal 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 AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
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
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
GD655-3E0, GD675-3E0 23
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-
AV Standard – – – – – – – 4.6
er D
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-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
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”.
24 GD655-3E0, GD675-3E0
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
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
GD655-3E0, GD675-3E0 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
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 components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, 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 Number
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
26 GD655-3E0, GD675-3E0
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
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 gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
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 anti-friction compound (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 tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment 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 the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten 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 equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment 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 disulphide 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 loosened, 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 loosened 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 leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
GD655-3E0, GD675-3E0 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts 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 mounting parts for
looseness.
If any bolt or nut is loosened, 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”.
28 GD655-3E0, GD675-3E0
Method of disassembling and connecting push-pull type coupler 1

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 receiving 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 about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is 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,
prepare an oil receiving 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 about 3.5 mm. This does not
indicate abnormality, however.
GD655-3E0, GD675-3E0 29
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 hexag-
onal 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 discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 GD655-3E0, GD675-3E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
GD655-3E0, GD675-3E0 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
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 corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 GD655-3E0, GD675-3E0
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

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 diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
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.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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}
GD655-3E0, GD675-3E0 33
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} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 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 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 — —
7. 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
series 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
34 GD655-3E0, GD675-3E0
8. 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
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
GD655-3E0, GD675-3E0 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method 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 hori-
zontal 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
millimeters 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 2.047 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 2.874 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
36 GD655-3E0, GD675-3E0
Millimeters to inches
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
50 1.969 2.008 2.047 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 2.874 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

1 l = 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
GD655-3E0, GD675-3E0 37
Liters to U.K. Gallons

1 l = 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
38 GD655-3E0, GD675-3E0
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
GD655-3E0, GD675-3E0 39
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 Fahren-
heit 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 Centi-
grade 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 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 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 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 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
40 GD655-3E0, GD675-3E0
SEN01778-01

© 2006 KOMATSU
All Rights Reserved
42
SEN01780-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
General assembly drawing................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ........................................................................................................................................11
Fuel, coolant, and lubricant selection................................................................................................. 12
GD655-3E0, GD675-3E0 1
SEN01780-00 01 Specification
Specification and technical data 1

General assembly drawing 1
(Unit: mm)
Item GD655-3E0 GD675-3E0
A Overall length 8,715 8,715
Overall height (with full height cab) 3,350 3,345
B
Overall height (with low height cab) 3,120 3,115
C Overall width 2,550 2,550
2 GD655-3E0, GD675-3E0
Specifications 1
GD655-3E0
Machine model GD655-3E0

Serial number 51501 and up
Machine weight 15,400
On front axle kg 4,100
On rear axle 11,300
Overall length 8,715
Overall width 2,550
Overall height (top of muffler) 3,000
Dimensions
Overall height (with ROPS cab) 3,120

Wheel base mm 6,070
Distance between centers of tandem wheels 1,535
Tread (Front) 2,130
Tread (Rear) 2,130
Ground clearance 370
1st 3.3
2nd 4.7
3rd 6.7
4th 9.7
Forward km/h
5th 14.6
6th 21.2
Travel speed
7th 29.1
Performance
8th 42.2
1st 4.3
2nd 8.8
Reverse km/h
3rd 19.3
4th 38.3
Maximum drawbar pull kN {kg} 88.7 {9,040}
Gradeability deg. 24
Min. turning radius m 6.9
Static stability deg. 35
GD655-3E0, GD675-3E0 3

Engine model SAA6D114E-3
4-cycle, water cooled,
overhead valve,
Type
direct-injection type
with turbocharger and aftercooler
Cylinder number – bore x stroke mm 6 – 114 x 135
Piston displacement l {cc} 8.27 {8,270}
kW/rpm 134.2 – 149.2/1,900
Flywheel horsepower
{HP/rpm} {180 – 200/1,900}
Engine
Performance
Nm/rpm 830.6 – 975.8/1,450

Maximum torque
{kgm/rpm} {84.7 – 99.5/1,450}
Max. speed at no load rpm 2,225
Min. speed at no load rpm 825
g/kWh 218.3
Fuel consumption ratio
{g/HPh} {162.9}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 60 A
Battery 12 V, 112 Ah x 2
Radiator type Aluminum looper 4-line
3-element, single-stage
Torque converter
Automatic shifting, wet-type clutch
Multiple shaft
Power train
Fully automatic electric, automatic shifting type,

Transmission
pump force feed type
8 forward speeds, 4 reverse speeds
Reduction gear Spiral bevel gear, single-stage reduction
Rear axle Fully floating tandem type
Tandem Double-row chain drive
Type Reverse Elliott, angle type
Front
axle
Max. leaning angle 16

Steering
Type Fully hydraulic type

Steering
system
Steering angle deg. 49

Articulate angle deg. 23
4 GD655-3E0, GD675-3E0

Tires (front) 14.00-24-10PR
Tires (rear) 14.00-24-10PR
Steering, operating
Tires
kPa
Inflation pressure (front) 216 {2.2}
system
{kg/cm2}
kPa
Inflation pressure (rear) 216 {2.2}
{kg/cm2}
Steering related cylinders Control valve Hydraulic pump Brakes
Main brake Rear 4-wheel braking, multiple-disc wet type

Parking brake Dry disc type
Type x No. Komatsu LPV90 Variable swash plate type x 1
Discharge at rated rpm l/min. 194
MPa
Set pressure 20.6 {210}
{kg/cm2}
Type x No. 4-spool type x 2 (CLSS)
Control method Hydraulic type
Steering Leaning Articulating
Type Double-acting piston type

Hydraulic system
Cylinder bore mm 50 80 90
Piston rod outside diameter mm 35 40 50
Piston stroke mm 330 160 325
Blade Blade Blade Drawbar

Ripper
Type lift side shift tilt side shift
Work equipment cylinders
Double-acting piston type

Cylinder bore mm 80 80 80 80 120
Piston rod outside diameter mm 50 50 40 45 55
Piston stroke mm 1,160 1,250 300 585 540
Scarifier
Type
Cylinder bore mm 90
Piston rod outside diameter mm 50
Piston stroke mm 300
GD655-3E0, GD675-3E0 5

Blade dimension (Length x Height x Thickness) 3,658 x 660 x 22
Cutting edge dimension
1,829 x 153 x 16 – 2
(Length x Width x Thickness – Number)
mm
Max. lift above ground 505
Max. cutting depth 815
Blade base 2,600
Blade load kN {kg} 70.3 {7,170}
Blade
Turning angle (with scarifier) deg. 360 (130)

Max. shoulder reach outside rear tires (Frame straight)
2,000
(left)
mm
Max. shoulder reach outside rear tires (Frame straight)
2,000
(right)
Cutting angle —
[Standard] deg. 37
[Adjustable] 32 – 81
6 GD655-3E0, GD675-3E0
GD675-E0

Machine weight 15,810
On front axle kg 4,300
On rear axle 11,510
Overall length 8,715
Overall width 2,550
Overall height (top of muffler) 3,000
Dimensions
Overall height (with ROPS cab) 3,115

Wheel base mm 6,070
Distance between centers of tandem wheels 1,535
Tread (Front) 2,130
Tread (Rear) 2,130
Ground clearance 370
1st 3.3
2nd 4.7
3rd 6.7
4th 9.7
Forward km/h
5th 14.6
6th 21.2
Travel speed
7th 29.1
Performance
8th 42.2
1st 4.3
2nd 8.8
Reverse km/h
3rd 19.3
4th 38.3
Maximum drawbar pull kN {kg} 90.3 {9,210}
Gradeability deg. 24
Min. turning radius m 6.9
Static stability deg. 35
GD655-3E0, GD675-3E0 7
Machine Model GD675-3E0

Serial Number 51301 and up
Engine model SAA6D114E-3
4-cycle, water cooled,
overhead valve,
Type
direct-injection type
with turbocharger and aftercooler
Cylinder number – bore x stroke mm 6 – 114 x 135
Piston displacement l {cc} 8.27 {8,270}
kW/rpm 134.2 – 149.2/1,900
Flywheel horsepower
{HP/rpm} {180 – 200/1,900}
Engine
Performance
Nm/rpm 830.6 – 975.8/1,450

Maximum torque
{kgm/rpm} {84.7 – 99.5/1,450}
Max. speed at no load rpm 2,225
Min. speed at no load rpm 825
g/kWh 218.3
Fuel consumption ratio
{g/HPh} {162.9}
Starting motor 24V, 7.5kW
Alternator 24V, 60A
Battery 12V, 112Ah x 2
Radiator type Aluminum looper 4-line
3-element, single-stage
Torque converter
Automatic shifting, wet-type clutch
Multiple shaft
Power train
Fully automatic electric, automatic shifting type,

Transmission
pump force feed type
8 forward speeds, 4 reverse speeds
Reduction gear Spiral bevel gear, single-stage reduction
Rear axle Fully floating tandem type
Tandem Double-row chain drive
Steering system Front axle
Type Reverse Elliott, angle type
Max. leaning angle 16

Steering
Type Fully hydraulic type

Steering angle deg. 49
Articulate angle deg. 23
8 GD655-3E0, GD675-3E0

Tires (front) 14.00-24-12PR
Tires (rear) 14.00-24-12PR
Steering, operating
Tires
kPa
Inflation pressure (front) 245 {2.5}
system
{kg/cm2}
kPa
Inflation pressure (rear) 245 {2.5}
{kg/cm2}
Steering related cylinders Control valve Hydraulic pump Brakes
Main brake Rear 4-wheel braking, multiple-disc wet type

Parking brake Dry disc type
Type x No. Komatsu LPV90 Variable swash plate type x 1
Discharge at rated rpm l/min. 194
MPa
Set pressure 20.6 {210}
{kg/cm2}
Type x No. 4-spool type x 2 (CLSS)
Control method Hydraulic type
Steering Leaning Articulating
Type Double-acting piston type

Hydraulic system
Cylinder bore mm 50 80 90
Piston rod outside diameter mm 35 40 50
Piston stroke mm 330 160 325
Blade Blade Blade Drawbar

Ripper
Type lift side shift tilt side shift
Work equipment cylinders

Cylinder bore mm 80 80 80 80 120
Piston rod outside diameter mm 50 50 40 45 55
Piston stroke mm 1,160 1,250 300 585 540
Scarifier
Type
Cylinder bore mm 90
Piston rod outside diameter mm 50
Piston stroke mm 300
GD655-3E0, GD675-3E0 9

Blade dimension (Length x Height x Thickness) 3,658 x 660 x 25
Cutting edge dimension
1,829 x 153 x 16 – 2
(Length x Width x Thickness – Number)
mm
Max. lift above ground 505
Max. cutting depth 815
Blade base 2,600
Blade load kN {kg} 73.7 {7,520}
Blade
Turning angle (with scarifier) deg. 360 (130)

Max. shoulder reach outside rear tires (Frame
2,000
straight) (left)
mm
Max. shoulder reach outside rear tires (Frame
2,000
straight) (right)
Cutting angle —
[Standard] deg. 37
[Adjustable] 32 – 81
10 GD655-3E0, GD675-3E0
Weight table 1
k Use the weight table when handling individual parts or when transporting the entire machine.
Unit: kg
Machine model GD655-3E0 GD675-3E0
Serial number 51501 and up 51301 and up
Engine assembly (dry) 800 800
Radiator assembly (dry) 119 119
Transmission assembly (dry) 810 810
Transmission pump 9 9
Final drive assembly 727 727
Tandem drive (one side) 940 940
Front axle assembly, except leaning cylinder 548 548
Parking brake assembly 26 26
Wheel assembly (front) 151 x 2 179 x 2
Wheel assembly (rear) 151 x 4 179 x 4
Scarifier assembly 530 530
Hydraulic pump 49 49
Fuel tank and hydraulic tank (both dry) 264 264
Circle rotation motor 10 10
Steering cylinder assembly 12 x 2 12 x 2
Leaning cylinder assembly 15 15
Articulating cylinder assembly 25 x 2 25 x 2
Blade lift cylinder assembly 53 x 2 53 x 2
Blade side-shift cylinder assembly 48 48
Blade power tilt cylinder assembly 19 19
Drawbar side-shift cylinder assembly 33 33
Scarifier cylinder assembly 24 24
Drawbar assembly 771 771
Blade assembly 752 752
Circle gear 542 542
Circle rotation gear assembly 119 119
Front frame assembly 1,800 1,800
Rear frame assembly 1,006 1,006
Ripper 886 886
Operator's compartment assembly and controls 251 251
GD655-3E0, GD675-3E0 11
Fuel, coolant, and lubricant selection 1

According to temperature
a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
Ambient temperature
Recommended
Reservoir Fluid type
-22 -4 14 32 50 68 86 104 122ºF Komatsu fluids
-30 -20 -10 0 10 20 30 40 50ºC
(Note.1) Komatsu EOS0W30
(Note.1) Komatsu EOS5W40
Engine oil pan Engine oil Komatsu EO10W30-DH
Komatsu EO15W40-DH
Komatsu EO30-DH
Power train oil

Transmission case TO10
(Note.2)
Hydraulic system Power train oil TO10
Final drive case

Power train oil TO30
Tandem drive sase
GO90
Circle reverse gear

Gear oil GO80
case
GO75
Hyper grease
G2-T, G2-TE
(Note.3)
Grease fitting
Lithium EP grease G2-LI
Work equipment
Lubricants with
LM-G, LM-P
molybdenum disulfide
Supercoolant
Cooling system AF-NAC
AF-NAC (Note.4)
ASTM Grade No.1-D S15
Fuel tank Diesel fuel
q ASTM: American Society of Testing and Material
12 GD655-3E0, GD675-3E0
Remark
q When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic
maintenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil

Fuel sulphur content
in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
q When starting the engine in atmospheric temperature of lower than 0ºC, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10ºC or
more in the day time.
q Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change inter-
val in half.
q There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature in the table.
q We recommend Komatsu genuine oil, which has been specifically formulated and approved for use in
engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
GD655-3E0, GD675-3E0 13
SEN01780-00

© 2006 KOMATSU
All Rights Reserved
14
SEN01782-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Cooling line .......................................................................................................................................... 2
Fan drive .............................................................................................................................................. 3
GD655-3E0, GD675-3E0 1
SEN01782-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Cooling line 1
1. Torque converter oil cooler Specification

2. Aftercooler q Radiator
3. Radiator Core type: Aluminum looper 4-line
4. Reservoir tank Total heat dissipation area: 47.261 m2
q Oil cooler
A. Torque convertor oil cooler input port Core type: CF40-1, 3.5/2P
B. Torque convertor oil cooler output port Total heat dissipation area: 9.32 m2
C. Aftercooler input port (from turbocharger) q Aftercooler
D. Aftercooler output port (for intake manifold) Core type: 4.0/2P
E. Radiator coolant inlet Total heat dissipation area: 21.69 m2
F. Radiator coolant outlet
2 GD655-3E0, GD675-3E0
Fan drive 1
1. Fan drive pulley

2. Drive pulley
3. V-belt
4. Tension pulley
GD655-3E0, GD675-3E0 3
SEN01782-00

© 2006 KOMATSU
All Rights Reserved
4
SEN01783-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Power train
Power train...................................................................................................................................................... 2
Power train diagram ............................................................................................................................. 2
Transmission hydraulic piping .............................................................................................................. 3
Transmission control ............................................................................................................................ 4
Torque converter .................................................................................................................................. 5
Torque converter control valve ........................................................................................................... 10
Transmission .......................................................................................................................................11
Transmission control valve................................................................................................................. 32
ECMV................................................................................................................................................. 34
Main relief valve and torque converter relief valve............................................................................. 40
Final drive........................................................................................................................................... 42
GD655-3E0, GD675-3E0 1
Power train 1
Power train diagram 1
q The power produced by diesel engine (5) goes 1. Cooling fan

to transmission (4) through torque converter 2. Hydraulic pump
with lock-up clutch (3). 3. Torque converter
q Transmission (4), with a multiple shaft mecha- 4. Transmission
nism and a hydraulic control unit combined, 5. Engine assembly
allows an easy selection of eight forward 6. Drive shaft
speeds and four reverse speeds. Through 7. Final drive
drive shaft (6), the power is transmitted from 8. Tandem drive
the transmission to the final drive (7). Here, 9. Tire
final drive (7) directs the power to the right and 10. Wheel brake
left, and the power is transmitted to the left and 11. Shaft
right tandem drives (8) through shaft (11).
q Tandem drive (8) transmits the power to the
wheel by a chain and the machine travels.
2 GD655-3E0, GD675-3E0
Transmission hydraulic piping 1
1. Transmission oil filter

2. Transmission oil filter inlet hose
3. Transmission oil filter outlet hose
4. Transmission pump
5. Transmission pump tube
6. Transmission assembly
7. Transmission oil filler/oil level check hole
GD655-3E0, GD675-3E0 3
Transmission control 1
1. Gear shift lever Gear shift lever positions

2. Transmission controller 1. Reverse
3. Communication controller 2. Forward
3. Parking
4. Neutral
5. 1 range (forward, reverse)
9. 5 range (forward)
4 GD655-3E0, GD675-3E0
Torque converter 1
1. PTO drive gear (Number of teeth: 70) Specifications

2. Pump Type: 3-element, 1-stage, 2-phase
3. Race with modulation
4. Drive case with lockup clutch
5. Stator Lockup clutch: wet type single-disc clutch
6. Turbine hydraulic control
7. Lockup clutch piston (with modulation valve)
8. Lockup clutch housing (Number of teeth: 72) Stall torque ratio: 2.17
9. Pilot
10. Boss
11. Lockup clutch disc
12. Free wheel
13. Guide
14. Stator shaft
15. Transmission input shaft
GD655-3E0, GD675-3E0 5
6 GD655-3E0, GD675-3E0
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.010 Repair by hard
71.954 71.9
–0.040 chromium-plating
or replace
Inside diameter of pilot seal ring +0.025
2 35 35.5
contact surface +0.025
Inside diameter of clutch piston seal +0.081
260 260.1
ring contact surface +0.081
3 –0.01
Wear of clutch housing Width 5 4.5
–0.04 Replace
seal ring
Thickness 6 ±0.15 5.85
Inside diameter of clutch housing +0.089
4 340 340.5
seal ring contact surface +0.089
Inside diameter of PTO drive gear +0.040
5 125 125.5 Repair by hard
seal ring contact surface +0.040
chromium-plating
Inside diameter of stator shaft seal +0.030 or replace
6 55 55.5
ring contact surface +0.030
Inside diameter of race free wheel +0.005
7 88.882 88.912
transmission surface –0.008
Outside diameter of stator shaft free +0.008
8 72.217 72.187
wheel transmission surface –0.005
Inside diameter of sliding portion of +0.015
9 72.32 72.4
bushing +0.015 Replace
Thickness of sliding portion of bush- –0.1
10 5 4.5
ing –0.1
11 Thickness of clutch disc 5 ±0.1 4.5
Backlash between PTO drive gear
12 0.160 – 0.407
and PTO idler gear
GD655-3E0, GD675-3E0 7
Power transmission route

When lockup clutch is "disengaged" When lockup clutch is "engaged"
Drive case (3) is disconnected from boss (9) and Drive case (3) is connected to boss (9) and turbine
turbine (8) and lockup torque converter works as an (8) and lockup torque converter is locked up.
ordinary torque converter.
The power from engine The power from engine

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) Drive case (3), pump (5) and PTO drive gear (6)
rotate together rotate together
O O
Oil is used as medium Lockup clutch (4)
O O
Turbine (8) and boss (9) 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
also used as power for driving the pump after also used as power for driving the pump after
being transmitted through PTO idler gear (7). being transmitted through PTO idler gear (7).
8 GD655-3E0, GD675-3E0
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve, and
then it flows through inlet port (A) and oil pas-
sage 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 turbine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again. However, part of the
oil passes between turbine (4) and stator (5)
and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
transmission.
GD655-3E0, GD675-3E0 9
Torque converter control valve 1
A: To clutch 1. Proportional solenoid connector

P: From pump 2. Lockup clutch ECMV
T: Drain 3. Seat
Dr: Drain 4. Fill switch connector
P1: Clutch oil pressure pick-up port 5. Fill switch
6. Pressure detection valve
7. Pressure control valve
8. Proportional solenoid
10 GD655-3E0, GD675-3E0
Transmission 1
A: From power train pump

B: To oil cooler
1. Work equipment pump installation port 6. Transmission case (front)

2. Power train, differential lock pump installation 7. Transmission case (rear)
port 8. Transmission output shaft speed sensor
3. Transmission control valve 9. Torque converter control valve
4. Transmission oil temperature sensor 10. Main relief valve and torque converter relief
5. Oil filler tube mounting port valve
GD655-3E0, GD675-3E0 11
1. Torque converter 10. Output shaft

2. Input shaft 11. 2nd clutch
3. FL clutch 12. 1st clutch
4. Upper shaft 13. R clutch
5. FH clutch 14. Fun pulley drive shaft
6. Lower shaft 15. Fun pulley coupling
7. 3rd clutch 16. PTO idler gear A (Number of teeth: 53)
8. Coupling 17. PTO gear A shaft
9. 4th clutch 18. PTO gear A (Number of teeth: 62)
12 GD655-3E0, GD675-3E0
14 GD655-3E0, GD675-3E0
Unit: mm
Standard Tolerance Standard Clearance

Clearance between input shaft size Shaft Hole clearance limit
1
bearing and front case
–0.018 +0.030
150 0 – 0.048 —
–0.018 +0.030
Clearance between input shaft –0.018 +0.022 –0.013 –
2 100 —
bearing and rear case –0.015 –0.013 0.037
Clearance between upper shaft –0.018 +0.030
3 100 0 – 0.045 —
bearing and front case –0.015 +0.030
Clearance between upper shaft –0.018 +0.022 –0.013 –
110 —
4
Clearance between upper shaft +0.034 –0.018 –0.049 –
60 —
bearing and upper shaft +0.021 –0.015 –0.021
Clearance between lower shaft –0.018 +0.026 –0.014 –
5 140 —
bearing and front case –0.018 –0.014 0.044
Clearance between lower shaft –0.018 +0.026 –0.014 –
6 130 —
Clearance between output shaft –0.018 +0.026 –0.014 –
7 140 —
bearing and front case –0.018 –0.014 0.044
Clearance between output shaft –0.018 +0.004
8 160 0 – 0.065 —
bearing and rear case –0.025 +0.030
Clearance between PTO idler gear –0.018 +0.004 –0.018 –
90 —
A bearing and front case –0.015 –0.018 0.019
9
Clearance between PTO idler gear +0.018 –0.018 –0.030 –
50 —
A bearing and PTO idler gear A +0.002 –0.012 –0.002
Clearance between fan drive shaft –0.018 +0.030
80 0 – 0.043 — Replace
bearing and rear case –0.013 +0.030
10
Clearance between fan drive shaft +0.025 –0.018 –0.037 –
35 —
bearing and fan drive shaft +0.009 –0.012 –0.009
Clearance between PTO gear A –0.018 +0.030
90 0 – 0.045 —
shaft bearing and front case (front) –0.015 +0.030
11 Clearance between PTO gear A
+0.020 –0.018 –0.032 –
shaft bearing and PTO gear A shaft 50 —
+0.009 –0.012 –0.009
(front)
Clearance between PTO gear A –0.018 +0.030
110 0 – 0.045 —
shaft bearing and front case (rear) –0.015 +0.030
12 Clearance between PTO gear A
+0.030 –0.018 –0.045 –
shaft bearing and PTO gear A shaft 70 —
+0.011 –0.015 –0.011
(rear)
Width of input shaft seal ring groove
13 +0.18
(front) 2.5 2.7
+0.10
Width of input shaft seal ring groove +0.076
14 3.2 3.5
(center) +0.076
Inside diameter of seal ring contact +0.05
50 50.1
surface of case and retainer +0.06
15
+0.076
Width of each shaft seal ring groove 3.2 3.5
+0.076
Outside diameter of oil seal contact –0.074
16 80 79.8
surface of output coupling –0.074
Outside diameter of oil seal contact –0.074
17 65 64.8
surface of fan pulley coupling –0.074
GD655-3E0, GD675-3E0 15
Unit: mm

Clearance between PTO idler gear size Shaft Hole clearance limit
B bearing and front case –0.018 +0.004 –0.018 –
1 90 —
–0.015 –0.018 0.019
Clearance between PTO idler gear +0.018 –0.018 –0.030 –
50 —
B bearing and PTO idler gear B +0.002 –0.012 –0.002
Clearance between PTO gear B –0.018 +0.030
90 0 – 0.045 —
shaft bearing and front case (front) –0.015 +0.030
2 Clearance between PTO gear B
+0.020 –0.018 –0.032 –
shaft bearing and PTO gear B shaft 50 — Replace
+0.009 –0.012 –0.009
(front)
Clearance between PTO gear B –0.018 +0.030
100 0 – 0.045 —
shaft bearing and front case (rear) –0.015 +0.030
3 Clearance between PTO gear B
+0.030 –0.018 –0.045 –
shaft bearing and PTO gear B shaft 70 —
+0.011 –0.015 –0.011
(rear)
Clearance between R idler gear –0.018 –0.049 –0.073 –
100 —
bearing and R idler gear –0.015 –0.073 –0.034
4
Clearance between R idler gear +0.032 –0.018 –0.047 –
70 —
bearing and rear case +0.002 –0.015 –0.002
16 GD655-3E0, GD675-3E0
5. PTO gear B (Number of teeth: 62) Outline

6. PTO gear B shaft q The transmission adopted is a "forward 8-gear
7. PTO idler gear B (Number of teeth: 53) speed and reverse 4-gear speed" transmission
8. R idler gear (Number of teeth: 37) which consists of the counter-shaft type, con-
9. Strainer stant mesh spur gear mechanisms and the
10. Drain plug disc clutches.
q The transmission selects one rotation direction
and rotation speed by fixing the counter-shaft
type, constant mesh spur gear mechanisms
and 2 out of 7 sets disc clutch with the oil pres-
sure 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 combina-
tion of the FL, FH, R clutches and 4 speed
clutches.
Number of plates and discs used

Clutch No. Number of plates Number of discs
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 respective gear

speeds and reduction ratio
Operated
Gear speed Reduction ratio
clutches
Forward 1st FL x 1st 9.950
Forward 2nd FH x 1st 6.685
Forward 3rd FL x 2nd 4.879
Forward 4th FH x 2nd 3.367
Forward 5th FL x 3rd 2.222
Forward 6th FH x 3rd 1.533
Forward 7th FL x 4th 1.118
Forward 8th FH x 4th 0.772
Neutral — —
Reverse 1st R x 1st 7.549
Reverse 2nd R x 2nd 3.702
Reverse 3rd R x 3rd 1.686
Reverse 4th R x 4th 0.848
GD655-3E0, GD675-3E0 17
FL, R clutch
A: R clutch oil port 1. R clutch gear (Number of teeth: 25)

B: FL clutch oil port 2. R clutch
C: Lubricating oil port 3. FL and R cylinders
D: Lockup clutch oil port 4. FL clutch
5. FL clutch gear (Number of teeth: 28)
6. Input gear (Number of teeth: 36)
7. Input shaft
Unit: mm

Clearance between input shaft size Shaft Hole clearance limit
8
bearing and input shaft (front)
+0.030 –0.018 –0.045 –
60 —
+0.011 –0.015 –0.011
Clearance between input shaft +0.034 –0.018 –0.049 –
9 55 —
bearing and input shaft (rear) +0.021 –0.015 –0.021
10 Clutch plate Thickness 1.7 ±0.05 1.5
Replace
Strain — 0.1 0.15
Thickness 2.2 ±0.08 1.8
11 Clutch disc
Strain — 0.1 0.25
Load of wave spring 1,010 N ±101 N 859 N
12
(Testing height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
13 Thrust washer thickness 3 ±0.1 2.7
14 End play of R clutch gear 0.29 – 0.69
15 End play of FL clutch gear 0.30 – 0.76
18 GD655-3E0, GD675-3E0
FH, 1st clutch
A: FH clutch oil port 1. Upper gear (Number of teeth: 42)

B: 1st clutch oil port 2. 1st clutch gear (Number of teeth: 26)
C: Lubricating oil port 3. 1st clutch
4. FH and 1st cylinders (Number of teeth: 62)
5. FH clutch
6. FH clutch gear (Number of teeth: 55)
7. Upper shaft
Unit: mm

Clearance between upper shaft size Shaft Hole clearance limit
8
bearing and upper shaft (front)
+0.034 –0.018 –0.049 –
55 —
+0.021 –0.015 –0.021
Strain — 0.1 0.15
Replace
Thickness 2.2 ±0.08 1.8
10 Clutch disc
Strain — 0.1 0.25
11
13 End play of 1st clutch gear 0.26 – 0.74
14 End play of FH clutch gear 0.39 – 0.79
GD655-3E0, GD675-3E0 19
2nd, 3rd clutch
A: 2nd clutch oil port 1. Lower gear (Number of teeth: 29)

B: 3rd clutch oil port 2. 2nd clutch gear (Number of teeth: 61)
C: Lubricating oil port 3. 2nd clutch
4. 2nd and 3rd cylinders (Number of teeth: 77)
5. 3rd clutch
6. 3rd clutch gear (Number of teeth: 55 and 41)
7. Lower shaft
Unit: mm

Clearance between lower shaft size Shaft Hole clearance limit
8
bearing and lower shaft (front)
+0.030 –0.018 –0.045 –
65 —
+0.011 –0.015 –0.011
Clearance between lower shaft +0.054 –0.018 –0.069 –
9 60 —
bearing and lower shaft (rear) +0.044 –0.015 –0.044
Replace
Strain — 0.1 0.15
Thickness 2.2 ±0.08 1.8
11 Clutch disc
Strain — 0.1 0.25
12
14 End play of 2nd clutch gear 0.35 – 0.85
15 End play of 3rd clutch gear 0.38 – 0.82
20 GD655-3E0, GD675-3E0
4th clutch
A: 4th clutch oil port 1. Output gear (Number of teeth: 44)

B: Lubricating oil port 2. 4th clutch
C: Lubricating oil port 3. 4th cylinders (Number of teeth: 42)
4. Output shaft
Unit: mm

Clearance between output shaft size Shaft Hole clearance limit
5
bearing and output shaft (front)
+0.030 –0.018 –0.045 –
65 —
+0.011 –0.015 –0.011
Clearance between output shaft +0.030 –0.018 –0.045 –
6 75 —
bearing and output shaft (rear) +0.011 –0.015 –0.011
Strain — 0.1 0.15
Thickness 2.2 ±0.08 1.8 Replace
8 Clutch disc
Strain — 0.1 0.25
9
Inside diameter of seal ring contact +0.030
70 70.1
surface of cylinder +0.030
11
Width of output shaft seal ring +0.076
3.2 3.5
groove +0.030
12 End play of 4th clutch gear 0.30 – 0.70
GD655-3E0, GD675-3E0 21
Operation of the disc clutch

When clutch is "engaged" (fixed) When clutch is "disengaged" (released)
q The oil sent from the ECMV flows through the q When the oil sent from the ECMV is shut off,
oil passage of shaft (1), is pressure-fed to the pressure of the oil acting on the back face of
back side of piston (2), and pushes piston (2) piston (2) goes down.
to the right. q Piston (2) is pushed back to the left by repul-
q Piston (2) compresses plates (3) and discs (4) sive force of wave spring (7).
and the rotation of discs (4) is stopped by the q The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear
q As the internal teeth of disc (4) are meshed (5) are released.
with clutch gear (5), shaft (1) and clutch gear q When the clutch is released, the oil in the
(5) transfer the power as a unit. backside of piston is drained by the centrifugal
q The oil is drained from oil drain hole (6), but the force through oil drain hole (6) to prevent the
drain amount is less than the amount of oil clutch from being partially applied.
supplied, so there is no influence on the actua-
tion of the clutch. a Oil drain hole (6) is made of only with the 2nd,
3rd, and 4th clutches.
22 GD655-3E0, GD675-3E0
Power transmitting route

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

The power from the torque o (from left bottom) o (from center bottom)
converter O O
O 1st clutch (11) Output gear (25)
Input shaft (1) O O
O 1st clutch gear (14) Output shaft (26)
FL and R cylinders (2) O
O 2nd and 3rd cylinders (20)
FL clutch (3) O
O Lower shaft (21)
FL clutch gear (5) O
O Lower gear (22)
FH and 1st cylinders (12) O
O (To right top) o
(To center top) o
GD655-3E0, GD675-3E0 23
Forward 2nd gear speed
FH clutch (10) and 1st clutch (11) are fixed hydraulically.

converter O O
O 1st clutch (11) Output shaft (26)
Input shaft (1) O
O 1st clutch gear (14)
Input gear (7) O
FH clutch gear (9) O
O Lower shaft (21)
FH clutch (10) O
O Lower gear (22)
O Output gear (25)
(To center top) o O
(To right top) o
24 GD655-3E0, GD675-3E0
Forward 3rd gear speed
FL clutch (3) and 2nd clutch (18) are fixed hydraulically.

converter O O
O Upper shaft (13) Lower gear (22)
Input shaft (1) O O
O Upper gear (15) Output gear (25)
FL and R cylinders (2) O O
O 2nd clutch gear (16) Output shaft (26)
FL clutch (3) O
O 2nd clutch (18)
O Lower shaft (21)
(To center top) o O
(To right top) o
GD655-3E0, GD675-3E0 25
Forward 4th gear speed
FH clutch (10) and 2nd clutch (18) are fixed hydraulically.

converter O O
Input shaft (1) O O
O Upper gear (15) Output gear (25)
Input gear (7) O O
O 2nd clutch gear (16) Output shaft (26)
O 2nd clutch (18)
FH clutch (10) O
O Lower shaft (21)
(To center top) o O
(To right top) o
26 GD655-3E0, GD675-3E0
FL clutch (3) and 3rd clutch (19) are fixed hydraulically.

The power from the torque o (from left bottom)
converter O
O 3rd clutch gear (17)
Input shaft (1) O
O 3rd clutch (19)
FL clutch (3) O
O Lower shaft (21)
O Lower gear (22)
O Output gear (25)
(To right top) o O
Output shaft (26)
GD655-3E0, GD675-3E0 27
FH clutch (10) and 3rd clutch (19) are fixed hydraulically.

converter O O
O 3rd clutch gear (17) Output shaft (26)
Input shaft (1) O
O 3rd clutch (19)
Input gear (7) O
O Lower shaft (21)
FH clutch (10) O
O Lower gear (22)
O Output gear (25)
(To center top) o O
(To right top) o
28 GD655-3E0, GD675-3E0
FL clutch (3) and 4th clutch (24) are fixed hydraulically.

converter O
Input shaft (1) O
O 4th clutch gear (23)
O 4th clutch (24)
FL clutch (3) O
O Output shaft (26)
FL clutch gear (5)
O
FH and 1st cylinders (12)
O
(To right top) o
GD655-3E0, GD675-3E0 29
FH clutch (10) and 4th clutch (24) are fixed hydraulically.

converter O
Input shaft (1) O
O 4th clutch gear (23)
Input gear (7) O
O 4th clutch (24)
O Output shaft (26)
FH clutch (10)
O
FH and 1st cylinders (12)
O
(To right top) o
30 GD655-3E0, GD675-3E0
Reverse 1st gear speed
R clutch (4) and 1st clutch (11) are fixed hydraulically.

converter O O
O R idler gear (8) 1st clutch gear (14)
Input shaft (1) (Output rotation is reversed O
O through R idler gear (8).) 2nd and 3rd cylinders (20)
FL and R cylinders (2) O O
O Upper gear (15) Lower shaft (21)
R clutch (4) O O
R clutch gear (6) O O
O FH and 1st cylinders (12) Output gear (25)
(To center top) o O O
1st clutch (11) Output shaft (26)
O
(To right top) o
GD655-3E0, GD675-3E0 31
Transmission control valve 1
32 GD655-3E0, GD675-3E0
A: From power train pump Operation table of ECMV

B: To torque converter control valve ECMV
C: FL clutch oil pressure pickup port Gear FL FH R 1st 2nd 3rd 4th
D: R clutch oil pressure pickup port speed
E: FH clutch oil pressure pickup port F1 Q Q
F: 1st clutch oil pressure pickup port F2 Q Q
G: 2nd clutch oil pressure pickup port F3 Q Q
H: 3rd clutch oil pressure pickup port
J: 4th clutch oil pressure pickup port F4 Q Q
F5 Q Q
1. FL clutch ECMV F6 Q Q
2. R clutch ECMV F7 Q Q
3. FH clutch ECMV
4. 1st clutch ECMV F8 Q Q
5. 2nd clutch ECMV R1 Q Q
6. 3rd clutch ECMV R2 Q Q
7. 4th clutch ECMV R3 Q Q
8. Seat
9. Last chance filter R4 Q Q
N
q The oil from the pump flows through the oil fil-
ter to the transmission front case. The oil is
then diverged to the main relief circuit and
clutch actuation circuit.
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 also keeps
the clutch pressure constant during travel.
q If the FL, FH, R, or 1st – 4th ECMV is selected,
the regulated oil pressure is supplied to the
selected clutch to set the transmission in the
desired gear speed.
GD655-3E0, GD675-3E0 33
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch 1. Fill switch connector

P: From pump 2. Proportional solenoid connector
T: Drain 3. Pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch oil pressure pickup port 5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
*1:
Clutch used Printing on nameplate
Lockup, FL, FH, R,
A*******
1st, 2nd, 3rd, 4th
34 GD655-3E0, GD675-3E0
ECMV for lockup clutch Operation

Outline When traveling in torque converter range
q This valve acts to set the lockup clutch oil pres-
sure to the set pressure, and also to switch the
lockup clutch.
It forms a modulation wave pattern, so the
lockup clutch is engaged smoothly to reduce
the shock when shifting gear. In addition, it pre-
vents generation of peak torque in the power
train. As a result, it provides a comfortable ride
for the operator and greatly increases the
durability of the power train.
Torque converter travel o direct travel
When shifting gear (direct travel)

q When traveling in torque converter range, cur-
rent is not supplied to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and
lockup clutch is "released".
Also at this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to pressure
detection valve (4).
GD655-3E0, GD675-3E0 35
When traveling in direct range

(Torque converter travel o direct travel)
During filling Pressure adjustment
q When traveling in direct (lockup) range, current q As current is conducted to proportional sole-
is supplied to proportional solenoid (1), the oil noid (1), the solenoid generates thrust in pro-
pressure force balanced with the solenoid portion to the current. The pressure is settled
force is applied to chamber (B) and pushes as the sum of this thrust of the solenoid, thrust
pressure control valve (3) to the left. As a generated by the oil pressure in clutch port and
result, pump port (P) and clutch port (A) are the repulsive force of pressure control valve
opened and oil starts filling the clutch. If the spring (2) is balanced.
clutch is filled with oil, oil pressure detection
valve (4) is operated, and fill switch (5) is
turned "ON".
36 GD655-3E0, GD675-3E0
ECMV for gear speed clutch ECMV and proportional solenoid

Outline of ECMV q For each ECMV, 1 proportional solenoid is
q The ECMV consists of 1 pressure control valve installed.
and 1 fill switch. The proportional solenoid generates thrust
q Pressure control valve shown below according to the command cur-
This valve receives the current sent from the rent from the controller.
transmission controller with a proportional The thrust generated by the proportional sole-
solenoid, and then converts it into oil pressure. noid is applied to the pressure control valve
q Fill switch spool to generate oil pressure as shown in the
This switch detects that the clutch is filled with figure below. Accordingly, the thrust is changed
oil and has the following functions. by controlling the command current to operate
1. Outputs a signal (a fill signal) to the controller the pressure control valve to control the flow
to notify that filling is completed when the and pressure of the oil.
clutch is filled with oil.
2. Keeps outputting signals (fill signals) to the Current – propulsion force characteristics of
controller to notify whether oil pressure is proportional solenoid
applied or not while oil pressure is applied to
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

ECMV and fill switch
Range B: During filling
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned "ON" by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
GD655-3E0, GD675-3E0 37
Operation of ECMV Before shifting gear [when draining]

q ECMV is controlled with the command current (Range A in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, 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).
Also at this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
38 GD655-3E0, GD675-3E0
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is applied to proportional solenoid (1) q As current is conducted to proportional sole-

with no oil in the clutch, the oil pressure force noid (1), the solenoid generates thrust in pro-
balanced with the solenoid force is applied to portion to the current. The pressure is settled
chamber (B) and pushes pressure control as the sum of this thrust of the solenoid, thrust
valve (3) to the left. This opens pump port (P) generated by the oil pressure in clutch port and
and clutch port (A) to feed oil in the clutch. the repulsive force of pressure control valve
When the clutch is filled with oil, pressure spring (2) is balanced.
detection valve (4) actuates to turn "ON" fill
switch (5).
GD655-3E0, GD675-3E0 39
Main relief valve and torque converter relief valve 1
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body
–0.035 +0.013 0.035 –
28 0.078
–0.045 +0.013 0.058
Clearance between torque con- –0.035 +0.013 0.035 –
2 22 0.078
verter relief valve and valve body –0.045 +0.013 0.058
Standard size Repair limit
Replace
Installed
Free length Installed load Free length Installed load
3 Main relief valve spring (outside) length
245 N 233 N
108 82.5 104.8
{25.0 kg} {23.8 kg}
290 N 276 N
4 Main relief valve spring (inside) 108 82.5 104.8
{29.6 kg} {28.1 kg}
153 N 145 N
5 Torque converter relief valve spring 50 42 48.5
{15.6 kg} {14.8 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
11. Seat P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port
40 GD655-3E0, GD675-3E0
Outline Operation of main relief valve

Torque converter relief valve
q The torque converter relief valve constantly
regulates the torque converter inlet circuit
pressure below the set pressure to protect the
torque converter from abnormally high pres-
sure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve regulates the pressure in
the transmission and parking brake hydraulic
circuits to the set pressure.
Set pressure: 2.47 MPa {25.2 kg/cm2} q The oil from the hydraulic pump flows to cham-
(At rated engine speed) ber (F) through the filter, port (C) of the relief
valve and orifice (a) of main relief valve (1).
Operation
Operation of torque converter relief valve
q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
q The oil from the main relief valve is conducted (F) pushes piston (2) and the resulting resist-
to the torque converter through port (E) and, at ing force pushes spool (1) leftward, opening
the same time, also conducted to chamber (G) ports (C) and (E).
through orifice (b) of torque converter relief Above operation conducts the oil from port (E)
valve (3). to the torque converter.
q As the oil pressure to the torque converter
goes beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting resisting force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained
through port (A).
GD655-3E0, GD675-3E0 41
Final drive 1
Standard final drive (non-spin differential)
1. Cage
2. Non-spin differential
3. Coupling
4. Bevel pinion (Number of teeth: 12)
5. Bevel gear (Number of teeth: 43)
6. Shaft
7. Sprocket (Number of teeth: 12)
8. Breather
9. Drain plug
10. Oil filler tube
42 GD655-3E0, GD675-3E0
Unit: mm
11 Preload of bevel pinion bearing Starting rotation torque: 8.7 – 11.7 Nm {0.89 – 1.19 kgm}
Starting rotation torque:
12 Preload of bevel gear bearing (Item 11) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm}
(after setting, measure at pinion bearing) Adjust
Backlash between bevel pinion and Standard size

13
bevel gear 0.25 – 0.33
GD655-3E0, GD675-3E0 43
Planetary final drive (with differential lock)
1. Shaft (Number of teeth: 24) 10. Gear (Number of teeth: 10)

2. Coupling 11. Gear (Number of teeth: 20)
3. Bevel pinion (Number of teeth: 12) 12. Gear (Number of teeth: 66)
4. Bevel gear (Number of teeth: 43) 13. Gear (Number of teeth: 20)
5. Shaft 14. Breather
6. Sprocket (Number of teeth: 20) 15. Drain plug
7. Plate 16. Solenoid valve for differential lock-up
8. Disc 17. Oil supply pipe
9. Piston 18. Grease fitting
44 GD655-3E0, GD675-3E0
Unit: mm
19 Preload of bevel pinion bearing Starting rotation torque: 8.7 – 11.7 Nm {0.89 – 1.19 kgm}
Starting rotation torque:
20 Preload of bevel gear bearing
(Item 19) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} Adjust
Backlash between bevel pinion and Standard size
21
bevel gear 0.25 – 0.33
GD655-3E0, GD675-3E0 45
Solenoid valve for differential lock-up
Unit: mm
Differential oil pressure Standard Limit
(Differential oil temperature 50 ± 5°C,
16 Adjust
between engine low idle (800 ± 50 2.84 – 3.1 MPa {29.0 – 31.6 kg/cm 2} Max. 2.84 MPa {29.0 kg/cm2}
rpm) and high idle (2,225 ± 50 rpm))
46 GD655-3E0, GD675-3E0
Outline
q When the motor grader works with its blade at
a propulsion angle or its body inclined, its front
part is pushed to the right or left by the reaction
force. Since it must travel straight, resisting the
reaction force, it is not equipped with a differ-
ential.
q Since the motor grader is articulated, its rear
wheels are slipped sideways rather frequently
when it turns. To increase the durability of the
rear wheels, an optional final drive having a dif-
ferential can be installed.
q The optional final drive has a differential lock-
up mechanism, which can be controlled with
the switch from the operator’s seat.
Operation (with differential lock-up)

q The power transmitted from the engine to the
transmission passes through the meshing of
bevel pinion (1) and bevel gear (2), and is then
transmitted shaft (3) o (4) o sprocket (5).
q The differential is switched between ON and
LOCK (OFF) by using hydraulic power to push
together or separate disc (6) and plate (7).
q Even when the differential lock is switched ON,
if the machine is travelling at high speed (F6-
F8), the controller acts to automatically cancel
the differential lock.
GD655-3E0, GD675-3E0 47
SEN01783-00

© 2006 KOMATSU
All Rights Reserved
48
SEN01784-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Steering system
Steering system .............................................................................................................................................. 2
Steering hydraulic piping drawing ........................................................................................................ 2
Steering valve (Q/Amp manual Orbit-roll type)..................................................................................... 3
Priority valve....................................................................................................................................... 10
Accumulator pressure governor valve................................................................................................ 18
Front axle ........................................................................................................................................... 20
GD655-3E0, GD675-3E0 1
Steering system 1
Steering hydraulic piping drawing1
1. Steering valve
2. Steering wheel
3. Priority valve
4. Accumulator charge valve
5. Hydraulic tank
6. Hydraulic pump
7. Steering cylinder
2 GD655-3E0, GD675-3E0
Steering valve (Q/Amp manual Orbit-roll type) 1
1. Gland
2. Valve body
3. Check valve
4. Gerotor
5. Spacer
6. Cover
7. Spacer
8. Drive shaft
9. Sleeve
10. Spool
11. Center pin
12. Center spring
GD655-3E0, GD675-3E0 3
Outline 1. Variable ratio steering function

The Q/Amp manual Orbit-roll used on this machine The amount of oil pushed out of the steering
has a flow amplification function. This function is pump, in other words, the steering discharge
provided by the structure of the Orbit-roll valve and amount, varies according to the steering wheel
orifice. With this, the steering pump speed range speed. When the steering wheel is turned at
varies to change the steering discharge amount; in low speed, the steering discharge is small; and
particular, at high speed it has the characteristic of when the steering wheel is turned at high
providing an amplified flow above the metering speed, the steering discharge is large.
amount of the Gerotor (Variable ratio steering func-
tion). For this reason, when the machine is traveling
at high speed, if the steering wheel is turned at
The Gerotor used for this function has the following low speed, the steering discharge is small.
features. This makes fine compensation of the steering
q Fine compensation of the steering is possible possible, and enables superior travel at high
at high speed to ensure stable steering. speed.
q Quick turns are possible when the machine is
traveling at low speed or when it is stationary. When the machine is stationary or traveling at
q Emergency steering is possible with the Orbit- low speed, if the steering wheel is turned at
roll control used independently. high speed, a large steering discharge is easily
ensured, so quick turns are possible.
4 GD655-3E0, GD675-3E0
2. Flow amplification function

q In addition to the metering by the Gerotor
of the conventional Orbit-roll, there is a
variable internal orifice with a bypass flow
control function, so this makes it possible
to send a large oil flow to the steering cyl-
inder. In this way, even with a small Orbit-
roll, a large amount of oil can be sent to
the steering cylinder when traveling at
high speed.
1. Q/Amp manual Orbit-roll

q An Orbit-roll with an emergency steering
function using a Q/Amp Orbit-roll is called
a Q/Amp manual Orbit-roll. To achieve this
function, the oil does not pass through the
metering (Orbit-roll) but uses the charac-
teristics of a bypass orifice (characteristics
of flow amplification orifice AA) and closes
the hole during emergency steering (valve
at maximum flow position).
q This type of Orbit-roll has great merits
when it is used in the steering system of
medium sized machines.
q Normally, only an Orbit-roll with a small
discharge volume can achieve actual
emergency steering when the Orbit-roll is
used independently. When selecting an
Orbit-roll with a large discharge volume, it
is necessary to provide an emergency
source of pressure oil.
With this Q/Amp manual Orbit-roll, the
system is simplified, and as a result, the
reliability is improved.
Steering lock-to-lock characteristics

(Variable capacity steering system of Q/Amp steering speed)
GD655-3E0, GD675-3E0 5
Structure q The top of drive shaft (3) is engaged with cen-

q The shaft connected to the steering wheel ter pin (7) and made one with sleeve (9). The
meshes with the spline at the top of the spool bottom of drive shaft (3) is engaged with the
and the spool (10) is fitted inside the sleeve spline of rotor (1) of the Gerotor set (combina-
(9). In addition, the spool and sleeve are con- tion of rotor (1) and stator (11)).
nected by the center pin (7) (not touching the q Four ports in the valve body connect to the
spool when the steering wheel is not being pump circuit, tank circuit, and circuits to the
used). head and bottom ends of the steering cylin-
ders. Also, a check valve inside the body con-
nects the port at the pump end and the port at
the tank end. Thus, if the engine or pump fail,
oil can be sucked in directly from the tank
because of this check valve.
6 GD655-3E0, GD675-3E0
Connection between hand pump and sleeve
q The diagrams above show the connections

with the sleeve ports connecting the suction
and discharge ports of the Gerotor.
q When turning the wheel to the right, the vertical
grooves in the spool connect ports (a), (c), (e),
(g), (i), and (k) to the pump side. Simulta-
neously, ports (b), (d), (f), (h), (j), and (i) con-
nect to the head end of the steering cylinder in
the same way.
q In the diagram above left, ports (1), (2), (3) are
the discharge ports and connect to ports (l),
(b), and (d). Thus, the oil is sent to the cylinder.
q Turning the steering wheel 90° changes the
condition to that shown in the diagram above
right. Ports (1), (2), and (3) are suction ports
and connect to ports (i), (k), and (a). Ports (5),
(6), and (7) are discharge ports and connect to
ports (d), (f), and (h).
q In this way, the ports acting as the discharge
ports of the hand pump connect to the ports
going to the steering cylinder. And the ports
acting as suction ports connect to the pump
circuit.
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.
GD655-3E0, GD675-3E0 7
q Adjust the discharge amount to match the

amount while turning the steering wheel. The
oil from this pump always passes through this
hand pump. For each 1/7 turn of the steering
wheel, the internal tooth gear of the hand
pump advances by one tooth. An amount of oil
equal to this movement is discharged. Thus,
the discharge oil amount is directly propor-
tional to the amount the steering wheel is
turned. If the pump or engine fail, the condition
is exactly the same. Thus, the same amount of
oil is discharged as when the pump is normal.
Differences between trochoid pump and steering pump hand pump

Trochoid pump
q The trochoid pump is divided into an inlet port

and an outlet port. When the shaft rotates as
shown above, oil is sucked in from the inlet
port and discharged from the outlet port as
shown in stage 2 and 6.
Steering pump hand pump
q With the hand pump, inlet and outlet ports exist

at the bottom of the internal teeth of the stator.
Rotating the shaft connects the steering pump
and port as shown in stage 2 and 3 above.
Also, oil is sucked in. Rotating the shaft further,
the steering cylinder and port connect as
shown in stage 5 and 6 above. The oil is deliv-
ered to the cylinder. This action is performed at
each port.
8 GD655-3E0, GD675-3E0
Role of centering spring

q The centering spring (4) consists of 4 X-
shaped leaf springs and 2 flat leaf springs. It is
assembled between the spool (10) and sleeve
(9) as shown in the diagram on the right.
q Turning the wheel, the spool compresses the

spring. A difference (angle variation) is gener-
ated in the turning angle of the spool and
sleeve. As a result, the spool port and sleeve
connect and oil is directed to the cylinder.
However, when the steering wheel is stopped,
the hand pump rotation stops also. Thus, oil is
no longer sent to the cylinder and the oil pres-
sure increases.
To prevent this situation, when the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the angle variation of the sleeve and spool.
Thus, the steering wheel returns to the NEU-
TRAL position.
GD655-3E0, GD675-3E0 9
Priority valve 1
1. Relief valve P : From pump

2. Orifice EF : To accumulator pressure governor valve
3. Spring (To work equipment circuit)
4. Spool CF1 : To accumulator pressure governor valve
5. Orifice (To brake circuit)
6. Orifice CF2 : To steering valve
7. Fitting face of accumulator pressure governor LS1 : To accumulator pressure governor valve
valve (To pilot circuit)
LS2 : To accumulator pressure governor valve
(To pilot circuit)
T : To accumulator pressure governor valve
(To hydraulic tank)
10 GD655-3E0, GD675-3E0
Outline
q If the hydraulic systems for both the work
equipment and steering and brake are covered
by one pump, all the oil flow is consumed by
the work equipment circuit. Thus, there is a
lack of oil for the steering and brake circuit. To
prevent this dangerous situation, a valve is
installed to ensure that priority is given to the
oil flow to the steering and brake circuit.
q If a large flow of oil is sent to the steering cir-
cuit even when the steering is at neutral, the oil
flow to the work equipment circuit will be
reduced and poor efficiency results. To prevent
this situation and to ensure a quick response
when operating the steering, this valve keeps
the steering circuit oil flow to a minimum
(approx. 1 l/min) when the steering is at neu-
tral, and to send the rest of the oil to the work
equipment circuit. In addition, this valve is a
load-sensing type that ensures the necessary
flow even when operating the steering.
q The built-in relief valve regulates the steering
circuit pressure to prevent generation of abnor-
mal pressure.
GD655-3E0, GD675-3E0 11
Valve circuit diagram
12 GD655-3E0, GD675-3E0
Operation When this flow from port (CF) passes through

1. When engine is stopped orifices (e) and (b), a difference in pressure of
Spool (1) is pushed to the right by spring (2). In approx. 0.98 MPa {10 kg/cm 2 } is formed on
this condition, port (CF) is opened to the maxi- both sides of the orifices. The pressure in
mum and port (EF) is closed. chamber (B) = pressure in chamber (C) + 0.98
MPa {10 kg/cm2}, so spool (1) is pushed to the
left and tries to close portion (d).
If the area of the opening at portion (d)
becomes smaller, the oil flow in the drain circuit
passing through orifice (b) becomes smaller,
so the differential pressure on both sides of ori-
fice (b) becomes smaller. Spool (1) is pushed
to the right by spring (2), and the opening at
portion (d) again opens. When the oil flow
becomes larger, the spool again moves to the
left. This is repeated until a balance is reached.
The forces acting on chamber (B) and cham-
ber (C) are as follows:
q Force in left direction (converted to
hydraulic force):
PB (=1.57 MPa {16 kg/cm2})
q Force in right direction: PC + 0.98 MPa
{10 kg/cm2} (=1.57 MPa {16 kg/cm2})
(0.98 MPa {10 kg/cm 2 } is the hydraulic
force converted for spring (2))
2. When engine is started (steering and main

control valves at neutral)
The oil from the pump flows from port (A) to
port (CF) and to the steering and brake line,
but the steering valve is closed, so the pres-
sure at port (CF) rises.
The oil in chamber (A) from the pump passes
through orifice (a) in spool (1), enters chamber
(B), and pushes spool (1) to the left.
The steering valve is closed, so the oil at port
(CF) flows to the brake accumulator line and
charges the brake accumulator. The accumu-
lator charge pressure passes through the LS
and PLS lines and is transmitted to the servo
valve of the pump. The pump then supplies the
necessary oil flow and pressure. The accumu-
lator charge oil flow is controlled by orifice (e).
When the accumulator pressure rises and the
charging is completed, the governor valve is
opened.
The oil from orifice (b) flows in chamber (C)
and is drained through orifice (c) and steering
valve. The flow rate in the LS circuit is about 1
l/min.
GD655-3E0, GD675-3E0 13
3. Steering operated (accumulator not

charged, main control valve at neutral)
When the steering wheel is turned, port (CF)
and the steering cylinder are connected. When
this happens, the pressure in chamber (C)
becomes higher, and spool (1) is pushed to the
right by spring (2). The area of the opening of
portion (d) becomes larger, so the oil from the
pump passes through port (CF) when the
steering wheel is being turned, and the neces-
sary oil flow goes from the steering valve to the
steering cylinder.
If the steering wheel is turned quickly, and the

area of the variable throttle in the steering
valve becomes larger, the difference in pres-
sure on both sides of the variable throttle
inside the steering valve becomes smaller, and
the pressure in the LS circuit rises. (The pres-
sure in chamber (B) drops.)
At the same time, the oil pressure in chamber

(C) also rises, so spool (1) is moved further to
the right, and the area of the opening of portion
(d) also becomes larger. This sends a large oil
flow to the steering cylinder.
On the other hand, if the steering wheel is

turned slowly, the throttle of the variable orifice
becomes smaller, so the differential pressure
on both sides of the variable throttle inside the
steering valve becomes larger. The pressure in
chamber (B) then becomes larger than the
pressure in chamber (C), so spool (1) is
pushed to the left, and the area of the opening
of portion (d) becomes smaller to match the
flow of oil needed for the steering valve. It
becomes balanced in this position.
In other words, spool (1) moves in accordance

with the flow of oil needed for port (CF) to
maintain the differential pressure between
chamber (C) and chamber (B) at 0.98 MPa {10
kg/cm2}, and adjusts the opening of portion (d).
(In this way, all the oil not needed for the steer-
ing can be sent to port (EF).)
When the oil from port (CF) enters the steering

cylinder and load is applied, the pressure in the
circuit rises. This signal becomes PLS and is
fed back to the pump servo valve. The angle of
the swash plate in the pump is changed to
i nc r ea s e th e di s c ha r ge a mo un t, a nd t o
increase the pressure in the circuit. In this way,
the PLS circuit acts to detect the hydraulic load
on the steering and feeds back this information
to the pump.
14 GD655-3E0, GD675-3E0
4. Steering cylinder at end of stroke 5. Steering valve at neutral, work equipment

When the steering cylinder reaches the end of control lever operated
its stroke, and the operator continues to turn If the work equipment control lever is operated,
the steering wheel, the flow of oil to the cylin- pressure (PA) changes to 1.96 – 24.5 MPa {20
der is stopped regardless of the opening of the – 250 kg/cm2}. However, the steering valve is
steering valve. at neutral, so the condition is the same as in
There is no flow of oil, so the CF and LS pres- Section 2. "When engine is started (steering
sure rise together with the pressure at pump and main control valves at neutral)", and the
port (P), and at the same time, pressure cham- force acting on spool (1) is constant regardless
ber (B) and chamber (C) also rise, and spool of pressure (PA).
(1) is moved to the right. If pressure (PA) rises, the pressure at port (CF)
If pressure chamber (C) goes above 15.21 also rises momentarily, and the amount of oil
MPa {155 kg/cm2}, steering relief valve opens flowing through orifice (b) increases. A large
and drains the oil in chamber (C). Because of difference in pressure is created, so spool (1)
this flow of oil, a difference in pressure on both is pushed to the left, and the area of the open-
sides of orifices (b) and (e) is created, and ing of portion (d) becomes smaller. The oil flow
pressure chamber (C) becomes lower than is automatically adjusted so that only 1 l/min.
pressure chamber (B). flows.
As a result, spool (1) moves to the left to a posi-
tion where the oil flow inside the spool is 1 l/
min. Spool (1) stabilizes at a position where por-
tion (d) of the spool is throttled, and this pre-
vents the large loss of oil if the circuit is relieved.
If spool (1) moves too far to the left, portion (d)
is closed and the oil stops flowing. The flow of
oil through orifice (b) stops, so pressure cham-
ber (C) and pressure chamber (B) become the
same, and spool (1) is moved again to the right
by spring (2) to open portion (d).
Because of this repeated action, the pressure
in the steering circuit is maintained at a maxi-
mum of 15.21 MPa {155 kg/cm2}.
GD655-3E0, GD675-3E0 15
6. Steering, work equipment operated simulta- 2) When the load on the steering circuit is
neously less than the load on the work equipment
1) When the load on steering circuit is higher circuit, circuit (CF) satisfies the demand
than the load on the work equipment cir- for the amount of oil and oil pressure for
cuit, the actuation condition is the same as the steering, but compared with port (CF),
in Section 3, "Steering operated (main when the pressure at port (EF) is higher,
control valve at neutral)". the flow of oil passing through portion (d)
increases and the pressure in chamber
Port (CF) is at the same pressure as (B) rises.
chamber (A), and port (EF) is throttled by
portion (I) until it balances at the same As a result, spool (1) moves to the left,
pressure as the pressure needed for the and the area of the opening at portion (d)
work equipment. In other words, the oil becomes smaller. It balances so that the
pressure in the main circuit for the pump is pressure and oil flow matches the needs
sent to the steering circuit. of port (CF). In other words, the pressure
and oil flow needed for the steering circuit
is supplied to the steering circuit by priority
regardless of the pressure in the work
equipment circuit.
16 GD655-3E0, GD675-3E0
7. When brake accumulator is being charged

When the brake is operated, the pressure
inside the brake accumulator goes down. If the
pressure goes down to 9.42 MPa {96 kg/cm2},
the brake accumulator pressure governor
valve closes, the flow of oil from orifice (C) to
the steering valve stops, and the LS pressure
rises. After this, the procedure is the same as
when the engine is started, and the charging of
oil pressure to the brake accumulator is com-
pleted.
8. Steering and brake accumulator charging

actuated at same time
1) If the load in the steering circuit is higher
than the load in the brake accumulator
charge circuit, the load in the steering cir-
cuit for normal travel becomes lower than
5.89 MPa {60 kg/cm 2 }. Operating the
steering when the machine is stationary
may create such a situation, but after a
few seconds, the accumulator charging
will be completed, so in reality there is
almost no effect.
2) When load in brake charge circuit is

higher than load in steering circuit
This pattern is normal when both circuits
are operated at the same time. The steer-
ing valve discharges an amount of oil to
match the operating angle of the steering,
so when an oil flow matching the operat-
ing angle of the steering is sent to the
steering cylinder. The steering valve then
automatically closes and this gives an
operating feeling that is the same as with
normal operations.
GD655-3E0, GD675-3E0 17
Accumulator pressure governor valve 1
1. Pressure governor valve EF1 : To left main control valve

2. Solenoid (For releasing LS pressure) EF2 : To right main control valve
3. Accumulator shuttle valve A1 : To brake control
4. Fitting face of priority valve A2 : To brake control
LSS : From steering valve
LSP1 : From parking and bank control valve
LSP2 : From LS pressure reducing valve
T : To hydraulic tank
EF : From priority valve

CF1 : From priority valve
LS1 : From priority valve
LS2 : From priority valve
T : From priority valve
18 GD655-3E0, GD675-3E0
Outline
q The accumulator pressure governor valve is
connected to the priority valve and used as a
path for the oil from the priority valve to the
main control valve and control the oil flow to
the brake circuit.
q The oil flowing in the brake circuit is distributed
by the accumulator shuttle valve to the front
and rear brake circuits to heighten the pres-
sure in the brake accumulator. The accumula-
tor charge pressure is transmitted by the
pressure governor valve to the servo valve of
the hydraulic pump.
If it lowers to 9.36 MPa {95.4 kg/cm 2 }, it is
raised.
If it is raised to 13.38 MPa {141 kg/cm2}, it is
stopped rising.
q The LS pressure relief valve is installed to
improve the startability of the engine (particu-
larly in the cold season). While the starting
motor is running, the solenoid operates to
drain the oil sent by the hydraulic pump to the
servo valve to reduce the load on the pump.
GD655-3E0, GD675-3E0 19
Front axle 1
1. Tie rod Specifications

2. Steering cylinder Toe-in: –5 mm
3. Support axle Camber: 0°
4. Leaning rod
5. Leaning cylinder
6. Bracket
7. Hub shaft
20 GD655-3E0, GD675-3E0
Unit: mm
Standard
Tolerance Standard Clearance
size
Clearance between center pin and clearance limit
8 Shaft Hole
bushing
55 –0.030 +0.197 0.167 –
3.0
–0.076 +0.137 0.273
Clearance between king pin and –0.025 +0.142 0.105 – Replace bushing
9 45 2.0
bushing –0.064 +0.080 0.206
Clearance between axle end pin –0.025 +0.142 0.105 –
10 45 2.0
and bushing –0.064 +0.080 0.206
Clearance between ball joint and –0.060 +0.020 0.060 –
11 55 1.0
bushing –0.090 +0.020 0.110
12 Preload of hub bearing Start to rotate: 157 – 196 Nm {16 – 20 kgm} Adjust
GD655-3E0, GD675-3E0 21
Function of front axle 2. Prevention of side slipping of front wheels

1. Lessening blade angling and up-and-down (leaning system)
movement q The front wheels can be tilted to the left or
q The front axle is fixed in the center with a right. This is called the leaning system,
center pin to the frame so that it can oscil- and is to prevent the front wheel from slip-
late 16°. This, like the tandem system, ping sidewards and to reduce the turning
restricts the up-and-down movement of radius.
the blade to a minimum when one front Operations with blade at propulsion angle
wheel rides over an object or falls into a are frequent among grader operations. In
hole. When the front wheel rides over an proportion to the propulsion angle a side
object (height-H), the center point of the slipping force acts on the blade to cause
front axle rises H/2, as shown in drawing. side slipping.
Because of possible rocking of front axle
blade movement rises only H/4 while hold- q Also, the distribution of weight on the front
ing its horizontal posture. Unless the and rear wheels is about 3:7, and when
whole oscillating range (left, right 16°) of the blade cuts into the ground, the load on
the front axle is used, the blade moves up- the front wheels decreases and it is easier
and-down holding its horizontal posture. for the front wheels to slip sideward.
To counteract this side slipping, the front
wheels are leaned to make them more
resistant, and this changes the center of
the load on the front axle and the center of
gravity of the machine and prevents side
slipping.
22 GD655-3E0, GD675-3E0
q When the wheel is leaned that angle

between the center line of the leaned tire
and the perpendicular line is called the
"Leaning angle". Leaning angle is the dis-
tance S = 2 x x x r covered by the tire as it
advances, and the side with the greater
load radius, in order to advance more than
the side with the less load radius,
advances in the direction of the leaning.
Using this characteristic, the turning
radius can be lessened when the leaning
operation is carried out.
q When backing, leaning should be

reversed to the leaning for forward opera-
tion by turning a steering wheel in the
same direction.
Leaning angle is 16°
GD655-3E0, GD675-3E0 23
SEN01784-00

© 2006 KOMATSU
All Rights Reserved
24
SEN01785-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Brake system
Brake system .................................................................................................................................................. 2
Blake hydraulic piping .......................................................................................................................... 2
Brake valve .......................................................................................................................................... 4
Wheel brake ......................................................................................................................................... 8
Slack adjuster....................................................................................................................................... 9
Accumulator ........................................................................................................................................11
Parking brake ..................................................................................................................................... 12
Parking brake and bank control valve ................................................................................................ 13
GD655-3E0, GD675-3E0 1
Brake system 1
Blake hydraulic piping 1
1. Wheel brake (front) 5. Stop lamp switch

2. Wheel brake (rear) 6. Brake valve
3. Accumulator (front) 7. Accumulator pressure governor valve
4. Accumulator (rear) 8. Priority valve
2 GD655-3E0, GD675-3E0
9. Slack adjuster (front)

10. Slack adjuster (rear)
GD655-3E0, GD675-3E0 3
Brake valve 1
1. Piston
2. Spool
3. Spool
A : To rear slack adjuster

B : To front slack adjuster
PA : To accumulator
PB : To accumulator
T : To hydraulic tank
4 GD655-3E0, GD675-3E0
Unit: mm

Clearance between pedal mounting size Shaft Hole clearance limit
4
hole and bracket
–0.025 +0.013 0.175 –
— 0.25
–0.075 +0.013 0.025
–0.025 +0.013 0.175 –
5 Clearance between roller and pin — 0.25
–0.075 +0.013 0.025
Size Tolerance Repair limit
6 Outside diameter of roller 0
30 29.2
–0.5
Replace
Installed Installed Permissible
Free length Free length
7 Control spring height load load
80 N
54.5 49.7 33.4 —
{8.1 kg}
8 Control spring 29.1 — — 28.7 —
60.8 N
9 Return spring 86.2 58 78 —
{6.2 kg}
17.7 N
10 Spring 17 16.5 16.2 —
{1.8 kg}
16.7 N
11 Return spring 31.5 19.5 28 —
{1.7 kg}
GD655-3E0, GD675-3E0 5
Operation 2. When the operation is in balance at the rear

1. Depressing the brake pedal (front) brake
Depressing the brake pedal causes the piston When the brake cylinder-fills with oil and the
(1) and spring (2) to make the spools (3, 4) pressure between port PA (port PB) and port A
move down. The port a (port b) close and oil (port B) increase, the oil entering port e (port f)
now flows from port PA to port A and port PB from orifice c (orifice d) of spool (3) (spool 4)
and port B. Oil then flows from port A (port B) up against the spring (2), and port PA (port PB)
to the rear (front) slack adjuster and actuate and port A (port B) are shut off. When this situ-
the brakes. When this happens, the slack ation happens, drain port a remains closed.
adjuster makes the flow of oil to the left and Thus, the oil entering the rear (front) slack
right brakes the same to ensure the same adjuster is held and the brake remains actu-
braking effect on both the left and right sides. ated.
6 GD655-3E0, GD675-3E0
3. Releasing the brake

Removing the force from the pedal removes
the force at the piston (1). This action causes
back pressure from the brake cylinder and the
force of the spool return spring to move the
spools (3, 4) up. Drain port a (port b) now
opens. The oil from the slack adjuster flows to
the hydraulic tank return circuit and the brake
released.
GD655-3E0, GD675-3E0 7
Wheel brake 1
1. Guide pin
2. Brake piston
Unit: mm
Size Repair limit
3 Disc thickness
3.8 ± 0.1 3.3 ± 0.1
4 Plate thickness 2.3 ± 0.08 —
5 Total thickness of disc and plate 26.7 ± 0.8 24.7 ± 0.8
Replace
Installed Installed
Free length Installed load
6 Return spring height load
654 N
76.5 60.5 75.0
{66.7 kg}
8 GD655-3E0, GD675-3E0
Slack adjuster 1
1. Bleeder
2. Check valve
3. Piston
A: Inlet port
B: Outlet port
Function Specifications
q The slack adjuster is installed in the brake oil Piston actuation pressure:
line from the brake valve to the brake piston. 0.01 ± 0.01 MPa {0.1 ± 0.1 kg/cm2}
The slack adjuster provides a fixed time lag Check valve cracking pressure:
when applying the brakes. 0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2}
Check valve closing pressure:
0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}
q It also fixes the quantity of oil fed by each
application of the brake to prevent generation
of peak pressure.
Unit: mm

size Shaft Hole clearance limit
4 Clearance between body and piston
–0.030 +0.074 0.030 –
— 0.25
–0.076 +0.074 0.150
Replace
Installed Installed Permissible
Free length Free length
5 Slack adjuster spring height load load
43.2 N
198 38 — —
{4.4 kg}
66.7 N
6 Spring 38.8 33 — —
{6.8 kg}
GD655-3E0, GD675-3E0 9
Operation q Depressing the brake pedal further and

1. Brake pedal depressed the oil pressure discharged from the brake
q Before depressing the brake pedal, the valve goes above the set pressure, the
piston is returned by the distance of stroke check valve (3) opens and the pressure
S (full stroke). Depressing the brake pedal applied to port C acts as the braking force.
discharges the oil from the brake valve Thus, when the brake is applied, the time
and flows from port P of the slack adjuster. lag is a fixed value.
The oil is then divided to the left and right
cylinders (2). The force of the oil moves
the piston (4) by stroke S to the left and
right.
2. Brake pedal released

q Releasing the brake pedal causes the pis-
ton (4) to return by action of the brake
return spring (8) by an amount equivalent
q Depressing the brake pedal moves the to the oil for stroke S. Thus, the brake
brake piston (7) a distance of stroke S. In releases. In other words, the return stroke
this condition, the closer the clearance T of brake piston (7) is determined by the
between the brake piston and the disc is amount of oil for stroke S of the slack
to zero (0), the greater the braking force adjuster. The time lag of the brake is
becomes. always kept constant, regardless of disc
brake wear.
10 GD655-3E0, GD675-3E0
Accumulator 1
1. Valve assembly
2. Top cover
3. Cylinder
4. Piston
The accumulator is installed between the pressure Gas used: Nitrogen
governor valve and brake valve. Cylinder (3) is Amount of gas: 3000 cc
charged with nitrogen gas. Even after the engine Gas charging pressure (at 20 ± 5°C):
stops, braking force is kept by the pressure of the 3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}
nitrogen gas compressed by free piston (4). The
compressibility of the nitrogen gas absorbs the pul-
sating pressure from the hydraulic pump.
GD655-3E0, GD675-3E0 11
Parking brake 1
1. Piston Outline
2. Adjustment bolt q The parking brake is a disc type, and is
3. Caliper installed to the final drive.
4. Disc q The parking brake is applied mechanically by
the force of the spring inside the caliper, and is
released by hydraulic force.
q The parking brake caliper is secured to the
final drive case. The disc is installed to the final
drive coupling and rotates together with the
coupling.
Unit: mm
5 Disc thickness
10.4 9.4
9.5 Replace
6 Pad thickness 12.5 (Remaining thickness when pad
groove has disappeared)
12 GD655-3E0, GD675-3E0
Parking brake and bank control valve 1
1. Solenoid valve for bank control Outline

2. Solenoid valve for parking brake The parking brake control valve has the solenoid
valves for parking brake and bank control.
AP : From accumulator If the solenoid for the parking brake is turned on,
B1 : To bank control cylinder hydraulic oil is supplied to the parking brake to
B2 : To bank control cylinder release the parking brake.
QC : To parking brake If the solenoid for the bank control is turned on,
ST : (Plugged) hydraulic oil is supplied to the bank control cylinder
BR : (Plugged) to move the lock pin in the pulling out direction.
T1 : (Plugged)
T2 : To hydraulic tank
T3 : To accumulator pressure governor valve
T4 : (Plugged)
GD655-3E0, GD675-3E0 13
SEN01785-00

© 2006 KOMATSU
All Rights Reserved
14
SEN01786-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Tandem drive........................................................................................................................................ 2
Main frame ........................................................................................................................................... 5
GD655-3E0, GD675-3E0 1
Undercarriage and frame 1

Tandem drive 1
For standard final drive
1. Breather 5. Plate
2. Hub shaft 6. Oil level plug
3. Sprocket (45 teeth) 7. Drain plug
4. Disc
Unit: mm
No. Check Item Criteria Remedy
8 Hub bearing preload Turning torque: 11 – 16 Nm {1.15 – 1.65 kgm} Adjust
Size Repair limit
9 Extension of chain (10 links) Replace
317.5 322.26
2 GD655-3E0, GD675-3E0
For planetary final drive
1. Breather 5. Plate
2. Hub shaft 6. Oil level plug
3. Sprocket (20 teeth) 7. Drain plug
4. Disc
Unit: mm
No. Check Item Criteria Remedy
8 Hub bearing preload Turning torque: 11 – 16 Nm {1.15 – 1.65 kgm} Adjust
Size Repair limit
9 Extension of chain (10 links) Replace
508.0 515.62
GD655-3E0, GD675-3E0 3
Outline
Power from the final drive is transmitted to the front
and back rear wheels by chain.
The tandem cases can swing up and down 13°
each. All four wheels are in contact with the ground
even when the ground is rough restricting the up-
and-down movement of the blade to a minimum.
Operation
The movement of the blade of a motor grader when
its rear wheel rides over an obstacle as follows:
1. When both left and right wheels ride over an
object (height: H) at the same time, the center
of the rear axle rises H/2 as figure below
shows, and because the blade is situated
about halfway between the front and rear
axles, its movement further becomes H/4.
2. When only one left rear wheel rides over an

object (height: H), the rise at the center of rear
axle is H/2 at its left end as figure below shows
and H/4 at the center line of machine and on
the real axle.
The movement of the center part of the blade
is half of that, which is H/8.
4 GD655-3E0, GD675-3E0
Main frame 1
1. Articulate cylinder
2. Front frame
3. Rear frame
4. Upper center pin
5. Lower center pin
GD655-3E0, GD675-3E0 5
SEN01786-00

© 2006 KOMATSU
All Rights Reserved
6
SEN01787-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Hydraulic system
Hydraulic system............................................................................................................................................. 2
Work equipment hydraulic piping drawing ........................................................................................... 2
Hydraulic pump .................................................................................................................................. 10
Main control valve .............................................................................................................................. 33
CLSS.................................................................................................................................................. 44
GD655-3E0, GD675-3E0 1
Hydraulic system 1
Work equipment hydraulic piping drawing 1
Main piping (1/2)
1. Main control valve (left) 5. LS pressure reducing valve

2. Main control valve (right) 6. Priority valve
3. Hydraulic tank 7. Accumulator pressure governor valve
4. Hydraulic pump
2 GD655-3E0, GD675-3E0
Main piping (2/2)
GD655-3E0, GD675-3E0 3
High pressure piping (1/3)

Left side
4 GD655-3E0, GD675-3E0
High pressure piping (2/3) 1. Pilot check valve – drawbar shift

Right side 2. Pilot check valve – leaning
3. Pilot check valve – articulate
4. Pilot check valve – right blade lift
5. Main control valve – right
6. Articulate cylinder
7. Main control valve
8. Pilot check valve – left blade lift
9. Pilot check valve – blade tip
10. Blade lift cylinder
GD655-3E0, GD675-3E0 5
High pressure piping (3/3)
1. Swivel joint
2. Drawbar side-shift cylinder
3. Blade tilt cylinder
6 GD655-3E0, GD675-3E0
Lifter lock piping
1. Parking and bank control valve Function

2. Bank pin The lifter bracket (3) is fixed by the bank pin (2).
3. Lifter bracket When setting in the bank cutting position, operate
control lever. This uses hydraulic oil to push piston.
The pin can be removed and the bracket can be
rotated.
GD655-3E0, GD675-3E0 7
Bank pin
1. Pin
2. Piston
3. Cover
4. Shaft
5. Case
6. Bushing
8 GD655-3E0, GD675-3E0
Hydraulic pump 1
PA : Pump discharge a The main pump consists of one unit formed by

PA1 : Pump pressure detection port the pump, servo piston, PC valve, and LS
PA2 : LS pump pressure port valve.
PA3 : Drain port The explanation in Structure, function and
PDA : Pump air bleed maintenance standard is divided into two parts:
PD1 : Pump drain the pump and the PC valve + LS valve.
PD2 : Pump drain
PEN : Control pressure detection port
PLS : LS pressure input
PS : Pump suction
10 GD655-3E0, GD675-3E0
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
GD655-3E0, GD675-3E0 11
Pump
Function
q The engine rotation and torque transmitted to
the pump shaft is converted into hydraulic
energy, and pressurized oil is discharged
according to the load.
q It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by q Cylinder block (7) seals the pressure oil to
spline a, and shaft (1) is supported by the front valve plate (8) and carries out relative rotation.
and rear bearings. This surface is designed so that the oil pres-
q The tip of piston (6) is a concave ball, and shoe sure balance is maintained at a suitable level.
(5) is caulked to it to form one unit. Piston (6) q The oil inside each cylinder chamber of cylin-
and shoe (5) form a spherical bearing. der block (7) is sucked in and discharged
q Rocker cam (4) has flat surface A, and shoe through valve plate (8).
(5) is always pressed against this surface while
sliding in a circular movement. Rocker cam (4)
brings high pressure oil at cylindrical surface B
with cradle (2), which is secured to the case
and forms a static pressure bearing when it
slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
12 GD655-3E0, GD675-3E0
Operation (The diagram shows chamber F at the end

1. Operation of pump of the suction process and chamber E at
1) Cylinder block (7) rotates together with the end of the discharge process.)
shaft (1), and shoe (5) slides on flat sur-
face A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle (α)
between center line X of rocker cam (4)
and the axial direction of cylinder block (7)
changes. (Angle (α) is called the swash
plate angle.)
3) If center line X of rocker cam (4) is in line

with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does
not carry out any suction or discharge of
oil. (In actual fact, the swash plate angle
never becomes 0.)
2) Center line X of rocker cam (4) maintains 4) In other words, there is a proportional rela-
swash plate angle (α) in relation to the tionship between swash plate angle (α)
axial direction of cylinder block (7), and and the pump discharge amount.
flat surface A moves as a cam in relation
to shoe (5).
In this way, piston (6) slides on the inside
of cylinder block (7), so a difference
between volumes E and F is created
inside cylinder block (7). The suction and
discharge is carried out by this difference
F – E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged
during that stroke.
At the same time the volume of chamber F
becomes larg er, and as the volu me
becomes bigger, the oil is sucked in.
GD655-3E0, GD675-3E0 13
2. Control of discharge amount

q If the swash plate angle (α) becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases. Swash plate angle (α) is changed
by servo piston (1).
q Servo piston (1) moves in reciprocating direc-
tions according to the signal pressure from the
PC and LS valves. This straight movement is
transmitted to rocker cam (4). Rocker cam (4)
supported on the cylindrical surface of cradle
(2) slides in rotational directions.
q Servo piston (1) has different pressure receiv-
ing areas on its top and bottom. Main pump
discharge pressure (self pressure) PA is con-
stantly led in the pressure chamber on the
small-diameter piston side (upper side).
q LS valve output pressure PEN is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
by the difference between pressure PA on the
small-diameter piston side and pressure PEN
on the large-diameter piston side and the ratio
of the pressure receiving area of the small-
diameter piston to that of the large-diameter
piston.
14 GD655-3E0, GD675-3E0
PC valve, LS valve, servo piston
PA : Pump discharge pressure Servo piston

PA2 : LS pump pressure inlet 1. Servo piston
PA3 : Drain 2. Lever
PLS : LS pressure inlet 3. Spring
PC valve
4. Piston
5. Spring
6. Seat
7. Spring
8. Spool
9. Sleeve
10. Plug
LS valve
11. Plug
12. Sleeve
13. Spring
14. Spool
16 GD655-3E0, GD675-3E0
LS valve
Function
q The LS valve controls the pump discharge
amount according to the amount of movement
o f t h e c o n t r o l l e v e r, t h a t i s t h e o i l f l o w
demanded by the actuator.
q The LS valve detects the oil flow demanded by
the actuator from the differential pressure
dPLS between inlet pressure PA2 of the con-
trol valve and control valve outlet pressure
PLS and controls main pump discharge
amount Q. (PA2 is called the LS pump pres-
sure, PLS is called the LS pressure, and dPLS
is called the LS differential pressure.)
q In other words, the pressure loss (= LS differ-
ential pressure dPLS) generated by the oil
flowing from the pump through the open area
of the control valve spool is detected. Pump
discharge amount Q is so controlled that this
pressure loss will remain constant to supply oil
from the pump according to the demand of the
actuator.
q Main pump discharge pressure PA, LS pump
pressure PA2, and LS pressure PLS are led in
the LS valve. The relationship between LS dif-
ferential pressure dPLS and pump discharge
amount Q changes as shown in the figure
below.
GD655-3E0, GD675-3E0 17
Operation
1. When control valve is at HOLD position
18 GD655-3E0, GD675-3E0
q LS pressure PLS from the control valve outlet

is led in spring chamber a of the LS valve. LS
pump pressure PA2 at the control valve inlet is
lead in chamber b at the sleeve end on the
opposite side.
q The position of spool (14) is determined by the
resultant of "LS pressure PLS and force of
spring (13)" and the level of pump pressure
PA2.
q Before the engine is started, servo piston (1) is
pushed down (toward the maximum swash
plate angle side) by spring (3).
q After the engine is started, if all the control
valves are in neutral, no oil flows to the outlet
side of the control valves and LS pressure PLS
is 0 MPa {0 kg/cm2}. (Spring chamber a is con-
nected through the control valve spool to the
drain circuit.) At this time, LS pump pressure
PA2 is kept at the unload pressure of about 2.8
MPa {29 kg/cm2}.
q Accordingly, spool (14) is pushed to the right
and ports c and d are connected and pump
pressure PA is led through port d into chamber
X on the large diameter side of servo piston
(1).
q Pump pressure PA is constantly led in cham-
ber Y on the small diameter side of servo pis-
ton (1). Since the force applied to the large
diameter side is larger because of the area dif-
ference between both ends of servo piston (1),
servo piston (1) moves toward the minimum
swash plate angle side (upper side).
GD655-3E0, GD675-3E0 19
2. When opening area of control valve is maximum (lever operated fully)
20 GD655-3E0, GD675-3E0
q If the control lever is moved to the stroke end

and the open area of the control valve is
increased, LS differential pressure dPLS
between LS pump pressure PA2 and LS pres-
sure PLS is reduced.
q LS pressure PLS led in spring chamber a of
the LS valve becomes near LS pump pressure
PA2 and spool (14) is pushed to the left by the
resultant of "LS pressure PLS and force of
spring (13)". As a result, port c is closed and
ports d and e are connected.
q Accordingly, the oil applied to chamber X on
the large diameter side of servo piston (1)
flows through ports d and e to port f of the PC
valve.
q Since the oil in port f of the PC valve is drained
through the piston into the pump case at this
time, the drain pressure is also applied to
chamber X on the large diameter side of servo
piston (1).
q Consequently, servo piston (1) is moved
toward the maximum swash plate angle side
(lower side) by pump pressure PA applied to
chamber Y on the small diameter side.
GD655-3E0, GD675-3E0 21
3. When opening area of control valve is small (small movement of lever)
22 GD655-3E0, GD675-3E0
q When the control lever is operated finely or set

in the HOLD position and the open area of the
control valve is reduced, LS differential pres-
sure dPLS between LS pump pressure PA2
and LS pressure PLS is increased.
q At this time, the mechanism operates as
described in "1. When control valve is at HOLD
position". LS pump pressure PA2 pushes spool
(14) to the right and servo piston (1) moves
toward the minimum swash plate angle side
(upper side).
q In other words, on the basis of the LS set dif-
ferential pressure of 2.35 MPa {24 kg/cm2} for
the LS valve and in the range from the HOLD
position of the control valve to the minimum
open area of the control valve (in the fine con-
trol operation), when LS differential pressure
dPLS is higher than 2.35 MPa {24 kg/cm2}, the
swash plate angle reduces. When the open
area of the control valve increases and LS dif-
ferential pressure dPLS lowers below 2.35
MPa {24 kg/cm 2 }, the swash plate angle
increases.
GD655-3E0, GD675-3E0 23
4. When pump flow is amount demanded by control valve
24 GD655-3E0, GD675-3E0
q Let the pressure receiving area on the large PC valve

diameter side of servo piston (1) be A1, the Function
pressure receiving area on the small diameter q When discharge pressure PA rises and the
side be A2, the pressure applied on the large open area of the control valve is wide, the LS
diameter side be PEN, and the pressure valve increases pump discharge amount Q. At
applied on the small diameter side be PA. this time, the PC valve controls discharge
q When the oil flow from the pump reaches the amount Q so that it will not exceed a certain
flow rate demanded by the control valve, LS level according to discharge pressure PA. That
pump pressure PA2 applied to port b of the LS is, the PC valve performs approximate equal
valve is balanced with the resultant of "LS horsepower control so that the pump absorp-
pressure PLS and the force of spring (13)" tion horsepower will not exceed the engine
applied to spring chamber a and spool (14) is horsepower.
stopped at an almost intermediate point. q In other words, when the load increases and
q As a result, ports c, d, and e are opened pump discharge pressure PA rises during
almost equally. Then, some of the pump oil work, pump discharge amount Q is reduced.
from port c flows in port d and the other is When pump discharge pressure PA lowers,
drained through port e into the tank case. pump discharge amount is increased.
Accordingly, the pressure of this oil is reduced q The relationship between pump discharge
to about 1/2 and applied to chamber X on the pressure PA and pump discharge amount Q is
large diameter side of servo piston (1). shown below.
q At this time, since the relationship of the pres-
sure receiving areas of servo piston (1) is as
A2 : A1 = 1 : 2, the ratio of pressure PA to
pressure PEN applied to both ends of servo
piston (1) is 2 : 1. Accordingly, the same force
is applied to both ends of servo piston (1), and
then servo piston (1) is stopped at the current
position and the oil flow demanded by the con-
trol valve is balanced with the pump discharge.
q The spring force is so adjusted that PA2 – PLS
will be dPLS and will approximately equal 2.35
MPa {24 kg/cm2} to determine the balancing
point of spool (14).
q In other words, when the open area of the con-
trol valve is 1/2, the swash plate angle is also
1/2, and when the open area of the control
valve is 1/4, the swash plate angle is also 1/4.
The pump discharge is changed according to
the open area of the control valve by keeping
LS differential pressure dPLS at 2.35 MPa {24
kg/cm2}.
q For example, if the spool is balanced at 1/4 of
the open area of the control valve and then the
open area of the control valve is increased to
3/4, LS differential pressure dPLS lowers tem-
porarily. Accordingly, the LS valve operates to
increase the pump discharge. After the swash
plate angle increases to 3/4, however, LS dif-
ferential pressure dPLS rises to 2.35 MPa {24
kg/cm2} and the spool is balanced at this point.
GD655-3E0, GD675-3E0 25
Operation
1. When actuator load is large (pump discharge pressure PA is high)
26 GD655-3E0, GD675-3E0
q When the load on the actuator increases and

pump discharge pressure PA rises, spool (8) is
pushed to the left because of the relationship
between the sectional areas of parts S1 and
S2 of the spool (S1 > S2).
q As a result, ports f and g are connected and
pump discharge pressure PA flows through
port g to port f and port f is disconnected from
the drain circuit.
q If the LS valve increases the pump discharge
amount, spool (14) of the LS valve moves to
the left and ports d and e are connected.
q As a result, pump discharge pressure PA from
port f of the PC valve flows through port e of
the LS valve to port d, and then flows in cham-
ber X on the large diameter side of servo pis-
ton (1) to stop servo piston (1).
q If pump discharge pressure PA rises further,
spool (8) moves to the left and servo piston (1)
is moved by the pressure in chamber X on the
large diameter side toward minimum swash
plate angle side (upper side).
q If servo piston (1) moves up, piston (4) is
moved through lever (2) to the right. Accord-
ingly, springs (5) and (7) are compressed and
they push back spool (8) to the right.
q If spool (8) is pushed back to the right and
ports f and g are disconnected, servo piston
(1) stops moving up.
q At this time, servo piston (1) stops higher
(nearer to the minimum swash plate angle)
than when the pump discharge pressure is low.
GD655-3E0, GD675-3E0 27
2. When actuator load becomes smaller (pump discharge pressure PA drops)
28 GD655-3E0, GD675-3E0
q When the load on the actuator is reduced and

pump discharge pressure PA lowers, spool (8)
is pushed back to the right by the forces of
springs (5) and (7).
q As a result, ports g and f are disconnected and
port f is connected to the drain circuit.
q At this time, if the LS valve increases the pump
discharge amount, the PC valve does not limit
the oil flow. Accordingly, as explained in the
section of the LS valve, the oil in chamber X on
the large diameter side of servo piston (1)
flows through ports d and e of the LS valve and
port f of the PC valve to the drain circuit.
q As a result, servo piston (1) is moved by the
pressure in chamber Y on the small diameter
side toward the maximum swash plate angle
side (lower side).
GD655-3E0, GD675-3E0 29
3. Action of spring
30 GD655-3E0, GD675-3E0
q The forces of springs (5) and (7) of the PC

valve vary with the swash plate angle of the
pump.
q If servo piston (1) moves, lever (2) moves and
piston (4) moves to the right or left according to
the turning direction of lever (2).
q If piston (4) moves to the right, springs (5) and
(7) are compressed first. If piston (4) moves to
the right further, spring (5) touches seat (6) and
only spring (7) works as a spring. That is, the
forces of springs (5) and (7) change as piston
(4) compresses or releases those springs.
q The pump absorption torque curve showing
the relationship between pump discharge pres-
sure PA and discharge amount Q is broken as
shown in the following figure, since the spring
constants of springs (5) and (7) are different.
q In other words, if pump discharge pressure PA
rises, pump discharge amount Q is reduced,
and if pump discharge pressure PA lowers,
pump discharge amount Q is increased.
GD655-3E0, GD675-3E0 31
Main control valve 1

Left 4-spool valve (1/3)
P : Pump port (from main pump) A2 : To blade shift cylinder bottom

PP : PP port (to main pump) B2 : To blade shift cylinder head
LS : LS port (to main pump) A3 : To circle motor
T : Tank port (to tank) B3 : To circle motor
TS : Seal drain port (to tank) A4 : To blade tilt cylinder bottom
A1 : To left blade lift cylinder bottom B4 : To blade tilt cylinder head
B1 : To left blade lift cylinder head
GD655-3E0, GD675-3E0 33
34 GD655-3E0, GD675-3E0
1. Spool (blade tilt) 9. Pressure compensation valve R (blade tilt)

2. Spool (circle) 10. Pressure compensation valve R (circle)
3. Spool (blade shift) 11. Pressure compensation valve R (blade shift)
4. Spool (Left blade lift) 12. Pressure compensation valve R (left blade lift)
5. Pressure compensation valve F (left blade lift) 13. LS bypass plug
6. Pressure compensation valve F (blade shift) 14. Unload valve
7. Pressure compensation valve F (circle) 15. Safety-suction valve
8. Pressure compensation valve F (blade tilt)
Unit: mm
Free length Installed
Installed load Free length Installed load
16 Spool return spring x OD length
34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
34.8 N 27.9 N Replace spring if
17 Spool return spring (circle) 87.7 x 19.7 25.4 —
{3.55 kg} {2.84 kg} damaged or
Pressure compensation valve 6.9 N 5.52 N deformed
18 23 x 8.4 15 —
spring (R) {0.7 kg} {0.56 kg}
Pressure compensation valve 7.45 N 5.98 N
19 15.4 x 6 8 —
spring (F) {0.76 kg} {0.61 kg}
137 N 110 N
20 Unload valve spring 35.25 x 19 20.5 —
{14 kg} {11.2 kg}
GD655-3E0, GD675-3E0 35
Right 4-spool valve (1/3)
P : Pump port (from main pump)

PP : PP port (to main pump)
LS : LS port (to main pump)
T : Tank port (to tank)
TS : Seal drain port (to tank)
A1 : To right blade lift cylinder bottom
B1 : To left blade lift cylinder head
A2 : To leaning cylinder head
B2 : To leaning cylinder bottom
A3 : To articulating cylinder head
B3 : To articulating cylinder bottom
A4 : To drawbar shift cylinder head
B4 : To drawbar shift cylinder bottom
GD655-3E0, GD675-3E0 37
38 GD655-3E0, GD675-3E0
1. Spool (right blade lift) 8. Pressure compensation valve F (drawbar shift)

2. Spool (leaning) 9. Pressure compensation valve R (drawbar shift)
3. Spool (articulating) 10. Pressure compensation valve R (articulating)
4. Spool (drawbar shift) 11. Pressure compensation valve R (leaning)
5. Pressure compensation valve F (right blade 12. Pressure compensation valve R (right blade
lift) lift)
6. Pressure compensation valve F (leaning) 13. LS relief valve
7. Pressure compensation valve F (articulating) 14. Main relief valve
Unit: mm
34.8 N 27.8 N Replace spring if
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg} damaged or
Pressure compensation valve 6.9 N 5.52 N deformed
16 23 x 8.4 15 —
spring (R) {0.7 kg} {0.56 kg}
17 15.4 x 6 8 —
spring (F) {0.76 kg} {0.61 kg}
GD655-3E0, GD675-3E0 39
P : Pump port (from main pump) B2 : To left blade lift cylinder head
PP : PP port (to main pump) A3 : To blade shift cylinder bottom
LS : LS port (to main pump) B3 : To blade shift cylinder head
T : Tank port (to tank) A4 : To circle motor
TS : Seal drain port (to tank) B4 : To circle motor
A1 : To ripper cylinder bottom A5 : To blade tilt cylinder bottom
B1 : To ripper cylinder head B5 : To blade tilt cylinder head
A2 : To left blade lift cylinder bottom
GD655-3E0, GD675-3E0 41
42 GD655-3E0, GD675-3E0
1. Spool (blade tilt) 11. Pressure compensation valve R (blade tilt)

2. Spool (circle) 12. Pressure compensation valve R (circle)
3. Spool (blade shift) 13. Pressure compensation valve R (blade shift)
4. Spool (left blade lift) 14. Pressure compensation valve R (left blade lift)
5. Spool (ripper) 15. Pressure compensation valve (ripper)
6. Pressure compensation valve F (ripper) 16. LS bypass plug
7. Pressure compensation valve F (left blade lift) 17. Unload valve
8. Pressure compensation valve F (blade shift) 18. Safety-suction valve
9. Pressure compensation valve F (circle) 19. Safety-suction valve
10. Pressure compensation valve F (blade tilt)
Unit: mm
34.8 N 27.9 N
56.27 x 20.1 25.4 —
{3.55 kg} {2.84 kg}
34.8 N 27.9 N
21 Spool return spring 87.7 x 19.7 25.4 —
{3.55 kg} {2.84 kg} Replace spring if
Pressure compensation 6.9 N 5.52 N damaged or
22 23 x 8.4 15 — deformed
valve spring (R) {0.7 kg} {0.56 kg}
Pressure compensation 7.45 N 5.98 N
23 15.4 x 6 8 —
valve spring (F) {0.76 kg} {0.61 kg}
137 N 110 N
24 Unload valve spring 35.25 x 19 20.5 —
{14 kg} {11.2 kg}
25 18.9 x 8.4 15 —
spring (R) {1.6 kg} {1.28 kg}
GD655-3E0, GD675-3E0 43
CLSS 1
1. Outline of CLSS
Features
CLSS stands for Closed center Load Sensing Sys-
tem, and has the following features.
1) Fine control not influenced by load.
2) Control enabling digging even with fine control.
3) Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations.
4) Energy saving using variable pump control.
Structure
q The CLSS consists of a variable capacity sin-
gle piston pump, control valve, and actuators.
q The pump body consists of the main pump, the
PC valve and LS valve.
44 GD655-3E0, GD675-3E0
2. Basic principle
1) Control of pump swash plate angle
q The pump swash plate angle (pump dis-
charge amount) is controlled so that LS
differential pressure (dPLS) (the differ-
ence between pump pressure (PP) and
control valve outlet port LS pressure
(PLS)) (load pressure of actuator) is con-
stant.
q (LS pressure (dPLS) = Pump discharge
pressure (PP) – LS pressure (PLS))
q If LS differential pressure (dPLS)
becomes lower than the set pressure of
the LS valve, the pump swash plate
becomes larger; if it becomes higher than
the set pressure of the LS valve, the pump
swash plate becomes smaller.
a For details of the operation, see "Hydraulic
pump".
GD655-3E0, GD675-3E0 45
2) Pressure compensation control

q Valves (pressure compensation valves)
are installed on the inlet side of the control
valves to balance the load. When the
actuators are operated simultaneously,
pressure difference (ΔP) between the
upstream (inlet) of the spool of each valve
and downstream (outlet) is kept constant
by the pressure compensation valves,
regardless of the load (pressure). Accord-
ingly, the oil flow from the pump is distrib-
uted (compensated) in proportion to the
open areas (S1) and (S2) of the operated
valves.
46 GD655-3E0, GD675-3E0
3. Functions and operation of each valve

Hydraulic circuits and names of valves
1. Unload valve 4. Pressure compensation valve

2. LS relief valve 5. Safety-suction valve
3. Main relief valve 6. LS pressure reducing valve
GD655-3E0, GD675-3E0 47
Unload valve
1) When control valve is at HOLD
Function
q When the control valve is at HOLD, pump dis-
charge amount Q discharged by the minimum
swash plate angle is released to the tank cir-
cuit. When this happens, pump discharge
pressure PP is set to 2.9 MPa {30 kg/cm2} by
spring (2) inside the valve.
LS pressure PLS: 0 MPa {0 kg/cm2}.
Operation
q At the left end of the spool (1), pump pressure PP : Pump circuit
PP is acting on area S1, and at the right end of PLS : LS circuit
spool (1), pump pressure PP is acting on area T : Tank circuit
S2, and LS pressure PLS is acting on area S3. A : To valves
q When the control valve is at HOLD, LS pres- B : To pump LS valve
sure PLS is not generated, so only pump dis-
charge pressure PP has any effect, and PP is
set by the load of spring (2).
q As pump discharge pressure PP rises and
becomes PP x S1 = PP x S2 + spring force of
spring (2), spool (1) is moved to the right.
Pump circuit PP is then connected to tank cir-
cuit T through the drill hole.
q In this way, pump discharge pressure PP is set
to 2.9 MPa {30 kg/cm2}.
48 GD655-3E0, GD675-3E0
2) During fine control of control valve opera-

tion
Function
q During the fine control of the control valve,
when the demand flow for the actuator is within
the amount discharged by the minimum swash
plate angle of the pump, pump discharge pres-
sure PP is set to LS pressure PLS + 2.9 MPa
{30 kg/cm2}. When the difference in pressure
between pump discharge pressure PP and LS
pressure PLS reaches the load of spring (2)
(2.9 MPa {30 kg/cm2}), the unload valve opens,
so LS differential pressure dPLS becomes 2.9
MPa {30 kg/cm2}.
Operation
q When fine control is carried out on the control PP : Pump circuit
valve, LS pressure PLS is generated and acts PLS : LS circuit
on area S3 at the right end of spool (1). When T : Tank circuit
this happens, the area of the opening of the A : To valves
control valve spool is small, so there is a big B : To pump LS valve
difference between LS pressure PLS and
pump discharge pressure PP.
q When the difference in pressure between
pump discharge pressure PP and LS pressure
PLS reaches the load of spring (2), spool (1)
moves to the right, and pump circuit PP and
tank circuit T are connected.
q In other words, pump discharge pressure PP is
set to a pressure equal to the force of spring
(2) (2.9 MPa {30 kg/cm2}) + LS pressure PLS,
and LS differential pressure dPLS becomes
2.9 MPa {30 kg/cm2}.
GD655-3E0, GD675-3E0 49
3) When control valve is operated

Function
q When the control valve is being operated and
the demand flow for the actuator becomes
greater than the pump discharge from the min-
imum swash plate angle, the flow of the oil out
to tank circuit T is shut off, and all the pump
discharge amount Q flows to the actuator cir-
cuit.
Operation
q When the control valve is operated to a larger PP : Pump circuit
stroke, LS pressure PLS is generated and acts PLS : LS circuit
on area S3 at the right end of spool (1). When T : Tank circuit
this happens, the area of the opening of the A : To valves
control valve spool is large, so the difference B : To pump LS valve
between LS pressure PLS and pump dis-
charge pressure PP is small.
q For this reason, the difference in pressure
between pump discharge pressure PP and LS
pressure PLS does not reach the load of
spring (2) (2.9 MPa {30 kg/cm2}), so spool (1)
is pushed to the left by spring (2).
q As a result, pump circuit PP and tank circuit T
are shut off, and all the pump discharge
amount Q flows to the actuator circuit.
50 GD655-3E0, GD675-3E0
Introduction of LS pressure
Function q It actually reduces pump pressure PP at reduc-
q The LS pressure is the actuator load pressure ing valve (3) of the pressure compensation
at the outlet port end of the control valve. valve to the same pressure as actuation circuit
pressure A, and sends it to the LS circuit PLS.
Operation
q When spool (1) is operated, pump pressure PP q Actuator circuit pressure PA (=A) acts on the
flows from flow control valve (2) and notch a in left end of reducing valve (3); the reduced
a spool (1) through bridge passage b to actua- pump pressure PP acts on the other end.
tor circuit A. q As a result, reducing valve (3) is balanced at a
q At the same time, reducing valve (3) also position where actuator circuit pressure PA
moves to the right, so pump pressure PP has and the pressure of spring chamber PLS1 are
its pressure reduced by the pressure loss at the same. Pump pressure PP reduced at notch
notch C. It is introduced to LS circuit PLS, and C becomes actuator circuit pressure A and is
then goes to spring chamber PLS1. taken to LS circuit pressure PLS.
q When it happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (see
the section on the LS bypass plug).
GD655-3E0, GD675-3E0 51
Pressure compensation valve

Function
q During compound operations, if the load pres-
sure becomes lower than the other actuator
and the oil flow tries to increase, compensation
is received. (When this happens, the other
actuator being used for compound operation
(right side) is at a higher load than the actuator
on this side (left side).)
Operation
q If the load pressure of the other actuator (right q In this way, the pressure difference between
side) becomes higher during compound opera- upstream pressure PPA and downstream pres-
tions, the oil flow in actuator circuit A on this sure PA of both spools used during compound
side (left side) tries to increase. operations is the same, so the pump flow is
q If this happens, the LS pressure PLS of the divided in proportions to the area of opening of
other actuator acts on spring chamber PLS1, notch a of each spool.
and reducing valve (1) and flow control valve
(2) are pushed to the left (i).
q Flow control valve (2) throttles the area of
opening between pump circuit PP and spool
upstream PPA, and pressure loss is generated
between PP and PPA.
q Flow control valve (2) and reducing valve (1)
are balanced in position where the difference
in pressure between PLS and PA acting on
both ends of reducing valve (2) and the pres-
sure loss between PP and PPA on both sides
of flow control valve (2) are the same.
52 GD655-3E0, GD675-3E0
LS bypass plug
Function
q It releases the residual pressure of LS pres-
sure PLS.
q It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with
this discarded throttled flow, it creates a pres-
sure loss in the throttled flow of the spool or
shuttle valve, and increases the stability by
lowering the effective LS differential pressure.
Operation
q The pressurized oil for LS circuit PLS passes PP : Pump circuit
from clearance filter a (formed by the clear- PLS : LS circuit
ance between LS bypass plug (1) and the T : Tank circuit
valve body) through orifice b and flows to the A : To valves
bank circuit T. B : To pump LS valve
GD655-3E0, GD675-3E0 53
LS relief valve
A: L.H. control valve (unload section)

B: R.H. control valve (LS relief section)
Function Operation
q Even if the LS orifice functions, if another actu- q If the LS circuit pressure PLS goes up and
ator is relieved in compound operation, the reaches the set pressure of LS relief valve (1),
actuator speed is lower than in single opera- PLS is kept constant.
tion. q When this happens, the pump circuit PP is set
q When another actuator is relieved, if the speed to PLS + the spring force of unload valve (2).
lowers remarkably, the working performance is q The relief amount of pump circuit PP flows
lowered. To prevent this, the LS relief valve is from unload valve (2) to circuit T. (Pump mini-
employed. mum swash plate flow).
q A small pilot relief valve installed to the LS cir- q Relief valve (3) is a backup for the LS relief
cuit controls the maximum pressure. valve and has the function of a surge absorp-
q The unload valve works as a relief valve tion valve.
installed to the main control valve and relieves
the oil.
q In addition, since the LS differential pressure
equivalent to the set pressure of the unload
valve is secured, the actuator speed does not
lower even if another actuator is relieved.
54 GD655-3E0, GD675-3E0
LS reducing valve
A: To main control valve

B: To pump LS port
C: From steering valve LS port
D: From steering valve P port
E: To pump PP port
Function Operation
q The LS differential pressure (dPLS) of the q Pump pressure PCF and LS pressure PLS (st)
main control valve and the steering valve are are brought in from the steering valve.
set to different values; the value for the main q The PCF pressure is taken as the base pres-
control valve is higher. sure, and LS pressure PLS (v) reduced from
q If the steering is operated with this circuit, the PLS (st) by the load of spring (1) is taken to the
pump discharges the maximum flow. The main control valve.
excess oil is relieved by the unload valve of the q Check valve (2) is installed to prevent the PP
main control valve, so there is a large energy pressure when the work equipment is operated
loss. To prevent this, the steering LS pressure from entering the steering valve.
is reduced and is set to the same value as the
LS differential pressure of the main control
valve. This reduces the loss.
GD655-3E0, GD675-3E0 55
SEN01787-00

© 2006 KOMATSU
All Rights Reserved
56
SEN01788-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Work equipment
Work equipment .............................................................................................................................................. 4
Work equipment control ....................................................................................................................... 4
Hydraulic system.................................................................................................................................. 6
Hydraulic tank ...................................................................................................................................... 9
Swivel joint ......................................................................................................................................... 10
Pilot check valve .................................................................................................................................11
Blade accumulator, float valve ........................................................................................................... 15
Blade float device............................................................................................................................... 18
Circle rotation motor ........................................................................................................................... 20
Hydraulic cylinder............................................................................................................................... 22
Circle, drawbar ................................................................................................................................... 24
Blade .................................................................................................................................................. 26
Circle rotation gear ............................................................................................................................. 28
GD655-3E0, GD675-3E0 1
Scarifier .............................................................................................................................................. 32
Ripper................................................................................................................................................. 34
2 GD655-3E0, GD675-3E0
Work equipment 1
Work equipment control 1
1. Steering adjustment knob Outline

2. R.H. blade lift lever Steering tilt mechanism:
3. Leaning lever Rotate the steering adjustment knob (1) to release
4. Articulation lever the lock. Set steering to a suitable position, and
5. Drawbar shift lever then tighten the lever.
6. Blade rotation lever
7. Blade tilt lever Console box tilt mechanism:
8. Blade shift lever Depress the steering control tilt pedal (11) and
9. Ripper, scarifier lever (if equipped) adjust the console box. The tilt angle can be
10. L.H. blade lift lever adjusted steplessly to a maximum of 24°.
11. Steering control tilt pedal
In this way, it is possible for the operator to set the
steering and control levers to the optimum position.
4 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 5
Hydraulic system 1
Structure of system
Outline of system 3) The pressure loss caused by flow resis-

1. Hydraulic pump tance in the piping varies according to the
1) The hydraulic oil inside the hydraulic tank temperature. At low temperature, the nec-
passes through the hydraulic pump and is essary control pressure may be lacking,
sent to the priority valve. and the necessary flow may not be pro-
2) The hydraulic pump is the source of vided. But to prevent this, pressure PP
hydraulic power for the steering brake, which is close to each piece of equipment
work equipment, parking brake, and bank is brought to the hydraulic pump, and the
control lock pin. When there is a demand pressure generated by the hydraulic pump
from the equipment, it generates an oil is controlled so that the differential pres-
flow of the necessary amount and pressure between PP and LS is 2.35 MPa {24
sure to match the demands of the equip- kg/cm2}.
ment. 4) In addition, it checks the pressure and dis-
= LS pressure + control pressure charge amount of the hydraulic pump, and
2.35 MPa {24 kg/cm2} ensures the resilience of the engine when
At neutral, the steering LS pressure there is compound operation or when
0.8 to 1.1 MPa {8 to 11 kg/cm 2 } + 2.35 there is excessive load caused by PQ
MPa {24 kg/cm2} + pressure loss in piping control when controlling at PQ = constant
= 3.24 to 3.63 MPa (33 to 37 kg/cm2}. value.
6 GD655-3E0, GD675-3E0
5) When there are no demands for oil from 3. Brake circuit

the steering or work equipment (the sys- 1) The oil that is given priority and ensured
tem is at neutral), the swash plate in the for the circuit has its pressure raised to the
hydraulic pump is held at a position where necessary pressure by the priority valve
a fixed minimum flow is discharged so that and is charged in the brake accumulators
the hydraulic pump can respond swiftly to inside the piping of the two systems.
any rapid operation of the steering wheel 2) If the brake is used and the pressure goes
or work equipment. down to 9.36 MPa {95 kg/cm2 } the accu-
mulator pressure governor valve is actu-
2. Steering circuit ated and the brake accumulator is
1) The priority valve is provided to ensure the charged to the specified pressure of 13.4
necessary oil flow and to give priority to MPa {137 kg/cm2}.
the oil flow in the steering brake system, 3) Even after the engine is stopped, braking
which is closely related to safety, rather is possible for a limited time using the
than to the work equipment. pressure inside the brake accumulator.
2) The steering valve is an energy saving 4) When the brake accumulator pressure
closed center type which lets the hydraulic goes down, the force releasing the parking
oil flow only when necessary. When the brake is reduced and the parking brake is
steering is not being operated, it stops the automatically applied by the force of the
flow of oil. spring. If the machine is stopped for a cer-
When the steering wheel is operated, the tain time, the parking brake is automati-
pressure (LS pressure) passes through cally applied, and it can only be released
the accumulator pressure governor valve by starting the engine.
o LS pressure regulator valve, and goes 5) In postures such as the bank cut posture
to the servo valve of the hydraulic pump to or shoulder reach posture, when changing
ensure the necessary flow. It also gener- the posture of the work equipment, the
ates pressure so that Pb = LS pressure + lifter lock pin is removed and installed.
2.35 MPa {24 kg/cm2} + pressure loss in When doing this, the accumulator is also
piping. At the same time, the LS pressure used as the source of hydraulic power.
is transmitted to the priority valve through 6) The brakes are the most important
the accumulator pressure governor valve. devices for ensuring safety, so charging
Priority is given to the steering circuit by always starts immediately after the engine
keeping the spool at a position where it is started. But particularly when starting in
can provide the necessary oil flow to the c o l d w e a th e r, i f t h e a c c u m u l at o r i s
steering circuit, regardless of whether charged during the starting operation,
there is any demand for oil from the work there will be an excessive load on the
equipment. hydraulic pump, and this will make it diffi-
3) The steering valve is a Q-Amp type that cult to start the engine. To prevent this, an
provides good control at high speed and electromagnetic LS pressure release
can also ensure the steering ability if the valve is installed in the accumulator pres-
engine should stall or if any problem sure governor valve. This cancels the
should occur in the variable pump. charging of the accumulator when the
4) The maximum pressure in the steering cir- starting motor is cranking and makes it
cuit is determined by the relief valve inside easier to start the engine.
the priority valve. It is different from the
hydraulic pressure for the work equip-
ment.
GD655-3E0, GD675-3E0 7
4. LS pressure regulator valve 5. Control valve

1) To improve the response when the steer- 1) The control valve is closed center type, so
ing is operated suddenly and to ensure a at neutral when the work equipment is not
quick response for the work equipment, a being used, the hydraulic oil returns from
specified minimum flow of oil is dis- the unload valve to the hydraulic tank. The
charged from the hydraulic pump, so an unload pressure 3.1 MPa {32 kg/cm 2 }
unload valve is installed to the control when the engine is at low idle and 3.5
valve. MPa {35 kg/cm2} when it is at full throttle.
2) When the steering is operated, the steer- 2) When the work equipment control valve
ing LS pressure rises and the pump dis- lever is operated, the pressure at the
charge pressure is increased. For this valve inlet side is transmitted to the
reason, the steering Pb pressure also hydraulic pump as Pb. At the same time,
rises, but the function of the priority valve the maximum pressure for the work equip-
sends the excess oil used for the steering ment load passes through the LS line and
to the control valve. When this happens, if is transmitted to the hydraulic pump, so
the control valve is open, this excess oil the necessary oil flow is sent from the
flow is relieved by the unload valve and hydraulic pump.
returns to the tank. This causes an energy 3) At the hydraulic relief, the upper limit for
los s, s o when the steer ing brak e i s the LS pressure is determined by the LS
charged and the oil is not being used for relief valve. The control valve is a closed
the work equipment, a signal is sent to the center load sensing valve, and has a pro-
unload valve. The control valve is set to portional flow and proportional dividing
on-load and shuts off the flow of oil back to pressure compensation function. It also
the hydraulic tank to prevent loss of has a built-in unload valve, LS relief valve,
energy. a surge absorption valve. This gives it the
3) The internal shuttle valve transmits the following features.
higher of the steering brake charge LS q The operating effort is light and the
pressure and the work equipment LS lever travel is short.
pressure to the pump to make it possible q It is possible to adjust each work
to carry out simultaneous operations. equipment to the optimum cylinder
4) The excess oil flow for the steering brake set speed.
is sent to the control valve. q The raise and lower speeds (cylinder
extending and retracting speeds) are
th e s am e, s o t he h ei gh t c an b e
adjusted.
q There is a wide fine control range.
q A constant movement position can be
obtained, regardless of the load.
q The work equipment can be operated
with small movements of the lever
and fine control is easy.
q Operations are certain even during
simultaneous operations.
q Simultaneous operations are possible
even when there is lack of oil.
q Other work equipment moves even
when there is hydraulic relief.
When used in combination with the CLSS

hydraulic pump, it has the following fea-
tures.
q The work equipment speed is fixed,
regardless of the engine speed.
q The neutral loss is reduced.
q The relief loss is reduced.
q There is little problem of the engine
stalling even during compound opera-
tions or when there is a large load.
8 GD655-3E0, GD675-3E0
Hydraulic tank 1
1. Filter
2. Filter by-pass
3. Oil filler
4. Oil filler strainer
5. Strainer
GD655-3E0, GD675-3E0 9
Swivel joint 1
1. Plug a. Blade tilt cylinder head

2. Plate b. Blade tilt cylinder bottom
3. Cover c. Blade shift cylinder head
4. Shaft d. Blade shift cylinder bottom
5. Rotor
10 GD655-3E0, GD675-3E0
Pilot check valve 1

For blade lift (right), leaning, articulating, drawbar shift
1. Piston
2. Check valve
3. Body
4. Piston
5. Check valve
A: From control valve

B: From control valve
C: To cylinder head
D: To cylinder bottom
Operation
When the hydraulic cylinder is extended, the con-
trol valve is operated and oil from the pump enters
port A, opens check valve (5), and flows to port D.
When pressure is generated, the oil from orifice a
pushes up piston (1), then opens check valve (2),
connects port C and port B, and flows to the drain
port.
Hunting occurs when check valve (2) opens and
closes to compensate for changes in the pressure
at the bottom end and head end, but even if the
pressure at port A goes down, orifice a is provided,
so there is a damper effect to prevent check valve
(2) from closing immediately.
GD655-3E0, GD675-3E0 11
For blade lift (left)
1. Check valve
2. Plug
3. Body
4. Piston
5. Relief valve
The check valve with safety valve prevents hydrau-

lic drift of the cylinder and also protects the cylinder
from abnormal pressure caused by external force.
When the blade lift is raised to the maximum posi-
tion and the drawbar is shifted to the side, the draw-
bar stopper and lifter come into contact.
The check valve with safety valve installed to the
blade lift cylinder (left) acts to prevent damage to
the work equipment caused by this contact.
Operation
When the lever is operated to retract the cylinder,
oil from the pump enters chamber A1 and pushes
check valve (1). It then passes through chamber B1
and flows to the chamber at the head of the cylinder
to push the cylinder piston. The oil at the cylinder
bottom end flows back through chamber B2 and
chamber A2 and returns to the tank.
When the lever is operated to extend the cylinder,
the oil from the pump enters chamber A2 and flows
through chamber B2 to the cylinder bottom end. As
the pressure in chambers A2 and B2 rises, piston
(4) is pushed. This pushes open check valve (1),
and the oil at the cylinder head flows from chamber
B1 through the throttle of check valve (1). It then
flows from chamber A1 back to the tank.
If there is any shock to the work equipment during
operations, and the pressure in chamber B1 rises
to an abnormal pressure of 28.4 MPa {290 kg/cm2}
or more, relief valve (5) is pushed open and the oil
flows to chamber B2. This raises the work equip-
ment and relieves the shock.
12 GD655-3E0, GD675-3E0
For blade tilt, ripper
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve

Operation
When the lever is operated to extend the cylinder,
oil from the pump enters chamber A1 and pushes
piston (2) and check valve (4). It then passes
through chamber B1 and flows to the chamber at
the bottom end of the cylinder. The oil at the cylin-
der head flows back through chamber B2 and
chamber A2 and returns to the tank.
When the lever is operated to retract the cylinder,
the oil from the pump enters chamber A2. As the
pressure in chamber A2 rises, check valve (1) is
pushed. This pushes open check valve (1), and the
oil flows to the cylinder head from chamber B2.
If shock causes abnormal pressure of over
For blade tilt: 24.5 MPa {250 kg/cm2},
For ripper: 21.5 MPa {219 kg/cm2} in chamber B2, it
pushes open relief valve (5) and oil flows to cham-
ber B1 to relieve the shock.
GD655-3E0, GD675-3E0 13
For scarifier
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve
A1: From control valve

A2: From control valve
B1: To cylinder head
B2: To cylinder bottom

Operation
Operating the lever to retract the cylinder, oil from
the pump enters chamber A1 and pushes check
valve (1). Oil then passes through chamber B1 and
flows to the chamber at the head of the cylinder to
push the cylinder piston. The oil at the bottom of the
cylinder flows back through chamber B2 and cham-
ber A2 and returns to the tank.
Operating the lever to extend the cylinder, oil from

the pump enters chamber A2 and flows through
chamber B2 to the bottom of the cylinder. As pres-
sure increases in chambers A2 and B2, pressure
pushes the piston (4) and opens the check valve
(1). The oil at the cylinder head flows from chamber
B1 through the throttle of check valve (1). It then
flows from chamber A1 back to the tank.
If there is any shock to the work equipment during
operations, and the pressure in chamber B1 rises
to an abnormal pressure of 24.5 MPa {250 kg/cm2}
or more, relief valve (5) is pushed open and the oil
flows to chamber B2. This raises the work equip-
ment and relieves the shock.
14 GD655-3E0, GD675-3E0
Blade accumulator, float valve 1 q The blade float can be used in clearing fresh
snow. It allows only the weight of the work
Outline equipment to push against the snow, making it
q The blade accumulator prevents excessive possible to carry out operations following the
load and pushing up by the blade in propulsion ups and downs on the road surface, allowing
work on roads where there are many buried fresh snow to be cleared effectively at high
rocks. In this way, it improves the durability of speed, while increasing the safety of the oper-
the work equipment and blade, and reduces ation.
operator fatigue.
The blade accumulator can also be used effec-
tively in snow-clearing operations on com-
pacted s now. It is possi ble to ca rry out
operations following the ups and downs on the
road surface, so the snow can be cleared
smoothly.
For blade lift (left)
1. Body A: From main control valve

2. Piston B: From main control valve
3. Check valve C: To cylinder head
4. Check valve D: To cylinder bottom
5. Piston
GD655-3E0, GD675-3E0 15
For blade lift (right)
1. Body A: From main control valve

2. Check valve B: From main control valve
3. Piston C: To cylinder head
4. Piston D: To cylinder bottom
5. Check valve
16 GD655-3E0, GD675-3E0
Accumulator
For blade float
1. Valve assembly
2. Top cover
3. Cylinder
4. Cylinder
When oil pressure is applied to the blade cylinder, Gas used: Nitrogen gas
the pressure oil flows to the accumulator through Amount of gas: 1,000 cc
the solenoid valve and the oil flows into cylinder (4). Gas charging pressure: 2.0 ± 0.1 MPa
Thereby, nitrogen gas is compressed and piston {20 ± 1.0 kg/cm2}
moves upper side. Consequently, the shock (at 20 ± 5°C)
imposed on the blade cylinder is reduced by the
compressible amount of the nitrogen gas.
When the oil pressure in the blade cylinder drops,
the piston moves to lower side by the gas pressure
in cylinder (3), and the oil in cylinder (4) sends to
the blade cylinder until the oil pressure in the cylin-
der balances to that in blade cylinder circuit. The
flow of oil in the accumulator hydraulic circuit is
repeated smoothly to reduce the shock imposed on
the blade.
GD655-3E0, GD675-3E0 17
Blade float device 1
18 GD655-3E0, GD675-3E0
1. Blade float and accumulator switch

2. Blade accumulator, float valve
3. Blade lift cylinder
4. Proximity switch
5. Blade lift control valve
6. Pilot check valve
Outline
q When the lift lever is at N position, and the
blade float and accumulator switch (1) is
pushed to FLOAT position, blade accumulator,
float valve (2) is actuated, and the bottom and
head ends of the blade lift cylinder (3) are con-
nected to the drain circuit. This sets the blade
in a float condition.
q When the blade float and accumulator switch
(1) is pushed to FLOAT position, and the blade
lift lever is operated to the RAISE or LOWER
position, proximity switch (4) turns the blade
float and accumulator switch (1), and the blade
returns to normal RAISE or LOWER condition,
and this condition maintained. If the blade lift
lever is returned to the N position, the blade is
placed in floating condition.
q If the blade and accumulator switch (1) is
pushed to FLOAT position with the blade
raised, the blade will suddenly drop.
GD655-3E0, GD675-3E0 19
Circle rotation motor 1
1. Output shaft
2. Flange
3. Shaft seal
4. Taper roller bearing for heavy loads
5. Main drive
6. O-ring
7. Giroller
8. Valve drive
9. Wear compensation mechanism valve
10. PF1/2 rolling port
11. Check valve
12. Valve plate
20 GD655-3E0, GD675-3E0
Outline
The circle rotation motor is a small, compact low-
speed torque motor and the giroller carries out
planetary motion. Therefore, it can provide the
same torque as other types of hydraulic motors
using a mechanical reduction gear when the reduc-
tion ratio is 1 : 6.
A hydraulic balance type disc valve is used for the
valve mechanism. A high-precision giroller is used,
so leakage is small.
The valve parts are assembled independently from
the power transmission mechanism, so accurate
valve timing can always be obtained, providing sta-
ble performance over long periods.
A taper roller bearing for heavy loads is assembled
to the output shaft, so it can withstand high radial
loads and high thrust loads.
Operation
The high-pressure oil flowing into the motor passes
through disc valve (1), enters giroller (2), and the
star of giroller (2) moves in a planetary motion. Of
this planetary motion, only the rotation is taken off
by main drive (3) to rotate output shaft (4).
When this happens, disc valve (1) is driven by
valve drive (4). The relationship between the posi-
tions of the 12 ports of disc valve (1) and the 7 ports
(5) of the valve plate changes, and the position of
the hydraulic oil flowing to giroller (2) changes in
turn.
GD655-3E0, GD675-3E0 21
Hydraulic cylinder 1
Unit: mm

–0.025 +0.132 0.031 –

Steering 35 0.519
–0.087 +0.006 0.219
–0.025 +0.164 0.032 –
Blade lift 50 0.551
–0.087 +0.007 0.251
Blade side –0.025 +0.164 0.032 –
50 0.551
shift –0.087 +0.007 0.251
–0.025 +0.152 0.032 –
Clearance between Drawbar shift 45 0.539
–0.087 +0.007 0.239
1 piston rod and
bushing –0.025 +0.132 0.031 –
Leaning 40 0.519
–0.087 +0.006 0.219
–0.025 +0.164 0.032 –
Articulate 50 0.551
–0.087 +0.007 0.251
–0.025 +0.132 0.031 –
Blade tilt 40 0.519 Replace bushing
–0.087 +0.006 0.219
–0.025 +0.164 0.032 –
Scarifier 50 0.551
–0.087 +0.007 0.251
–0.030 +0.163 0.036 –
Ripper 55 0.567
–0.104 +0.006 0.267

–0.06 +0.02
Steering 55 0.06 – 0.11 1.0
–0.09 +0.02
Clearance between
2 piston rod support Blade lift –0.05 +0.1
80 0.05 – 0.25 1.0
and bushing –0.15 +0.1
Blade side –0.025 +0.142 0.105 –
40 1.0
shift –0.064 +0.080 0.206
–0.05 +0.1
Drawbar shift 80 0.05 – 0.25 1.0
–0.15 +0.1
22 GD655-3E0, GD675-3E0
Unit: mm
–0.025 +0.142 0.104 –
Leaning 50 1.0
–0.064 +0.080 0.206
–0.025 +0.142 0.104 –
Articulate 50 1.0
–0.064 +0.080 0.206
Clearance between
–0.025 –0.012 0.013 –
2 piston rod support Blade tilt 40 1.0
–0.064 –0.012 0.064
and bushing
–0.025 +0.142 0.105 –
Scarifier 50 1.0
–0.064 +0.080 0.206
–0.030 +0.174
Ripper 60 0.13 – 0.25 1.0
–0.076 +0.100
–0.025 –0.012 0.013 –
Steering 35 1.0
–0.064 –0.012 0.064
–0.080 +0.062 0.080 –
Blade lift 45 1.0
–0.142 +0.062 0.204
Replace bushing
Blade side –0.025 +0.142 0.105 –
40 1.0
shift –0.064 +0.080 0.206
–0.05 +0.10
Clearance between Drawbar shift 80
–0.15 +0.10
0.05 – 0.25 1.0
cylinder bottom
–0.025 +0.142 0.105 –
3 (yoke, support ball Leaning 45 1.0
–0.064 +0.080 0.206
joint, support) and
bushing –0.025 +0.142 0.105 –
Articulate 50 1.0
–0.064 +0.080 0.206
–0.025 –0.012 0.013 –
Blade tilt 40 1.0
–0.064 –0.012 0.064
–0.025 +0.142 0.105 –
Scarifier 50 1.0
–0.064 +0.080 0.206
–0.100 +0.174 0.200 –
Ripper 60 1.0
–0.174 +0.100 0.348
Steering 245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)
Blade lift 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Blade side
618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
shift
Piston nut tighten- Drawbar shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
4
ing torque Leaning 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41)
Articulate 1420 ± 142 Nm {145 ± 14.5 kgm} (width across flats: 55)
Blade tilt 647 ± 64.7 Nm {66 ± 6.6 kgm} (width across flats: 41)
Scarifier 785 ± 78.5 Nm {80 ± 8 kgm} (width across flats: 46)
Ripper 1770 ± 77 Nm {180 ± 18 kgm} (width across flats: 60)
Retighten
Steering 392 ± 39.2 Nm {40 ± 4 kgm}
Blade lift 588 ± 58.8 Nm {60 ± 6 kgm}
Blade side
588 ± 58.8 Nm {60 ± 6 kgm}
shift
Cylinder head tight- Drawbar shift 588 ± 58.8 Nm {60 ± 6 kgm}

5
ening torque Leaning 588 ± 58.8 Nm {60 ± 6 kgm}
Articulate 677 ± 67.7 Nm {69 ± 6.9 kgm}
Blade tilt 588 ± 58.8 Nm {60 ± 6 kgm}
Scarifier 677 ± 67.7 Nm {69 ± 6.9 kgm}
Ripper 981 ± 98.1 Nm {100 ± 10 kgm}
GD655-3E0, GD675-3E0 23
Circle, drawbar 1
24 GD655-3E0, GD675-3E0
1. Circle Outline
2. Drawbar q The drawbar is an important piece of equip-
3. Blade lift cylinder ment which supports the circle and blade. If
4. Drawbar side shift cylinder ball joint (6) is worn, use shim (5) to adjust the
5. Shim clearance at the joint so that there is no exces-
6. Ball joint sive play.
7. Lifter bracket (Upper) q When adjusting the clearance at the contact
8. Shim portions of guides (15), (18), and (20), adjust
9. Lifter bracket (Lower) with shims (14), (17), and (19), and adjustment
10. Yoke bolt (13).
11. Pin q There are two cylinders installed in the lifter for
12. Bushing moving the blade device. Brackets (7) and (9)
13. Adjustment bolt are installed by the guide, which is welded to
14. Shim the main frame. They can be revolved by
15. Guide revolving the guide by extracting a pin (11)
16. Bolt controlled from the operator's seat. There are
17. Shim four insertion holes altogether for the pin stop-
18. Guide ping revolution. Holes b, c and d, e are used
19. Shim for the blade to make a bank cut to left or right.
20. Guide At other times, holes a are used.
q These a get used much more than other holes
and bushing (12) is used in it to make the
clearance between the pin and the hole at a
minimum. (This clearance amplifies the up and
down movement of the blade.) Also, the clear-
ance between the bracket and the guide
welded to the frame can be adjusted with
shims (8).
Unit: mm

21 Wear of drawbar ball joint end Adjust or replace
–0.050 +0.100 0.050 –
150 —
–0.100 +0.100 0.200
Clearance between yoke and bush- –0.030 +0.220 0.190 –
22 75 0.6 Replace bushing
ing –0.076 +0.160 0.296
Standard clearance Clearance limit Replace yoke or
23 Axial clearance of yoke
0.8 to 1.3 2.0 bushing
Clearance between circle and draw-

24 0 to 3.0 1.0 to 2.0 Adjust or replace
bar
GD655-3E0, GD675-3E0 25
Blade 1
1. Adjuster 3. Drawbar side-shift cylinder

2. Blade tilt cylinder 4. Blade side-shift cylinder
26 GD655-3E0, GD675-3E0
Function
q Side edge installed to the blade is designed so
that it can be used twice by turning it upside
down and moving it to the other (left or right)
side.
q A power tilt device is installed to adjust the cut-
ting angle of the blade. Adjustment can be
made freely between 32° and 81° using a sin-
gle lever. The guide acts as a bushing for the
sliding parts when shifting the blade to the
side. If the clearance from the sliding parts is
too large and the finishing accuracy cannot be
obtained, adjust the shims or replace the
guide.
Unit: mm
5 Wear of cutting edge
From blade holder: 32 From blade holder: 10
6 Wear of side edge From blade holder: 48 From blade holder: 25
7a Height 368 364
Wear of blade rail Replace
7b Thickness 25 21
8a Height 8 5
Wear of blade rail
Width of
8b guide 25 33
groove
GD655-3E0, GD675-3E0 27
Circle rotation gear 1
1. Drain plug
2. Worm wheel
3. Oil filler plug
4. Joint
5. Shear pin
6. Worm gear
28 GD655-3E0, GD675-3E0
Unit: mm
Tolerance Standard Clearance
Standard size
Clearance between worm wheel Shaft Hole clearance limit
7
shaft and bushing
+0.291 +0.057 Replace bushing
75 0.281 – 0.02 0.4
+0.077 +0.010
Clearance between worm wheel +0.035 +0.057 0.052 –
8 75 0.4
shaft and bushing +0.005 +0.010 0.025
Backlash between worm and worm Standard clearance Clearance limit

9 Replace
wheel 0.3 – 0.4 2.0
Clearance between pinion gear and
10 0.1 – 0.5 0.6 Adjust
wear plate
11 Pinion gear wear Replace
25 20
Starting torque: 2.9 – 7.8 Nm {0.3 – 0.8 kgm}
12 Wormshaft bearing preload Adjust
when worm wheel is not meshed
GD655-3E0, GD675-3E0 29
With slip clutch
1. Floating seal Outline

2. Shaft q The circle rotation gear is driven by an oil
3. Case motor connected to worm gear shaft (12).
4. Worm wheel q Pinion gear shaft (2) has a clutch mechanism,
5. Plate and if an abnormal rotating force is transmitted
6. Disc from the blade, disc (6) slips to prevent break-
7. Spring age of the blade.
8. Cover q The clutch pressure of this clutch mechanism
9. Shim is adjusted by the thickness of shim (9).
10. Pinion gear
11. Drain plug
12. Worm gear shaft
13. Oil motor
30 GD655-3E0, GD675-3E0
Scarifier 1
32 GD655-3E0, GD675-3E0
1. Lift arm
2. Scarifier cylinder
3. Scarifier body
4. Wedge
Unit: mm
5 Tooth wear Replace tooth
450 330
6 Point tooth wear 450 407 Replace point
GD655-3E0, GD675-3E0 33
Ripper 1
1. Bracket Outline
2. Rod q Ripper lifting height and digging depth can be
3. Shank controlled with ripper cylinder (4). Since the
4. Ripper cylinder point tips cut into the ground under the load of
the ripper’s heavy weight, the ripper easily per-
forms heavy-duty digging work that cannot be
done by the scarifier.
Unit: mm

5 Clearance between pin and bushing
–0.025 +0.142 0.105 –
50 0.5
–0.050 +0.080 0.292
–0.030 +0.054
6 Clearance between pin and bushing 60 0.03 – 0.13 0.5 Replace
–0.076 +0.054
Clearance between trunnion and –0.100 +0.174 0.200 –
7 60 0.5
bushing –0.174 +0.100 0.348
8 Point wear
290 150
34 GD655-3E0, GD675-3E0
SEN01788-00

© 2006 KOMATSU
All Rights Reserved
36
SEN01789-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Air conditioner (If equipped) ................................................................................................................. 2
GD655-3E0, GD675-3E0 1
Cab and its attachments 1

Air conditioner (If equipped) 1
1. Condenser
2. Air conditioner compressor
3. Receiver-dryer
2 GD655-3E0, GD675-3E0
4. Air conditioner unit

4a. Hot water heater
4b. Evaporator
4c. Blower unit
GD655-3E0, GD675-3E0 3
SEN01789-00

© 2006 KOMATSU
All Rights Reserved
4
SEN01790-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine starting circuit ........................................................................................................................... 2
Engine stop circuit................................................................................................................................ 4
Preheat circuit ...................................................................................................................................... 5
Automatic shift control system ............................................................................................................. 6
Transmission controller ........................................................................................................................ 8
Monitor ............................................................................................................................................... 14
Sensors .............................................................................................................................................. 17
Communication controller .................................................................................................................. 23
KOMTRAX terminal system (if equipped) .......................................................................................... 24
GD655-3E0, GD675-3E0 1
Electrical system 1
Engine starting circuit 1
Function current also flows in the pull-in coil of the fuel

q The neutral safety circuit is employed to shut-off solenoid to supply the fuel at the maxi-
secure safety when the engine is started. This mum rate so that the engine will be started
circuit allows the engine to start only when the easily.
gear shift lever is in the P (Parking) position. q If the gear shift lever is in the P (Parking) posi-
q When the engine is started, storing pressure in tion, a current flows from gear shift lever termi-
the accumulator of the brake circuit is canceled nal 6 to the neutral relay coil to connect
temporarily to reduce the load of the hydraulic contacts 1 and 2 of the neutral relay.
pump on the engine for the ease of starting of While the gear shift lever is not in the P (Park-
the engine. ing) position, the current does not flow from
In addition, the engine start auxiliary switch is gear shift lever terminal 6. Accordingly, any
installed to reduce the load on the engine and current does not flow in the neutral relay coil
stabilize the engine rotation when the engine is and the starting circuit is not formed.
started at low temperature. q A current flows from starting switch terminal C
through neutral relay terminals 1 and 2 to the
Operation starting motor to start the engine.
q If the starting switch is turned from the OFF q At this time, another current flows from starting
position to the START position, a current flows switch terminal C to the engine startup sole-
from starting switch terminal BR to the battery noid to temporarily cancel storing pressure in
relay to "close" the contacts of the battery the brake accumulator so that the load on the
relay. engine will be reduced and the engine will be
q The current flows in the holding coil of the sole- started easily.
noid to supply fuel. It also flows in the fuel
shut-off timer to "close" the contacts of the fuel
shut-off relay for about 3 seconds. Then, the
2 GD655-3E0, GD675-3E0
q After the engine is started, if the starting switch

is turned to the ON position, the current flowing
from starting switch terminal C is turned OFF,
and the current flowing through neutral relay
terminals 3 and 5 to the starting motor is
turned off consequently.
The current flowing in the engine startup sole-
noid is turned OFF, the solenoid is returned to
the normal state, and the hydraulic pump starts
storing pressure in the accumulator.
q A current keeps flowing from starting switch
terminal ACC to the engine controller.
q If the engine start auxiliary switch is held even
after the engine is started in when the tempera-
ture is low, a current flows to the engine startup
solenoid to reduce the load of the hydraulic
pump on the engine while the switch is held.
GD655-3E0, GD675-3E0 3
Engine stop circuit 1
Stopping engine
q Return the starting key to the OFF position,
and the ACC power supply is turned OFF and
the engine controller stops fuel injection imme-
diately to stop the engine.
4 GD655-3E0, GD675-3E0
Preheat circuit 1
Preheating
q If the starting key is turned to the ON position,
the engine controller operates the heater relay
automatically according to the engine coolant
temperature to preheat the engine.
q The preheat indicator keeps lighting while the
preheat operation.
q If the starting key is turned to the START posi-
tion while the preheater is in operation, the
engine controller turns the heater relay OFF to
stop preheating.
GD655-3E0, GD675-3E0 5
Automatic shift control system 1

System diagram
Outline
q The automatic shift control system receives the
shift position signal from the gear shift lever,
the transmission speed signal, and signals
from other switches and sensors. The trans-
mission controller automatically shifts the
transmission to the most suitable speed range.
In addition to shift control the transmission
controller also drives and controls the torque
converter lock-up solenoid.
6 GD655-3E0, GD675-3E0
Transmission controller 1
Outline
q This transmission controller controls the sys-
tem using a built-in computer, which has the
following functions:
q Upshifts and downshifts in relation to the accel-
erator pedal angle.
q Drives and controls the torque converter lock-
up solenoid.
q Installed separately from the gear shift lever.
8 GD655-3E0, GD675-3E0
Connector signals
CN1 CN3 CN4
Pin Input/ Pin Input/ Pin Input/
Signal name Signal name Signal name
No. Output No. Output No. Output
Transmission temperature Transmission output revolu-
1 NC Output 1 Input 1 Input
sensor tion sensor
2 NC Output 2 NC Input 2 NC Input
3 NC Output 3 Accelerator potentio meter Input 3 RS232C TXD –
4 NC Output 4 NC Input 4 RS232C RXD –
5 NC Output 5 NC Input 5 NC –
6 GND Input 6 NC Output 6 NC –
7 Power supply (+24V) Input 7 Sensor power supply (+5V) Output 7 Engine revolution sensor Input
8 Back-up alarm relay Output 8 Neutral signal (lever) Input 8 Flash ROM writer switch –
9 NC Output 9 NOT_P (lever) Input 9 GND (puls) Output
10 NC Output 10 Differential select switch Input 10 RS232C GND –

Differential control relay Torque converter temperature
11 Output 11 Input 11 NC –
(if equipped) sensor
12 GND Input 12 NC Input 12 NC –
13 Power supply (+24V) Input 13 Inching potentio meter Input

(if equipped)
14 NC Input CN5
Pin Input/
CN2 15 NC Input No. Signal name Output
Pin Input/
Signal name 16 GND (sensor) Output 1 GND (puls) Output
No. Output
Transmission input revolution
1 Power supply for A-solenoid Input 17 GND (sensor) Output 2 Input
sensor
2 1st solenoid (+) Output 18 Logic A (lever) Input 3 GND Input
3 3rd solenoid (+) Output 19 Stop lamp signal Input 4 GND Input
4 2nd solenoid (+) Output 20 Inching select switch Input 5 NC Input
5 4th solenoid (+) Output 21 HI set switch Input 6 Forward (lever) Input
6 Parking release relay Output 22 VHP select switch Input 7 Logic B (lever) Input
7 FL solenoid (+) Output 23 NC Input 8 Logic D (lever) Input

Input/ Differential switch
8 FH solenoid (+) Output 24 SNET 9 Input
Output (if equipped)
9 R solenoid (+) Output 25 FL clutch oil pressure switch Input 10 GND (puls) Output
10 Lock up solenoid (+) Output 26 R clutch oil pressure switch Input 11 Tier 3 select switch Input
11 PGND Input 27 2nd clutch oil pressure switch Input 12 Low set switch Input
12 Power supply for A-solenoid Input 28 4th clutch oil pressure switch Input 13 Initialize switch Input
13 1st, 3rd solenoid (–) Input 29 Reset switch Input 14 Reverse (lever) Input
Differential oil temperature
14 1st, 3rd solenoid (–) Input 30 alarm signal (if equipped) Input 15 Logic C (lever) Input
15 2nd, 4th solenoid (–) Input 31 Error memory reset switch Input 16 Logic E (lever) Input
Input/
16 2nd, 4th solenoid (–) Input 32 SNET 17 Lock-up switch Input
Output
17 FL solenoid (–) Input 33 FH clutch oil pressure switch Input
18 FH solenoid (–) Input 34 1st clutch oil pressure switch Input
19 R solenoid (–) Input 35 3rd clutch oil pressure switch Input
20 Lock-up solenoid (–) Input 36 Lock-up clutch oil pressure Input

switch
21 PGND Input
GD655-3E0, GD675-3E0 9
Clutches used
ECMV Speed range
Low High R 1st 2nd 3rd 4th
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
10 GD655-3E0, GD675-3E0
Gear shift lever position

Gear shift lever position and automatic gear shifting range
q The gear shifting range for each gear shift lever position is as shown in the chart below.
q As the transmission mode selector switch is operated, the gear shift pattern and lock-up/torque con-
verter pattern changes.
q When the transmission mode switch is in “MODE 1”, the gear is shifted manually at each lever position.
q When the transmission mode switch is in “MODE 2”, the gear is shifted manually at the lever positions of
F1 – F4 and R1 – R4 but shifted automatically at the lever positions of F5 – F8 according to the travel
speed. (Automatic gear shifting)
Manual
Lever Speed Range
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 B
R2 B
R3 A
R4 A
Auto
Lever Speed Range
position N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
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
R4 A
A = Does not lockup
B = Locks up
C = Locks up automatically
GD655-3E0, GD675-3E0 11
Gear shifting diagram

q Gear shifting range
q As the transmission mode selector switch is operated, the gear shift pattern changes.
Manual
Auto
12 GD655-3E0, GD675-3E0
Automatic gear shift wiring diagram Overrun prevention function

q Transmission mode switch: Auto q When shifting gears suddenly, the transmis-
q Lever position: F5 – F8 sion may enter a speed range that does not
match the position of the lever. This action pre-
vents the engine from overrunning. When this
situation occurs, a short warning sound is
given to warn the operator. Reducing the
machine’s travel speed automatically shifts the
transmission to the position selected by the
lever.
Ultra low-speed travel control

q When the gear shift lever is at F1, the trans-
mission is in the torque converter mode, the
accelerator pedal is not depressed, and if the
travel speed is less than 1.8 km/h (1.1 mph),
the transmission enters the ultra low-speed
travel control mode and maintains the travel
speed at 1 km/h.
VHP specification machine

q With the VHP specification machine, switching
between the standard output and high output
of the engine is possible, as shown in the dia-
gram below, by turning the lock-up switch ON/
OFF.
Transmission mode switch
Auto Manual
F1
Standard output
F2 Standard output
F3
F4
F5
High output
F6 High output
F7
F8
GD655-3E0, GD675-3E0 13
Monitor 1
Monitor panel
1. Engine coolant temperature gauge 20. Differential lock pilot lamp (if equipped)
2. Torque converter oil temperature gauge 21. Maintenance caution lamp
3. Turn signal pilot lamp 22. Water separator monitor
4. Engine tachometer 23. Lift arm lock pin pilot lamp (if equipped)
5. Head lamp high beam pilot lamp 24. Blade accumulator pilot lamp (if equipped)
6. Articulation gauge 25. Blade float pilot lamp (if equipped)
7. Working pilot lamp 26. Central caution lamp
8. Speedometer 27. Character display
9. Shift indicator
10. Fuel gauge Right side panel
11. Parking brake pilot lamp 28. Starting switch
12. Brake oil pressure caution lamp 29. Hazard lamp switch
13. Engine coolant temperature caution lamp 30. Working lamp switch (if equipped)
14. Engine oil pressure caution lamp 31. Blade accumulator/float switch (if equipped)
15. Engine preheating pilot lamp 32. Cigarette lighter
16. PRM SET pilot lamp 33. Lift arm lock switch
17. Differential oil temperature caution lamp 34. Front wiper switch (top)
(if equipped)
18. Torque converter oil temperature caution lamp
19. Battery charge circuit caution lamp
14 GD655-3E0, GD675-3E0
Monitor items display
Category Symbol Item indicated Indicated range Description
Differential oil temperature More than 120° C
Torque converter oil temperature More than 110° C
Less than 4.2 MPa Off when normal, lights up

Caution Brake oil pressure
{42.5 kg/cm2} when problem detected
When charge is defec-

Battery charge
tive
Less than 49 kPa

Engine oil pressure
{0.5 kg/cm2}
Turn signal indicator When operated
Parking brake When operated Lights up when operated
Pilot Head lamp beam When operated
Lights up when blade accu-

Blade float When operated mulator/float switch is at
FLOAT
While starting, lights up

When electricity flows in
Engine preheating When auto preheating is
the preheating circuit
activated
GD655-3E0, GD675-3E0 15
Category Symbol Item indicated Indicated range Description
Lights up when blade accu-

Blade accumulator When operated mulator/float switch is at
ACCUMULATOR
Working lamp When operated
Pilot Lights up when operated
Differential control When operated
Lift arm lock When cancelled Lights up when not locked
Displays while starting

switch is ON
— Engine coolant temperature
Indicator shows engine
coolant temperature

— Articulate switch is ON
Indicator shows angle
Gauges

— Fuel
switch is ON

switch is ON
— Torque converter oil temperature
Indicator shows torque con-
verter oil temperature

Speed- switch is ON
— Speedometer
ometer Indicator shows vehicle
speed
Digital display:
Message
— Message center displays speed range,
center
error code, travel speed
16 GD655-3E0, GD675-3E0
Sensors 1
Accelerator pedal
1. Pedal
2. Sensor
GD655-3E0, GD675-3E0 17
Engine coolant temperature sensor

Torque converter oil temperature sensor (for machine monitor)
1. Connector
2. Plug
3. Thermistor
Temperature (°C) 50 ± 0.2 60 ± 0.2 80 ± 0.2 100 ± 0.3 106 ± 0.3 120 ± 0.3
Resistance (z) 80 ± 10 56.3 ± 5 29.5 ± 2.5 16.5 ± 0.9 14.3 ± 0.5 10 ± 0.3
Function
q The engine coolant temperature sensor is q The torque converter oil temperature sensor is
installed to the engine cylinder block. As the installed to the torque converter outlet port on
engine temperature changes, so does the sen- the transmission. If it senses the torque con-
sor’s resistance. The gauge on the monitor verter outlet oil temperature, its resistance
panel moves to indicate the engine tempera- changes. The resistance is converted into tem-
ture. perature and displayed on the monitor panel.
Brake oil pressure switch
1. Pressure sensor Function

2. Cable q This electronic switch uses a semiconductor.
3. Connector When the brake oil pressure (accumulator
pressure) drops below a specified value, the
switch turns ON. This action causes the brake
oil pressure lamp to light up and warn of a
problem.
18 GD655-3E0, GD675-3E0
Transmission speed sensor
1. Sensor Function
2. Locknut q Two transmission speed sensors are screwed
3. Wiring harness into the transmission case: one sensor detects
4. Connector transmission input shaft speed and the other
sensor detects output shaft speed.
q Gears are installed to the transmission input
shaft and output shaft. When the tip of a gear
tooth passes the sensor, an electrical pulse is
generated, which is detected by the sensor.
The speed is calculated by the transmission
controller. This information controls the trans-
mission.
Differential oil temperature sensor
1. Sensor Function
2. Wiring harness q The differential oil temperature sensor is a
3. Connector bimetal type. It detects the temperature of the
oil in the differential case. If the oil temperature
exceeds 120°C, the switch turns ON. This sig-
nal is sent to the transmission controller and is
also used to control the transmission.
GD655-3E0, GD675-3E0 19
Hydraulic oil temperature sensor

Transmission oil temperature sensor
Torque converter oil temperature sensor (for transmission controller)
1. Thermistor Function
2. Plug q The hydraulic oil sensor, transmission oil tem-
3. Wiring harness perature sensor, and torque converter oil tem-
4. Connector perature sensor are installed at the hydraulic
tank. These sensors use a thermistor to detect
the temperature. The sensors connect to the
transmission controller and used to control the
transmission.
Articulation sensor
1. Lever Function
q The articulation sensor is installed to the cen-
ter of the frame. This sensor uses a variable
resistor. The resistor ’s resistance varies
according to lever movement. The amount of
resistance determines the angle displayed on
the gauge, which is located on the monitor
panel.
20 GD655-3E0, GD675-3E0
Fuel level gauge sensor
1. Float Function
2. Arm q The fuel level gauge sensor is installed to the
3. Variable resistor rear side of the fuel tank and its float moves up
4. Connector and down according to the fuel level in the
tank.
The float moves the variable resistor and
changes its resistance through the arm.
The change of the resistance is converted into
a change of voltage is transmitted to the fuel
level gauge, then the fuel level gauge pointer
indicates the fuel level in the fuel tank.
GD655-3E0, GD675-3E0 21
Inching pedal potentiometer
1. Connector Function
2. Case q This sensor is installed to the inching pedal.
3. Shaft The sensor detects the pedal angle when
4. Element depressing the pedal.
5. Bearing q Inside the potentiometer, the pedal angle is
6. Contact converted into a voltage signal. A variable
7. Mold resistor adjusts the 5 volt source signal as the
pedal angle changes. The adjusted voltage
signal is now sent to the transmission control-
ler.
22 GD655-3E0, GD675-3E0
Communication controller 1
Connector signal
Deutsch-40P [CR 310]
Pin Pin
Signal name Input/Output Signal name Input/Output
No. No.
1 PWR_IN_batt Input 21 GND_PWR —
2 PWR_CTR_key Input 22 PWR_OUT_5V Output
3 PWR_CTR_ext Input 23 NC Input
4 NC Input 24 Articulate potentio Input
5 RPM set MODE-MANUAL Input 25 RPM set-DECEL/RESUME Input
6 NC Input 26 Brake accumu. press. sw-R Input
7 NC Output 27 NC Output
8 Output accel Output 28 COMM_CAN_H_0 Input/Output
9 NC Output 29 NC Output
10 NC Output 30 PWR_IN_bry Input
11 PWR_IN_batt Input 31 GND_PWR —
12 PWR_CTR_key Input 32 GND_SIG_A/GND_SIG_P —
13 NC Input 33 NC Input
14 NC Input 34 RPM set MODE-AUTO Input
15 RPM set-ACCEL/SET Input 35 Brake accumu. press. sw-F Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input/Output
18 S_NET Input/Output 38 COMM_CAN_L_0 Input/Output
19 NC Input 39 CAN0_SH Input/Output
20 NC Input 40 GND_ACT —
GD655-3E0, GD675-3E0 23
KOMTRAX terminal system (if equipped) 1
q The KOMTRAX terminal transmits various

kinds of machine information wirelessly. Per-
sons to operate the KOMTRAX can refer to the
information at office to provide various kinds of
services for customers.
a To provide the services, you need to make
an arrangement for starting the
KOMTRAX terminal service separately.
Information transmittable from KOMTRAX ter-

minal system includes the following.
1) Travel history
2) Service meter
and others.
24 GD655-3E0, GD675-3E0
KOMTRAX communication mode

TC300
1. DRC connector (40 poles) connecting part Outline

2. (Not connected) q The KOMTRAX terminal can obtain various
3. GPS antenna connector connecting part kinds of machine information from network sig-
4. Orbcomm nals or input signals in the machine, and trans-
mit the information via the communication
antenna. The terminal is equipped with a CPU
(central processing unit), and has wireless
communication and GPS functions as well.
q The terminal is provided with a LED lamp and
a 7-segment display lamp as a display unit.
The display unit is used for inspection and
maintenance.
Input and output signals

DRC connector
Pin Pin
Signal name Input/Output Signal name Input/Output
No. No.
1 (If equipped) Input 21 Inspection mode Input
2 (If equipped) Output 22 Inspection mode Input
3 (If equipped) Input 23 (If equipped) Input
4 (If equipped) Input 24 EX GND —
5 (If equipped) Output 25 EX GND —
6 (If equipped) — 26 (If equipped) Input
7 (If equipped) Input/Output 27 C terminal input (Hi side) Input
8 (If equipped) Input/Output 28 R terminal input Input
9 (If equipped) — 29 (If equipped) —
10 (If equipped) Input/Output 30 (If equipped) Output
11 (If equipped) — 31 (If equipped) (5V max) Input
12 (If equipped) Input 32 (If equipped) (5V max) Input
13 (If equipped) Input 33 (If equipped) Input
14 (If equipped) Output 34 Fuel sensor Input
15 (If equipped) Output 35 (If equipped) Output
16 (If equipped) Input 36 ACC input Input
17 (If equipped) Input 37 Power supply GND (If equipped) —
18 (If equipped) Output 38 Power supply GND (If equipped) —
19 (If equipped) Output 39 Permanent power supply (12V/24V) Input
20 Relay output Output 40 Permanent power supply (12V/24V) Input
*: Never connect to NC or malfunctions or failure *: Never connect to NC or malfunctions or failure

will occur will occur
GD655-3E0, GD675-3E0 25
SEN01790-00

© 2006 KOMATSU
All Rights Reserved
26
SEN01834-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard value table for engine ........................................................................................................... 2
Standard value table for chassis .......................................................................................................... 3
GD655-3E0, GD675-3E0 1
SEN01834-00 20 Standard value table
Standard service value table 1

Standard value table for engine 1
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard value
Cate- Service limit
Check item Measurement condition Unit for new
gory value
machine
High idle 2,225 ± 50 2,225 ± 50
• Engine coolant temperature:
Rotation speed Low idle rpm 825 ± 50 825 ± 50
Within operating range
Rated speed 1,900 1,900
Intake air pressure • At rated output kPa 133 – 173 107
(Boost pressure) • On aftercooler outlet side {mmHg} {1,000 – 1,300} {800}
Exhaust • All speed range
°C Max. 650 Max. 650
temperature • Ambient temperature: 20°C
At sudden
• Engine coolant temperature: Bosch Max. 2.5 Max. 2.5
Exhaust gas color acceleration
Within operating range index
Engine
At high idle Max. 1.0 Max. 2.0

Intake valve 0.305 0.152 – 0.559
Valve clearance • At cold mm
Exhaust valve 0.559 0.381 – 0.813
• Engine coolant temperature: Within operating
kPa Max. 1.6 Max. 2.55
Blow-by pressure range
{mmH2O} {Max. 160} {Max. 260}
• At rated output
0.34 – 0.59 Min. 0.21
• SAE15W-40 oil At rating
MPa {3.5 – 6.0} {Min. 2.1}
Engine oil pressure • Engine coolant temperature:
{kg/cm2} Min. 0.15 Min. 0.08
Within operating range At low idle
{Min. 1.5} {Min. 0.8}
Oil temperature • All speed range (In oil pan) °C 80 – 110 Max. 120
2 GD655-3E0, GD675-3E0
Standard value table for chassis 1

GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
Check item Measurement condition Unit value for new
gory value
machine
Accelerator pedal • Amount of up-down movement of tip of pedal mm 56 ± 10 —
• Engine stopped Stroke 87 ± 10 —
• Tip of pedal Play 0 —
• Stroke: Between released posi-
tion – pressed position Height
Inching pedal mm 178 ± 5 —
• Play: At released position (Released)
• Height: Released position and
Height
pressed position above floor 91 ± 5 —
(Pressed)
level
PoN 35 ± 5 —
N o F1 30 ± 5 —
F1 o F2 30 ± 5 —
F2 o F3 30 ± 5 —
F3 o F4 30 ± 5 —
F4 o F5 30 ± 5 —
• Engine stopped
Gear shift lever F5 o F6 mm 30 ± 5 —
Strokes of lever, pedal and steering wheel
• Tip of lever
F6 o F7 30 ± 5 —
F7 o F8 30 ± 5 —
N o R1 30 ± 5 —
R1 o R2 30 ± 5 —
R2 o R3 30 ± 5 —
R3 o R4 30 ± 5 —
• Engine at low idle
• Float front wheels Number of
Rotation 6–7 —
• Number of rotations: Between rotations
Steering wheel steering stroke ends
• Play: Between rotation start
point of steering wheel and point Play mm 0 – 10 —
where wheels start turning
• Engine stopped
• Tip of pedal Stroke 58 ± 4 58 ± 10
Brake pedal • Stroke: Between released posi- mm
tion – braking position Play Max. 5 —
• Play: At released position
Left blade lift N o Forward
22 ± 2.2 —
cylinder lever N o Reverse
N o Forward
Scarifier lever 22 ± 2.2 —
N o Reverse
• Engine stopped N o Forward
Blade rotation lever mm 22 ± 2.2 —
• At center of lever knob N o Reverse
N o Forward
Articulation lever 22 ± 2.2 —
N o Reverse
Drawbar side shift N o Forward
22 ± 2.2 —
lever N o Reverse
GD655-3E0, GD675-3E0 3
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
gory value
machine
N o Forward
Strokes of lever, pedal
Power tilt lever 22 ± 2.2 —

N o Reverse
and steering wheel
N o Forward
Leaning lever 22 ± 2.2 —
• Engine stopped N o Reverse
mm
Blade side shift • At center of lever knob N o Forward
22 ± 2.2 —
lever N o Reverse
Right blade lift N o Forward
22 ± 2.2 —
cylinder lever N o Reverse
• Engine stopped
N Max. 69
Accelerator pedal • At 150 mm from center of pedal rotation —
{kg} {Max. 7}
• Max. value in travel between low and high
• Engine stopped
N Max. 93
Inching pedal • At 150 mm from center of pedal rotation —
{kg} {Max. 9.5}
• Max. value in stroke
Max. 39
PoN —
{Max. 4.0}
Max. 39
N o F1 —
{Max. 4.0}
Max. 39
F1 o F2 —
Operating efforts of lever, pedal and steering wheel
{Max. 4.0}
Max. 39
F2 o F3 —
{Max. 4.0}
Max. 39
F3 o F4 —
{Max. 4.0}
Max. 39
F4 o F5 —
• Engine stopped {Max. 4.0}
• At center of lever knob N Max. 39
Gear shift lever F5 o F6 —
• Max. value in travel to just before {kg} {Max. 4.0}
finish of gear shifting Max. 39
F6 o F7 —
{Max. 4.0}
Max. 39
F7 o F8 —
{Max. 4.0}
Max. 39
N o R1 —
{Max. 4.0}
Max. 39
R1 o R2 —
{Max. 4.0}
Max. 39
R2 o R3 —
{Max. 4.0}
Max. 39
R3 o R4 —
{Max. 4.0}
• Engine at low idle N Max. 29
Steering wheel —
• During travel in F1 {kg} {Max. 3.0}
• Engine at high idle
N 276 ± 27.5
Brake pedal • At 150 mm from center of pedal rotation —
{kg} {28.1 ± 2.8}
• Max. value in travel to stop machine completely
4 GD655-3E0, GD675-3E0
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
gory value
machine
Left blade lift N o Forward Max. 26
—
cylinder lever N o Reverse {Max. 2.7}
Operating efforts of lever, pedal and steering wheel
N o Forward Max. 26
Scarifier lever —
N o Reverse {Max. 2.7}
N o Forward Max. 26
Blade rotation lever —
N o Forward Max. 26
Articulation lever —
• Engine stopped
Drawbar side shift N o Forward N Max. 26
• At center of lever knob —
lever N o Reverse {kg} {Max. 2.7}
• Max. value in stroke
N o Forward Max. 26
Power tilt lever —
N o Forward Max. 25
Leaning lever —
Blade side shift N o Forward Max. 26
—
lever N o Reverse {Max. 2.7}
Right blade lift N o Forward Max. 26
—
cylinder lever N o Reverse {Max. 2.7}
• Engine coolant temperature: Operating range
Power train oil pressure and pump performance Rotation speed
• Torque converter oil temperature: 60 – 80°C

Torque converter • Engine at high idle
rpm 1,689 ± 100 —
stall speed • Engine stall speed when wheel brake pedal is
pressed and inching pedal is released with
engine at full throttle and gear in R4
2.4 ± 0.1 2.4 ± 0.1
Low idle
Power train main {24.5 ± 1.0} {24.5 ± 1.0}
relief pressure 2.46 ± 0.2 2.46 ± 0.2
High idle
{25.1 ± 2.0} {25.1 ± 2.0}
Torque converter 0.88 ± 0.05 0.88 ± 0.05
• Torque converter oil tempera- High idle
inlet pressure {9.0 ± 0.5} {9.0 ± 0.5}
ture: 60 – 80°C
Torque converter 0.59 ± 0.05 0.59 ± 0.05
• Engine at low idle or high idle High idle MPa
outlet pressure {6.0 ± 0.5} {6.0 ± 0.5}
• During no-load travel with gear {kg/cm2}
Torque converter shift lever in P position or each 2.01 ± 0.15 2.01 ± 0.15
lockup clutch gear speed High idle
{20.5 ± 1.5} {20.5 ± 1.5}
pressure
Transmission FL 1.96 – 2.45 1.96 – 2.45
High idle
clutch pressure {20 – 25} {20 – 25}
Transmission R 2.06 – 2.45 2.06 – 2.45
High idle
GD655-3E0, GD675-3E0 5
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
gory value
machine
Transmission FH 1.96 – 2.45 1.96 – 2.45
High idle
Power train oil pressure and
Transmission 1st • Torque converter oil tempera- 1.96 – 2.45 1.96 – 2.45
High idle
pump performance
clutch pressure ture: 60 – 80°C {20 – 25} {20 – 25}

Transmission 2nd • Engine at low idle or high idle MPa 1.96 – 2.45 1.96 – 2.45
High idle
clutch pressure • During no-load travel with gear {kg/cm2} {20 – 25} {20 – 25}
Transmission 3rd shift lever in P position or each 1.96 – 2.45 1.96 – 2.45
gear speed High idle
Transmission 4th 1.96 – 2.45 1.96 – 2.45
High idle
Power train pump • Torque converter oil temperature: 60 – 80°C
l/min 135 —
delivery • Engine at high idle
F1 3.3 ± 0.17 —
F2 4.7 ± 0.24 —
F3 6.7 ± 0.34 —
Power train performance
F4 9.7 ± 0.49 —
F5 14.6 ± 0.37 —
• Torque converter oil tempera-
ture: 60 – 80°C F6 21.2 ± 1.06 —
Travel speed km/h
• During travel at rated engine F7 29.1 ± 1.46 —
speed (1,900 rpm)
F8 42.1 ± 2.11 —
R1 4.3 ± 0.22 —
R2 8.8 ± 0.44 —
R3 19.3 ± 0.97 —
R4 38.3 ± 1.92 —
Differential
Differential lock
• Final drive oil temperature: 45 – 55°C
pressure MPa 2.84 – 3.10 Max. 2.84
[Differential lock {kg/cm2} {29.0 – 31.6} {Max. 29.0}
• When differential lock is ON
specification]
• Hydraulic oil temperature: 45 – 55°C +0.7
Steering oil MPa 18.1 +0
• Engine at high idle —
pressure {kg/cm2} +7
{185 +0 }
• When steering cylinder is relieved
• Hydraulic oil temperature: 45 – 55°C
Oil leakage through
• Engine at high idle cc/min 0 —
Steering
steering cylinder
• When steering cylinder is relieved
• On flat paved road rad 0
Camber —
• Camber: Leaning angle of king pin {°} {0}
Toe-in • Toe-in: Difference between distance between mm –5 ± 5 —
tire front centers and that between tire rear
centers rad 0.279 ± 0.017
Leaning angle —
• Leaning angle: Leaning angle of front tire {°} {16 ± 1}
• Measure side of tire with dial gauge
Tire runout mm Max. 7 —
(both front and rear wheels)
Tire
Tire inflation • GD655-3E0: 14.00-24-10PR kPa 220 {2.2} —

pressure • GD675-3E0: 14.00-24-12PR {kg/cm2} 250 {2.5} —
6 GD655-3E0, GD675-3E0
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
gory value
machine
+0.2 +0.2
Cut-in 9.36 +0 9.36 +0
• Hydraulic oil temperature: 45 – pressure +2
{95.5 +0 }
+2
{95.5 +0 }
Brake accumulator
55°C
charge pressure +0.98 +0.98
• Engine at high idle Cut-out 12.26 +0 12.26 +0
pressure MPa +10 +10
{kg/cm2} {125 +0 } {125 +0 }

+0.10 +0.10
Wheel brake oil • Engine stopped (after accumulator pressure is 3.9 –0.31 3.9–0.31
pressure increased) +1
{40 –3 }
+1
{40 –3 }
• When brake pedal is pressed
Brake
• Engine stopped (after accumulator pressure is

Wheel brake oil kPa 98 98
increased)
pressure reduction {kg/cm2} {1.0} {1.0}
• Pressure reduction in 5 minutes while brake
pedal is pressed
• Engine stopped (after accumulator pressure is
Parking brake oil MPa 9.36 – 13.24 9.36 – 13.24
increased)
pressure {kg/cm2} {95.5 – 135} {95.5 – 135}
• Turn starting switch ON and set gear shift lever
in N position.
Max. 18.4
Stopping distance • Engine at high idle
m Max. 17.7 (ISO3450 =
with wheel brake • When brake is applied at speed of 38.2 km/h
18.4 m)
(as per ISO3450)
Blade
5 —
Stroke and operating effort
rotation only
Control valve spool
• Engine stopped Other than mm
of control valve
stroke
blade 6 —
rotation
Blade Max. 109.8
—
rotation only {Max. 11.2}
Operating effort of • Engine stopped N
control valve spool • Max. value in stroke Other than {kg} Max. 73.5
blade —
{Max. 7.5}
rotation
• Hydraulic oil temperature: 45 – Unload 2.8 ± 0.98
—
55°C pressure {29 ± 10}
Work equipment oil pressure and
Work equipment oil

• Unload pressure: When all work Work equip-
pressure 20.6 ± 1.0
equipment is in neutral ment relief —
{210 ± 10}
pump performance
• Work equipment relief pressure: pressure

When blade lift cylinder is raised MPa
{kg/cm2}
LS differential • During blade rotation operation (Pa = 14.7 MPa 2.35 ± 0.1
—
pressure {150 kg/cm2}) {24 ± 1}
• LS differential pressure = Pump pressure – LS
pressure
Steering, brake and • Hydraulic oil temperature: 45 – 55°C
work equipment • Engine at low idle l/min 76 —
pump delivery • Rotate blade (Measure during operation)
GD655-3E0, GD675-3E0 7
GD655-3E0
Machine model
GD675-3E0
Engine SAA6D114E-3
Standard
Cate- Service limit
gory value
machine
Raise 2.7 ± 0.4 4.0
Blade lifting speed
Lower 2.7 ± 0.4 4.0
Left side shift 9.1 ± 1.1 11.0
Blade side shift
speed • Hydraulic oil temperature: 35 – Right side
9.1 ± 1.1 11.0
45°C shift
• Engine at high idle Left side shift 7.3 ± 1.1 10.0
Drawbar side shift • Blade lift: Lift in cylinder travel of
speed 350 mm. Measure right and left Right side
7.5 ± 1.1 10.0
shift
Work equipment speed
sides separately.
• Blade side shift: Shift in cylinder Left rotation 8.8 ± 1.3 12.0
Blade rotation stroke
speed Right
• Drawbar side shift: Shift in cylin- 8.8 ± 1.3 12.0
rotation sec
der stroke when blade bottom
height is 100 mm Wide dig-
4.05 ± 0.7 7.0
• Blade rotation: Rotation of 90° ging angle
Power tilt speed
• Power tilt: In cylinder stroke Narrow dig-
4.58 ± 0.8 7.0
• Articulation: In cylinder stroke ging angle
(during travel)
Left turn 7.17 ± 1.0 14.0
Articulation speed • Leaning: In cylinder stroke
• Scarifier lifting: In cylinder travel Right turn 7.17 ± 1.0 14.0
of 180 mm Left leaning 2.37 ± 0.4 6.0
Leaning speed
Right leaning 2.46 ± 0.4 6.0
Scarifier lifting Raise 2.0 ± 0.3 3.0
speed Lower 2.0 ± 0.3 3.0
• Right and left blade lift cylinders: Raise stroke
end
Blade hydraulic drift
• Hydraulic oil temperature: 40 ± 5°C
(No load on 10 20
• Engine stopped
cylinder)
• Cylinder extraction in 10 minutes after finish of
setting
Work equipment hydraulic drift and oil leakage
mm
• Right and left blade lift cylinders: Lower stroke
end (Push-up of machine)
(Raising of 20 35
• Engine stopped
machine)
• Cylinder retraction in 10 minutes after finish of
setting
Work equipment
• Engine at high idle cc/min 0 0
cylinder oil leakage
• When cylinder is relieved
• Scarifier cylinder: Raise stroke end
Scarifier hydraulic • Hydraulic oil temperature: 40 ± 5°C
drift (No load on • Engine stopped 10 20
cylinder) • Cylinder extraction in 10 minutes after finish of
setting
• Scarifier cylinder: Lower stroke end (Push-up mm
of machine)
Scarifier hydraulic
drift (Raising of 20 35
• Engine stopped
machine)
• Cylinder retraction in 10 minutes after finish of
setting
8 GD655-3E0, GD675-3E0
SEN01834-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01835-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting and troubleshooting ................................................................................... 3
Measuring exhaust color ...................................................................................................................... 6
Measuring exhaust temperature .......................................................................................................... 7
Measuring intake air pressure (boost pressure)................................................................................... 9
Measuring blowby pressure ................................................................................................................11
Measuring engine oil pressure ........................................................................................................... 12
Measuring engine speed.................................................................................................................... 13
Testing fan belt tension ...................................................................................................................... 13
Testing air conditioner compressor belt tension ................................................................................. 14
Measuring torque converter stall speed ............................................................................................. 15
Checking clutch oil pressure .............................................................................................................. 16
Checking torque converter oil pressure ............................................................................................. 17
Adjusting speed sensor...................................................................................................................... 18
Flushing torque converter and transmission circuit............................................................................ 20
Testing brake disc .............................................................................................................................. 21
GD655-3E0, GD675-3E0 1
SEN01835-01 30 Testing and adjusting
Testing and adjusting parking brake................................................................................................... 22

Method for emergency release of parking brake................................................................................ 24
Testing and adjusting parking brake pad clearance ........................................................................... 25
Testing accumulator charge pressure ................................................................................................ 26
Testing and adjusting work equipment oil pressure............................................................................ 27
Testing and adjusting LS differential pressure.................................................................................... 28
Adjusting PC valve ............................................................................................................................. 30
Bleeding air from hydraulic circuit ...................................................................................................... 31
Measuring internal cylinder leakage................................................................................................... 32
Testing and adjusting differential lock oil pressure [Differential lock specification]............................. 34
Measuring steering and brake oil pressure ........................................................................................ 36
Bleeding air from brake piping............................................................................................................ 37
Charging nitrogen gas for brake, work equipment accumulator......................................................... 38
Testing and adjusting circle guide clearance...................................................................................... 40
Testing and adjusting slip clutch type rotary device ........................................................................... 42
Memorizing idle and full position procedure ....................................................................................... 44
Initial learning method for transmission controller .............................................................................. 45
Inspection procedure of diode ............................................................................................................ 47
2 GD655-3E0, GD675-3E0
Testing and adjusting, Part 1 1

Tools for testing, adjusting and troubleshooting 1
Check or Sym-
Part No. Part name Remarks
measurement item bol
1 799-201-9001 Handy smoke checker
Bosch index 0 – 9
Measuring exhaust color A Commercially
2 Smoke meter (with standard color)
available
Coolant temperature, oil
temperature and exhaust B 799-101-1502 Digital temperature gauge –99.9 – 1299°C
temperature
Air boost pressure –101 – 200 kPa
C 799-201-2202 Boost gauge kit
(boost pressure) (–760 – 1500 mmHg)
1 799-201-1504 Blowby checker 0 – 4,900 Pa {0 – 500 mm H2O}
Measuring blowby pressure D
2 799-201-1511 Nozzle Orifice diameter: 7.67 mm
Pressure gauge
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
Measuring engine oil 1 {25, 60, 400, 600 kg/cm2}
E
pressure Pressure gauge
790-261-1204 Digital hydraulic tester
58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic gauge 0.98 MPa {10 kg/cm2}
1 799-203-8001 Multi-tachometer Digital display
Measuring torque converter
F L: 60 – 2,000 rpm
stall speed 2 795-790-2500 Adapter H: 60 – 19,999 rpm
Pressure gauge
Checking clutch oil pressure G {25, 60, 400, 600 kg/cm2}
Pressure gauge
58.8 MPa {600 kg/cm2}
Pressure gauge
Testing accumulator charge
H 799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
pressure
{25, 60, 400, 600 kg/cm2}
Pressure gauge
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting work Pressure gauge
J
equipment oil pressure 790-261-1204 Digital hydraulic tester
58.8 MPa {600 kg/cm2}
799-101-5160 RC 1/8
2 Nipple
799-101-5220 M10 x 1.25
Pressure gauge
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge
Testing and adjusting LS 58.8 MPa {600 kg/cm2}
K
differential pressure 799-101-5160 RC 1/8
2 Nipple
799-101-5220 M10 x 1.25
Differential pressure
3 799-401-2701 DC 12V
gauge
4 799-261-1231 Elbow M10 x 1.25 (RC 1/8)
GD655-3E0, GD675-3E0 3
Check or Sym-
Part No. Part name Remarks
measurement item bol
Pressure gauge
1 {25, 60, 400, 600 kg/cm2}
Measuring steering, brake Pressure gauge
L
oil pressure 790-261-1204 Digital hydraulic tester
58.8 MPa {600 kg/cm2}
799-101-5160 RC 1/8
2 Nipple
799-101-5220 M10 x 1.25
Pressure gauge
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
differential lock oil pressure Pressure gauge
M
(Differential lock 790-261-1204 Digital hydraulic tester
58.8 MPa {600 kg/cm2}
specification)
799-101-5220 Nipple
2 M10 x 1.25
07002-11023 O-ring
799-401-3100 Adapter (size 02) —
Oil pressure N 799-401-3200 Adapter (size 03) —
799-401-3300 Adapter (size 04) —
79A-264-0021 0 – 294 N {0 – 30 kg}
Operating effort P Push-pull scale
79A-261-0091 0 – 490 N {0 – 50 kg}
Commercially
Stroke Q Scale —
available
Troubleshooting of wiring 799-601-2500 —
R T-adapter assembly
harnesses and sensors 799-601-9200 For DT series
Measuring voltage and Commercially
S Tester —
resistance values available
Charging accumulator T 792-610-1700 Charging tool —
Procedure for moving
machine when transmission U 794-423-1190 Plug —
valve fails
Removal and installation of
Commercially 3.26mm torque wrench
boost pressure and temper- - available
Torque wrench
(KTC Q4T 15 or equivalent)
ature sensors
engine oil pressure sensor - 795-799-6210 Socket 27mm deep socket
21mm deep socket

Commercially (MITOLOY 4ML-21 or equivalent)
Socket
Removal and installation of available Applied engine serial number :
engine coolant temperature - 26850008 - 26857026
sensor 19mm deep socket
795T-981-1010 Socket Applied engine serial number :
26857027 -
4 GD655-3E0, GD675-3E0
- : Push tool
GD655-3E0, GD675-3E0 5
Measuring exhaust color 1 2. Connect the air hose of the probe hose accel-
erator switch to the tool A2.
a Exhaust gas color measurement tools a Keep the air pressure supply below 1.47
Sym- MPa {15 kg/cm2}.
Part No. Part name
bol
1 799-201-9001 Handy smoke checker 3. Connect the power cord to the AC 100V
A Commercially socket.
2
available
Smoke meter a When connecting the cord, check that the
power switch of tool A2 is OFF.
q When measuring in the field where is no air or
electric power supply, use tool A1; when
recording formal data, use tool A2.
a Increase the coolant temperature to the operat-
ing temperature range before measuring.
Measuring with A1
1. Install the filter paper to tool A1.
2. Insert the exhaust gas suction port into the

exhaust pipe.
3. Accelerate the engine suddenly while simulta-

neously operating the handle of tool A1.
4. Loosen the cap nut of the suction pump and fit
4. Remove the filter paper and compare it with the filter paper.
the scale supplied to judge the condition. a Fit the filter paper securely so that exhaust
gas cannot leak.
5. Turn the power switch of tool A2 ON.
6. Accelerate the engine suddenly while simulta-

neously depressing the accelerator pedal of
tool A2 to collect the exhaust gas color on the
filter.
7. Place the filter paper used to catch the exhaust

gas color on top of at least 10 sheets of
unused filter paper inside the filter paper
holder.
8. Read the value shown.

Measuring with A2
1. Insert the probe [1] into the outlet port of the
exhaust pipe (1) and tighten the clip to secure
the probe to the exhaust pipe.
6 GD655-3E0, GD675-3E0
Measuring exhaust temperature 1 3. Procedure for measuring exhaust temperature

periodically for Pm clinic
a Measuring instruments for exhaust temperature a To prevent the torque converter from over-
Sym- heating, stabilize the exhaust temperature
Part No. Part name
bol first by performing the full stall operation
B 799-101-1502 Digital thermometer gauge (stalling the torque converter and relieving
the hydraulic system) and then stall only the
k Stop the machine on a level ground, set the torque converter and measure the exhaust
gear shift lever in the P position, and set temperature.
chocks under the wheels. 1) Start the engine, set the gear shift lever in
k Install and remove the measuring instru- the P position, and set the fuel control
ments after the exhaust manifold is cooled. lever in the low idle position.
a Measure the exhaust temperature under the 2) Move the right and left blade lift cylinders
following conditions. to the raise stroke end with the right and
q Engine coolant temperature: left blade lift control levers.
Within operating range 3) Change the machine monitor screen to
q Torque converter oil temperature: "Torque converter stall function" and pre-
Within operating range pare for stalling the torque converter.
q Hydraulic oil temperature: 45 – 55°C a For the operating method, see "Spe-
cial functions of machine monitor
1. Open the engine right side cover and remove (EMMS)".
exhaust temperature pickup plug (1) of the a The engine speed is displayed on the
exhaust manifold. upper line and the torque converter oil
temperature is displayed on the lower
line.
2. Install sensor [1] of digital thermometer B and

connect them to meter [2].
a Clamp the wiring harness of the digital 4) While pressing down the brake pedal
thermometer so that it will not touch a hot securely, set the gear shift lever in the F1
part during measurement. position.
a Even if the gear shift lever is set in the
F1 position, the gear speed is set in
F8 when the torque converter is
stalled actually.
5) Press the accelerator pedal slowly to stall
the torque converter and relieve the
hydraulic system by setting the right and
left blade lift control levers in the raise
position (full stall operation) at high idle.
k Keep pressing the brake pedal
securely.
a Continue this operation until the
exhaust temperature reaches about
670°C of the standard temperature.
GD655-3E0, GD675-3E0 7
6) After the exhaust temperature reaches

about the target temperature, return the
right and left blade lift control levers to the
neutral position and measure the exhaust
temperature while only the torque con-
verter is stalled.
7) After measuring, return the accelerator
pedal to the low idle position immediately
and return the gear shift lever to the P
position.
k Do not operate the gear shift lever
while pressing the accelerator pedal.
If it is operated so, the inside of the
transmission may be broken.
4. When measuring maximum exhaust temperature

for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital ther-
mometer (Set the thermometer in the
PEAK mode, and the maximum tempera-
ture will be recorded automatically).
a The exhaust temperature largely depends
on the ambient temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q Corrected value [°C] = Measured value +
2 × (20 – Ambient temperature)
5. After finishing measurement, remove the mea-

suring instrument and return the removed
parts.
8 GD655-3E0, GD675-3E0
Measuring intake air pressure 3. Run the engine at a medium or higher speed
(boost pressure) 1 and drain the oil from the hose.
a Insert the connecting parts of the gauge
a Measuring instrument for intake air pressure and hose about a half and open the self-
(boost pressure) seal on the hose side repeatedly, and the
Sym- oil will be drained.
bol
Part No. Part name a If Pm kit (A) is available, you may drain
C 799-201-2202 Boost gauge kit the oil by using the oil draining coupling
(790-261-1130) in that kit.
k Stop the machine on a level ground, set the a If oil is left in the hose, the gauge does not
gear shift lever in the P position, and set work. Accordingly, be sure to drain the oil.
chocks under the wheels.
k Be careful not to touch a hot part of the 4. Start the engine, set the gear shift lever in the
engine when removing or installing the P position, and hold the fuel control lever in the
measuring instrument. low idle position.
a Measure the intake air pressure (boost pressure)
under the following conditions. 5. Change the machine monitor screen to
q Engine coolant temperature: "Torque converter stall function" and prepare
Within operating range for stalling the torque converter.
q Torque converter oil temperature: a For the operating method, see "Special
Within operating range functions of machine monitor (EMMS)".
q Hydraulic oil temperature: 45 – 55°C a The engine speed is displayed on the
upper line and the torque converter oil
1. Open the engine left side cover and remove temperature is displayed on the lower line.
intake air pressure pickup plug (1) of the intake
air connector.
2. Install nipple [1] of boost gauge kit C and con-

nect it to gauge [2].
GD655-3E0, GD675-3E0 9
6. While pressing down the brake pedal securely,

set the gear shift lever in the F1 position.
a Even if the gear shift lever is set in the F1
position, the gear speed is set in F8 when
the torque converter is stalled actually.
7. Press the accelerator pedal slowly to stall the

torque converter at high idle and measure the
intake air pressure (boost pressure) at this
time.
k Keep pressing the brake pedal securely.
8. After measuring, return the accelerator pedal

to the low idle position immediately and return
the gear shift lever to the P position.
k Do not operate the gear shift lever
while pressing the accelerator pedal. If
it is operated so, the inside of the
transmission may be broken.
9. After finishing measurement, remove the mea-

suring instrument and return the removed
parts.
10 GD655-3E0, GD675-3E0
Measuring blowby pressure 1 q If it is impossible to run the engine at the rated

output or perform a stall operation, measure
a Measuring tools for blow-by pressure while the engine is running at high idle. The
Sym- value obtained in this case is about 80 percent
Part No. Part name
bol of the blowby pressure at the rated output.
1 799-201-1504 Blowby checker a The blowby pressure may vary largely with the
D engine condition. If the measured value is
2 799-201-1511 Nozzle
judged abnormal, check for oil consumption
Before measuring the blowby pressure, heighten increase, bad exhaust gas color, oil deteriora-
the coolant temperature to the operating range. tion, high speed of oil deterioration, etc., which
are related to the abnormal blowby pressure.
1. Connect the nozzle D2 of the blowby checker
D1 to the end of the engine breather hose (1).
2. Connect the nozzle D2 to the blowby checker

D1.
3. Run the engine at the rated output and mea-

sure the blowby pressure.
k Take care not to touch the hot or rotat-

ing parts during measurement.
a The regular blowby pressure is measured

while the engine is running at the rated output.
q In the field, perform a stall operation for an
approximate value.
GD655-3E0, GD675-3E0 11
Measuring engine oil pressure 1

a Engine oil pressure measurement tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic gauge
1. Open the cover of engine left side, and remove

the oil pressure measurement plug (1) of the
cylinder block.
5. Detach the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
2. Install nipple [1] of hydraulic tester E1 and con-

nect hydraulic tester E2 (9.8 MPa {10 kg/cm2})
by hose [2].
3. Start the engine and raise the temperature of

the engine to the operating range.
4. Measure the engine oil pressure at low idle

and also at high idle.
12 GD655-3E0, GD675-3E0
Measuring engine speed 1 Testing fan belt tension 1

Measure the engine speed under the following con- 1. Testing belt tension
dition. Measure the deflection (A) of the belt when the
q Coolant temperature: Within operating range belt is pressed with a force of approx. 98 N {10
q Power train oil temperature: 60 – 80°C kg} at a point midway between the fan pulley
q Hydraulic oil temperature: 40 – 55°C and tension pulley.
1. Preparatory work
Turn the starting switch ON and set the
machine monitor to the "Real-time monitor" of
the Service mode to display the engine speed.
a For the operating method, see "Real-time
monitor of machine monitor".
2. Measuring low idle speed

1) Start the engine.
2) Set the gear shift lever in the "P" range,
set the work equipment control lever in
neutral, release the brake pedal and mea-
sure the engine speed.
(Unit: mm)
3. Measuring high idle speed
1) Start the engine and press the accelerator Belt Deflection (A)
pedal fully. New belt 11.8 – 12.8
2) Set the gear shift lever in the "P" range, After adjusting tension 14.0 – 15.6
set the work equipment control lever in
neutral, release the brake pedal and mea- 2. Adjusting the belt tension
sure the engine speed. 1) Loosen the nut (1).
2) Loosen the locknut (2), then turn the
4. Measuring torque converter stall speed adjustment nut (3) to adjust the belt ten-
1) Set the transmission mode switch to "TC sion.
AUTO". 3) After adjusting the belt tension, tighten the
2) Start the engine. nut (1) and then the locknut (2).
3) Press the brake pedal securely and set
the gear shift lever to "R4".
a Before going to the next step, check
that the gear shift indicator displays
R4.
4) While pressing down the brake pedal,
press the accelerator pedal fully.
5) Immediately after the torque converter oil
temperature gauge enters the top level of
the green range, release the accelerator
pedal and return the gear shift lever to "N".
6) Repeat steps 3) – 5) 3 times.
7) Perform steps 3) – 5) again and measure
the engine speed when the torque con-
verter oil temperature gauge enters the
3rd level of the green range.
a Immediately after finishing the mea-
surement, return the gear shift lever
to the "P" range and run the engine at
high idle to lower the torque converter
oil temperature.
GD655-3E0, GD675-3E0 13
Testing air conditioner

compressor belt tension 1
1. Testing belt tension
Measure the deflection (a) of the belt when the
belt is pressed with a force of approx. 98 N {10
kg} at a point midway between the fan pulley
and tension pulley.
(Unit: mm)
Belt Deflection (a)
New belt 15 – 16
After adjusting 17 – 19
2. Adjusting the belt tension

1) Loosen the locknut (1), then turn the
adjustment nut (2) and move the compres-
sor (4) with the shaft (3) at the center to
adjust the belt tension.
2) After adjusting the belt tension, tighten the
locknut (1).
14 GD655-3E0, GD675-3E0
Measuring torque converter stall 2. Start the engine and run at low idle.
speed 1
3. Depress the brake pedal. Stop the engine and
a Measuring tools for torque converter stall move the gear shift lever to TOP reverse
speed speed (R4).
Sym-
Part No. Part name 4. Measure the speed when the accelerator pedal
bol
1 799-203-8001 Multi-tachometer is set to the full throttle position.
F a Measure when the engine speed is stable.
2 795-790-2500 Adapter
k Do not touch the hot parts when measur-

ing. And ensure that no one is near the
machine during the procedure.
a Measure the torque converter stall speed

under the following conditions:
q Coolant temperature: within operating range
q Power train oil temperature: 60 – 80°C
q Hydraulic oil temperature: 45 – 55°C
1. Remove the cap from the engine speed pick-

up port, install the adapter assembly F2 and
multi-tachometer sensor [1], then connect to
the main body F1.
GD655-3E0, GD675-3E0 15
Checking clutch oil pressure 1

a Checking tools for clutch oil pressure
Sym-
Part No. Part name
bol
G
k Set the front frame and rear frame facing

straight to the front, then secure in position
with the lock pin.
k Raise the tandem drive with a hydraulic
jack and raise the 4 rear wheels off the
ground.
k Set the blade at right angles to the chassis
and lower the blade completely to the
ground.
k The oil is hot, so be careful not to burn
yourself.
k Stop the engine before removing or install-
ing the plug or pressure gauge.
a Oil temperature when measuring: 60 – 80°C
1. Checking transmission modulating oil pressure

(Clutch circuit oil pressure)
1) Measure the main relief oil pressure and
check that it is normal.
2) Remove the plugs (1) through (7) from the
places to be measured, then install tool G. ECMV clutch actuation table
All gauges: 5.88 MPa {60 kg/cm2} ECMV
Plug Oil pressure Plug Oil pressure FL FH R 1st 2nd 3rd 4th
No. circuit No. circuit Speed
Range
1 FL clutch 5 R clutch
F1 Q Q
2 FH clutch 6 3rd clutch
3 1st clutch 7 4th clutch F2 Q Q
4 2nd clutch — — F3 Q Q
Plug size: Rc1/8 or 1/4 F4 Q Q

F5 Q Q
3) Run the engine at low idle and shift the
gear shift lever to the speed range (oil F6 Q Q
pressure circuit) to be measured. F7 Q Q
4) Run the engine at full throttle and mea-
F8 Q Q
sure the clutch pressure of that circuit.
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
N
16 GD655-3E0, GD675-3E0
Checking torque converter oil 3. Torque converter outlet port pressure

pressure 1 1) Measurement port: 3 (Rc 1/8)
2) Start the engine and measure the pres-
k Set the front frame and rear frame facing sure at low idle and high idle.
straight to the front, then secure in position
with the lock pin. 4. Torque converter lock-up port pressure
k Raise the tandem drive with a hydraulic 1) Measurement port: 4 (Rc 1/4)
jack and raise the 4 rear wheels off the 2) Start the engine and measure the pres-
ground. sure at high and low idle.
k Set the blade at right angles to the chassis
and lower the blade completely to the
ground.
k The oil is at high temperature, so be careful
not to burn yourself.
k Stop the engine before removing or install-
ing the plug or pressure gauge.
a Oil temperature: 60 – 80°C
1. Main relief pressure

1) Measurement port: 1 (Rc 1/8)
sure at low idle and high idle.
2. Torque converter inlet port pressure

1) Measurement port: 2 (Rc 1/8)
sure at low idle and high idle.
GD655-3E0, GD675-3E0 17
Adjusting speed sensor 1 2. Transmission input shaft speed sensor

1) Screw the sensor (4) in by hand until the
1. Engine speed sensor sensor tip contacts the gear (2).
1) Screw the sensor (1) in by hand until the a When positioning the sensor tip in
sensor tip contacts the gear (2). contact with the gear, tighten lightly
a When positioning the sensor tip in by hand and check that it is in con-
contact with the gear, tighten lightly tact. Never use a wrench or any other
by hand and check that the sensor in tool to tighten the sensor.
contact. Never use a wrench or any 2) When the sensor (4) tip contacts the gear
other tool when tightening. (2), screw the sensor out 1/2 – 1 turn.
Standard clearance (a): 0.68 – 1.13 mm
3) Tighten the locknut (3).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
a Tighten the sensor carefully to pre-
vent excessive force being applied to
the sensor wiring.
a Be careful not to scratch the sensor
tip or let any iron filings or powder
stick to the tip.
2) When the sensor (1) tip contacts the gear

(2), screw the sensor out 1/2 to 1 turn.
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
a Tighten the sensor carefully to pre-
vent excessive force being applied to
the sensor wiring.
stick to the tip.
18 GD655-3E0, GD675-3E0
3. Transmission output shaft speed sensor

1) Screw the sensor (5) in by hand until the
sensor tip contacts the gear (2).
a When positioning the sensor tip in
contact with the gear, tighten lightly
by hand and check that sensor is in
contact. Never use a wrench or any
other tool to tighten the sensor.
2) When the sensor (5) contacts the gear (2),

turn the sensor out 1/2 to 1 turn.
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
a Tighten carefully and take action to
prevent any excessive force from
being applied to the sensor wiring.
stick to the tip.
GD655-3E0, GD675-3E0 19
Flushing torque converter and 4. Perform the flushing as follows.

transmission circuit 1 1) After starting the engine, run the engine
for approx. 20 minutes at low idle, without
a Metal particles and other dirt in the torque con- operating the gear shift lever.
verter and transmission hydraulic circuit will a From time to time, increase the
reduce the torque converter and transmission engine speed to approx. 1,500 rpm.
life, and will cause internal damage. To prevent a If the ambient temperature is low and
this situation, flush the system to remove the the engine coolant temperatur e
dirt in the hydraulic circuit. gauge does not enter the green
range, continue the warming-up oper-
1. Flush the circuit, if the following conditions ation longer.
apply. 2) Travel or perform the actual operations for
1) If there has been any breakage of the at least 20 minutes.
torque converter, transmission, or hydrau- a Use all the speed ranges (FOR-
lic equipment, and metal particles are cir- WARD, REVERSE, and 1st – 8th).
culating in the hydraulic circuit. 3) Repeat the procedure in Step 4.1) and run
2) When the torque converter and transmis- the engine at low idle for approx. 20 min-
sion have been overhauled or repaired. utes.
2. Cleaning the filter 5. Replace the flushing element.

1) After removing the filter, remove the drain 1) Using the procedure in Step 2.1), replace
plug (1) and drain the system. the flushing element with the standard ele-
ment (714-07-28712).
2) Add oil and check the level again.
6. Replace the transmission fail-safe filter.

1) Remove the mounting bolt (3) of the filter
assembly (2), then remove the filter
assembly.
2) Remove the element (4) and replace it
with a new element.
a If there is any dirt inside the filter case
(5), wash the case.
3) Install a new O-ring (6) to the outside cir-
cumference of the case (5).
a Coat the outside circumference of the
2) Remove the transmission oil filter, clean O-ring with a small amount of grease.
the inside, then reinstall the element for a 4) Install the case (5).
second flushing. 3 Case bolts:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3. Fill the transmission case with oil. 5) Install the filter assembly (2).
Add fresh oil through the oil filler port to the
specified level, and run the engine to circulate
the oil through the system. Then check the
level again.
5 Transmission case: 45 l
20 GD655-3E0, GD675-3E0
Testing brake disc 1

k Stop the machine on flat ground and put
blocks under the front wheels.
1. Remove the rear wheel assembly. For details,

see "Removal of rear wheel assembly".
2. Apply the brake, remove the cap (1), then push

in the pin (2).
3. Measure the height of the pin tip (2) and the

guide end face (3).
Height (new part): 1.8 – 2.0 mm
4. If the pin tip (2) and the guide end face (3) are
level, replace the disc.
GD655-3E0, GD675-3E0 21
Testing and adjusting parking brake 1
k Stop the machine on a flat ground, set the 4) Calculate the total clearance.
gear shift lever in the P position and set a If the total clearance (c + d) is 2.5 mm
chocks to the tires. or larger, it must be adjusted.
q Total clearance (c + d) when pads are
1. Measuring pad thickness new: 0.5 – 0.8 mm
1) Start the engine, increase the accumulator
pressure and then stop the engine. 3. Adjusting pad clearance
2) Turn the starting switch ON and set the 1) Start the engine, increase the accumulator
gear shift lever in the N position. pressure and then stop the engine.
3) Measure thicknesses (a) and (b) of the 2) Turn the starting switch ON and set the
front and rear pads. gear shift lever in the N position.
q Thicknesses (a) and (b) are 3 mm or 3) Remove plug (3) and loosen locknut (4).
larger: Pads can be used as they are. 4) Set the brake calipers free according to
q Thicknesses (a) and (b) are less than the following procedure.
3 mm: Pads cannot be used. Replace 1] Loosen double nut (5) and then
them. loosen bolt (6) about 5 turns.
2] Loosen locknut (7) and then loosen
2. Measuring pad clearance bolt (8) about 3 turns.
1) Start the engine, increase the accumulator a Move the locknut toward the mount
pressure and then stop the engine. bracket.
2) Turn the starting switch ON and set the 5) Tighten adjustment bolt (9) until front and
gear shift lever in the N position. rear pads (1) touch disc (2).
3) Measure clearances (c) and (d) between 6) Tighten bolt (8) until it touches polyure-
each of front and rear pads (1) and disc thane spring (10) and then tighten it 1/2
(2). turn more.
22 GD655-3E0, GD675-3E0
7) Tighten locknut (7) toward the mount

bracket.
3 Locknut:
242 – 302 Nm {24.7 – 30.8 kgm}
(Target: 272 Nm {27.7kgm})
8) Loosen adjustment bolt (9) and adjust the
total clearance (a + b) of front and rear
pads (1).
q Total clearance (a + b): 0.5 – 0.8 mm
9) While touching the tip of bolt (6) to install-
ing face, adjust double nut (5) so that
clearances (a) and (b) in between front
and rear pads (1) and disc (2) will come to
be even, and then tighten double nut (5).
3 Double nut:
24.1 – 30.1 Nm {2.46 – 3.07 kgm}
(Target: 27.1 Nm {2.76 kgm})
10) Fix adjustment bolt (9) with locknut (4).
3 Locknut:
102.8 – 128.2 Nm {10.5 – 13.1 kgm}
(Target: 115.5 Nm {11.8 kgm})
11) Check clearances (a) and (b) between
each of front and rear pads (1) and disc
(2) again.
12) Install plug (3).
13) Set the gear shift lever in the P position
and check that there is no clearance
between each of the front and rear pads
(1) and disc (2).
a If the adjustment work takes more than 15
minutes, perform steps 1) and 2) halfway
to increase the accumulator pressure and
then continue the work.
GD655-3E0, GD675-3E0 23
Method for emergency release of 3. Drive or tow the machine to a safe place.
parking brake 1 a After moving the machine, set chocks
securely to the tires.
a If any problem occurs in the electrical system
or hydraulic system of the parking brake and 4. After repairing the parking brake, adjust the
the parking brake is not released, it is possible pad clearance, referring to "Testing and adjust-
to release the parking brake temporarily as fol- ing parking brake".
lows.
k If any problem occurs in the hydraulic sys-
tem, there is a strong possibility that the
brake will not work properly, so after releas-
ing the parking brake, always tow the
machine at low speed to a safe place.
k When carrying out the operation to release
the parking brake, stop the machine on
level ground and check that the surround-
ing area is safe before starting the opera-
tion. If the parking brake must be released
on a slope in an emergency or other
unavoidable situation, set chocks to the
tires securely.
1. Remove plug (1).
2. Loosen locknut (2) and turn adjustment bolt (3)

counterclockwise.
a Turn the adjustment bolt until a clearance
is made between the brake pad and disc.
24 GD655-3E0, GD675-3E0
Testing and adjusting parking 7) Tighten the bolt (9) so that the front and
brake pad clearance 1 rear pads (1) contact disc (2).
8) Tighten the bolt (8) until it contacts the
k Stop the machine on flat ground and put urethane spring (10), then tighten the bolt
blocks under the front wheels. an additional 1/2 turn.
9) Tighten nut (7).
3 Nut:
1. Checking the parking brake pad clearance
1) Start the engine, charge the accumulator 242 – 302 Nm {24.7 – 30.8 kgm}
with hydraulic oil, then stop the engine. (Target: 272 Nm {27.7 kgm})
2) Turn the engine starting switch to the ON
10) Loosen the adjustment bolt (9) to adjust
position and set the gear shift lever to the
so that the total clearance (a + b) between
N position.
the disc and pads is 0.5 – 0.8 mm.
3) Measure the front and rear clearances (a
and b) between the parking brake pad (1)
and disc (2).
4) If the total clearance (a + b) is more than
2.5 mm, follow the procedure for adjusting
the parking brake pad clearance below to
adjust the clearance.
a Total clearance for new part (a + b):
0.5 – 0.8 mm
11) Position the bolt tip (6) in contact with the

bracket (11). Turn the bolt and adjust so
that the clearance (a and b) between the
disc (2) and pads (1) is uniform. Tighten
the double nut (5).
3 Double nut:
24.1 – 30.1 Nm {2.46 – 3.07 kgm}
(Target: 27.1 Nm {2.76 kgm})
2. Adjusting the parking brake pad clearance 12) Secure the adjustment bolt (9) with the
locknut (4).
3 Locknut:
1) Start the engine, charge the accumulator
with hydraulic oil, then stop the engine.
2) Turn the engine starting switch ON and 102.8 – 128.2 Nm {10.5 – 13.1 kgm}
set the gear shift lever to the N position. (Target: 115.5 Nm {11.8 kgm})
3) Measure parking brake pad (1) thickness. 13) Check the clearance between the disc (2)
q If thickness is 3 mm or more: Use again and pads (1) again.
q If thickness is less than 3 mm: Replace 14) Install the plug (3).
4) Remove the plug (3); loosen the locknut 15) Set the gear shift lever to the P position
(4). and check that the clearance between the
5) Loosen the double nut (5), then loosen the pads (1) and disc (2) is removed.
bolt (6) five turns. k If the adjustment procedure for steps 3)
6) After loosening the nut (7), loosen the bolt thru 15) takes longer than 15 minutes,
(8) three turns. perform the adjustment procedure con-
tinuously after completing the proce-
dure in steps 1) and 2).
16) Turn the engine starting switch OFF.
GD655-3E0, GD675-3E0 25
Testing accumulator charge 5. Charge fully (to the cut-out pressure) with the
pressure 1 engine at full throttle, then stop the engine.
Turn the starting switch to the ON position and
a Testing tool for accumulator charge pressure press and release the brake pedal repeatedly.
Sym- At this time, if the low brake oil pressure cau-
Part No. Part name tion buzzer sounds before the brake pedal is
bol
H 799-101-5002 Hydraulic tester pressed 10 times, check the accumulator gas
pressure.
q For the method of checking the accumula-
a Hydraulic oil temperature: 45 – 55°C
k Stop the engine and depress the brake tor gas pressure, see "Charging nitrogen
pedal slowly at least 30 times to release the gas for brake, work equipment accumula-
pressure inside the accumulator circuit. tor".
1. Remove the accumulator inlet port pressure

switch (1) (Rc 1/4), then install tool H (39.2
MPa {400 kg/cm2}).
2. Measure the accumulator charge cut-out pres-

sure. Start the engine, run the engine at low
idle, and measure the rise in pressure. The
point where the pressure stops rising is the
cut-out pressure.
3. Measure the accumulator charge cut-in pres-

sure. Start the engine, run the engine at low
idle, wait for the accumulator charge cut-out,
then depress and release the brake repeatedly
to lower the pressure. The point where the
pressure starts to rise again is the cut-in pres-
sure.
4. After stopping the engine, press and release

the brake pedal slowly at least 20 times repeat-
edly, then run the engine at low idle. The initial
pressure at this time is the accumulator gas
charge pressure, which is 3.4 ± 0.1 MPa {35 ±
1.0 kg/cm2}.
26 GD655-3E0, GD675-3E0
Testing and adjusting work Adjusting

equipment oil pressure 1 1. Adjusting the LS relief valve
a If the work equipment oil pressure is not
a Testing and adjusting tools for work equipment normal, adjust the LS relief valve (2) as
oil pressure follows.
Sym- 1) Loosen the locknut (3) and turn the adjust-
Part No. Part name
bol ment screw (4) as follows.
799-101-5002 Hydraulic tester q To INCREASE the pressure, turn
1 CLOCKWISE.
J q To DECREASE the pressure, turn
799-101-5160
2 Nipple COUNTER-CLOCKWISE.
799-101-5220
k Stop the engine, loosen the oil filler cap

slowly to release the pressure inside the
hydraulic tank.
a Oil temperature when measuring: 45 – 55°C
1. Measuring unload oil pressure

1) Remove the pressure measurement plug
(1) (M10 × 1.25).
2) Fit the nipple J2, then install the oil pres-
sure gauge J1 (5.9 MPa {60 kg/cm2}).
3) Run the engine at full throttle and mea-
sure the oil pressure with all levers at
HOLD.
a One turn of the adjustment screw equals
2. Measuring work equipment pressure (relief 15.1 MPa {154 kg/cm2}
2) After adjusting, tighten the locknut (3).
3 Locknut:
pressure)
1) Remove the pressure measurement plug
(1) (M10 × 1.25). 68.6 – 78.5 Nm {7 – 8 kgm}
2) Fit the nipple J2, then install the oil pres-
sure gauge J1 (39.2 MPa {400 kg/cm2}). a After completing the adjustment, use the mea-
3) Run the engine at full throttle and measurement procedure above to check the oil
sure the relief pressure; operate the blade pressure again.
lift lever to the RAISE position.
GD655-3E0, GD675-3E0 27
Testing and adjusting LS 3) Connect the differential pressure gauge

differential pressure 1 K3.
a Testing and adjusting tools for LS differential

pressure
Sym-
Part No. Part name
bol
1
799-101-5160
K 2 Nipple
799-101-5220
3 799-401-2701 Differential pressure gauge
4 799-261-1231 Elbow
1. Measuring LS differential pressure with the

main relief differential pressure gauge a Connect the LS pump pressure (1) to
1) Remove the high-pressure (1) and low- the high-pressure side of the differen-
pressure (2) measurement plugs. tial pressure gauge and LS pressure
(2) to the low-pressure side.
4) Set to the conditions in Table 1, and mea-
sure the LS differential pressure.
Table 1
Differential
Accelerator Operation pressure
(MPa {kg/cm2})
2.84 – 3.9
Full Levers at neutral
{29 – 40}
Blade lever 2.35 ± 0.1
Full
(operate fully to raise) {24 ± 1}
2) Fit the elbow K4 and nipple K2.
28 GD655-3E0, GD675-3E0
2. Measuring with an oil pressure gauge Adjusting the LS valve

a Measure with the same gauge. When measuring the differential pressure under the
1) Remove the high-pressure (1) and low- above conditions and the pressure is not within the
pressure (2) oil measurement plugs. standard value, adjust as follows.
1. To adjust the differential pressure, loosen the

locknut (2) and turn the screw (3).
q CLOCKWISE to increase pressure
q COUNTERCLOCKWISE to decrease
pressure
One turn of the adjustment screw equals 1.3
MPa {13.3 kg/cm2}
2. After adjusting, tighten the locknut (2).

3 Locknut: 49 – 63.7 Nm {5 – 6.5 kgm}
a Always measure the differential pressure
while adjusting.
2) Fit the elbow K4 and nipple K2.
3) Connect the differential pressure gauge

K1 (39.2 MPa {400 kg/cm2}).
a Use a gauge with a scale in units of
1.0 MPa {10 kg/cm2}.
sure the LS pump pressure.
a Read the gauge indicator while stand-
ing directly in front of it.
sure the LS pressure.
a Read the gauge indicator while stand-
ing directly in front of it.
LS differential pressure = (LS pump pres-
sure) – (LS pressure)
GD655-3E0, GD675-3E0 29
Adjusting PC valve 1
a If the load becomes high and the engine speed
drops, or the engine speed remains normal
and the work equipment becomes slower, but
the pump discharge pressure and the LS differ-
ential pressure are normal, adjust the PC
valves as follows.
1. Loosen the locknut (1) and turn the sleeve (2)

to adjust as follows.
q If the work equipment speed is slow, turn
CLOCKWISE.
q If the engine speed drops, turn COUNTER-
CLOCKWISE.
a Turning the sleeve clockwise increases
the pump absorption torque.
a Turn the adjustment sleeve within a range
of 180° to the left or right.
2. After adjusting, tighten the locknut (1).

3 Locknut: 88 – 113 Nm {9 – 11.5 kgm}
30 GD655-3E0, GD675-3E0
Bleeding air from hydraulic circuit1 3. Bleeding air from the hydraulic cylinder
1) Start the engine and run at idle for approx.
1. Bleeding air from the pump 5 minutes.
1) Loosen the air bleed plug (1), and bleed 2) Run the engine at low idle, and raise and
the air from the pump. lower the boom 4 to 5 times in succession.
a When air no longer is discharged with the a Operate the piston rod to approx. 100 mm
oil, the air bleeding operation is com- before the end of its stroke. Do not relieve
pleted. the circuit under any circumstances.
2) Tighten the plug (1).
3 Plug:
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
14.7 – 19.6 Nm {1.5 – 2.0 kgm} idle and operate the piston rod to the end
a Precautions when starting the engine of its stroke to relieve the circuit.
After completing the above procedure and 4) Repeat Steps 2) and 3) to bleed the air
starting the engine, run the engine at low from all the cylinders.
idle for 10 minutes.
2. Bleeding air from the pump circuit

1) Start the engine, remove the plugs (1) and
(2), and bleed the air.
a When air no longer is discharged with the
oil, the air bleeding operation is com-
pleted.
2) Tighten the plugs (1) and (2).
GD655-3E0, GD675-3E0 31
Measuring internal cylinder Blade shift cylinder

leakage 1
a If the hydraulic drift of the work equipment is
not within the standard value, measure the
amount of leakage inside the cylinder as fol-
lows to judge if cause of the hydraulic drift is in
the cylinder or in the control valve.
q If the amount of leakage is within the stan-
dard value, the problem is with the control
valve.
q If the amount of leakage is not within the
standard value, the problem is with the
cylinder.
a Oil temperature when measuring: 45 – 55°C.
Power tilt cylinder
1. Fully extend the cylinder rod to be measured,
then stop the engine.
a When measuring the blade lift and the
scarifier cylinders, lower the work equip-
ment to the ground, remove the joint at the
rod end from the work equipment, then
extend the cylinder.
2. Disconnect the piping at the head end, and

block the piping (1) at the chassis end with a
blind plug.
k Be careful not to disconnect the piping at
the bottom end.
3. Start the engine, then run the engine at high

idle and apply the relief pressure to the bottom Drawbar shift cylinder
end of the cylinder.
4. Wait 30 seconds, then measure the amount of

oil that leaks during the next minute.
a Minimum leakage: 10 cc
Blade lift cylinder

L.H. R.H.
32 GD655-3E0, GD675-3E0
Leaning cylinder
Articulation cylinder
R.H. L.H.
Ripper cylinder
GD655-3E0, GD675-3E0 33
Testing and adjusting differential 3) Start the engine and turn differential lock
lock oil pressure [Differential lock switch [1] ON.
specification] 1
a Testing and adjusting tools for differential lock
oil pressure
Sym-
Part No. Part name
bol
1
M
799-101-5220 Nipple
2
07002-11023 O-ring
k Stop the machine on a level ground, set the

gear shift lever in the P position, and lock
the tires with chocks. 4) Run the engine at high idle and measure
a Test and adjust the differential lock pressure the differential lock pump outlet pressure.
under the following conditions.
q Final drive case oil temperature: 45 – 55°C
Testing
1. Testing differential lock pump outlet pres-
sure
1) Remove oil pressure pickup plug (1) from
the differential lock valve inlet piping.
5) After finishing measurement, remove the

measuring instruments and return the
removed parts.
2. Measuring differential lock valve outlet

pressure
1) Remove oil pressure pickup plug (2) from
the differential lock valve outlet piping.
2) Install nipple M2 and connect the oil pres-
sure gauge of hydraulic tester M1.
a Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
34 GD655-3E0, GD675-3E0
2) Install nipple M2 and connect the oil pres- Adjusting

sure gauge of hydraulic tester M1. Adjusting differential lock relief valve
a Use the oil pressure gauge of 5.9 a If both of the differential lock pump outlet pres-
MPa {60 kg/cm2}. sure and differential lock valve outlet pressure
3) Start the engine and turn differential lock are below 2.8MPa {29 kg/cm2}, adjust differen-
switch [1] ON. tial lock relief valve (3) according to the follow-
ing procedure.
4) Run the engine at high idle and measure

the differential lock pump outlet pressure. 1. While fixing adjustment screw (4), loosen lock-
nut (5).
2. Turn adjustment screw (4) to adjust the pres-

sure.
a If the adjustment screw is
q turned to the right, the pressure is
heightened.
q turned to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjust-
ment screw: 0.989 MPa {10.1 kg/cm2}
3. While fixing adjustment screw (4), tighten lock-

nut (5).
5) After finishing measurement, remove the 3 Locknut: 8 Nm {0.81 kgm}
measuring instruments and return the
removed parts.
4. After finishing adjustment, check again that the

oil pressure is normal according to the above
procedure.
GD655-3E0, GD675-3E0 35
Measuring steering and brake oil 2. Measuring the brake circuit pressure
pressure 1 a After charging the brake accumulator fully
with oil pressure, stop the engine.
a Measuring tools for steering, brake oil pressure 1) Remove the air bleed plug (2) (Rc 1/4).
Sym-
Part No. Part name
bol
1
L
799-101-5160
2 Nipple
799-101-5220
k Stop the machine on flat ground, apply the

parking brake, and lower the blade com-
pletely to the ground.
k Stop the engine, loosen the oil filler cap
slowly to release the pressure inside the
hydraulic tank.
2) Fit the nipple L2, then install the oil pres-
1. Measuring the steering circuit pressure
sure gauge L1 (5.88 MPa {60 kg/cm2}).
1) Remove the oil pressure measurement
plug, 10 × 1.25, (1) at the front of the
pump.
2) Fit the nipple L2, then install the oil pres-
sure gauge L1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle, and mea-
sure the oil pressure after relieving the left
or right steering circuits (operate to end of
the stroke).
3) Measure the oil pressure after depressing

the brake pedal.
a After measuring the oil pressure, install the
plug and bleed the air from the system.
36 GD655-3E0, GD675-3E0
Bleeding air from brake piping 1 2. Bleeding the air between the slack adjuster
k
and the brake
Stop the machine on flat ground and put 1) Install the vinyl tube (4) to the tip of the air
blocks under the front wheels. bleed valve (3).
a Start the engine and charge the accumulator.
1. Bleeding the air between the brake valve

and the slack adjuster
1) Open the battery cover, then install vinyl
tube (2) to the tip of air bleed valve (1) at
the top face of the slack adjuster.
2) Depress the brake pedal and loosen the

air bleed valve (3) 3/4 turns, then close the
valve and release the pedal.
3) Continue this procedure until no more
bubbles exit with the oil discharged from
the air bleed valve (3).
4) Bleed the air from the brake air bleed
2) Depress the brake pedal and loosen the valves at four places on the left and right.
air bleed valve (1) 3/4 turns, then close the
valve and release the pedal.
3) Continue this procedure until no more
bubbles exit with the oil discharged from
the air bleed valve (1).
4) Bleed the air from the slack adjuster air
bleed valves at 2 places on the left and
right.
GD655-3E0, GD675-3E0 37
Charging nitrogen gas for brake, 7. Turn the handle [1] slowly clockwise to push
work equipment accumulator 1 the piston of the gas valve (1).
1. Before charging with gas, check that the oil 8. Open the valve of the nitrogen cylinder slowly
pressure is completely released. and charge the cylinder (bladder) with nitrogen
a If the oil pressure is not released, it is gas.
impossible to charge with the nitrogen a While doing this step, close the nitrogen
gas. cylinder valve from time to time, wait for
the charging assembly pressure gauge [4]
2. Turn the charging assembly handle [1] coun- to become stable, and check the dis-
terclockwise and raise it to the point where it played pressure.
stops.
9. When the gas is charged to the specified pres-
3. Turn the bleed plug handle [2] counterclock- sure, close the valve of the nitrogen cylinder
wise to open it. securely.
a If the pressure in the cylinder is too high,
turn the handle [2] counterclockwise grad-
ually to release the excessive pressure.
1) Accumulator (721-32-10240, capacity: 3 l):

q Specified pressure at 20 ± 5°C:
3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}
q The relationship between the temperature
and pressure of the charged gas at the
time of charging is as follows.
q Px = 35 (kg/cm2) × {273 + t (°C)} / {273
+20(°C)}
Px: Pressure of charged gas
t: Gas temperature when charging
4. Remove the cap from the gas valve (1), then (nearly ambient temperature)
assemble the charging assembly to the gas 35: Specified gas pressure
valve (1).
2) Accumulator (721-32-10250, capacity: 1 l):
q Specified pressure at 20 ± 5°C:
2.0 ± 0.1 MPa {20 ±1.0 kg/cm2}
q The relationship between the temperature
and pressure of the charged gas at the
time of charging is as follows.
q Px = 20 (kg/cm2) × {273 + t (°C)} / {273 +
20 (°C)}
Px: Pressure of charged gas
t: Gas temperature when charging
(nearly ambient temperature)
20: Specified gas pressure
10. Turn the handle [1] counterclockwise. Return

5. Connect the nitrogen cylinder and charging the gas valve piston to its original position.
assembly with hose assembly [3]. Then, turn the handle [2] counterclockwise to
release the gas remaining inside the hose and
6. Open the nitrogen cylinder valve slightly, take charging assembly.
care that the gas does not discharge quickly,
and let the gas flow at a pressure from 0.20 to 11. Remove the charging assembly from the accu-
0.29 MPa {2 to 3 kg/cm2}. When the gas starts mulator.
to exit from the handle [2], turn the handle [2]
clockwise to stop the gas from escaping.
38 GD655-3E0, GD675-3E0
12. Use water or soapy water to check that the gas

is not leaking from the gas valve (1). Install the
cap and valve guard.
a After charging with nitrogen gas, check
the charge pressure about a week later to
verify pressure is maintaining. After that,
check once every month or once every six
months, according to the conditions of
use. Note that when the check is per-
formed, the pressure will go down. Thus,
add a slight charge to replace the pres-
sure that is lost.
GD655-3E0, GD675-3E0 39
Testing and adjusting circle guide Adjusting

clearance 1 1. Adjusting clearance in top-to-bottom direc-
k
tion
If the following conditions occur during Raise the blade, remove the bolts (1), (5), and
adjustment, replace the circle guide. (9), and circle guides (2), (6), and (10).
q When clearance (R) between the circle and cir- Adjust with shims.
cle guide is lost. a Standard shim thickness: 5.5 mm
q When the clearance between the tip (or root) of (Shim thickness: 1 mm, 0.5 mm)
the teeth of the circle gear and the root (or tip)
of the teeth of the pinion gear of the circle rota-
tion gear becomes zero (0).
Testing
1. Testing clearance in top-to-bottom direc-
tion
Let the blade hang and measure clearance (P)
between the top face of the circle and the bot-
tom face of the drawbar as shown in the dia-
gram.
Standard clearance (P): 1.5 ± 0.5 mm
2. Checking clearance in front-to-rear direc-

tion
Leave the blade hanging down, apply force to
the rear, then measure clearance (Q) between
the circle and circle guide as shown in the fig-
ure.
Standard clearance QF (front): 0 mm
QC (center): 0.7 mm
QR (rear): 1.5 mm
or QF = QR = 1 mm
40 GD655-3E0, GD675-3E0
2. Adjusting clearance in front-to-rear direc- 3. Adjusting clearance in left-to-right direction

tion 1) Loosen the bolt (9) and locknut (12),
1) Bring the blade lightly into contact with the extend bolt (11), and push the circle guide
ground. Loosen the bolt (1) and locknut (10) open to make QR = 0.
(4). Extend the bolt (3). Push the circle a Push open the left and right circle guides
guide (2) open to make QF = 0. (10) uniformly.
a Push open the left and right circle guides 2) Loosen the bolt (5) and locknut (8).
(2) uniformly. Extend the bolt (7), and push the circle
2) Adjust clearance (D) between the end guide (6) open to make QC = 0.
face of the flange at the bottom of the cir- a Push open left and right circle guides (6)
cle rotation gear and the sliding surface on uniformly.
the inside diameter of the circle. 3) When QR = 0, turn the bolt (11) back 1/4
Standard clearance at (D): turn, and tighten the locknut (12). Turn
15 – 17 mm (shear pin type) back the circle guide (10) until it contacts
20 – 22 mm (slip clutch type) the bolt (11). Then tighten the bolt (9).
3 Bolt:
490.3 – 608 Nm {50 – 62 kgm}
4) The standard clearance between the tip of
the teeth of the circle gear and the root of
the teeth of the pinion gear of the rotation
gear is from 1.5 to 3.0 mm.
5) When QC = 0, turn the bolt (7) back 1/2
turn and tighten locknut (8). Turn back the
circle guide (6) until it contacts the bolt (7).
Tighten the bolt (5).
3 Bolt:
490.3 – 608 Nm {50 – 62 kgm}
6) Check that the circle guide rotates even
when the work equipment is set to the 90°
3) When QF = 0, tighten locknut (4), then high bank position on the left and right.
tighten bolt (1).
3 Bolt:
490.3 – 608 Nm {50 – 62 kgm}
GD655-3E0, GD675-3E0 41
Testing and adjusting slip clutch 4. Run the engine at full throttle and operate the
type rotary device 1 circle rotation lever slowly to see if the clutch
slips.
Testing q Check by rotation of worm wheel (3).
1. Remove bolts (1) and cover (2). q If worm wheel (3) rotates and the blade
does not rotate, the clutch is slipping.
2. Check that you can see the internal teeth of
worm wheel (3) through the hole at (P). Adjusting
1. When clutch does not slip
1) Remove bolts (4) and holder (5) and add 1
shim 0.2 mm thick (6).
2) Install holder (5) and tighten bolts (4).
3 Bolt (4):
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
3. Press the blade against the ground and raise

the front wheel to lock the circle or fix the blade
end.
q How to raise the front wheel
1) Lower the blade to the ground and extend
the blade lift cylinder until the front wheels
are raised. 3) Check the clutch for slipping according to
2) Apply the parking brake. the "Testing" procedure.
4) Repeat steps 1) – 3) until the clutch slips
and set the clutch to the critical slipping
point.
5) If the clutch comes to slip, remove 1 shim
0.2 mm thick (6).
a After the shim is adjusted, the clutch
must not slip.
42 GD655-3E0, GD675-3E0
2. When clutch slips 3. Installation of cover

1) Remove bolts (4) and holder (5), and then 1) Install cover (2) and tighten bolts (1).
remove 1 shim 0.2 mm thick (6). 3 Bolt (1):
2) Install holder (5) and tighten bolts (4). 65.7 ± 6.8 Nm {6.7 ± 0.7 kgm}
3 Bolt (4):
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
Running in clutch
q After the clutch disc is replaced with new one,
3) Check the clutch for slipping according to run in the clutch according to the following pro-
the "Testing" procedure. cedure.
4) Repeat steps 1) – 3) until the clutch does a When installing the disc, apply oil GO #90
not slip and set the clutch to the critical to its both sides.
slipping point. 2) Set the clutch to the critical slipping point
5) At the critical slipping point, remove 1 according to adjusting steps 1 and 2.
shim 0.2 mm thick (6). 3) Add 1 shim 0.2 mm thick so that the clutch
a After the shim is adjusted, the clutch will slip.
must not slip. 4) Slip the clutch for 3.5 – 4.0 seconds.
q Run the engine at full throttle.
q The clutch rotates 1 turn while it is
slipping for 3.5 – 4.0 seconds.
5) Repeat step 2) by 20 – 25 times at inter-
vals of 3 minutes.
k If the clutch housing temperature

exceeds 50°C, stop the work until it
lowers to the normal temperature.
k If the clutch stops slipping during
the work, add 1 shim 0.2 mm thick.
6) Wait until the clutch is cooled to the nor-

mal temperature.
7) Set the clutch to the critical slipping point
again (according to steps 1 and 2).
8) Remove 1 shim 0.2 mm thick so that the
clutch will not slip.
GD655-3E0, GD675-3E0 43
Memorizing idle and full position 2. Memorizing the full position

procedure 1 1) Depress the accelerator pedal and inching
pedal fully.
Accelerator and inching potentiometer 2) Turn the starting switch to the ON position.
a If the accelerator pedal assembly and inching 3) Push the potentiometer set switch (1) up
pedal assembly have been replaced, perform for at least 1 second.
the operation to memorize the idle position and a If the buzzer sounds continuously for 2
full position after installing. seconds, the value for the accelerator and
inching potentiometer full position has
1. Memorizing the idle position been stored correctly.
1) Release the accelerator pedal and inching a If the buzzer sounds three times in a cycle
pedal, and leave the pedal free. of 1 second ON, 1 second OFF, the setting
2) Turn the starting switch to the ON position. has not been stored in memory.
3) Push the potentiometer set switch (1)
down for at least 1 second. Measuring voltage
a If the buzzer sounds 2 times, 0.1 second
Potentiometer
each, the value for the accelerator and Pedal Connector
voltage
inching potentiometer idle position has
been stored correctly. Accelerator T3-3 to T2-11 2.42 – 4.3
a If the buzzer sounds continuously for 1 Inching T8 C to B 3.2 – 4.0
second, the setting has not been stored in
memory.
Measuring voltage
Potentiometer
Pedal Connector
voltage
Accelerator T3-3 to T2-11 1–2
Inching T8 C to B 0.8 – 1.6
44 GD655-3E0, GD675-3E0
Initial learning method for 2. Resetting learned data

transmission controller 1 a Do as follows to return all the previously
learned control data in the controller to the
q The transmission controller is equipped with a default values.
self-compensating learning function that cor- 1) Check that the starting switch is at the
rects to a fixed level the differences in operat- OFF position.
ing feeling caused by the individual differences 2) Turn the starting switch ON. (Do not start
in the hydraulic valves and maintains a con- the engine.)
stant gear shifting feeling by compensating for 3) Push memory set/learning function initial-
the changes in the transmission clutches izing switch (1) down for at least 1 second,
caused by wear. then turn the starting switch OFF.
q If the transmission is overhauled or replaced,
or the hydraulic valves are replaced, the trans- 3. Method for learning correction for individual dif-
mission controller still has the control com- ferences in valves
mand values learned to match the previous q When correcting the individual differences in
transmission. For this reason, transmission the valves, do as follows. The correction oper-
shock, abnormal noise, or defective operating ation is for three types of clutch: FL, FH, and R.
feeling may occur. 1) Start the engine and run it at low idle.
q After operating the machine for a short time, (Depress the accelerator pedal, then let it
the controller will learn the condition of the new back fully.)
transmission and will gradually return to the 2) Push memory set/learning function initial-
optimum condition, but if it is desired to reset izing switch (1) up, then within 0.8 sec-
the condition quickly and to carry out learning onds, push the reset switch (2). Hold it in
again, it is possible to carry out resetting of the this condition for at least 1 second, then
learned data, learning of correction of individ- release the switch.
ual valve differences, and initial learning of sta-
bilized transmission feeling as follows.
1. Preparation of machine for learning of correc-

tion for individual differences in valves and ini-
tial learning of transmission feeling stabilization
q It is necessary to carry out the learning opera-
tion at the specified oil temperature, so do as
follows to raise the oil temperature.
1) Depress the brake pedal fully, set the gear
shift lever to R4, stall the torque converter,
and raise the transmission oil tempera-
ture. During the stall operation, keep the
gear shift lever at R4 and do not shift to
any other speed range. (If the stall opera- 3) The learning of the correction for individ-
tion is carried out in any speed range ual differences in the valves will start.
other than R4, there is danger that the q The transmission oil temperature is displayed
machine may pitch or the clutch may be on the controller LED during the correction of
damaged.) the individual differences in the valves.
2) Raise the machine and set it on a stand to 4) The corrected values are saved in the
keep the rear wheels off the ground controller memory and the correction
3) Operate the gear shift lever as follows to learning function is automatically com-
circulate the oil fully through the transmis- pleted.
sion valves and the whole of the case. 5) When the correction learning is com-
P o N o F1 o F2 o F3 o F4 o N o R1 pleted, the controller LED returns to the
o R2 o R3 o R4 o N normal display.
4) Use the above operation to raise the oil 6) Turn the starting switch OFF.
temperature to 50 – 60°C.
5) Set to N, run the engine at idle for 3 min-
utes, check again that the oil is at the
specified level, then turn the engine start-
ing switch OFF.
GD655-3E0, GD675-3E0 45
4. Initial learning method for stabilized transmis-

sion feeling
q To adjust the controller learning control data for
each clutch from the default settings to the
optimum values, always carry out resetting of
the learned data and learning of the correction
for individual differences in the valves, then do
as follows.
1) Start the engine and run at low idle.
2) Set the transmission mode switch to
[MANUAL].
3) Operate the gear shift lever as follows
three times in succession:
P o N o F1 o F2 o F3 o F5 o F3 o F2
o F1 o N o R1 o R2 o R3 o R4 o R3
o R2 o R1 o N
a When doing this, hold each speed range
for at least 3 seconds, then shift to the
next speed range.
a If FL, FH and R clutch fill switch short
occur during method, delete error and
check again by shifting through F1o F8
and R1 o R4.
46 GD655-3E0, GD675-3E0
Inspection procedure of diode 1 2. When using analog tester

1) Switch to resistance range.
a The direction of continuity of diode is marked 2) Check the deflection of needle while con-
on the surface of the diode. necting as follows.
1] Set red (+) test lead to diode anode
(P) side and black (–) test lead to
cathode (N) side.
2] Set red (+) lead to diode cathode (N)
side and black (–) test lead to anode
(P) side.
3) Based on the deflection of needle, judge
the quality of diode.
q Needle does not deflect with connec-
tion 1] but deflects with connection 2]:
Normal (however deflection range
(resistance value) varies depending
on the type of tester and measuring
range.)
1. When using digital tester q Needle deflects with both connection
1) Switch to diode range and check dis- 1] and 2]:
played value. Defective (internal short circuit)
a Voltage of internal battery is dis- q Needle does not deflect with either
played by normal tester. connection 1] or 2]:
2) Set red (+) test lead to diode anode (P) Defective (internal disconnection)
side and black (–) test lead to cathode (N)
side. Check displayed value.
3) Judge quality of diode from displayed
value.
q Displayed value does not change:
No continuity (defect)
q Displayed value changes:
Continue (normal) (note)
Note: In the case of silicon diode, the
value between 460 – 600 mV is displayed.
q Displayed value becomes 0 or near 0:
Short-circuiting of diode internal part
(defect)
GD655-3E0, GD675-3E0 47
SEN01835-01

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
48
SEN01836-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
30 Testing and adjusting 1

Testing and adjusting, Part 2
Testing and adjusting, Part 2........................................................................................................................... 2
Special functions of machine monitor (EMMS) .................................................................................... 2
Self-diagnosis display of gear shift lever ............................................................................................ 27
Handling of high-voltage circuit of engine controller .......................................................................... 28
Preparatory work for troubleshooting for electrical equipment system .............................................. 29
Moving machine when transmission valve fails ................................................................................. 30
Adjusting cab stopper bolt.................................................................................................................. 32
How to start operation of KOMTRAX terminal ................................................................................... 34
Lamp display of KOMTRAX terminal ................................................................................................. 37
Pm-clinic............................................................................................................................................. 40
GD655-3E0, GD675-3E0 1
Testing and adjusting, Part 2 1

Special functions of machine monitor (EMMS) 1
Display section a Language in figures and that on machine mon-

1. Character display (16 characters, 2 lines) itor:
Since English (default) is set on the machine
Operation section monitor when the machine is delivered, it is
2. Machine monitor mode selector switch 1 also used in the figures. The language used
U : Enter/Execute on the machine monitor can be changed to the
t : Cancel/Reset (Only ON/OFF screen) following 7 languages with the language selec-
3. Machine monitor mode selector switch 2 tion function, however (only in the operator
> : Right/Next/Go mode).
< : Left/Previous/Return 1) English, 2) Japanese, 3) Germany,
4) French, 5) Spanish, 6) Swedish, 7) Italian
a EMMS: Equipment Management Monitoring
System
2 GD655-3E0, GD675-3E0
Each mode and flow of function (Function table)

Operator mode Service mode
Electrical equipment system fault history display

1 Service meter/Integrated odometer display function 10
function [ELECTRIC FAULT]
[>] O I [<]
Mechanical equipment system fault history display
[U] O I [t] 11
function [MACHINE FAULT]
[>] O I [<]
Real-time monitoring function
2 Reverse integrated odometer display function 12
[REAL-TIME MONITOR]
[>] O I [<] [>] O I [<]
Maintenance monitor function and filter/oil replace- Reduced cylinder mode
3 13
ment time display function [CYLINDER CUT-OUT]
[>] O I [<] [>] O I [<]
No-injection cranking function
4 Telephone No. input function 14
[NO INJECTION]
[>] O I [<] [>] O I [<]
Tuning function
5 Language selection function 15
[TUNING]
[>] O I [<] [>] O I [<]
Maintenance monitor function
6 Speedometer/gear shift indicator selection function 16
[MAINTENANCE MONITOR]
[>] O I [<] [>] O I [<]
Operation information display function
7 Monitor brightness adjustment function 17
[OPERATION INFO]
[>] O I [<]
Option selection function
O [Automatic] 18
[OPTIONAL SELECTION]
[>] O I [<]
Low idle fixing function
8 Action code display function 19
[ENG LOW IDLE]
[>] O [>] O I [<]
Initializing function (Special for factory)
9 Failure code display function 20
[INITIALIZE]
Operator mode
a No. 2 – No. 7 are displayed endlessly according to the switch operations.
a When a fault occurs, No. 8 is displayed, regardless of the current screen of No. 1 – No. 7.
a If no switch is operated for 30 seconds,
q No. 1 is displayed automatically: While no fault is occurring.
q No. 8 is displayed automatically: While a fault is occurring.
a If no switch is operated for 10 seconds after No. 9 is changed to No. 1 by switch operation, No. 8 is dis-
played automatically.
Service mode
a No. 10 – No. 20 are displayed endlessly according to the switch operations.
a Once an ID is input/entered, it is effective until the starting switch is turned OFF, even if the mode is
changed.
GD655-3E0, GD675-3E0 3
Each mode and flow of function (Display on panel)
4 GD655-3E0, GD675-3E0
Functions in operator mode (Outline) 3. Maintenance monitor function and filter/oil

a Only outline of the operator mode is described replacement time display function
in this section. For details of the contents/ 1) Filter/Oil replacement time display func-
operation of each function/mode, see the tion (Automatic display)
Operation and Maintenance Manual.
1. Service meter/Integrated odometer display

function
If a filter or an oil comes near the replace-

ment time, the machine monitor displays
the information on that filter or oil automat-
ically to call the operator's attention to the
If the starting switch is turned ON, the service maintenance.
meter is displayed on the upper line and the a For details of the display method, see
integrated odometer is displayed on the lower the "Structure, function and mainte-
line after the self-check. nance standard" volume or Opera-
a For details of the display method, see the tion and Maintenance Manual.
"Structure, function and maintenance
standard" volume or Operation and Main- 2) Maintenance monitor function (Selection
tenance Manual. function)
2. Reverse integrated odometer display function
After maintenance of a filter or an oil, the

replacement time of that filter or oil dis-
The machine monitor displays the reverse inte- played on the machine monitor can be
grated odometer according to the switch oper- reset by switch operation.
ation. a For details of the display method, see
a For details of the display method, see the the "Structure, function and mainte-
"Structure, function and maintenance nance standard" volume or Opera-
standard" volume or Operation and Main- tion and Maintenance Manual.
tenance Manual. a The replacement interval can be set
in the service mode.
GD655-3E0, GD675-3E0 5
4. Telephone No. input function 6. Speedometer/gear shift indicator selection

function
The telephone No. to be set in the machine

monitor can be input/change/reset by switch The speedometer display section can be
operation. changed to the gear shift indicator display sec-
a When action code "E03" is displayed, the tion. The gear shift indicator indicates the gear
telephone No. and "CALL" are also dis- speed which the controller actually outputs to
played. the transmission, not the gear shift lever posi-
a For details of the display method, see the tion.
"Structure, function and maintenance a For details of the display method, see the
standard" volume or Operation and Main- "Structure, function and maintenance
tenance Manual. standard" volume or Operation and Main-
tenance Manual.
5. Language selection function
7. Monitor brightness adjustment function
The language used on the machine monitor

can be selected by switch operation. The brightness of LCD1 and LCD2 of the mon-
a In the service mode, English is always itor panel can be adjusted.
used. a For details of the display method, see the
a For details of the display method, see the "Structure, function and maintenance
"Structure, function and maintenance standard" volume or Operation and Main-
standard" volume or Operation and Main- tenance Manual.
tenance Manual.
6 GD655-3E0, GD675-3E0
8. Action code display function
If an abnormality occurs in the machine, the

machine monitor displays action code auto-
matically to urge the operator to take a proper
remedy, depending on the level of the abnor-
mality.
a In the above example, action code "E03"
and "CALL + Telephone No." are dis-
played alternately.
a If action codes "E01" and "E02" are dis-
played, "CALL + Telephone No." is not dis-
played.
a Action codes and actions urged on operator

Action CALL +
Action urged on operator (Contents of Operation and Maintenance Manual)
code Telephone No.
• If a part to be serviced is displayed and the maintenance caution lamp lights up, check and
service the displayed part after the work is finished or when the operator changes.
E01 Not displayed
• If "E01" and "MAINTENANCE" are displayed simultaneously, check the failure code and ask
your Komatsu distributor for repair.
• If an item related to overrun is displayed, operate at moderate engine speed and machine
speed.
• If an item related to overheat is displayed, stop the machine and operate the engine at
E02 Not displayed
medium speed with no load.
• If the action code is still displayed after the above action, check the failure code and ask your
Komatsu distributor for repair.
• If this code is displayed, stop the machine immediately and then check the failure code and
E03 Displayed
ask your Komatsu distributor for repair.
GD655-3E0, GD675-3E0 7
9. Failure code display function a The failure code display function displays
the following information.
While an action code is displayed on the

machine monitor, if the [>] button is pressed q Part A: Failure code
once, the failure code(s) occurring currently (4-digit portion code + 2-digit phenomenon
are displayed. code)
q [>] button: Display failure code q Part B: Controller code
a The failure codes detected in the past are (MON: Machine monitor)
classified into the electrical system and (ENG: Engine controller)
mechanical system and recorded as the (TM: Transmission controller)
fault histories (For details, see the service q Part C: Failed system
mode). a For details of the displayed failure codes,
a If multiple failure codes are occurring, the see the failure code table in "Trouble-
next one is displayed each time the [>] shooting when failure code is displayed
button is pressed. (Display of code)".
a After all the failure code occurring cur- a The information displayed by the failure
rently are displayed, if the [>] button is code display function is partly different
pressed further, the screen returns to the from that displayed by the fault history dis-
service meter/integrated odometer play function (service mode).
screen.
If the [>] button is pressed again, the fail-
ure codes are displayed again from the
first one.
a If no switch is operated for 60 seconds
while this screen is displayed, the screen
changes to the action code display screen
automatically.
8 GD655-3E0, GD675-3E0
Functions in service mode 3) Inputting/Entering ID

Operation to select service mode Input an ID with the buttons.
a When using the service mode, change the a ID: 6491
screen by the following special operation. q [>] button: Increase number
q [<] button: Decrease number
1) Check of screen q [U] button: Enter number at cursor
Check that the machine monitor is in the and move cursor to the
operator mode and displays the "Service/ right
Integrated odometer", "Action code", or q [t] button: Return to initial screen
"Failure code" screen. (See note)
Note: If the cursor is at the left end, the
2) Display of ID input initial screen screen returns to the ordinary
Hold down the following 2 buttons similarly screen (operator mode). If the cur-
for 5 seconds to display the ID input initial sor is not at the left end, it returns
screen. to the left end.
q [t] button and [<] button a If no switch is operated for 60 sec-
a If these buttons are held down for 5 onds while the ID input screen is dis-
seconds, no items are displayed on played, the screen changes to the
the screen. After checking this condi- ordinary screen automatically.
tion, release the buttons.
4) Display of menu initial screen

Enter all of the 4 digits of the ID and dis-
play the menu initial screen of the service
mode.
a Once an ID is input/entered, it is
effective until the starting switch is
turned OFF.
GD655-3E0, GD675-3E0 9
5) Selection of service mode menu 6) Finish of mode/function

On the menu screen, press the [>] button The current mode or function can be fin-
or [<] button, and the menus in the service ished by either of the following methods,
mode are displayed endlessly in the fol- regardless of the currently used function
lowing order. and its hierarchy (level).
a The menu/information is displayed on (1) When continuing operation in another
the parts marked with *. mode or function:
q [>] button: Go to next menu Press the [t] button and return to the
q [<] button: Return to previous menu mode screen or menu screen to be
(1) ELECTRIC FAULT: Electrical equip- used next.
ment system fault history display a The [t] button is used as the
function enter button on the "YES/NO".
(2) MACHINE FAULT: Take care.
Mechanical equipment system fault a If you have returned to the ordi-
history display function nary screen (operator mode) by
(3) REAL-TIME MONITOR: mistake, carry out the operation
Real-time monitoring function from step 1) above (You do not
(4) CYLINDER CUT-OUT: need to input the ID at this time).
Reduced cylinder mode (2) When finishing operations perfectly:
(5) TUNING: Tuning function Turn the starting switch OFF.
(6) MAINTENANCE MONITOR:
Maintenance monitor function
(7) OPTION SELECTION:
Option selection function
(8) MACHINE:
Model selection function
(Special for factory)
(9) ENG LOW SIDE:
Low idle fixing function
(10) T/C STALL:
Torque converter stall function
10 GD655-3E0, GD675-3E0
10. Electrical equipment system fault history dis- 3) Displayed fault history information
play function [ELECTRIC FAULT] The following information is displayed with
The machine monitor records the information the electrical equipment system fault his-
of the past faults and currently occurring faults tory display function.
of the electrical system by failure code. This q Part 1: Record No.
information can be displayed by the following q Part A: Failure code (4-digit portion
operation. code + 2-digit phenomenon
code)
1) Selection of menu q Part 2: Number of occurrence (Num-
On the service mode menu screen, select ber of past occurrence of the
"ELECTRIC FAULT". same code)
a The total number of the currently q Part 3: Elapsed time 1: (Elapsed time
recorded fault histories is displayed after first occurrence mea-
on the parts marked with "**". sured by service meter)
q Part 4: Elapsed time 2: (Elapsed time
after last occurrence mea-
sured by service meter)
a A currently occurring failure code
blinks.
a For details of the displayed failure
codes, see the failure code table in
"Troubleshooting when failure code is
displayed (Display of code)".
a The information displayed by the elec-
trical equipment system fault history
display function is partly different from
that displayed by the failure code dis-
play function (Operator mode).
2) Display of fault history information
While the menu is selected, press the [U]
button to display the recorded fault history
information.
q [U] button: Enter menu
a If no fault history is recorded, "–" is

displayed on all the display parts.
GD655-3E0, GD675-3E0 11
4) Selection of fault history information 6) Clearing of all fault histories

While the fault history information is dis- 1] While the fault history information is
played, if [>] button or [<] button i s displayed, press the [>] button or [<]
pressed, another recorded fault history button to display the all clear screen.
information is displayed. a If the fault history information
q [>] button: Go to information of next screens are selected in order, the
record No. all clear menu screen is dis-
q [<] button: Return to information of played.
previous record No. 2] Press the [U] button once to display
a If the fault history information screens the all clear screen.
are selected in order, the all clear q [U] button: Enter all clear menu
menu screen is displayed. 3] Operate the buttons according to the
displayed instruction.
5) Clearing of each fault history q [<] button: Select YES
1] While the fault history to be cleared is q [>] button: Select NO
displayed, press the [U] button once q [t] button: Enter
t o d is pl ay the on e- by - on e c l ear a Information of a currently occur-
screen. ring fault (which is blinking) can-
q [U] button: Display clear screen not be cleared.
2] Operate the buttons according to the
displayed instruction.
q [<] button: Select YES
q [>] button: Select NO
q [t] button: Enter
a Information of a currently occur-
ring fault (which is blinking) can-
not be cleared.
12 GD655-3E0, GD675-3E0
11. Mechanical equipment system fault history dis- 3) Displayed fault history information
play function [MACHINE FAULT] The following information is displayed with
The machine monitor records the information the mechanical equipment system fault
of the past faults and currently occurring faults history display function.
of the mechanical system by failure code. This q Part 1: Record No.
information can be displayed by the following q Part A: Failure code (4-digit portion
operation. code + 2-digit phenomenon
code)
1) Selection of menu q Part 2: Number of occurrence (Num-
On the service mode menu screen, select ber of past occurrence of the
"MACHINE FAULT". same code)
a The total number of the currently q Part 3: Elapsed time 1: (Elapsed time
recorded fault histories is displayed after first occurrence mea-
on the parts marked with "**". sured by service meter)
q Part 4: Elapsed time 2: (Elapsed time
after last occurrence mea-
sured by service meter)
a A currently occurring failure code
blinks.
a For details of the displayed failure
codes, see the failure code table in
"Troubleshooting when failure code is
displayed (Display of code)".
a The information displayed by the
mechanical equipment system fault
history display function is partly differ-
ent from that displayed by the failure
code display function (Operator mode).
2) Display of fault history information
button to display the recorded fault history
information.
a If no fault history is recorded, "–" is

displayed on all the display parts.
GD655-3E0, GD675-3E0 13
4) Selection of fault history information 12. Real-time monitoring function

While the fault history information is dis- [REAL-TIME MONITOR]
played, if [>] button or [<] button i s The machine monitor can monitor the machine
pressed, another recorded fault history condition in real time by the signals from vari-
information is displayed. ous switches, sensors, and actuators installed
q [>] button: Go to information of next to the machine. The following 2 types of dis-
record No. play are available in the real-time monitoring
q [<] button: Return to information of function.
previous record No. q Display of only 1-item (for each controller)
a If the fault history information screens q Simultaneous display of 2 items (Input of
are selected in order, the all clear code)
menu screen is displayed.
1) Selection of menu
5) Clearing of fault history information (No On the service mode menu screen, select
clearing) "REAL-TIME MONITOR".
a The fault history information of the
mechanical system cannot be
cleared.
2) Display of sub menu

button to display the sub menu initial
screen.
3) Selection of sub menu

On the sub menu screen, press the [>] but-
ton or [<] button, and the sub menus are dis-
played endlessly in the following order.
a The sub menu is displayed on the
parts marked with *.
q [>] button: Go to next menu
q [<] button: Return to previous menu
14 GD655-3E0, GD675-3E0
(1) MONITOR PANEL: 3] Press the [>] button or [<] button to

Machine monitor system select an item to be monitored.
(2) TRANSMISSION1: q [>] button: Go to next item
Transmission controller system 1 q [<] button: Return to previous item
(3) TRANSMISSION2: a The monitoring items scroll in the
Transmission controller system 2 order set internally.
(4) ENGINE: Engine controller system a If the button is held down, the
(5) 2 ITEMS: Display of 2 items items scroll fast.
5) Information displayed in 1-item monitor-

ing mode
The following information is displayed in
the 1-item monitoring mode.
q Part A: Display of item
q Part 1: Monitoring code (5 digits)
q Part 2: Monitoring data (including unit)
a When the monitoring data is
q a number: The number + unit are
displayed.
q not a number: Letters are dis-
played.
a For details, see the monitoring code
4) Setting of 1-item monitoring table.
1] On the sub menu screen, select the
"controller system to be monitored".
6) Setting of 2-item monitoring

1] On the sub menu screen, select "2
2] While the sub menu is selected, press ITEMS".
the [U] button to display the monitor-
ing information initial screen.
q [U] button: Enter sub menu
GD655-3E0, GD675-3E0 15
2] While the sub menu is selected, press 7) Information displayed in 2-item monitor-
the [U] button to display the monitoring mode
ing code input screen. The following information is displayed in
q [U] button: Enter sub menu the 2-item monitoring mode.
3] Directly input the monitoring codes of q Part 1: Monitoring code 1
the 2 items to be monitored with the q Part A: Monitoring data 1 (including
buttons. unit)
q [>] button: Increase number at q Part 2: Monitoring code 2
cursor q Part B: Monitoring data 2 (including
q [<] button: Decrease number at unit)
cursor a When the monitoring data is
q [U] button: Enter number at cur- q a number: The number + unit are
sor displayed.
q [t] button: Return to code input q not a number: Letters are dis-
screen played.
a If the monitoring code on the left a For details, see the monitoring code
side is entered, the cursor moves table.
to the monitoring code on the
right side.
8) Holding and resetting of monitoring data

While the machine monitor is monitoring, if
4] If both monitoring codes are entered, the [U] button is pressed, the monitoring
the screen changes to the 2-item dis- data is held and the [U] mark blinks.
play screen. If the [U] button is pressed again, the
monitoring data becomes active again.
16 GD655-3E0, GD675-3E0
Monitoring code table
MONITOR PANEL [Machine monitor system]

No. Monitoring item Display of item Monitoring code Data display range Unit
1 Engine speed ENG SPEED 01001 0 – 3000 rpm
2 Coolant temperature COOLANT TEMP 04103 –40 – 210 °C
3 Fuel level FUEL SENSOR 04200 0.00 – 5.00 V
4 Fuel level FUEL SENSOR 04201 0 – 150 z
5 Charge level ALTERNATOR R 04302 0.0 – 30.0 V
6 Monitor software version VERSION 20200 8-digit —
7 Application version VERSION (APP) 20221 01000000 —
8 Data version VERSION (DATA) 20222 00010001 —
9 Part No. PART NUMBER 20227 8-digit —
10 Serial No. SERIAL NUMBER 20402 8-digit —
11 Input signal D_IN_0-7 D–IN–––0–––––7 40921 01010101 —
12 Input signal D_IN_8-10 D–IN–––8––––10 40922 01000000 —
13 Output signal D_OUT_0-1 D–OUT–01 40925 01000000 —
TRANSMISSION [Transmission controller system]

1 Torque converter oil temperature TC OIL TEMP 30100 24 – 131 °C
2 Transmission output shaft speed T/M SPEED: OUT 31400 0 – 3000 rpm
COMMUNICATION [Communication controller system]

1 Application version VERSION (APP) 20239 01000000 —
2 Data version VERSION (DATA) 20240 00010001 —
3 Software version VERSION 20241 8-digit —
4 Part No. PART NUMBER 20251 8-digit —
5 Serial No. SERIAL NUMBER 20408 8-digit —
6 Accelerator position, output THROT OUT 31708 0.00 – 5.10 V
7 Input signal D_IN_0-7 D–IN–––0–––––7 40967 01010101 —
8 Output signal D_OUT_0-7 D–OUT–0–––––7 40969 01010101 —
9 Output signal D_OUT_8-15 D–OUT–8––––15 40970 01010101 —
10 Output signal D_OUT_16-23 D–OUT–16–––23 40971 01010101 —
11 Voltage of articulate angle sensor ARTICULATE 43904 0.00 – 5.10 V
12 Resistance of articulate angle sensor ARTICULATE 43905 0.00 – 655.35 z
13 Throttle lower limit value output THROT LIMIT LO 44201 0 – 100.0 %
GD655-3E0, GD675-3E0 17
MACHINE MONITOR [Machine monitor system]

1 Machine model MACHINE ID (H) 00400 8-digit —
2 Machine model MACHINE ID (L) 00401 8-digit —
3 Engine speed ENG SPEED 01002 0 – 4000 rpm
4 Battery voltage POWER SUPPLY 03200 0.0 – 480.0 V
5 Coolant temperature COOLANT TEMP 04104 –40 – 210 °C
6 Voltage of coolant temperature sensor COOLANT TEMP 04105 0.00 – 5.00 V
7 Selection of engine mode POWER MODE 17500 0–4 —
8 Idle validation signal IVS 1 18300 ON or OFF —
9 Idle validation signal IVS 2 18301 ON or OFF —
10 Intake air temperature INTAKE TEMP 18400 –50 – 200 °C
11 Voltage of intake air temperature sensor INTAKE TEMP 18401 0.00 – 5.00 V
12 Boost temperature CHG TEMP 18500 –50 – 200 °C
13 Voltage of boost temperature sensor CHG TEMP 18501 0.00 – 5.00 V
14 Final injection rate command (weight unit) INJECT COMMAND 18600 0 – 1000 mg
15 Engine output torque OUTPUT TORQUE 18700 –24000 – 24000 Nm
16 State of WIF sensor WATER IN FUEL 18800 ON or OFF —
17 Controller inside temperature ECM IN TEMP 18900 –40 – 210 °C
18 Build version BUILD VER 20216 8-digit —
19 Calibration data version CAL VER 20217 8-digit —
20 Serial No. of hardware ECM S/N 20400 0 – 49999999 —
21 Accelerator pedal position THROTTLE POS 31701 0 – 100 %
22 Final accelerator opening angle FINAL THROTTLE 31706 0 – 100 %
23 Voltage of accelerator pedal sensor THROTTLE POS 31707 0.00 – 5.00 V
24 Final common rail pressure command PFIN PRESS COMMAND 36200 0 – 400 MPa
25 Final injection timing command TFIN INJECT TIMING 36300 –180.0 – 180.0 CA
26 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
27 Voltage of common rail pressure sensor RAIL PRESS 36402 0.00 – 5.00 V
28 Boost pressure CHG PRESS-A 36500 –99.9 – 999.9 kPa
29 Voltage of boost pressure sensor CHG PRESS-A 36502 0.00 – 5.00 V
30 Converted torque TORQUE RATIO 36700 0 – 100 %
31 Instantaneous fuel consumption FUEL RATE 37300 0.0 – 999.9 L/h
32 Ambient pressure AMBIENT PRESS 37400 –99.9 – 999.9 kPa
33 Voltage of ambient pressure sensor AMBIENT PRESS 37402 0.00 – 5.00 V
18 GD655-3E0, GD675-3E0
13. Reduced cylinder mode [CYLINDER CUT-OUT] 3) Setting of cylinder to be cut out
The machine monitor has the reduced cylinder Select a cylinder to be cut out by switch
mode to cut out a cylinder (injector) for trouble- operation.
shooting of the engine. q [>] button: Selector cursor moves to
right
1) Starting of engine q [<] button: Selector cursor moves to
a Since a failed cylinder is detected by left
the change of engine speed in the q [U] button: Enter cylinder
reduced cylinder mode, keep the q [t] button: Return to menu screen
engine running during the following a If a cylinder to be cut out is entered
operation. with the [U] button, the machine
m o ni t or c o m m un i c a te s wi t h t h e
2) Selection of menu engine controller. The cylinder No.
1] On the service mode menu screen, blinks during the communication.
select "CYLINDER CUT-OUT". After communication is finished, the
cylinder No. lights up and the box
under it becomes black. The cylinder
is cut out under this condition.
a Single or multiple cylinders can be cut
out.
2] While the menu is selected, press the

[U] button to display the cylinder
selection screen.
a The cylinder No. and engine
speed are displayed simulta- 4) Resetting of cylinder cut out
neously. a Reset the cylinder cut out according
to the setting procedure.
GD655-3E0, GD675-3E0 19
14. Tuning function [TUNING]

After a part of the machine is disassembled
and assembled or a controller is replaced, the
machine monitor can tune each part.
The following item can be selected in the tun-
ing function mode.
q Tuning of items related to articulate angle
sensor
On the service mode sub menu screen,
select "TUNING".
2) Display of sub menu

button to display the sub menu initial
screen.
3) Selection of sub menu

On the sub menu screen, press the [>]
button or [<] button, and the sub menus
are displayed endlessly in the following
order.
a The sub menu is displayed on the
parts marked with *.
q [>] button: Go to next menu
q [<] button: Return to previous menu
(1) 01: ARTICULATE
(Articulate meter 0-point tuning)
20 GD655-3E0, GD675-3E0
<Tuning procedure of actual machine>

For the actual tuning procedure in each tuning
menu, see the following.
(1) Tuning procedure for articulate meter 0-

point
This tuning is performed to have the communi-
cation controller recognize the 0-point of the
articulate angle (straight travel posture).
1) Set the machine in the straight travel pos-
ture and set the articulate lock pin in the
lock position.
2) Check that the articulate angle sensor is
installed normally.
a Installed length (a) of rod (1) must be
normal (50 mm).
a Installed length (b) of rod (2) must be
normal (160 mm).
GD655-3E0, GD675-3E0 21
15. Maintenance monitor function 3) Displayed filter/oil replacement interval

[MAINTENANCE MONITOR] setting items
The machine monitor can set the maintenance If a maintenance item is selected, the fol-
intervals of various filters and oils which are lowing are displayed.
the basis of the filter/oil replacement time. q Part 1: Code (2 digits)
The maintenance monitor function can be q Part A: Filter/Oil replacement inter-
turned ON and OFF. val setting item
q Part 2: Currently set interval
1) Selection of menu q Part 3: Number replacement times
On the service mode menu screen, select up to now
"MAINTENANCE MONITOR".
4) Change of interval
2) Selection of filter/oil replacement interval 1] While the setting item is selected,
setting item press the [U] button to display the
1] While the menu is selected, press the interval change screen.
[U] button to display the setting item q [U] button: Select change func-
initial screen. tion
2] Select an item to be set by pressing
the [>] button or [<] button.
q [>] button: Next item
q [<] button: Previous item
a The setting items are displayed
endlessly in the order set inter-
nally (See the filter/oil replace-
ment interval setting item table).
a "Default setting" and "All item
timer ON/OFF setting" are
included in the setting items (See
the filter/oil replacement interval
setting item table).
22 GD655-3E0, GD675-3E0
2] Press the [U] button again to display 5) Default setting function/operation

the interval input screen. a All the setting items can be changed
q [U] button: Enter change function to the initial values (default values)
a The current interval is displayed and the maintenance monitor function
on the lower line of the screen. can be set effective by this operation,
regardless of the setting of each item.
1] While a setting item is selected, press
the [U] button to display the setting
screen.
q [U] button: Select setting func-
tion.
3] Input a new interval with the buttons.

q [>] button: Increase number at
cursor
q [<] button: Decrease number at
cursor
q [U] button: Enter number at cur-
sor 2] Press the [U] button again, and the
q [t] button: Return to item selec- change confirmation screen is dis-
tion screen played. Then, operate according to
a Since the interval must be a 4- the displayed instruction.
digit value, input "0" to a position q [<] button: Select YES
where no digit is required. q [>] button: Select NO
4] After all the positions of the interval q [t] button: Enter
are entered, the change confirmation
screen is displayed. Then, operate
according to the displayed instruction.
q [t] button: Enter
GD655-3E0, GD675-3E0 23
6) All item timer ON/OFF setting function/

operation
a The maintenance timer function of all
the setting items can be turned ON
and OFF.
1] While a setting item is selected, press
the [U] button to display the setting
screen.
q [U] button: Select setting func-
tion.
3] Press the [U] button again, and the

change confirmation screen is dis-
played. Then, change the setting
screen with the [<] button and [>] but-
ton.
q [t] button: Enter
2] Press the [U] button again, and the

change confirmation screen is dis-
played. Then, change the setting
screen with the [<] button and [>] but-
ton.
a If the setting screen is changed,
the upper half of the following fig-
ure is displayed first.
q [<] button: Select OFF screen
q [>] button: Select ON screen
Filter/Oil setting items and replacement intervals

No. Item Code Display Replacement interval (h)
1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG FILT 500
3 Fuel prefilter 41 FUEL P FILT 500
4 Fuel filter 03 FUEL FILT 1000
5 Hydraulic oil filter 04 HYD FILT 1000
6 Corrosion resistor 06 CORR RES 1000
7 Transmission oil 12 TM OIL 1000
8 Transmission oil filter 13 TM FILT 1000
9 Axle oil 15 AXLE OIL 1000
10 Hydraulic oil 10 HYD OIL 2000
11 Circle case oil 36 CR CASE OIL 2000
12 Tandem case oil 37 TD CASE OIL 2000
13 Default setting — INITIALIXE —
14 All item timer ON/OFF setting — ALL ITEMS —
24 GD655-3E0, GD675-3E0
16. Option selection function [OPTIONAL SELEC-

TION]
The machine monitor can set the tire size,
speedometer unit, and machine monitor back
light according to the option specification.
GD655-3E0, GD675-3E0 25
17. Low idle fixing function [ENG LOW IDLE] 18. Initializing function [INITIALIZE]
The machine monitor has a function of fixing a This function is special for the factory and
the engine speed to low idle forcibly. This not used for the service.
function is used to prevent the engine from
running at high speed to break the hydraulic
system when it is started again after disassem-
bled and assembled.
On the service mode menu screen, select
"ENG LOW IDLE".
2) Setting of function
While the sub menu is selected, press the
[U] button to enter the function.
q [U] button: Enter function
a If the following screen is displayed,
the function is effective and the
engine speed is fixed to low idle,
regardless of operation of the accel-
erator pedal and fuel control lever.
3) Resetting of function
While the function is effective, press the
[t] button, and the screen returns to the
previous screen and the function is reset.
q [t] button: Reset function
26 GD655-3E0, GD675-3E0
Self-diagnosis display of gear shift lever 1
q The gear shift lever has error indicator (1) for self-diagnosis.
q If the gear shift lever detects an error by itself, it outputs the N signal to stop the machine, regardless of
the selected gear speed.
q Particularly when the gear shift lever is moved, if it is not set in position (it is held between gear speed
positions), the previous gear speed is held for 10 seconds and then the gear shift lever outputs the N
signal to stop the machine. (In this case, if the gear shift lever is returned to the N position and set in the
desired gear speed again, it operates normally again.)
q For errors other than above, see the troubleshooting volume.
q The self-diagnosis display of the gear shift lever is shown in the following table.
Display of indicator Condition Remedy
Return gear shift lever to N position and then set it
Turned ON 1 time and OFF Gear shift lever is held between gear in desired gear speed. If error is not reset by this
for 2 seconds repeatedly speeds. operation, gear shift lever may have trouble. Carry
out related troubleshooting.
Turned ON 2 times and OFF Non-existing gear speed is selected. Since the gear shift lever may have trouble, carry
for 2 seconds repeatedly Electric circuit may have trouble. out related troubleshooting.
Turned ON 3 times and OFF Since the gear shift lever may have trouble, carry
Electric circuit has short circuit.
for 2 seconds repeatedly out related troubleshooting.
Restart engine. If condition does not change, gear
Turned ON 4 times and OFF Gear shift lever system must be
shift lever may have trouble. Carry out related trou-
for 2 seconds repeatedly reset.
bleshooting.
Since the ground wire or power supply circuit may
Kept ON Power supply is unstable.
have trouble, carry out related troubleshooting.
OFF Gear shift lever is normal. —
GD655-3E0, GD675-3E0 27
Handling of high-voltage circuit of

engine controller 1
k The engine controller has a high-voltage

circuit (110 – 130 V) to drive the fuel injec-
tor. This circuit is connected to the wiring
harness an d con nectors between th e
engine controller and fuel injector.
a Normally, the engine controller outputs the
high voltage to the fuel injector only while the
engine is running and stops outputting if the
engine stops.
k If you touch the high-voltage circuit directly,
you may get an electric shock. To avoid this,
observe the following precautions.
1. The following connectors are used in the high-

voltage circuit.
q Engine controller connector: EC1
q Injector connectors: C9, C10, C11
q Injector head terminal (in head cover)
2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to
turn the starting switch OFF.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit 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.
28 GD655-3E0, GD675-3E0
Preparatory work for

troubleshooting for electrical
equipment system 1
a When carrying out troubleshooting for an elec-
tric circuit related to the machine monitor,
engine controller, or transmission controller,
expose the related connectors according to the
following procedure.
1. Machine monitor
1) Remove the 4 mounting bolts and pull out
machine monitor (1) toward the operator's
seat.
3. Transmission controller
a The transmission controller is installed in
the right side box.
1) Remove the 4 mounting bolts and cover
(3).
2) Insert or connect troubleshooting T-adapt-

ers in or to connectors FP1 and FP2 of the
machine monitor.

ers in or to connectors T1, T2, T3-1, T3-2,
T4 and T5 of the transmission controller.
a Since the connectors are fixed with
screws, loosen those screws before
disconnecting.
a When returning the connectors,
tighten the screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
2. Engine controller
a The engine controller is installed to the
side of the engine on the left side of the
machine.
ers in or to connectors EC1, EC2 and EC3
of engine controller (2).
a Since the connectors are fixed with
screws, loosen those screws before
disconnecting.
a When returning the connectors, tighten
the screws to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
GD655-3E0, GD675-3E0 29
Moving machine when 2. Disconnect wiring connectors (2). (14 places)

transmission valve fails 1
a If the machine cannot be moved because of a
failure in any part of the transmission valve
system (electrical system, solenoid valves,
spools, etc.), it is possible to mov e the
machine by installing plug (K).
k Plug (K) is only for emergency use when
the machine cannot be moved by any other
means because of a failure in the transmis-
sion control valve system. It is only used to
move the machine from a dangerous work-
ing area to a safe place for repairs.
k When carrying out this operation, keep
strictly to the procedure and pay careful 3. Depending on the direction for moving the
a t t e n t i on t o s a f e t y w he n mo vi n g t h e machine (forward or reverse), remove the fol-
machine.
k
lowing 2 ECMV solenoids (3) and install plug
To prevent the machine from moving, lower (K).
the work equipment completely to the q FORWARD: FL solenoid and 2nd solenoid
ground, apply the parking brake, and put q REVERSE: R solenoid and 2nd solenoid
blocks under the tires. a If there is any mistake in the selection of
k Carry out operation with the engine the solenoid to remove, there is danger
stopped.
k
that the transmission may be damaged.
Be careful not to burn yourself if the oil is a Install plug (K) with the protruding surface
hot. facing the ECMV. Check also that there is
an O-ring installed to the mating surface.
1. Remove valve cover (1) at front of transmis-
a Be careful not to let any dirt or mud get
sion.
inside the removed solenoid or valve.
a Clean around the ECMV and remove all
dirt and dust.
30 GD655-3E0, GD675-3E0
4. Depress the brake pedal securely.
5. Start the engine, release the parking brake,

then release the brake pedal gradually to allow
the machine to start, then move the machine.
k Remove the blocks under the tires.
k When the engine is started, the transmis-
sion is also engaged to start the machine.
To ensure safety when starting the engine,
check carefully that the direction of travel
and area around the machine are safe.
Always keep the brake pedal depressed
when starting.
k After moving the machine, stop the engine,
apply the parking brake, and put blocks
under the tires.
GD655-3E0, GD675-3E0 31
Adjusting cab stopper bolt 1 5. Check clearance (a) between door handle (5)
and cab (surface of glass).
1. Remove 4 stopper bolts (1). (Top, bottom, left, q Clearance (a) = 8 mm
right)
6. If clearance (a) is 8 mm, door striker (3) is not

angled to the left or right, and the center of
door striker (3) is aligned, the adjustment of
door striker (3) is correct.
a If the adjustment of the striker is correct,
go on to Step 10.
7. If the striker is angled to the left or right, install

door striker (3) so that installation height (b)
from the surface of door glass (6) is uniform.
q Installation height (b): 67 ± 1 mm (stan-
dard)
8. If clearance (a) is less than 8 mm, move the

2. Check that door striker (3) is properly set and mounting of door striker (3) out from the sur-
is not angled to the left or right. face of door glass (6) by an amount equal to
clearance (a) – 8 mm. Fit the door to the cab
3. Fit door striker (3) to lock (4) on the cab. again and check that clearance (a) is 8 mm.
4. Check that the centers of door striker (3) and 9. If the center of door striker (3) is not aligned,
lock (4) on cab are aligned. remove door link cover (2) and move door
striker (3) up or down to set it in the center.
10. Install 4 stopper bolts (1). (Top, bottom, left,

right)
11. Screw stopper bolts (1) fully into the cab, then
fit door striker (3) to lock (4) on the cab.
32 GD655-3E0, GD675-3E0
12. If there is a clearance at portion (c) of door

glass (6) and the rubber tip of stopper bolt (1),
the condition is correct.
a If there is a clearance at portion (c), go to
Step 15.
13. If there is no clearance at portion (c) of door
glass (6) and the rubber tip of stopper bolt (1)
(when the rubber tip is pushed against the
glass surface), replace stopper bolt (1).
a Remove 20Y-54-11611 (length below

head: 42 mm) and install 23A-952-1430
(length below head: 32 mm)
14. Fit door striker (3) to lock (4) on the cab, and
check again that there is a clearance at portion
(c) of door glass (6) and the rubber tip.
15. Turn the stopper bolt and put it in contact with

the surface of door glass (6). (Clearance at
portion (c) = 0)
16. With the clearance of stopper bolt (1) = 0, turn

the bolt 3 turns to the left (to move it out from
the surface of the glass).
GD655-3E0, GD675-3E0 33
How to start operation of 3) Disconnect test connector 1 and keep that

KOMTRAX terminal 1 condition for 5 seconds.
4) Turn on the starting switch ON and keep
In the case where the KOMTRAX terminal has that condition for 5 seconds.
already been installed at the plant before ship- 5) Disconnect test connector 2 and keep that
ment: condition for 5 seconds.
a Implement the following procedure in the case 6) Reconnect test connector 1 and keep that
where the KOMTRAX terminal has already condition for 5 seconds.
been installed at the plant before shipment (as 7) Reconnect test connector 2 and keep that
standard equipment). condition for 5 seconds.
8) Check that the 7-segment indicator lamp
1. Notification of model, model number and of the KOMTRAX terminal is indicating
serial number normally.
Notify the model, model number and serial
number of the machine to the KOMTRAX oper-
ations administrator.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client per-
sonal computer.
a Refer to "Manual for KOMTRAX opera-
tions administrator" for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted on the machine after the shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted
after shipment of the machine (retrofitted
machine).
1. Station opening check in machine side
a The KOMTRAX terminal and test connec-
tor are installed in the right console box.
a Complete procedures 4) – 7) in 30 sec-
onds.
1) Turn the starting switch OFF and wait for
at least 5 seconds and then move on to
the next step.
2) Check visually that test connectors 1 and
2 are connected. a Move on to the next step if you can
q Test connector 1: CHK0 check that the display is [Normal].
q Test connector 2: CHK1 a If the display is [Abnormal], start from
procedure 1) again.
34 GD655-3E0, GD675-3E0
9) Turn the starting switch to the starting

position, keep it more than 5 seconds, and
check that the engine does not start.
a If the engine starts up, start from pro-
cedure 1) again.
10) Return the starting switch to the ON posi-
tion and keep it there for 5 seconds.
a Do not return the starting switch to
the OFF position.
11) Turn the starting switch to the starting
position again and check that the engine
starts up.
12) Check that the 7-segment indicator lamp
of the KOMTRAX terminal is indicating
normally.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Communication trouble] is indi-
cated, check if there is any abnormal-
ity on the appearance of the
communication antenna or cable. If
there is any abnormality, repair it then
repeat from procedure 1) again. 13) Turn the starting switch OFF.
a If [GPS position data detection trou- 14) Check that the 7-segment indicator lamp
ble and communication trouble] is is indicating normally in 10 seconds.
indicated, check if there is any abnor- a If you can check that the display is
mality on the GPS antenna/cable or [Normal], that is the end of sign-up
communication antenna/cable. If test.
there is any abnormality, repair it and a If the display shows [Abnormal],
start from procedure 1) again. r ep eat fr om pr oc ed ur e 1) ag ai n
a If [Fuel sensor trouble] is indicated, because the sign-up test has not
check the display of [LED-C4] refer- been completed successfully.
ring to "Lamp display of KOMTRAX
terminal". If the fuel sensor is not rec-
ognized, check the fuel sensor har-
ness of the KOMTRAX terminal, and
then if there is any abnormality, repair
it and start from procedure 1) again.
GD655-3E0, GD675-3E0 35
2. Application for the start of use

a Application for the start of use should be
made only after the sign-up test is fin-
ished.
1) Notify to the KOMTRAX operations adminis-
trator of the following information concerning
the machine whose sign-up test on the
machine side is completed.
1] Information on the machine whose
sign-up test on the machine side is
completed.
(Model, model number and serial
number)
2] Part number and serial number of the
KOMTRAX terminal
3] Reading of the service meter when
the KOMTRAX terminal is installed
(0.1h unit)
2) The KOMTRAX operations administrator

registers the machine using KOMTRAX
client personal computer.
a Refer to "Manual for KOMTRAX opera-
tions administrator" for the procedure.
a Now the terminal is ready for use.
36 GD655-3E0, GD675-3E0
Lamp display of KOMTRAX terminal 1
Communication module LED 7-segment and dot for CPU

1. LED-A1 (Power indicator lamp) 12. 7-segment (number of unsent mails)
2. LED-A2 (Within corresponding area lamp) 13. Dot (GPS positioning status)
3. LED-A3 (During correspondence lamp)
4. LED-A4 (Internal transmitting lamp)
5. LED-A5 (Internal reception lamp)
CPU LED
6. LED-C1 (R signal and ACC signal status)
7. LED-C2 (Engine control output status)
8. LED-C3 (S-NET and C signal status)
9. LED-C4 (CAN status and fuel sensor status)
10. LED-C5 (Downloading and writing status)
11. LED-C6 (Downloading and writing status)
GD655-3E0, GD675-3E0 37
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 defect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side should be completed in advance in order
to use KOMTRAX system.
On the machines for which these procedures have not been completed yet, all the communication module
LEDs are off. This is not a defect.
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 should be connected to the KOMTRAX
terminal normally.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and should be connected to the KOMTRAX terminal nor-
mally.
Check of terminal LED displays

1. Contents of communication module LED displays
a LED displays should be checked with the starting switch ON.
No. LED Name/Function Display Contents of display
ON
1 LED-A1 Power indicator lamp The LED is ON when the electric power is normally supplied.
OFF
Within corresponding ON The LED is ON when the machine is within the corresponding
2 LED-A2
area lamp OFF area of the KOMTRAX system.
ON The LED is ON when the KOMTRAX terminal is connected to
During correspondence
3 LED-A3 the KOMTRAX server.
lamp OFF (The connection should be made only when it is necessary.)
ON The LED is ON when the CPU transmits data to the communi-
Internal transmitting
4 LED-A4 cation module.
lamp OFF (Transmitting should be made only when it is necessary.)
ON The LED is ON when the CPU receives data from the communi-
5 LED-A5 Internal reception lamp cation module.
OFF (Reception should be made only when it is necessary.)
38 GD655-3E0, GD675-3E0
2. Contents of CPU LED displays

a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC sig- Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
6 LED-C1 nal and alternator R sig-
nal Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
Engine control signal ON Engine control signal: ON
7 LED-C2
status OFF Engine control signal: OFF
ON S-NET: connected, starting switch C signal: OFF
S-NET connection sta- Fast blinking Starting switch C signal: ON
8 LED-C3 tus and starting switch C
signal status Slow blinking (Not used)
OFF S-NET: Unconnected, starting switch C signal: OFF
ON CAN: active (fuel sensor: no communication)
CAN status and fuel Fast blinking CAN: active (fuel sensor: in communication)
9 LED-C4
sensor status Slow blinking CAN: Inactive (fuel sensor: in communication)
OFF CAN: Inactive (fuel sensor: no communication)
Either one Download and wiring status (special function for system
10 LED-C5
Download and wiring is ON administrator)
status Both are
11 LED-C6 Normal operation method
OFF
a Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 second cycle
3. Contents of 7-segment and dot LED displays for CPU

a The LED displays should be checked with the starting switch ON.
7-seg- Number of unsent
12 0–9 Number of unsent mails
ment mails
GPS positioning has been completed. (Position has
ON
GPS positioning sta- been recognized. Refer to *.)
13 Dot
tus GPS positioning has not been completed. (Position has
OFF
not been recognized. Refer to *.)
* It may take more than 1 minute from turning on the starting switch to the completion of positioning even in
an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
GD655-3E0, GD675-3E0 39
Pm-clinic 1
Model Serial No. Service meter
GD655-3E0
h
GD675-3E0
User name Date of clinic Serviceman
/ /
Specifications
Blade Attachment Tire
3.7 m 14.00-24-10PR
4.0 m 14.00-24-12PR
17.5R25
Operating conditions
Quarry, mine Construction Type of soil Type of work
Coal Construction, civil engineering Rock Grading %
Gold Roads Soft Medium Hard Ditching %
Limestone Others ( ) Gravel Ripping %
Others ( ) Sand Bank cutting %
Sandy loam Travel %
Clay Snow removal %
Others ( ) %
Existence of abnormalities
Oil, coolant level check
Engine coolant level Hydraulic oil level Circle reverse gear case
Engine oil level Final drive
Transmission case Tandem case
Engine coolant temperature max. range Power train oil temperature max. range Ambient temperature Height above sea level
Ambient temperature Height above sea level

Max.
°C m
Min.
Existence of abnormalities
Operator's opinion
Visual check results
Failure code history
h h
Content: Content:
h h
Content: Content:
a Engine coolant temperature max. range a Power train oil temperature max. range
40 GD655-3E0, GD675-3E0
Pm-clinic measuring points (1/3)
Reference items (pages) in “Testing and adjusting, Part 1” for measurement procedure
*1. Engine speed: Measuring engine speed (Page 12)
*2. Blow-by pressure: Measuring blowby pressure (Page 10)
*3. Engine oil pressure: Measuring engine oil pressure (Page 11)
*4. Boost pressure: Measuring intake air pressure (boost pressure) (Pages 8 – 9)
*5. Exhaust temperature: Measuring exhaust temperature (Pages 6 – 7)
GD655-3E0, GD675-3E0 41
*6. Power train oil pressure: Checking clutch oil pressure (Page 15)
Checking torque converter oil pressure (Page 16)
42 GD655-3E0, GD675-3E0
*7. Steering oil pressure: Measuring steering and brake oil pressure (Page 35)
*8. Brake oil pressure: Measuring steering and brake oil pressure (Page 35)
*9. Work equipment oil pressure: Testing and adjusting work equipment oil pressure (Page 26)
*10. LS differential pressure: Testing and adjusting LS differential pressure (Pages 27 – 28)
GD655-3E0, GD675-3E0 43
Pm-clinic check sheet (1/3)

GD655-3E0 #
Machine serial No.
GD675-3E0 #
hour check Engine serial No. SAA6D114E-3 #
Work order Date Service meter Serviceman
/ / h
a Check after starting engine! Torque converter oil temperature must not exceed 90°C when torque converter is stalled! < >: Reference value
Standard value Service limit Measurement

Check item Measurement conditions Unit Pass Fail
for new machine value results
• Engine coolant temperature: Within Low idle 800 – 850 800 – 850
operating range High idle 2,175 – 2,275 2,175 – 2,275
Engine speed rpm
• Torque converter oil temperature: 60 – Torque con-
80°C 1,590 – 1,790 —
verter stall
kPa <Max. 1.6> <Max. 2.55>
Blow-by pressure • Torque converter stall
{mmH2O} {<Max. 160>} {<Max. 260>}
Rated 0.34 – 0.59 Min. 0.21
Engine
SAE15W-40 oil speed {3.5 – 6.0} {Min. 2.1}

MPa
Engine oil pressure Engine coolant temperature: Within
{kg/cm2} Min. 0.15 Min. 0.08
operating range Low idle
{Min. 1.5} {Min. 0.8}
kPa 133 – 173 Max. 107
Boost pressure • Torque converter stall
{mmHg} {1,000 – 1,300} {Max. 800}
Ambient
2.0 2.0
• Torque converter stall + Work equip- temperature
Exhaust temperature °C
ment relief Exhaust
Max. 650 Max. 650
temperature

2.12 – 2.52 2.12 – 2.52
Low idle
Power train main {21.7 – 25.7} {21.7 – 25.7}
relief pressure 2.26 – 2.66 2.26 – 2.66
High idle
• Torque converter oil temperature: 60 – {23.1 – 27.1} {23.1 – 27.1}
Torque converter inlet 80°C 0.83 – 0.93 0.83 – 0.93
High idle
pressure • Set gear shift lever in P position or {8.5 – 9.5} {8.5 – 9.5}
Torque converter out- each gear speed position and run 0.54 – 0.64 0.54 – 0.64
under no load. High idle
let pressure {5.5 – 6.5} {5.5 – 6.5}
Torque converter
Power train oil pressure
1.86 – 2.16 1.86 – 2.16

lockup clutch pres- High idle
{19 – 22} {19 – 22}
sure
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 control • Oil temperature: 60 – 80°C 1.96 – 2.45 1.96 – 2.45
1ST
valve set pressure • Engine at full throttle {20 – 25} {20 – 25}
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}

Cut-in 9.36 – 9.56 9.36 – 9.56
Brake accumulator • Hydraulic oil temperature: 45 – 55°C pressure {95.5 – 97.5} {95.5 – 97.5}
charge pressure • Engine at high idle Cut-out MPa 12.26 – 13.24 12.26 – 13.24
pressure {kg/cm2} {125 – 135} {125 – 135}
Brake
Wheel brake actuat- • Hydraulic oil temperature: 45 – 55°C 3.59 – 4.0 3.59 – 4.0
ing pressure • Engine at high idle {37 – 41} {37 – 41}
• Hydraulic oil temperature: 45 – 55°C Max. 18.4
Braking distance with
• Braking distance required when initial speed is 38.2 m Max. 17.7 (ISO 3450 =
wheel brake
km/h (under conditions by ISO 3450) 18.4 m)
44 GD655-3E0, GD675-3E0

MPa 18.1 – 18.8
Steering
Steering oil pressure • Engine at high idle —

{kg/cm2} {185 – 192}
• Steering relief
• Engine at low idle
Play of steering wheel mm 0 – 10 —
• Float front wheels.

Hydraulic tank sur-
Work equipment oil pressure
and LS differential pressure
• Engine stopped °C — —
face temperature
• Hydraulic oil temperature: 45 – 55°C Unload 1.82 – 3.78
—
• Engine at high idle pressure {19 – 39}
Work equipment oil • Unload pressure: All work equipment in
pressure neutral Work equip-
19.6 – 21.6
• Work equipment relief pressure: Blade ment relief MPa —
{200 – 220}
lift cylinder raise relief pressure {kg/cm2}
LS differential 2.25 – 2.45
• Engine at high idle —
pressure {23 – 25}
• During blade turning operation

Left blade lifting Raise 2.3 – 3.1 4.0
speed Lower 2.3 – 3.1 4.0
Right blade lifting Raise 2.3 – 3.1 4.0
speed Lower 2.3 – 3.1 4.0
Left shift 8.0 – 10.2 11.0
Blade side shift speed
Right shift 8.0 – 10.2 11.0
Drawbar side shift • Engine at high idle Left shift 6.2 – 8.4 10.0
Work equipment speed
speed • Blade lift: In 350-mm stroke of cylinder. Right shift 6.4 – 8.6 10.0
Operate right and left sides separately. Left turn 7.5 – 10.1 12.0
Blade turning speed • Blade side shift: In cylinder stroke
• Drawbar side shift: At 100 mm of blade Right turn 7.5 – 10.1 12.0
sec.
bottom height. In cylinder stroke. Wide cut-
3.35 – 4.75 7.0
Power tilt turning • Blade turn: From start of turn to 90° ting angle
speed • Power tilt: In cylinder stroke Narrow cut-
• Articulation: In cylinder stroke 3.78 – 5.38 7.0
ting angle
• Leaning: In cylinder stroke
Left turn 6.17 – 8.17 14.0
Articulation speed • Scarifier lifting: In 180 mm of stroke
Right turn 6.17 – 8.17 14.0
Left leaning 1.97 – 2.77 6.0
Leaning speed Right lean-
2.06 – 2.86 6.0
ing
Raise 1.7 – 2.3 3.0
Scarifier lifting speed
Lower 1.7 – 2.3 3.0
a Set blade and stop engine!

• Right and left blade lift cylinders: Raise stroke end
Blade hydraulic drift • Hydraulic oil temperature: 35 – 45°C
10 20
(No load on cylinder) • Engine stopped
Work equipment hydraulic drift and oil leakage
• Cylinder extraction in 10 minutes after finish of setting

• Right and left blade lift cylinders: Lower stroke end mm
(Push-up of machine)
• Hydraulic oil temperature: 35 – 45°C 20 35
(Raising of machine)
• Engine stopped
• Cylinder retraction in 10 minutes after finish of setting
Work equipment cyl-
• Engine at high idle cc/min 0 0
inder oil leakage
• When cylinder is relieved
• Scarifier cylinder at raise stroke end
Scarifier hydraulic
drift (No load on cylin- 10 20
• Engine stopped
der)
• Cylinder extraction in 10 minutes after finish of setting
• Scarifier cylinder at lower stroke end (Push-up of mm
Scarifier hydraulic machine)
drift (Raising of • Hydraulic oil temperature: 35 – 45°C 20 35
machine) • Engine stopped
• Cylinder retraction in 10 minutes after finish of setting
GD655-3E0, GD675-3E0 45

a Replace with spare plug

Visual check of final There must not be abnormally
FD
• Engine stopped —
drive drain plug much metal powder.

Front left wheel
Front right wheel
Rear left front wheel 14.00-24-10PR: 350 {3.5}
kPa
Tire
Tire inflation pressure 14.00-24-12PR: 450 {4.5}

Rear left rear wheel {kg/cm2} 17.5R25: 375 {3.75}
Rear right front wheel
Rear right rear wheel
Memo: Write phenomena and information you noticed during today's check.
46 GD655-3E0, GD675-3E0
SEN01836-00

© 2006 KOMATSU
All Rights Reserved
48
SEN01837-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table and fuse locations ............................................................................................................. 2
Failure code table................................................................................................................................. 2
Fuse locations ...................................................................................................................................... 6
GD655-3E0, GD675-3E0 1
SEN01837-01 40 Troubleshooting
Failure code table and fuse locations 1

Failure code table 1
Failure Applicable Action History Reference
Failure contents
code equipment code classification document No.
(DF1000) Neutral safety TM — —
2G42ZG Decrease of accumulator oil pressure (Front) MON E03 Mechanical system
2G43ZG Decrease of accumulator oil pressure (Rear) MON E03 Mechanical system
AB00L6 Signal of alternator disagrees with operating state of engine MON E03 Electrical system
AB00MA Malfunction of alternator MON E03 Mechanical system
B@BAZG Engine oil pressure too low ENG E03 Mechanical system
B@BCNS Engine overheat ENG E02 Mechanical system
B@CENS Torque converter oil temperature too high MON E02 Mechanical system
B@CKNS Differential oil overheat TM E02 Mechanical system
CA111 Abnormality in engine controller ENG E03 Electrical system
CA115 Abnormality in engine NE and Bkup speed sensors ENG E03 Electrical system
CA122 Charge pressure sensor too high ENG E03 Electrical system
CA123 Charge pressure sensor too low ENG E03 Electrical system
CA131 Throttle sensor too high ENG E03 Electrical system
CA132 Throttle sensor too low ENG E03 Electrical system
CA144 Coolant temperature sensor too high ENG E01 Electrical system
CA145 Coolant temperature sensor too low ENG E01 Electrical system Troubleshoot-
ing by failure
CA153 Charge temperature sensor too high ENG E01 Electrical system
code, Part 1
CA154 Charge temperature sensor too low ENG E01 Electrical system SEN01839-00
CA155 Charge temperature too high and engine speed derated ENG E03 Electrical system
CA187 Sensor power source 2 too low ENG E03 Electrical system
CA221 Atmospheric pressure sensor too high ENG E01 Electrical system
CA222 Atmospheric pressure sensor too low ENG E01 Electrical system
CA227 Sensor power source 2 too high ENG E03 Electrical system
CA234 Engine overspeed ENG E02 Mechanical system
CA238 Abnormal power source for Ne speed sensor ENG E03 Electrical system
CA271 Short circuit in fuel pump actuator ENG E03 Electrical system
CA272 Disconnection in fuel pump actuator ENG E03 Electrical system
CA281 Abnormal supply pump pressure balance ENG E03 Electrical system
CA322 Disconnection or short circuit in injector No.1 ENG E03 Electrical system
CA342 Abnormality in engine controller data consistency ENG E03 Electrical system
CA351 Abnormality in injector drive circuit ENG E03 Electrical system
CA352 Sensor power source 1 too low ENG E03 Electrical system
CA386 Sensor power source 1 too high ENG E03 Electrical system
CA428 Water detection sensor too high ENG E01 Electrical system
CA429 Water detection sensor too low ENG E01 Electrical system Troubleshoot-
ing by failure
CA435 Abnormality in engine oil pressure switch ENG E01 Electrical system
code, Part 2
CA441 Power supply voltage too low ENG E03 Electrical system SEN01840-00
CA442 Power supply voltage too high ENG E03 Electrical system
CA449 Common rail pressure too high (2) ENG E03 Electrical system
CA451 Common rail pressure sensor too high ENG E03 Electrical system
CA452 Common rail pressure sensor too low ENG E03 Electrical system
CA488 Charge temperature too high and torque derated ENG E03 Electrical system
2 GD655-3E0, GD675-3E0

Failure contents
CA553 Common rail pressure too high (1) ENG E03 Electrical system
CA559 Supply pump no pressure (1) ENG E03 Electrical system
CA689 Abnormality in engine Ne speed sensor ENG E03 Electrical system
CA731 Abnormality in engine Bkup speed sensor phase ENG E03 Electrical system
CA757 Loss of all engine controller data ENG E03 Electrical system
CA778 Abnormality in engine Bkup speed sensor ENG E03 Electrical system
CA1633 Abnormality in KOMNET ENG E03 Electrical system Troubleshoot-
ing by failure
CA2185 Accelerator pedal sensor power source too high ENG E03 Electrical system
code, Part 2
CA2186 Accelerator pedal sensor power source too low ENG E03 Electrical system SEN01840-00
CA2249 Supply pump no pressure (2) ENG E03 Electrical system
CA2265 Disconnection in electric lift pump ENG E01 Electrical system
CA2266 Short circuit in electric lift pump ENG E01 Electrical system
CA2311 Abnormal resistance in IMV solenoid ENG E03 Electrical system
CA2555 Disconnection in air intake heater relay ENG E01 Electrical system
CA2556 Short circuit in air intake heater relay ENG E01 Electrical system
D19CKZ Disconnection or short circuit in differential control relay TM E01 Electrical system
D19KKZ Differential lock-up relay : Disconnection TM E01 Electrical system
D5ZHL6 Terminal C signal does not match state of engine MON E01 Electrical system
DAQ0KK Power source voltage of transmission controller too low TM E03 Electrical system
DAQSKR Communication controller cannot recognize S-NET COM E03 Electrical system
DB2RKR Communication lost engine controller MON E03 Electrical system
DBF0KK Power source voltage of communication controller too low COM E03 Electrical system
DBF2KK Voltage of 24 V solenoid power supply system too low COM E01 Electrical system
DBFRKR Communication lost Communication controller MON E03 Electrical system
DD1PKB Power supply line short in RPM set switch COM E03 Electrical system
DD1QKB Short circuit in RPM set mode switch COM E03 Electrical system
DDTGKA Disconnection in lock-up clutch fill switch TM E03 Electrical system
Fill signal is ON when command current is OFF
DDTGKB TM E03 Electrical system
(lock-up clutch fill switch)
DDTHKA Disconnection in FH clutch fill switch TM E03 Electrical system
DDTHKB TM E03 Electrical system
(FH clutch fill switch)
DDTJKA Disconnection in FL clutch fill switch TM E03 Electrical system Troubleshoot-
Fill signal is ON when command current is OFF ing by failure
DDTJKB TM E03 Electrical system code, Part 3
(FL clutch fill switch)
SEN01965-01
DDTKKA Disconnection in 1st clutch fill switch TM E03 Electrical system
DDTKKB TM E03 Electrical system
(1st clutch fill switch)
DDTLKA Disconnection in 2nd clutch fill switch TM E03 Electrical system
DDTLKB TM E03 Electrical system
(2nd clutch fill switch)
DDTMKA Disconnection in 3rd clutch fill switch TM E03 Electrical system
DDTMKB TM E03 Electrical system
(3rd clutch fill switch)
DDTNKA Disconnection in R clutch fill switch TM E03 Electrical system
DDTNKB TM E03 Electrical system
(R clutch fill switch)
DDTPKA Disconnection in 4th clutch fill switch TM E03 Electrical system
DDTPKB TM E03 Electrical system
(4th clutch fill switch)
DF10KA Disconnection in transmission gear shift lever switch TM E03 Electrical system
DF10KB Short circuit in transmission gear shift lever switch TM E03 Electrical system
DGF1KX Transmission oil temperature out of range TM E03 Electrical system
GD655-3E0, GD675-3E0 3

Failure contents
DGT1KX Torque converter oil temperature out of range TM E01 Electrical system
DJF1KA Disconnection in fuel level sensor MON E01 Electrical system
DK10KX Input of accelerator pedal potentiometer out of normal range TM E01 Electrical system
DK70KX Input of inching pedal potentiometer out of normal range TM E03 Electrical system
DKD0KA Disconnection in articulate sensor COM E01 Electrical system
DLE2KA Disconnection in engine speed sensor TM E03 Electrical system
DLF1KA Disconnection in transmission input speed sensor TM E03 Electrical system
DLT3KA Disconnection in transmission output speed sensor TM E03 Electrical system
DV00KB Short circuit in caution buzzer MON E01 Electrical system
DW4BKA Disconnection in parking brake relay TM E03 Electrical system
DXH1KA Disconnection in lock-up ECMV solenoid TM E03 Electrical system Troubleshoot-
DXH1KY Power supply line short in lock-up ECMV solenoid TM E03 Electrical system ing by failure
DXH2KA Disconnection in FH clutch ECMV solenoid TM E03 Electrical system code, Part 3
SEN01965-01
DXH2KY Power supply line short in FH clutch ECMV solenoid TM E03 Electrical system
DXH3KA Disconnection in FL clutch ECMV solenoid TM E03 Electrical system
DXH3KY Power supply line short in FL clutch ECMV solenoid TM E03 Electrical system
DXH4KA Disconnection in 1st clutch ECMV solenoid TM E03 Electrical system
DXH4KY Power supply line short in 1st,3rd clutch ECMV solenoid TM E03 Electrical system
DXH5KA Disconnection in 2nd clutch ECMV solenoid TM E03 Electrical system
DXH5KY Power supply line short in 2nd,4th clutch ECMV solenoid TM E03 Electrical system
DXH6KA Disconnection in 3rd clutch ECMV solenoid TM E03 Electrical system
DXH7KA Disconnection in R clutch ECMV solenoid TM E03 Electrical system
DXH7KY Power supply line short in R clutch ECMV solenoid TM E03 Electrical system
DXHHKA Disconnection in 4th clutch ECMV solenoid TM E03 Electrical system
a Failure code:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical and mechanical
system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
COM : Communication controller system
a Action code:
Action code indicates what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history displayed function, a failure has been recorded.
4 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 5
Fuse locations 1
Connection table of fuse box, slow blow fuse and circuit breaker
a This connection table indicates the devices to which the power of the fuse box, slow blow fuse and cir-
cuit breaker is supplied. (A switch power supply is a device which supplies power while the stating
switch is in the ON position and a constant power supply is a device which supplies power while the
starting switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box, slow
blow fuse and circuit breaker to see if the power is supplied normally.
Locations and numbers of fuse boxes, slow blow fuse and circuit breaker
Fuse box
Fuse box I
Capacity
Type of power supply Fuse No. of circuit Destination of power
breaker
Switched power supply
1 5A Engine controller (B) circuit
starting switch ACC
2 10A Horn circuit
3 10A Back up alarm and lamp circuit
4 10A Brake lamp circuit
5 20A Illumination circuit
6 10A Transmission controller circuit
7 20A Front work lamp circuit
slow blow fuse (80A)
8 20A Rear work lamp circuit
9 10A Cigar lighter circuit
10 10A Solenoid power
11 20A Heater circuit
12 20A 12V converter circuit (if equipped)
13 10A Starting switch terminal B circuit
Constant power supply
14 10A Turn signal and hazard lamp circuit
15 10A Monitor and communication controller
6 GD655-3E0, GD675-3E0
Fuse box II
Capacity
Type of power supply Fuse No. Destination of power
of fuse
1 20A Wiper front upper circuit
2 20A Wiper front lower circuit
3 10A Beacon lamp, Defroster fan circuit (if equipped)
4 10A Cab work lamp circuit (if equipped)
5 5A Air conditioner controller
6 10A Cab work lamp circuit (if equipped)
7 10A Rear wiper circuit
8 5A Air conditioner compressor
9 5A Radio
10 —
11 20A Rear window defroster
12 —
Constant power supply 13 5A Constant power for cab option
slow blow fuse (30A) 14 15A Air conditioner blower fan circuit
15 —
GD655-3E0, GD675-3E0 7
Slow blow fuse, Circuit breaker
Slow blow fuse

Slow blow Capacity
Type of power supply Destination of power
fuse No. of fuse
Starting switch terminal B circuit, Turn signal circuit, Hazard lamp
Constant power supply 1 30A circuit, Monitor circuit, communication controller circuit, Cab option
circuit, Air conditioner blower fan circuit, Engine controller (B) circuit
Horn circuit, Back up alarm and lamp circuit, Brake lamp circuit, Illu-
mination circuit, Transmission controller circuit, Front work lamp cir-
cuit, Rear work lamp circuit, Cigar lighter circuit, Solenoid power,
Heater circuit, 12V converter circuit (if equipped), Wiper front upper
2 80A
Switched power supply circuit, Wiper front lower circuit, Beacon lamp, Defroster fan circuit
(if equipped), Cab work lamp circuit (if equipped), Air conditioner
controller, Wiper rear circuit, Air conditioner compressor, Radio,
Rear window defroster
3 120A Heater relay circuit
Circuit breaker
Circuit
Capacity
Type of power supply breaker Destination of power
of fuse
No.
Constant power supply 4 20A Engine controller (A) circuit
8 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 9

© 2009 KOMATSU
All Rights Reserved
10 GD655-3E0, GD675-3E0
SEN01838-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Testing before troubleshooting ............................................................................................................. 4
Classification and procedures of troubleshooting ................................................................................ 5
Connection table for connector pin numbers ....................................................................................... 6
T-adapter box and T-adapter table ..................................................................................................... 35
GD655-3E0, GD675-3E0 1
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely 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 coolant 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,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
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 troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask 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 this?
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?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 GD655-3E0, GD675-3E0
Sequence of events in troubleshooting 1
GD655-3E0, GD675-3E0 3
Testing before troubleshooting 1

Check item Criteria Remedy
1. Check of fuel level and type of fuel — Add fuel
2. Check for impurities in fuel — Clean or drain
3. Check fuel filter — Replace
4. Check hydraulic oil level — Add oil
5. Check hydraulic oil strainer — Clean or drain
6. Check transmission oil level strainer — Add oil
Lubricating 7. Check final drive oil level — Add oil

oil and cool-
ant 8. Check tandem drive oil level — Add oil
9. Check circle reverse gear oil level — Add oil
10. Check engine oil level (engine oil pan level) and type — Add oil
11. Check coolant level — Add coolant
12. Check dust indicator for clogging — Clean or replace
13. Check hydraulic oil filter — Replace
14. Check transmission oil filter — Replace

1. Check for looseness and corrosion of battery cable Retighten or
—
terminals replace
2. Check for looseness and corrosion of alternator harness Retighten or
Electrical —
terminals replace
equipment 3. Check for looseness and corrosion of starting motor Retighten or
—
harness terminals replace
4. Check operation of instruments — Repair or replace
Hydraulic 1. Check for abnormal noise and smell — Repair

and
2. Check for oil leakage — Repair
mechanical
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30 V Replace
2. Check battery electrolyte level — Refill or replace

3. Check for discoloration, burn-out of wiring, and peeling of
— Replace
harness coating
4. Check for missing wiring clamps and a slack of wire — Repair
Electrical 5. Check for water leaking on wiring
equipment Disconnect con-
(pay particularly careful attention to water leaking on —
nector and dry
connectors or terminals)
6. Check of blown or corroded fuse — Replace
7. Check alternator voltage (engine running at half throttle After running for several
Replace
or above) minutes: 27.5 – 29.5 V
8. Check of operating noise of battery relay (when turning
— Replace
the starting switch ON or OFF)
4 GD655-3E0, GD675-3E0
Classification and procedures of troubleshooting 1

Classification of troubleshooting code
Troubleshooting
Contents
code
Code display Troubleshooting by [electrical system] or [mechanical system] failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting procedures
If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows.
1. When machine monitor displays failure code

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2. When machine monitor does not display failure code, but failure history is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the fail-
ure history display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3. When a failure code is not displayed and failure history is not recorded either
If a problem occurs but the failure code display cannot be checked on the machine monitor, and also the
problem is not recorded by the failure history display function in the machine monitor service mode, the
problem of the electrical, hydraulic or mechanical system that cannot be detected by a controller may
have occurred.
In this case, check the symptom of the trouble and go to the applicable troubleshooting chart.
GD655-3E0, GD675-3E0 5
Connection table for connector pin numbers (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.
6 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 7
8 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 9
10 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 11
12 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 13
14 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 15
16 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 17
18 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 19
20 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 21
22 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 23
24 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 25
26 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 27
28 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 29
30 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 31
32 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 33
34 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 35
36 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 37
SEN01838-01
38
GD655-3E0, GD675-3E0 39
40 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 41
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column 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
799-601-3470 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
799-601-2810 Adapter for DLI 8 DLI-8P 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
799-601-7050 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
42 GD655-3E0, GD675-3E0
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

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
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 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for 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
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 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
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
GD655-3E0, GD675-3E0 43
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
799-601-9330 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* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
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* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 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
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
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,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
44 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 45

© 2009 KOMATSU
All Rights Reserved
46 GD655-3E0, GD675-3E0
SEN01839-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 1 .......................................................................................................... 3
Failure code [(DF1000)] Neutral safety ................................................................................................ 3
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front) ................................................ 4
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear) ................................................. 5
Failure code [AB00L6] Signal of alternator disagrees with operating state of engine .......................... 6
Failure code [AB00MA] Malfunction of alternator................................................................................. 8
Failure code [B@BAZG] Engine oil pressure too low ........................................................................ 10
Failure code [B@BCNS] Engine overheat ..........................................................................................11
Failure code [B@CENS] Torque converter oil temperature too high.................................................. 12
Failure code [B@CKNS] Differential oil overheat............................................................................... 13
Failure code [CA111] Abnormality in controller .................................................................................. 14
Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors ........................................ 15
Failure code [CA122] Charge pressure sensor too high .................................................................... 16
Failure code [CA123] Charge pressure sensor too low ..................................................................... 18
Failure code [CA131] Throttle sensor too high................................................................................... 20
Failure code [CA132] Throttle sensor too low .................................................................................... 22
GD655-3E0, GD675-3E0 1
Failure code [CA144] Coolant temperature sensor too high .............................................................. 24

Failure code [CA145] Coolant temperature sensor too low................................................................ 26
Failure code [CA153] Charge temperature sensor too high............................................................... 28
Failure code [CA154] Charge temperature sensor too low ................................................................ 30
Failure code [CA155] Charge temperature too high and engine speed derated................................ 32
Failure code [CA187] Sensor power source 2 too low ....................................................................... 34
Failure code [CA221] Atmospheric pressure sensor too high ............................................................ 36
Failure code [CA222] Atmospheric pressure sensor too low ............................................................. 38
Failure code [CA227] Sensor power source 2 too high...................................................................... 40
Failure code [CA234] Engine over speed........................................................................................... 42
Failure code [CA238] Abnormal power source for Ne speed sensor ................................................. 43
Failure code [CA271] Short circuit in fuel pump actuator ................................................................... 44
Failure code [CA272] Disconnection in fuel pump actuator ............................................................... 46
Failure code [CA281] Abnormal supply pump pressure balance ....................................................... 48
Failure code [CA322] Disconnection or short circuit in injector No.1 ................................................. 50
2 GD655-3E0, GD675-3E0
Troubleshooting by failure code, Part 1 1

Failure code [(DF1000)] Neutral safety 1
Action code Failure code Neutral safety
Trouble
— (DF1000) (Transmission controller system)
Contents of
• Starting switch was turned ON while lever is not in "P" or "N".
trouble
Action of
• Does not transmit trouble information.
controller
Problem that
appears on —
machine
Related
—
information
GD655-3E0, GD675-3E0 3
Failure code [2G42ZG] Decrease of accumulator oil pressure (Front) 1

Action code Failure code Decrease of accumulator oil pressure (Front)
Trouble
E03 2G42ZG (Machine monitor system)
Contents of • Front accumulator oil pressure switch detected front accumulator pressure reduction while engine
trouble was running.
Action of • Blinks warning lamp and sounds alarm buzzer.
controller • If trouble is repaired, system resets itself.
Problem that
appears on • Brake oil pressure caution lamp lights up while engine is running.
machine
Related
• Method of reproducing failure code: Start engine.
information
Cause Standard value when normal and remarks for troubleshooting

Front accumulator pressure A phenomenon seems to have caused front accumulator pressure
Possible causes
1 reduction (When system is reduction during operation of engine. Find and stop it and repair the
and standard
normal) damaged part.
value in normal
state Carry out troubleshooting for brake oil pressure caution lamp sys-
Defective brake oil pressure
2 tem in "E-12 While engine is running, emergency stop item lights
caution lamp system
up" in E mode.
4 GD655-3E0, GD675-3E0
Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear) 1

Action code Failure code Decrease of accumulator oil pressure (Rear)
Trouble
E03 2G43ZG (Machine monitor system)
Contents of • Rear accumulator oil pressure switch detected rear accumulator pressure reduction while engine
trouble was running.
controller • If trouble is repaired, system resets itself.
Problem that
appears on • Brake oil pressure caution lamp lights up while engine is running.
machine
Related
information

Rear accumulator pressure A phenomenon seems to have caused rear accumulator pressure
Possible causes
1 reduction (When system is reduction during operation of engine. Find and stop it and repair the
and standard
normal) damaged part.
value in normal
state Carry out troubleshooting for brake oil pressure caution lamp sys-
Defective brake oil pressure
caution lamp system
up" in E mode.
GD655-3E0, GD675-3E0 5
Failure code [AB00L6] Signal of alternator disagrees with operating

state of engine 1
Action code Failure code Signal of alternator disagrees with operation and stop of engine
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The engine does not start.
appears on
• After the starting switch is simply turned ON, the service meter advances.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Alternator Engine Voltage
Defective alternator
1 27.5 – 29.5 V
(Internal defect) Between terminal R Start
(Temperature of regu-
(E03) and chassis (Throttle: Above 1/2)
lator case: 25°C)
ground
Stopped Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes
and carry out troubleshooting
and standard
value in normal Hot short in wiring harness Between chassis ground and wiring harness
2
state (Contact with 24 V circuit) between alternator terminal R – FP2
Voltage Max. 1 V
(female) (9), – starter terminal R, – G01
(female) (28), – circuit branch end point
troubleshooting.
FP2 Engine Voltage
3 Defective machine monitor 27.5 – 29.5 V
Start
Between (9) and (Temperature of regu-
(Throttle: Above 1/2)
chassis ground lator case: 25°C)
Stopped Max. 1 V
6 GD655-3E0, GD675-3E0
Circuit diagram related to alternator
GD655-3E0, GD675-3E0 7
Failure code [AB00MA] Malfunction of alternator 1

Action code Failure code Malfunction of alternator
Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Deteriorated battery
appears on • The engine does not start.
machine • The service meter does not advance.
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

1 Deteriorated battery The battery may be deteriorated. Check it directly.
troubleshooting.
Alternator Engine Voltage
Defective alternator
2 27.5 – 29.5 V
(Internal defect) Between terminal R Start
(Temperature of regu-
(E03) and chassis (Throttle: Above 1/2)
lator case: 25°C)
ground
Stopped Max. 1 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
3
Possible causes (Disconnection or defective Wiring harness between alternator terminal Resis-
and standard contact of connector) Max. 1 z
R – FP2 (female) (9) tance
value in normal
a Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Grounding fault in wiring har-
4 ness Between chassis ground and wiring harness
(Contact with ground circuit) between alternator terminal R – FP2 Resis-
Min. 1 Mz
(female) (9), – starter terminal R, – G01 tance
(female) (28)
troubleshooting.
FP2 Engine Voltage
5 Defective machine monitor 27.5 – 29.5 V
Start
Between (9) and (Temperature of regu-
(Throttle: Above 1/2)
chassis ground lator case: 25°C)
Stopped Max. 1 V
8 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 9
Failure code [B@BAZG] Engine oil pressure too low 1

Action code Failure code Engine oil pressure too low
Trouble
E03 B@BAZG (Engine controller system)
Contents of • Signal circuit of engine oil low pressure switch was closed (connected to GND) while engine was
trouble running.
controller • Continues operation under normal control.
Problem that
• Engine oil pressure caution lamp lights up while engine is running.
appears on
• If machine is operated as it is, engine may be seized.
machine
Related
information

Possible causes Engine oil pressure reduction A phenomenon seems to have caused engine oil pressure reduc-
1
and standard (When system is normal) tion. Find and stop it and repair the damaged part.
value in normal Carry out troubleshooting for engine oil pressure caution lamp sys-
state Defective engine oil pressure
caution lamp system
up" in E mode.
10 GD655-3E0, GD675-3E0
Failure code [B@BCNS] Engine overheat 1

Action code Failure code Engine overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of
• Engine coolant temperature is above operating range.
trouble
controller • Limits fuel injection rate until coolant temperature lowers to operating range.
Problem that
• If machine is operated as it is, engine may be seized.
appears on
• Engine output lowers.
machine
• State (Temperature) of engine coolant can be checked with monitoring function.
Related
(Code: 04104 COOLANT TEMP)
information
• Method of reproducing failure code: Turn starting switch ON.

Possible causes
Overheat of engine coolant A phenomenon seems to have caused overheat of engine coolant.
and standard 1
(When system is normal) Find and stop it and repair the damaged part.
value in normal
state Defective engine coolant Carry out troubleshooting for "E-14 Indication of engine coolant tem-
2
temperature gauge system perature gauge is abnormal".
GD655-3E0, GD675-3E0 11
Failure code [B@CENS] Torque converter oil temperature too high 1

Action code Failure code Torque converter oil temperature too high
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• Torque converter oil temperature is above operating range.
trouble
Action of
• Blinks warning lamp and sounds alarm buzzer.
controller
Problem that
• Torque converter oil temperature caution lamp lights up while engine is running.
appears on
• If machine is operated as it is, torque converter may be seized.
machine
• State (Temperature) of torque converter oil can be checked with monitoring function.
Related
(Code: 30100 TC OIL TEMP)
information

Overheat of torque con-
Possible causes A phenomenon seems to have caused overheat of torque converter
1 verter oil (When system is
and standard oil. Find and stop it and repair the damaged part.
normal)
value in normal
state Defective torque converter
2 oil temperature caution lamp Carry out troubleshooting for failure code [DGT1KX].
system
12 GD655-3E0, GD675-3E0
Failure code [B@CKNS] Differential oil overheat 1

Action code Failure code Differential oil overheat
Trouble
E02 B@CKNS (Transmission controller system)
Contents of
• Differential oil temperature caution occurred.
trouble
Action of
• Blinks warning lamp and sounds alarm buzzer.
controller
Problem that
• Differential oil temperature caution lamp lights up while engine is running.
appears on
• If machine is operated as it is, differential may be seized.
machine
Related
information

Possible causes Overheat of differential oil A phenomenon seems to have caused overheat of differential oil.
1
and standard (When system is normal) Find and stop it and repair the damaged part.
value in normal Defective differential oil tem- Carry out troubleshooting for differential oil temperature caution
state 2 perature caution lamp sys- lamp system in "E-12 While engine is running, emergency stop item
tem lights up" in E mode.
GD655-3E0, GD675-3E0 13
Failure code [CA111] Abnormality in controller 1

Action code Failure code Abnormality in controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• An abnormality occurs in internal memory or internal power supply circuit.
trouble
Action of
• Takes no particular action.
controller
Problem that
appears on • Engine can not start.
machine
Related
—
information
Possible causes Cause Standard value when normal and remarks for troubleshooting
and standard
value in normal Internal defect of engine controller is suspected. (It cannot be diag-
1 Defective engine controller
state nosed.)
14 GD655-3E0, GD675-3E0
Failure code [CA115] Abnormality in engine Ne and Bkup speed

sensors 1
Action code Failure code Abnormality in engine Ne and Bkup speed sensors
Trouble
Contents of
• Abnormality occurred in both signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related
• Duplication of failure code: start the engine.
information
and standard
value in normal Defective connection of sen- The defective (wrong) connections of engine Ne and Bkup speed
1
state sor connector sensor connectors are suspected. Visually check it.
GD655-3E0, GD675-3E0 15
Failure code [CA122] Charge pressure sensor too high 1

Action code Failure code Charge pressure sensor too high
Trouble
Contents of • Excessively high voltage is detected at pressure signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge pressure.
controller
Problem that
appears on • Engine output is reduced.
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
Related checked in monitoring function.
information (Code: 36501 Boost pressure sensor voltage)
• Duplication of failure code: turn ON the starting switch.

Defective sensor power If failure code [CA227] is displayed at the same time, carry out trou-
1
source 2 system bleshooting for that in advance.
a Prepare with starting switch OFF, then start troubleshooting with
starting switch ON.
C4 Voltage
Defective boost pressure
2 and temperature sensor Between (2) – (4) Power source 4.75 – 5.25 V
[pressure signal circuit] Since voltage is measured with the harness connected, further diag-
nose the harness and the controller if the voltage is not normal, and
then make judgment after it is determined that there is no other
defective cause.
Hot short of harness starting switch ON.
3 (a contact with 5 V circuit or
Possible causes 24 V circuit) Between ground and wiring harness between
Voltage Max. 1 V
and standard EC1 (female) (44) – C4 (female) (1)
value in normal a Prepare with starting switch OFF, then start troubleshooting with
state starting switch OFF.
Harness short
4 Wiring harness between EC1 (female) (44) –
(Harness internal short) Resis- Min.
C4 (female) (1) and wiring harness among
tance 100 kz
EC1 (female) (37) – S10 – C4 (female) (2)
The connections among boost pressure and temperature sensor –
engine harness – engine controller are suspected to be defective.
Visually check it.
Defective wiring harness
5 • Connector is loose, lock is broken, seal is broken
connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
starting switch ON.
EC1 Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
16 GD655-3E0, GD675-3E0
Circuit diagram related to charge pressure and temperature sensor
GD655-3E0, GD675-3E0 17
Failure code [CA123] Charge pressure sensor too low 1

Action code Failure code Charge pressure sensor too low
Trouble
Contents of • Excessively low voltage is detected at pressure signal circuit of boost pressure and temperature sen-
trouble sor.
Action of
• Operates with a fixed charge pressure.
controller
Problem that
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
information (Code: 36502 CHG PRESS-A)

1
source 2 system bleshooting for that first.
starting switch ON.
C4 Voltage
2 and temperature sensor Between (2) – (4) Power source 4.75 – 5.25 V
[pressure signal circuit] Since voltage is measured with the harness connected, further diag-
defective cause.
Defective harness grounding starting switch OFF.
3
(Contact with ground circuit) Between ground and wiring harness between Resis- Min.
Possible causes
and standard EC1 (female) (44) – C4 (female) (1) tance 100 kz
Harness short
C4 (female) (1) and wiring harness among
tance 100 kz
Visually check it.
connector
insulation
starting switch ON.
EC1 Voltage
18 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 19
Failure code [CA131] Throttle sensor too high 1

Action code Failure code Throttle sensor too high
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of throttle sensor.
trouble
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
Action of abnormality occurs with the starting switch in the ON position.
controller • If the starting switch is turned to the ON position in the same abnormal condition, the controller oper-
ates with 100% value.
Problem that
appears on • Engine speed cannot be controlled by throttle sensor.
machine
• The signal voltage of throttle sensor can be checked in monitoring mode.
Related
(Code: 31707 THROTTLE POS)
information

Defective throttle sensor If failure code [CA2185] is displayed at the same time, carry out
1
power supply circuit troubleshooting for that first.
starting switch ON.
T9A Voltage
2 Defective decelerator pedal Between (1) – (3) Power source 4.75 – 5.25 V
Since voltage is measured with the harness connected, further diag-
defective cause.
Hot short of harness (a con- starting switch ON.
3 tact with 5 V circuit or 24 V
Possible causes Between ground and wiring harness between
circuit) Voltage Max. 1 V
and standard EC2 (female) (9) – T9A (female) (2)
value in normal
state
starting switch OFF.
Harness short
T9A (female) (2) and wiring harness between
tance 100 kz
EC2 (female) (22) – T9A (female) (1)
The connections among throttle sensor – body harness – engine
controller are suspected to be defective. Visually check it.
Defective wiring harness • Connector is loose, lock is broken, seal is broken
5
connector • Pin is corroded, bent, broken, pushed in, expanded.
insulation
starting switch ON.
EC2 Voltage
20 GD655-3E0, GD675-3E0
Circuit diagram related to fuel control dial
GD655-3E0, GD675-3E0 21
Failure code [CA132] Throttle sensor too low 1

Action code Failure code Throttle sensor too low
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of throttle sensor.
trouble
Problem that
appears on • Engine speed cannot be controlled by throttle sensor.
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
Related
(Code: 31707 THROTTLE POS)
information

Defective throttle sensor If failure code [CA2186] is displayed at the same time, carry out
1
power supply circuit troubleshooting for that first.
starting switch ON.
T9A Voltage
2 Defective decelerator pedal Between (1) – (2) Power source 4.75 – 5.25 V
defective cause.
3
Possible causes (Contact with ground circuit) Between ground and wiring harness between Resis- Min.
and standard EC2 (female) (9) – T9A (female) (2) tance 100 kz
value in normal
state
Harness short
T9A (female) (2) and wiring harness between
tance 100 kz
EC2 (female) (23) – T9A (female) (3)
The connections among throttle sensor – body harness – engine
controller are suspected to be defective. Visually check it.
5
insulation
starting switch ON.
EC2 Voltage
22 GD655-3E0, GD675-3E0
Circuit diagram related to fuel control dial
GD655-3E0, GD675-3E0 23
Failure code [CA144] Coolant temperature sensor too high 1

Action code Failure code Coolant temperature sensor too high
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
• Exhaust gas color becomes white.
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
information

Defective engine coolant starting switch OFF.
1
temperature sensor C3 (male) Resistance
Between (1) – (2) 0.18 – 160 kz
Disconnection in wiring har- starting switch OFF.
ness Wiring harness between EC1 (female) (15) – Resis-
2 Max. 10 z
(Disconnection or poor con- C3 (female) (2) tance
nector contact) Wiring harness among EC1 (female) (38) – Resis-
Max. 10 z
S13 – C3 (female) (1) tance
Possible causes a Prepare with starting switch OFF, then start troubleshooting with
and standard starting switch OFF.
Harness short
value in normal 3 Between EC1 (female) (15) – EC1 (female)
state all pins (With all connectors in the harness
tance 100 kz
disconnected)
The connections among engine coolant temperature sensor –
Visually check it.
connector
insulation
EC1 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
24 GD655-3E0, GD675-3E0
Circuit diagram related to coolant temperature sensor
GD655-3E0, GD675-3E0 25
Failure code [CA145] Coolant temperature sensor too low 1

Action code Failure code Coolant temperature sensor too low
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
information

Defective engine coolant C3 (male) Resistance
1
temperature sensor Between (1) – (2) 0.18 – 160 kz
Between (2) –
Min. 100 kz
chassis ground
2
EC1 (female) (15) – C3 (female) (2) tance 100 kz
Possible causes starting switch OFF.
and standard Harness short
3 Between EC1 (female) (15) – EC1 (female)
value in normal (Harness internal short) Resis- Min.
all pins (With all connectors in the harness
state tance 100 kz
disconnected)
The connections among engine coolant temperature sensor –
Visually check it.
connector
insulation
5 Defective engine controller EC1 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
26 GD655-3E0, GD675-3E0
Circuit diagram related to coolant temperature sensor
GD655-3E0, GD675-3E0 27
Failure code [CA153] Charge temperature sensor too high 1

Action code Failure code Charge temperature sensor too high
Trouble
Contents of • Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature.
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Code: 18501 CHG TEMP)

Defective boost pressure starting switch OFF.
1 and temperature sensor
C4 (male) Resistance
[temperature signal circuit]
Between (3) – (4) 0.18 – 160 kz
2 Max. 10 z
(Disconnection or poor con- C4 (female) (3) tance
nector contact) Wiring harness among EC1 (female) (47) – Resis-
Max. 10 z
S11 – C4 (female) (4) tance
Possible causes a Prepare with starting switch OFF, then start troubleshooting with
and standard starting switch OFF.
Harness short
value in normal 3 Between EC1 (female) (23) – EC1 (female)
state all pins (With all connectors in the harness
tance 100 kz
disconnected)
Visually check it.
connector
insulation
Between (23) – (47) 0.18 – 160 kz
28 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 29
Failure code [CA154] Charge temperature sensor too low 1

Action code Failure code Charge temperature sensor too low
Trouble
Contents of • Excessively low voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature.
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Code: 18501 CHG TEMP)

1 and temperature sensor C4 (male) Resistance
[temperature signal circuit] Between (3) – (4) 0.18 – 160 kz
2
Harness short
and standard 3 Between EC1 (female) (23) – EC1 (female)
value in normal all pins (With all connectors in the harness
tance 100 kz
state disconnected)
Visually check it.
connector
insulation
Between (23) – (47) 0.18 – 160 kz
30 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 31
Failure code [CA155] Charge temperature too high and engine speed
derated 1
Action code Failure code Charge air temperature too high and engine speed derated
Trouble
Contents of • The temperature signal of boost pressure and temperature sensor exceeds upper control limit tem-
trouble perature.
Action of
• Operates with limited output.
controller
Problem that
• Engine output is reduced.
appears on
• Engine stops.
machine
• The boost temperature can be checked in monitoring function.
Related
(Code: 18500 CHG TEMP)
information
• Duplication of failure code: Start the engine.

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Degradation of cooling per-
Possible causes 1 • Looseness and damage of fun belt
formance of aftercooler
and standard • Insufficient cooling air amount
value in normal • Clogging of aftercooler fin
state Abnormal rise in turbo- The abnormal rise in turbocharger outlet temperature is suspected.
2
charger outlet temperature Directly check the related parts.
Engine controller is possibly defective if no problem is found in
causes 1 – 2. (Internal failure which cannot be diagnosed)
32 GD655-3E0, GD675-3E0
Failure code [CA187] Sensor power source 2 too low 1

Action code Failure code Sensor power source 2 too low
Trouble
Contents of
• Excessively low voltage has been detected at sensor power source 2 circuit.
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information

a Disconnect connectors with starting switch OFF, then turn it ON for
troubleshooting.
Disconnect the Charge pressure and
C4
devices on the right temperature sensor
one at a time and try to Common rail pressure
C8
1 Defective sensor or harness duplicate the problem. sensor
If the failure code
changes from Bkup sensor C13
Possible causes
flashing to continu-
and standard
ously illuminating,
value in normal Engine harness EC1
that device or harness
state
is defective.
The connections among each sensor – engine harness – engine
controller are suspected to be defective.
• Connector is loose, lock is broken, seal is broken
2 Defective harness connector
insulation
34 GD655-3E0, GD675-3E0
Circuit diagram related to sensor power supply 2
GD655-3E0, GD675-3E0 35
Failure code [CA221] Atmospheric pressure sensor too high 1

Action code Failure code Atmospheric pressure sensor too high
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
• Operates with a fixed atmospheric pressure.
controller
Problem that
• Startability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37402 AMBIENT PRESS)
information

1
starting switch ON.
C29 Voltage
Defective atmospheric pres- Between (1) – (2) Power source 4.75 – 5.25 V
2
sure sensor
defective cause.
Hot short of harness (a con- starting switch ON.
Possible causes circuit) Between ground and wiring harness between
Voltage Max. 1 V
Harness short
C29 (female) (3) and wiring harness between
tance 100 kz
EC1 (female) (33) – C29 (female) (1)
The connections among atmospheric pressure sensor – engine har-
ness – engine controller are suspected to be defective. Visually
check it.
connector
insulation
starting switch ON.
EC1 Voltage
36 GD655-3E0, GD675-3E0
Circuit diagram related to atmospheric pressure sensor
GD655-3E0, GD675-3E0 37
Failure code [CA222] Atmospheric pressure sensor too low 1

Action code Failure code Atmospheric pressure sensor too low
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
controller
Problem that
• Startability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37402 AMBIENT PRESS)
information

1
starting switch ON.
C29 Voltage
Defective atmospheric pres- Between (1) – (2) Power source 4.75 – 5.25 V
2
sure sensor
defective cause.
3
(Contact with ground circuit) Between ground and wiring harness Resis- Min.
Possible causes
and standard between EC1 (female) (3) – C29 (female) (3) tance 100 kz
Harness short
tance 100 kz
The connections among atmospheric pressure sensor – engine har-
ness – engine controller are suspected to be defective. Visually
check it.
connector
insulation
starting switch ON.
EC1 Voltage
38 GD655-3E0, GD675-3E0
Circuit diagram related to atmospheric pressure sensor
GD655-3E0, GD675-3E0 39
Failure code [CA227] Sensor power source 2 too high 1

Action code Failure code Sensor power source 2 too high
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 2 circuit
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information

Possible causes
and standard 1
value in normal
state
insulation
cause 1. (Internal failure which cannot be diagnosed)
40 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 41
Failure code [CA234] Engine over speed 1

Action code Failure code Engine over speed
Trouble
Contents of
• The engine speed exceeds upper control limit speed.
trouble
Action of
• Stops operation of injector until the engine speed drops to the normal speed.
controller
Problem that
appears on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
Related
(Code: 01002 ENG SPEED)
information
• Duplication of failure code: Start engine and operate at high idle.

Possible causes 1 Improper fuel has been used. The use of improper fuel is suspected. Visually check it.
and standard The improper usage of equipped machine is suspected. Instruct the
value in normal 2 Improper usage
proper usage.
state
42 GD655-3E0, GD675-3E0
Failure code [CA238] Abnormal power source for Ne speed sensor 1

Action code Failure code Abnormal power source for Ne speed sensor
Trouble
Contents of
• Excessively low voltage is detected at power source circuit of engine Ne speed sensor.
trouble
Action of
• Continues the control by engine Bkup speed sensor signal.
controller
Problem that
• Engine is hard to start.
appears on
• Engine is hunting.
machine
Related
information

a Prepare with starting switch OFF, then turn it ON for troubleshoot-
ing.
Disconnect the
devices on the right
one at a time and try to Ne speed sensor C15
Defective sensor or wiring duplicate the problem.
1
harness If the failure code
Possible causes
and standard changes from
value in normal flashing to continu-
state ously illuminating, Engine harness EC1
is defective.
2
insulation
Circuit diagram related to engine Ne speed sensor
GD655-3E0, GD675-3E0 43
Failure code [CA271] Short circuit in fuel pump actuator 1

Action code Failure code Short circuit in fuel pump actuator
Trouble
Contents of
• Short circuit has been detected at drive circuit of supply pump actuator.
trouble
Action of
• No particular action
controller
Problem that • Engine speed does not increase from low idle.
machine • Fuel pressure of common rail increases above command value.
Related
information

Defective supply pump actu- starting switch OFF.
1
ator FUEL PUMP (male) Resistance
2
EC1 (female) (2) – FUEL PUMP (female) (1) tance 100 kz
and standard Harness short
3 Between EC1 (female) (2) – EC1 (female) all
value in normal (Harness internal short) Resis- Min.
pins (With all connectors in the harness dis-
state tance 100 kz
connected)
The connections among inlet metering valve – engine harness –
engine controller are suspected to be defective. Visually check it.
4
insulation
44 GD655-3E0, GD675-3E0
Circuit diagram related to supply pump actuator (metering unit)
GD655-3E0, GD675-3E0 45
Failure code [CA272] Disconnection in fuel pump actuator 1

Action code Failure code Disconnection in fuel pump actuator
Trouble
Contents of
• Disconnection is detected at drive circuit of supply pump actuator.
trouble
Action of
controller
Problem that
• Engine runs, but it does not stabilize.
appears on
• Fuel pressure of common rail increases above commanded value.
machine
Related
information

Defective supply pump actu- starting switch OFF.
1
ator FUEL PUMP (male) Resistance
Between (1) – (2) Max. 5 z
2 Max. 10 z
(Disconnection or poor con- FUEL PUMP (female) (1) tance
nector contact) Wiring harness between EC1 (female) (32) – Resis-
Max. 10 z
FUEL PUMP (female) (2) tance
Hot short of harness starting switch ON.
Possible causes 3
(a contact with 24 V circuit) Between ground and wiring harness between
and standard Voltage Max. 3 V
EC1 (female) (2) – FUEL PUMP (female) (1)
value in normal
state a Prepare with starting switch OFF, then start troubleshooting with
Harness short
pins (With all connectors in the harness dis-
tance 100 kz
connected)
The connections among inlet metering valve – engine harness –
engine controller are suspected to be defective. Visually check it.
5
insulation
46 GD655-3E0, GD675-3E0
Circuit diagram related to supply pump actuator (metering unit)
GD655-3E0, GD675-3E0 47
Failure code [CA281] Abnormal supply pump pressure balance 1

Action code Failure code Abnormal supply pump pressure balance
Trouble
Contents of • Due to the abnormality in supply pump mechanical system, response of fuel pressure feed is not
trouble appropriate.
Action of
controller
Problem that
• Engine does not start. Or it starts, but it does not stabilize.
appears on
• The pressure of high-pressure fuel is different in front side and rear side of supply pump.
machine
Related
information

Refer to “Bleeding air from fuel circuit” in Testing and adjusting, and
1 Residual air in the fuel circuit
bleed air from the fuel circuit.
Problem is possibly at the connections between common rail pres-
Possible causes sure sensor – engine harness – engine controller, so inspect them
and standard directly.
value in normal Defective wiring harness
state connector
insulation
48 GD655-3E0, GD675-3E0
Failure code [CA322] Disconnection or short circuit in injector No.1 1

Action code Failure code Disconnection or short circuit in injector No.1
Trouble
Contents of
• A disconnection or short circuit has been detected in No. 1 injector drive circuit.
trouble
Action of
controller
Problem that
• Poor combustions or hunting occurs.
appears on
machine
Related
information

If the following failure codes are displayed at the same time, engine
controller is internally defective: ([CA322] [CA324] [CA331])
a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
2 Defective No. 1 injector C9 (male) Resistance
switch still OFF.
Disconnection in wiring harness
Wiring harness between EC1 (female) (45) – Resis-
3 (Disconnection or defective Max. 2 z
C9 (3) – No. 1 injector (1) tance
contact of connectors)
Max. 2 z
switch still OFF.
Defective harness grounding
4
Possible causes between EC1 (female) (45) – C9 (3) – No. 1
tance 100 kz
and standard injector (1)
value in normal a Prepare with starting switch OFF and diagnose with starting
state switch still OFF.
Between EC1 (female) (45) – EC1 (female)
Resis- Min.
Harness short all pins
5 tance 100 kz
(Harness internal short) (All connectors in the harness disconnected)
Resis- Min.
all pins
tance 100 kz
(All connectors in the harness disconnected)
Since the problem is possibly at the connections between No. 1
injector – engine harness – engine controller, check for a defective
connection.
connector
insulation
switch still OFF.
Between (45) – (53) Max. 2 z
50 GD655-3E0, GD675-3E0
Circuit diagram related to injector No. 1
GD655-3E0, GD675-3E0 51

Trouble
Contents of
• A disconnection or short circuit has been detected in No. 5 injector drive circuit
trouble
Action of
controller
Problem that
appears on
machine
Related
information

switch still OFF.
Disconnection in wiring har- switch still OFF.
3 Max. 2 z
(Disconnection or defective C11 (3) – No. 5 injector (1) tance
contact of connectors) Wiring harness between EC1 (female) (60) – Resis-
Max. 2 z
switch still OFF.
4
tance 100 kz
Resis- Min.
5 tance 100 kz
Resis- Min.
all pins
tance 100 kz
connection.
connector
insulation
switch still OFF.
Between (46) – (60) Max. 2 z
52 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 53

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

switch still OFF.
3 Max. 2 z
Max. 2 z
switch still OFF.
4
Possible causes (Contact with ground circuit) Between ground and wiring harness Resis- Min.
between EC1 (female) (55) – C10 (3) – No. 3
and standard tance 100 kz
injector (1)
value in normal
state
switch still OFF.
Resis- Min.
5 tance 100 kz
Resis- Min.
all pins
tance 100 kz
Since problem is possibly at the connections between No. 3 injector –
engine harness – engine controller, check for a defective connection.
6
insulation
switch still OFF.
Between (55) – (52) Max. 2 z
Between (55) – ground Min. 100 kz
54 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 55

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

switch still OFF.
3 Max. 2 z
Max. 2 z
switch still OFF.
4
tance 100 kz
Resis- Min.
5 tance 100 kz
Resis- Min.
all pins
tance 100 kz
connection.
connector
insulation
switch still OFF.
Between (57) – (59) Max. 2 z
56 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 57

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

switch still OFF.
switch still OFF.
3 (Disconnection or defective Max. 2 z
Max. 2 z
switch still OFF.
4
tance 100 kz
Resis- Min.
5 tance 100 kz
Resis- Min.
all pins
tance 100 kz
connection.
connector
Pin is corroded, bent, broken, pushed in, expanded.
Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
switch still OFF.
Between (54) – (51) Max. 2 z
58 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 59

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

switch still OFF.
3 Max. 2 z
Max. 2 z
switch still OFF.
4
tance 100 kz
Resis- Min.
5 tance 100 kz
Resis- Min.
all pins
tance 100 kz
connection.
connector
insulation
switch still OFF.
Between (56) – (58) Max. 2 z
60 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 61
SEN01839-00

© 2006 KOMATSU
All Rights Reserved
62
SEN01840-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Failure code [CA342] Abnormality in engine controller data consistency ............................................ 3
Failure code [CA351] Abnormality in injector drive circuit.................................................................... 4
Failure code [CA352] Sensor power source 1 too low ......................................................................... 6
Failure code [CA386] Sensor power source 1 too high........................................................................ 8
Failure code [CA428] Water detection sensor too high...................................................................... 10
Failure code [CA429] Water detection sensor too low ....................................................................... 12
Failure code [CA435] Abnormality in engine oil pressure switch ....................................................... 14
Failure code [CA441] Power supply voltage too low .......................................................................... 16
Failure code [CA442] Power supply voltage too high ........................................................................ 18
Failure code [CA449] Common rail pressure too high (2).................................................................. 20
Failure code [CA451] Common rail pressure sensor too high ........................................................... 24
Failure code [CA452] Common rail pressure sensor too low............................................................. 26
Failure code [CA488] Charge temperature too high and torque derated ........................................... 28
Failure code [CA553] Common rail pressure too high (1).................................................................. 29
Failure code [CA559] Supply pump no pressure (1) .......................................................................... 30
GD655-3E0, GD675-3E0 1
Failure code [CA689] Abnormality in engine Ne speed sensor.......................................................... 32

Failure code [CA731] Abnormality in engine Bkup speed sensor phase ........................................... 34
Failure code [CA757] Loss of all engine controller data..................................................................... 36
Failure code [CA778] Abnormality in engine Bkup speed sensor ...................................................... 38
Failure code [CA1633] Abnormality in KOMNET ............................................................................... 40
Failure code [CA2185] Accelerator pedal sensor power source too high .......................................... 42
Failure code [CA2186] Accelerator pedal sensor power source too low............................................ 44
Failure code [CA2249] Supply pump no pressure (2) ........................................................................ 46
Failure code [CA2265] Disconnection in electric lift pump ................................................................. 48
Failure code [CA2266] Short circuit in electric lift pump..................................................................... 50
Failure code [CA2311] Abnormal resistance in IMV solenoid............................................................. 52
Failure code [CA2555] Disconnection in air intake heater relay......................................................... 54
Failure code [CA2556] Short circuit in air intake heater relay ............................................................ 56
2 GD655-3E0, GD675-3E0

Failure code [CA342] Abnormality in engine controller data consistency 1
Action code Failure code Abnormality in engine controller data consistency
Trouble
Contents of
• Data matching error has been detected in engine controller.
trouble
Action of
controller
Problem that
• Normal operation is continued.
appears on
• Engine stops or engine does not start.
machine
Related
information

Possible causes
Check the failure codes that are displayed at the same time. If any
and standard 1 Defective related circuits
other codes are displayed, carry out troubleshooting for those codes.
value in normal
state Internal defect of engine controller is suspected. (It cannot be diag-
nosed.)
GD655-3E0, GD675-3E0 3
Failure code [CA351] Abnormality in injector drive circuit 1

Action code Failure code Abnormality in injector drive circuit
Trouble
Contents of
• Trouble occurred in injector drive circuit.
trouble
Action of
• Limits engine output and continues operation (Limits common rail pressure).
controller
Problem that
appears on • Engine output drops.
machine
Related • Source voltage of engine controller can be checked with monitoring function.
information (Code: 03200 POWER SUPPLY)

If another failure code (failure code of trouble in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
If circuit breaker is turned OFF, circuit probably has ground fault
2 Defective circuit breaker
(See cause 4).
Wiring harness between EC3 (female) (3), Resis-
Max. 1 z
Disconnection in wiring har- (4) – ET100 tance
ness (Disconnection in wiring Resis-
3 Wiring harness between ET103 – ET102 Max. 1 z
or defective contact in con- tance
nector) Wiring harness between ET47 – battery relay Resis-
Max. 1 z
ET46 tance
Possible causes Wiring harness between EC3 (female) (1), Resis-
and standard Max. 1 z
(2) – engine ground (ET103) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Min. 1 Mz
(4) – ET100 tance
Ground fault in wiring har-
Wiring harness between ET103 – ET102 or Resis-
4 ness (Contact with GND cir- Min. 1 Mz
circuit branch end tance
cuit)
Wiring harness between ET47 – battery relay Resis-
Min. 1 Mz
ET46 tance
Min. 1 Mz
and carry out troubleshooting.
5 DEfective engine controller
EC3 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
4 GD655-3E0, GD675-3E0
Circuit diagram related to engine controller power supply
GD655-3E0, GD675-3E0 5
Failure code [CA352] Sensor power source 1 too low 1

Action code Failure code Sensor power source 1 too low
Trouble
Contents of
• Excessively low voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information

switch ON.
Disconnect the
devices on the right Atmospheric pres-
one at a time and try to C29
sure sensor
Defective sensor or wiring duplicate the problem.
1
harness If the failure code
changes from
flashing to continu-
Possible causes
ously illuminating, Engine harness EC1
and standard
value in normal
is defective.
state
Since the connections among atmospheric pressure sensor –
engine harness – engine controller are suspected to be defective,
check for a defective connection.
connector
insulation
3 Defective engine controller causes 1 – 2. (Since this is an internal defect, it cannot be diag-
nosed.)
6 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 7
Failure code [CA386] Sensor power source 1 too high 1

Action code Failure code Sensor power source 1 too high
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information

Since the connections among atmospheric pressure sensor –
engine harness – engine controller are suspected to be defective,
Possible causes check for a defective connection.
and standard 1 • Connector is loose, lock is broken, seal is broken
connector
value in normal Pin is corroded, bent, broken, pushed in, expanded.
state Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
cause 1. (Since this is an internal defect, it cannot be diagnosed.)
8 GD655-3E0, GD675-3E0
Failure code [CA428] Water detection sensor too high 1

Action code Failure code Water detection sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 WATER IN FUEL)
information

Defective fuel water detec- switch still OFF.
1
tion sensor WIF (female) Resistance
2 Max. 10 z
(Disconnection or defective WIF (male) (1) tance
Max. 10 z
S11 – WIF (male) (2) tance
switch still OFF.
Possible causes Harness short
and standard (Harness internal short) Resis- Min.
all pins
value in normal tance 100 kz
state
Problem is possibly at the connections between fuel water detection
sensor – engine harness – engine controller, so inspect them
directly.
connector
insulation
Defect in other locations than switch still OFF.
5
engine controller EC1 (female) Resistance
Between (14) – (47) Max. 10 z
6 Defective engine controller causes 1 – 5.
(Since this is an internal defect, it cannot be diagnosed.)
10 GD655-3E0, GD675-3E0
Circuit diagram related to fuel water sensor
GD655-3E0, GD675-3E0 11
Failure code [CA429] Water detection sensor too low 1

Action code Failure code Water detection sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 WATER IN FUEL)
information

switch still OFF.
Defective fuel water detec- WIF (female) Resistance
1
tion sensor Between (1) – (2) Max. 10 z
Between (1) –
Min. 100 kz
chassis ground
Defective harness grounding switch still OFF.
2
between EC1 (female) (14) – WIF (male) (1) tance 100 kz
switch still OFF.
Harness short
Possible causes 3 Between EC1 (female) (14) – EC1 (female)
and standard all pins
tance 100 kz
value in normal (All connectors in the harness disconnected)
state Problem is possibly at the connections between fuel water detection
sensor – engine harness – engine controller, so inspect them
directly.
connector
insulation
switch still OFF.
Defect in other locations than EC1 (female) Resistance
5
engine controller
Between (14) – (47) Max. 10 z
12 GD655-3E0, GD675-3E0
Circuit diagram related to fuel water sensor
GD655-3E0, GD675-3E0 13
Failure code [CA435] Abnormality in engine oil pressure switch 1

Action code Failure code Abnormality in engine oil pressure switch
Trouble
Contents of
• A problem has occurred in the engine oil pressure switch signal circuit
trouble
Action of
controller
Problem that
• Protection function by engine oil pressure does not operate.
appears on
• Engine oil pressure monitor does not display normally.
machine
Related
• Duplication of failure code: turn ON the starting switch or start the engine.
information

switch still OFF.
1 Defective engine oil switch
Between (1) – body Max. 10 z
Disconnection in wiring har- a Prepare with starting switch OFF and diagnose with starting
ness switch still OFF.
2
(Disconnection or defective Wiring harness between EC1 (female) (17) – Resis-
contact of connectors) Max. 10 z
C2 (female) (1) tance
switch still OFF.
Harness short
Possible causes (Harness internal short) Resis- Min.
all pins
value in normal
state Since the problem is possibly at the connections between engine oil
pressure switch – engine harness – engine controller, check for a
defective connection.
connector
insulation
5
Between (17) – ground Max. 10 z
14 GD655-3E0, GD675-3E0
Circuit diagram related to engine oil pressure switch
GD655-3E0, GD675-3E0 15
Failure code [CA441] Power supply voltage too low 1

Action code Failure code Power supply voltage too low
Trouble
Contents of
• Excessively low voltage has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
• Engine stops.
appears on
machine
Related
information

Loose or corroded battery
1 Battery terminal is possibly loose or corroded, so inspect it directly.
terminal
switch OFF and START.
2 Defective battery voltage Battery (1 unit) Starting switch Voltage
Between (+) – OFF Min. 12 V
(–) terminals START Min. 6.2 V
If fuse is blown, it is highly possible that a defective harness ground-
3 Defective fuse No. 9
ing, etc. has occurred in the circuit (refer to cause 5).
ness Wiring harness between ET102 – EC3 Resis-
4 Max. 10 z
(Disconnection or defective (female) (3), (4) tance
contact of connectors) Wiring harness between EC3 (female) (1), Resis-
Max. 10 z
Possible causes 5
and standard
value in normal between ET102 – EC3 (female) (3), (4) tance 100 kz
state a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Harness short
6 Between pins EC3 (female) (3), (4) – EC3
(female) (1), (2)
tance 100 kz
(Battery terminals disconnected)
• Since the problem is possibly at the connections between FS2 (9) –
body harness – engine controller, check for a defective connection.
7
insulation
switch ON and START.
Defect in other locations than EC3 (female) Starting switch Voltage
8
engine controller ON Min. 24 V
Between (3), (4) –
(1), (2) START Min. 12 V

16 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 17
Failure code [CA442] Power supply voltage too high 1

Action code Failure code Power supply voltage too high
Trouble
Contents of
• Excessively high voltage (36 V or more) has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

switch still OFF.
1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes a Prepare with starting switch OFF and start the engine to diag-
and standard nose.
value in normal 2 Defective alternator ER1 (male) Engine speed Voltage
state
Medium speed or
Between (6) – ground 27.5 – 29.5 V
higher
switch ON.
EC3 (female) Voltage
Between (3), (4) – (1), (2) Max. 32 V
18 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 19
Failure code [CA449] Common rail pressure too high (2) 1

Action code Failure code Common rail pressure too high (2)
Trouble
Contents of
• Excessively high pressure trouble (2) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine
• Common rail pressure can be checked with the monitoring function.
Related
(Code: 36400 RAIL PRESS)
information

1 Defective related circuits other codes are displayed, carry out troubleshooting for those
codes.
Air has possibly entered into the low pressure circuit, so inspect
directly in the following procedure:
1) Remove pressure inspection plug (on the outlet port) for the fuel
main filter.
2) Operate the feed pump for the fuel pre-filter.
2 Air in the low pressure circuit 3) Inspect the fuel and air leaking from the pressure inspection plug.
• If this error occurs during the air bleeding operation after the
fuel filter replacement, air is possibly remaining in the fuel cir-
cuit, so continue to run the engine at low idle for approximately
3 minutes. When air bleeding is complete, engine revolutions
become stable and the error display disappears.
a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel
low pressure circuit pressure inspection.
• Measurement on the outlet side of the fuel filter
Possible causes At high idle
Fuel low pressure Min. 0.48 MPa
and standard (When engine can
circuit pressure {Min. 4.9 kg/cm2}
value in normal be started)
state • Measurements on the inlet and outlet sides of the fuel filter
• Fuel low pressure circuit pressure drop
= fuel filter inlet pressure – fuel filter outlet pressure
Fuel low pressure Max. 0.14 MPa
Defective fuel low pressure At high idle
3 circuit pressure drop {Max. 1.4 kg/cm2}
circuit devices
suction pressure inspection.
• Measurement on the gear pump fuel inlet side of the supply pump
Fuel suction circuit
Max. 33.9 kPa
pressure At high idle
{Max. 254 mmHg}
(Gear pump side)
• Measurement on the fuel connector side
Max. 27.1 kPa
{Max. 203 mmHg}
(Fuel connector side)
a Inspect directly if fuel is leaking from the fuel tube for fuel cooler,
4 Defective fuel cooler if O-ring or seal washer is damaged, or if check valve is clogged
or damaged.
20 GD655-3E0, GD675-3E0

a Prepare with starting switch ON and diagnose with starting switch
ON.
Defective common rail pres- Monitoring code
5 Monitoring information
sure sensor (Monitor panel)
36400 When engine is 0 ± 0.39 MPa
Common rail pressure stopped {0 ± 4 kg/cm2}
Defective O-ring for supply
6 a Inspect directly if supply pump actuator O-ring is not damaged.
pump actuator
switch ON.
Monitoring code
Monitoring information
(Monitor panel)
36400 When engine is 0 ± 0.39 MPa
Common rail pressure stopped {0 ± 4 kg/cm2}
Possible causes Defective supply pump actu-
and standard
7
ator a Prepare with starting switch OFF, then start the engine to diag-
value in normal nose.
state • Measure after idling for at least 1 minute.
Monitoring code
Monitoring information
(Monitor panel)
36400 1.96 MPa
At low idle
Common rail pressure {20 kg/cm2}
Problem is possibly in the common rail fuel pressure sensor con-
nector or supply pump actuator, so inspect them directly.
8
insulation
Defective engine controller switch still OFF.
9
ground harness EC3 Resistance
Between (1), (2) – chassis ground Max. 10 z
10 Defective supply pump Supply pump is possibly defective if no problem is found in causes 1 – 9.
GD655-3E0, GD675-3E0 21
Circuit diagram related to common rail pressure sensor
22 GD655-3E0, GD675-3E0
Failure code [CA451] Common rail pressure sensor too high 1

Action code Failure code Common rail pressure sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
Related
information

1
source 2 circuit bleshooting for it first.
switch ON.
C8 Voltage
Defective common rail pres- Between (3) – (1) Power source 4.75 – 5.25 V
2
sure sensor
defective cause.
Hot short of harness (a con- switch ON.
Possible causes circuit) Between ground and wiring harness between
Voltage Max. 1 V
Harness short
tance 100 kz
Since the problem is possibly at the connections between common
rail pressure sensor – engine harness – engine controller, check for
a defective connection.
connector
insulation
switch ON.
EC1 Voltage
24 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 25
Failure code [CA452] Common rail pressure sensor too low 1

Action code Failure code Common rail pressure sensor too low
Trouble
Contents of
• Excessively low voltage is detected in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
Related
information

1
switch ON.
C8 Voltage
Defective common rail pres- Between (3) – (1) Power source 4.75 – 5.25 V
2
sure sensor
defective cause.
3
Possible causes
and standard EC1 (female) (25) – C8 (female) (2) tance 100 kz
Harness short
4 Wiring harnesses between EC1 (female)
(25) – C8 (female) (2) and among EC1
tance 100 kz
(female) (47) – S11 – C8 (female) (1)
Since the problem is possibly at the connections between common
rail pressure sensor – engine harness – engine controller, check for
connector
insulation
switch ON.
EC1 Voltage
26 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 27
Failure code [CA488] Charge temperature too high and torque derated 1
Action code Failure code Charge temperature too high and torque derated
Trouble
Contents of • The temperature signal of charge pressure and temperature sensor exceeds upper control limit tem-
trouble perature.
Action of
controller
Problem that
appears on • Engine output decreases.
machine
• The charge temperature can be checked in monitoring function.
Related
(Code: 18500 CHG TEMP)
information

The degradation of aftercooler cooling performance is suspected.
Directly check the following points:
Degradation of cooling per-
1 • Looseness and damage of fan belt
Possible causes formance of aftercooler
• Insufficient cooling air amount
and standard • Clogging of aftercooler fin
value in normal
state Abnormal rise in turbo- The abnormal rise in turbocharger outlet temperature is suspected.
2
charger outlet temperature Directly check the related parts.
nosed.)
28 GD655-3E0, GD675-3E0
Failure code [CA553] Common rail pressure too high (1) 1

Action code Failure code Common rail pressure high (1)
Trouble
Contents of
• Excessively high pressure trouble (1) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine
Related
information

codes.
Possible causes Defective connection of the ground terminal is suspected. Check

and standard the following terminals directly:
value in normal • Ground terminal of the machine body (negative terminal of the
Defective connection of the
state 2 battery)
ground terminal
• Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
Damaged O-ring of supply Since a damage of O-ring of supply pump actuator is suspected,
3
pump actuator visually check the O-ring.
GD655-3E0, GD675-3E0 29
Failure code [CA559] Supply pump no pressure (1) 1

Action code Failure code Supply pump no pressure (1)
Trouble
Contents of
• Loss of pressure feed (1) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Engine output is reduced.
Related
information

Since the fuel leakage to the outside is suspected, check for a leak-
1 Fuel leakage to the outside
age. (Visually check at low idle of the engine)
low pressure circuit pressure inspection.
• Measurement on the inlet side of the fuel filter
• Cranking speed: Min. 150 rpm
When cranking
circuit pressure {1.4 kg/cm2}
• Measurement on the outlet side of the fuel filter
At high idle
circuit pressure {4.9 kg/cm2}
• Measurements on the inlet and outlet sides of the fuel filter
• Fuel low pressure circuit pressure drop
Defective low pressure cir- = fuel filter inlet pressure – fuel filter outlet pressure
2
cuit device Fuel low pressure Min. 0.14 MPa
Possible causes At high idle
and standard circuit pressure drop {1.4 kg/cm2}
value in normal a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel
state suction pressure inspection.
• Measurement on the gear pump fuel inlet side of the supply pump
Max. 33.9 kPa
{Max. 254 mmHg}
(Gear pump side)
• Measurement on the fuel connector side
Max. 27.1 kPa
{Max. 203 mmHg}
(Fuel connector side)
a As for testing return amount of injector, see testing and adjusting
“Testing fuel return and leak amount”.
When cranking
Defective injector
(When engine Max. 100 cc/30 sec.
3 (Including high-pressure
Injector return cannot start)
pipes within the head)
amount At low idle
(When engine can Max. 300 cc/45 sec.
be started)
30 GD655-3E0, GD675-3E0

a As for testing return amount of supply pump, see testing and
adjusting “Testing fuel return and leak amount”.
When cranking
(When engine Max. 200 cc/30 sec.
4 Defective supply pump
Amount of supply cannot start)
pump return At low idle
(When engine can Max. 300 cc/30 sec.
be started)
a As for testing an amount of pressure limiter leak, see testing and
Possible causes adjusting “Testing fuel return and leak amount”.
5 Defective pressure limiter
and standard Pressure limiter
At low idle Max. 30 drops/min.
value in normal leak amount
state
Defective plunger of a Remove supply pump head and visually inspect the plunger for
6
supply pump damage.
Since a residual air in a low-pressure circuit is suspected, so inspect
directly according to the following procedure.
1)Remove pressure inspection plug (outlet side) of fuel main filter.
2)Operate feed pump of fuel pre-filter.
3)Check the leakage of fuel and air from pressure inspection plug.
7 Air in the low pressure circuit
• If this error occurs during the air bleeding operation after the fuel
filter replacement, air is possibly remaining in the fuel circuit, so
continue to run the engine at low idle for approximately 3 min-
utes. When air bleeding is complete, engine revolutions become
stable and the error display disappears.
GD655-3E0, GD675-3E0 31
Failure code [CA689] Abnormality in engine Ne speed sensor 1

Action code Failure code Abnormality in engine Ne speed sensor
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of
• Continues the control by engine Bkup speed sensor signal.
controller
Problem that • Engine is hunting.
appears on • Engine is hard to start.
machine • Engine output is reduced.
Related
information

Defective Ne speed sensor If failure code [CA238] is displayed at the same time, carry out trou-
1
power source circuit bleshooting for it first.
switch ON.
C15 Voltage
Defective engine Ne speed Between (1) – (2) Power source 4.75 – 5.25 V
2
sensor
defective cause.
Damaged engine Ne speed Since a damage or improper mounting gap of engine Ne speed sen-
Possible causes 3
sensor or improper gap sor is suspected, inspect it visually.
and standard
value in normal Damaged speed detection Since a damage of speed detection wheel is suspected, visually
4
state wheel check it.
5
(Disconnection or defective Wiring harness between EC1 (female) (27) – Resis- Max.
contact of connectors) C15 (female) (3) tance 10 z
6
Hot short in wiring harness (a switch ON.
7
contact with 5 V or 24 V circuit) Between ground and wiring harness between
Voltage Max. 1 V
EC1 (female) (27) – C15 (female) (3)
32 GD655-3E0, GD675-3E0

switch still OFF.
Wiring harnesses between EC1 (female)
Resis- Min.
Harness short (27) – C15 (female) (3) and between EC1
8 tance 100 kz
(Harness internal short) (female) (16) – C15 (female) (1)
Resis- Min.
(27) – C15 (female) (3) and between EC1
tance 100 kz
Possible causes (female) (48) – C15 (female) (2)
and standard Since the connections among engine Ne speed sensor – engine
value in normal harness – engine controller are suspected to be defective, check a
state the defective connection.
connector
insulation
switch ON.
EC1 Voltage
Circuit diagram related to engine Ne speed sensor
GD655-3E0, GD675-3E0 33
Failure code [CA731] Abnormality in engine Bkup speed sensor phase1

Action code Failure code Abnormality in engine Bkup speed sensor phase
Trouble
Contents of • Abnormal phase is detected from the signals of engine Ne speed sensor and engine Bkup speed
trouble sensor.
Action of
• Continues the control using engine Ne speed sensor signal.
controller
Problem that • Engine can not start or engine is hard to start.
appears on • Idle speed is not stable.
machine • Exhaust gas color becomes black.
Related
information

Damaged engine Ne speed Since a damage of engine Ne speed sensor is suspected, visually
1
sensor check it.
Damaged engine Bkup Since a damage of engine Bkup speed sensor is suspected, visually
2
speed sensor check it.
Since a defective mounting or a damage of speed detection ring on
the crankshaft side is suspected, carry out the inspection according
Defective mounting or dam- to the following procedure.
3 age of speed detection ring 1) Set the No.1 cylinder to the compression top dead center (align
on the crankshaft side the marks).
2) If the center of the cut-out portion on the speed detection ring is
aligned with the tip of Ne speed sensor, the mounting is normal.
Possible causes Since a defective mounting or a damage of speed detection gear on
and standard the camshaft side is suspected, carry out the inspection according
value in normal to the following procedure.
Defective mounting or dam-
state 1) Set the No.1 cylinder to the compression top dead center (align
4 age of speed detection gear
the marks).
on the camshaft side
2) Remove the Bkup speed sensor.
3) If you can see a groove on a side face of speed detection gear
through the mounting hole of the sensor, the mounting is normal.
Defective timing adjustment Since a defective timing adjustment of crankshaft and camshaft is
5
of crankshaft and camshaft suspected, inspect directly.
Defective connection of the ground terminal is suspected. Check
the following terminals directly:
• Ground terminal of the machine body (negative terminal of the
Defective connection of the
6 battery)
ground terminal
• Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
34 GD655-3E0, GD675-3E0
Failure code [CA757] Loss of all engine controller data 1

Action code Failure code Loss of all engine controller data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
• Engine may stop and can not restart.
appears on
• Monitoring function of monitor panel (engine controller system) may not operate normally.
machine
Related
information

codes.
Loose or corroded battery
2 Battery terminal is possibly loose or corroded, so inspect it directly.
terminal
switch OFF and START.
3 Defective battery voltage Battery (1 unit) Starting switch Voltage
Between (+) – OFF Min. 12 V
(–) terminals START Min. 6.2 V
If fuse is blown, it is highly possible that a defective harness ground-
4 Defective fuse No. 9
ing, etc. has occurred in the circuit.
Possible causes a Prepare with starting switch OFF and diagnose with starting
and standard switch still OFF.
value in normal Disconnection in wiring harness
Wiring harness between ET102 – EC3 Resis-
state 5 (Disconnection or defective Max. 10 z
(female) (3), (4) tance
Max. 10 z
Since the problem is possibly at the connections between ET102 –
body harness – engine controller, check for a defective connection.
6
insulation
switch ON and START.
7 Defective engine controller EC3 (female) Starting switch Voltage
Between (3), (4) – ON Min. 24 V
(1), (2) START Min. 12 V
36 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 37
Failure code [CA778] Abnormality in engine Bkup speed sensor 1

Action code Failure code Abnormality in engine Bkup speed sensor
Trouble
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
Action of
• Continue the control using engine Ne speed sensor signal.
controller
Problem that
appears on
• Output decreases.
machine
Related
information

1
switch ON.
C13 Voltage
Defective engine Bkup Between (1) – (2) Power source 4.75 – 5.25 V
2
speed sensor
defective cause.
Damaged engine Bkup
Since a damage of engine Bkup speed sensor or improper gap is
3 speed sensor or improper
suspected, visually check it.
Possible causes gap
and standard Damaged speed detection Since a damage of speed detection gear is suspected, visually
value in normal 4
gear check it.
state
5
(Disconnection or defective Wiring harness between EC1 (female) (26) – Resis- Max.
contact of connectors) C13 (female) (3) tance 10 z
switch still OFF.
6
between EC1 (female) (26) – C13 (female)
tance 100 kz
(3)
Hot short in wiring harness (a switch ON.
7 contact with 5 V or 24 V cir- Between ground and wiring harness
cuit) between EC1 (female) (26) – C13 (female) Voltage Max. 1 V
(3)
38 GD655-3E0, GD675-3E0

switch still OFF.
Resis- Min.
Harness short (26) – C13 (female) (3) and among EC1
8 tance 100 kz
(Harness internal short) (female) (37) – S10 – C13 (female) (1)
Resis- Min.
(26) – C13 (female) (3) and among EC1
tance 100 kz
Possible causes (female) (47) – S11 – C13 (female) (2)
and standard Since the connections among engine Bkup speed sensor – engine
value in normal harness – engine controller are suspected to be defective, check a
state the defective connection.
connector
insulation
switch ON.
EC1 Voltage
Circuit diagram related to engine Bkup speed sensor
GD655-3E0, GD675-3E0 39
Failure code [CA1633] Abnormality in KOMNET 1

Action code Failure code Abnormality in KOMNET
Trouble
Contents of • Engine controller detected an abnormal communication in the KOMNET communication circuit
trouble between pump controller and monitor panel.
Action of • Operate in a default mode.
controller • When the cause of the failure has been eliminated, it returns to normal.
Problem that • Machine may not operate normally because the informations which are exchanged through KOM-
appears on NET communication are not trasmitted properly.
machine (A symptom of failure depends on the location where it occurrs.)
Related
information

switch still OFF.
Disconnection in wiring har- Wiring harnesses between FP2 (female) (1),
Resis-
ness (6) – EC2 (female) (46), TCR (female) (28), Max. 1 z
1 tance
(Disconnection or defective CAN (male) (3), and CAN1 (female) (A)
contact of connectors) Wiring harnesses between FP2 (female) (3)
Resis-
– EC2 (female) (47), TCR (female) (38), Max. 1 z
tance
CAN (male) (10), and CAN1 (female) (B)
switch still OFF.
Between ground and wiring harnesses
between FP2 (female) (1), (6) – EC2 Resis-
Min. 1 Mz
Defective harness grounding (female) (46), TCR (female) (28), CAN tance
2
(Contact with ground circuit) (male) (3), and CAN1 (female) (A)
Possible causes between FP2 (female) (3) – EC2 (female) Resis-
Min. 1 Mz
and standard (47), TCR (female) (38), CAN (male) (10), tance
value in normal and CAN1 (female) (B)
state a Prepare with starting switch OFF and diagnose with starting
switch ON.
between FP2 (female) (1), (6) – EC2 Max.
Voltage
Hot short of wiring harness (female) (46), TCR (female) (28), CAN 5.5 V
3
(a contact with 24 V circuit) (male) (3), and CAN1 (female) (A)
between FP2 (female) (3) – EC2 (female) Max.
Voltage
(47), TCR (female) (38), CAN (male) (10), 5.5 V
and CAN1 (female) (B)
Defective terminal resis- a Prepare with starting switch OFF and diagnose with starting
tance in CAN switch still OFF.
4
(Internal short circuit and dis- CAN1 (male) Resistance
connection) Between (A) – (B) 120 ± 12 z
5 Defective pump controller causes 1 – 4. (Since this is an internal defect, it cannot be diag-
nosed.)
40 GD655-3E0, GD675-3E0
Circuit diagram related CAN communication
GD655-3E0, GD675-3E0 41
Failure code [CA2185] Accelerator pedal sensor power source too high 1
Action code Failure code Accelerator pedal sensor power source too high
Trouble
Contents of • Excessively high voltage (Min. 5.25 V) is detected in the circuit of accelerator pedal sensor power
trouble source.
Problem that
appears on • Engine speed cannot be controlled by accelerator pedal.
machine
Related
information

switch still OFF.
Between EC2 (female) (22) – all pins of EC2
Resis- Min.
(female)
Harness short tance 100 kz
1 (with T9A disconnected)
(Harness internal short)
Wiring harness between EC2 (female) (9) –
T9A (female) (2) and wiring harness Resis- Min.
Possible causes between EC2 (female) (22) – T9A (female) tance 100 kz
and standard (1)
value in normal
Since the connections among accelerator pedal – body harness –
state
engine controller are suspected to be defective, visually check
them.
connector
insulation
nosed.)
42 GD655-3E0, GD675-3E0
Circuit diagram related to accelerator pedal
GD655-3E0, GD675-3E0 43
Failure code [CA2186] Accelerator pedal sensor power source too low 1
Action code Failure code Accelerator pedal sensor power source too low
Trouble
Contents of
• Excessively low voltage is detected at accelerator pedal sensor power source circuit.
trouble
Problem that
appears on • Engine speed cannot be controlled by accelerator pedal.
machine
Related
information

1
EC2 (female) (22) – T9A (female) (1) tance 100 kz
switch still OFF.
Harness short
2 Between EC2 (female) (9) – all pins of EC2
Possible causes (Harness internal short) Resis- Min.
(female)
(with T9A also disconnected)
value in normal
state Since the connections among decelerator pedal – body harness –
engine controller are suspected to be defective, visually check
them.
connector
insulation
nosed.)
44 GD655-3E0, GD675-3E0
Circuit diagram related to accelerator pedal
GD655-3E0, GD675-3E0 45
Failure code [CA2249] Supply pump no pressure (2) 1

Action code Failure code Supply pump no pressure (2)
Trouble
Contents of
• Loss of pressure feed (2) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.
Related
information
and standard
value in normal 1 Carry out troubleshooting of [CA559].
state
46 GD655-3E0, GD675-3E0
Failure code [CA2265] Disconnection in electric lift pump 1

Action code Failure code
Trouble Disconnection in electric lift pump
E01 CA2265
Contents of
• Disconnection is detected in the drive circuit of electric lift pump actuator.
trouble
Action of
• Takes no paticular action.
controller
Problem that
machine
Related
information

Defective electric lift pump switch still OFF.
1 (Internal disconnection and
short circuit)
2 Max. 10 z
(Disconnection or defective C18 (female) (1) tance
Max. 10 z
Hot short of wiring harness switch ON.
3
(a contact with 12 V circuit) Between ground and wiring harness between
Voltage Max. 6 V
Possible causes EC1 (female) (1) – C18 (female) (1)
and standard a Prepare with starting switch OFF and diagnose with starting
value in normal switch still OFF.
state Harness short
pins
tance 100 kz
The connections among lift pump valve – engine harness – engine
5
insulation
6
Between (1) – (11) Max. 20 z
48 GD655-3E0, GD675-3E0
Circuit diagram related to electric lift pump actuator
GD655-3E0, GD675-3E0 49
Failure code [CA2266] Short circuit in electric lift pump 1

Action code Failure code
Trouble Short circuit in electric lift pump
E01 CA2266
Contents of
• Short circuit is detected in the drive circuit of electric lift pump actuator.
trouble
Action of
controller
Problem that
machine
Related
information

switch still OFF.
Defective electric lift pump C18 (female) Resistance
1
(internal short circuit)
2
(Contact with ground circuit) Between ground and wiring harness Resis- Max.
between EC1 (female) (1) – C18 (female) (1) tance 100 kz
Hot short of wiring harness switch ON.
3
(a contact with 24 V circuit) Between ground and wiring harness
Voltage Max. 6 V
between EC1 (female) (1) – C18 (female) (1)
Harness short
value in normal 4 Between EC1 (female) (1) – EC1 (female) all
state pins
tance 100 kz
The connections among lift pump valve – engine harness – engine
5
insulation
switch still OFF.
6
engine controller
Between (1) – (11) Max. 20 z
50 GD655-3E0, GD675-3E0
Circuit diagram related to electric lift pump actuator
GD655-3E0, GD675-3E0 51
Failure code [CA2311] Abnormal resistance in IMV solenoid 1

Action code Failure code Abnormal resistance in IMV solenoid
Trouble
Contents of
• Resistance value of supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
appears on • Engine output decreases.
machine
Related
information

codes.
switch still OFF.
Defective supply pump actu- FUEL PUMP (male) Resistance
2
ator
3 Max. 5 z
(Disconnection or defective FUEL PUMP (female) (1) tance
Max. 5 z
FUEL PUMP (female) (2) tance
value in normal 4
state
EC1 (female) (2) – FUEL PUMP (female) (1) tance 100 kz
Since the connections among inlet metering valve – engine harness
– engine controller are suspected to be defective, visually check for
connector
insulation
switch still OFF.
6
engine controller
52 GD655-3E0, GD675-3E0
Circuit diagram related to inlet metering
GD655-3E0, GD675-3E0 53
Failure code [CA2555] Disconnection in air intake heater relay 1

Action code Failure code Disconnection in air intake heater relay
Trouble
Contents of
• Disconnection is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below -4°C.
information

switch still OFF (diagnose by itself).
Heater relay Resistance
Between ET82 – Relay bracket 300 – 600 z
Defective preheat relay
1 a Prepare with starting switch OFF and diagnose with starting
(internal disconnection)
switch ON (diagnose by replacing with other relay)
Replace heater relay with other relay and carry out the procedure to
duplicate the failure code. If failure code changes from flashing to
steady ON, the relay is defective.
ness Wiring harness between EC2 (female) (40) – Resis- Max.
2
(Disconnection or defective ET82 tance 10 z
contact of connectors) Wiring harness between ET54 – ET53 (Slow Resis- Max.
Possible causes blow fuse) tance 10 z
and standard
value in normal
switch still OFF.
state Harness short
(female)
tance 100 kz
(with heater relay also disconnected)
The connections among preheat relay – body harness – engine con-
troller are suspected to be defective. Visually check them.
4
insulation
5
Between (40) – Engine GND 300 – 600 z
54 GD655-3E0, GD675-3E0
Circuit diagram related to engine preheat
GD655-3E0, GD675-3E0 55
Failure code [CA2556] Short circuit in air intake heater relay 1

Action code Failure code Short circuit in air intake heater relay
Trouble
Contents of
• Short circuit is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below –4°C.
information

switch still OFF (diagnose by itself).
Heater relay Resistance
Between ET82 – Relay bracket 300 – 600 z
Defective preheat relay
1 a Prepare with starting switch OFF and diagnose with starting
(internal disconnection)
switch ON (diagnose by replacing with other relay)
Replace heater relay with other relay and carry out the procedure to
duplicate the failure code. If failure code changes from flashing to
steady ON, the relay is defective.
2
EC2 (female) (40) – ET82 tance 100 kz
value in normal Harness short
state (Harness internal short) Resis- Min.
(female)
tance 100 kz
(with heater relay also disconnected)
The connections among preheat relay – body harness – engine
controller are suspected to be defective. Visually check them.
4
insulation
5
Between (40) – Engine ground 300 – 600 z
56 GD655-3E0, GD675-3E0
Circuit diagram related to engine preheat
GD655-3E0, GD675-3E0 57
SEN01840-00

© 2006 KOMATSU
All Rights Reserved
58
SEN01965-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Failure code [D19CKZ] Disconnection or short circuit in differential control relay................................ 4
Failure code [D19KKZ] Differential lock-up relay : Disconnection........................................................ 6
Failure code [DAQ0KK] Power source voltage of transmission controller too low ............................. 10
Failure code [DAQSKR] Communication controller cannot recognize S-NET ....................................11
Failure code [DB2RKR] Communication lost engine controller.......................................................... 12
Failure code [DBF0KK] Power source voltage of communication controller too low.......................... 14
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low................................ 16
Failure code [DBFRKR] Communication lost communication controller ............................................ 18
Failure code [DD1PKB] Power supply line short in RPM set switch .................................................. 20
Failure code [DD1QKB] Short circuit in RPM set mode switch .......................................................... 22
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch.................................................... 24
Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch) 25
Failure code [DDTHKA] Disconnection in FH clutch fill switch........................................................... 26
Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch) ....... 27
Failure code [DDTJKA] Disconnection in FL clutch fill switch ............................................................ 28
GD655-3E0, GD675-3E0 1
Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch) ......... 29
Failure code [DDTKKA] Disconnection in 1st clutch fill switch ........................................................... 30
Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)........ 32
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch .......................................................... 34
Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch)....... 36
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch .......................................................... 38
Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch)....... 40
Failure code [DDTNKA] Disconnection in R clutch fill switch ............................................................. 42
Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch).......... 43
Failure code [DDTPKA] Disconnection in 4th clutch fill switch........................................................... 44
Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch) ....... 46
Failure code [DF10KA] Disconnection in transmission shift lever switch ........................................... 48
Failure code [DF10KB] Short circuit in transmission shift lever switch............................................... 52
Failure code [DGF1KX] Transmission oil temperature out of range................................................... 56
Failure code [DGT1KX] Torque converter oil temperature out of range ............................................. 58
Failure code [DJF1KA] Disconnection in fuel level sensor................................................................. 60
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range ...................... 62
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range ............................ 64
Failure code [DKD0KA] Disconnection in articulate sensor ............................................................... 66
Failure code [DLE2KA] Disconnection in engine speed sensor ......................................................... 68
Failure code [DLF1KA] Disconnection in transmission input speed sensor ....................................... 69
Failure code [DLT3KA] Disconnection in transmission output speed sensor ..................................... 70
Failure code [DV00KB] Short circuit in caution buzzer....................................................................... 71
Failure code [DW4BKA] Disconnection in parking brake relay .......................................................... 72
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid .................................................... 74
Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid...................................... 75
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid................................................. 76
Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid .................................. 78
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid ................................................. 80
Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid................................... 82
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid................................................. 84
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid ........................... 85
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid................................................ 86
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid .......................... 87
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid ................................................ 88
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid ................................................... 89
Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid .................................... 90
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid ................................................ 92
2 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 3

Failure code [D19CKZ] Disconnection or short circuit in differential
control relay 1
Action code Failure code Disconnection or short circuit in differential control relay
Trouble
E01 D19CKZ (Transmission controller system)
Contents of
• There is disconnection or short circuit in differential lock relay circuit.
trouble
Action of
• Differential control relay output OFF.
controller
Problem that
• If there is short circuit, differential operates constantly. If there is disconnection, differential is locked
appears on
constantly
machine
Related
—
information

Defective differential control 1) Replace BR7 with a known good one.
1 relay
If the condition become normal, parking brake relay has a defect.
1) Turn starting switch OFF.
2) Disconnect T1 and BR7.
2 Hot short in wiring harness
Resis-
Between T1(female)(11) and BR7(female)(1) Max. 1 z
tance
Possible causes 1) Turn starting switch ON.

and standard Defective contact or open 2) Disconnect BR7.
3
value in normal circuit in wiring harness. Between BR7(female)(1) and chassis Resis-
Max. 1 z
state ground tance
2) Disconnect T1 and BR7.
4 Hot short in wiring harness 3) Turn starting switch ON.
Between T1(female)(11) and chassis ground Voltage Max. 1 V
If no problem is found in causes 1 to 3, it is suspected that transmis-
Defective transmission
5 sion controller is defective. (Troubleshooting cannot be carried out
controller
since it is internal defect.)
4 GD655-3E0, GD675-3E0
Circuit diagram related to differential control relay
GD655-3E0, GD675-3E0 5
Failure code [D19KKZ] Differential lock-up relay : Disconnection 1

Differential lock-up specification
Action code Failure code Differential lock-up relay : Disconnection
Trouble
E01 D19KKZ (Transmission controller system)
Contents of
• Differential lock-up relay circuit has disconnection or short circuit.
trouble
• Stops out putting signals to differential lock-up relay.
Action of • If cause of failure disappears, system resets itself.
controller • When circuit has short circuit, even if cause of failure disappears, system does not reset itself until
starting switch is turned OFF.
Problem that
appears on • IDifferential cannot be locked up.
machine
• Output state (ON/OFF) to differential lock-up relay can be checked with monitoring function.
Related (Code : TRANSMISSION-31903-DIFF RELAY)
information • Method of reproducing failure code : Turn starting switch to ON position + Operate differential lock-up
switch (ON).

a Prepare with starting switch OFF, then troubleshooting without
Defective differential lock-up turning starting switch to ON position.
1
switch (ON). BR7 (male) Resistance
Between (1) and (2) 200 -400 z
a Prepare with starting switch OFF, then troubleshooting without
turning starting switch to ON position.
Disconnection in wiring har- Wiring harness between T1 (female) (11) Resis-
2 Max. 1 z
ness and BR7 (female) (1) tance
Possible causes
Wiring harness between BR7 (female) (2) Resis-
and standard Max. 1 z
and ground (T19) tance
value in normal
state a Prepare with starting switch OFF, then troubleshooting without
Ground fault of wiring har- turning starting switch to ON position.
3
ness Between wiring harness (between T1 Resis-
Min. 1M z
(female) (11) - BR7 (female) (1)) and ground tance
a Prepare with starting switch OFF, then turn starting switch to ON
position and troubleshooting.
Defective transmission con- Differential lock-up
4 T1 Voltage
troller swith
Between (11) and OFF Max. 1 z
ground ON 20 - 30 V
6 GD655-3E0, GD675-3E0
Circuit diagram related to differential control relay
GD655-3E0, GD675-3E0 7
Failure code [D5ZHL6] Terminal C signal does not match state of

engine 1
Action code Failure code Terminal C signal does not match state of engine
Trouble
E01 D5ZHL6 (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.)
Action of • None in particular.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring func-
Related
tion (Code: 40921, D-IN-0) (Machine monitor system).
information
• Method of reproducing failure code: Set the starting switch to START position

Defective fuse No.1 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
1
box A (See cause 2.)
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch Starting switch Starting switch Resistance
2
(Internal disconnection)
START Max. 1 z
Between B and C
OFF, ON Min. 1 Mz
Wiring harness between terminal C – SP13 Resis-
Max. 1 z
(female) (3) tance
Wiring harness between SP13 (female) (5) – Resis-
Max. 1 z
Disconnection in wiring har- B28 (female) (7) tance
Possible causes ness Wiring harness between B28 (female) (7) – Resis-
3 Max. 1 z
and standard (Disconnection or defective B28 (female) (8) tance
value in normal contact of connector) Wiring harness between B28 (male) (8) – Resis-
state Max. 1 z
SP1 (male) (11) tance
Max. 1 z
B4 (male) (1) tance
Wiring harness between B4 (female) (1) – Resis-
Max. 1 z
TCR (female) (37) tance
Grounding fault in wiring har- without turning starting switch ON.
4 ness Between ground and wiring harness
(Contact with ground circuit) between terminal C – TCR (female) (37) – Resis-
Min. 1 Mz
tance
circuit branch end point
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
5 Defective machine monitor FP1 (female) Starting switch Voltage
Between (7) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V
8 GD655-3E0, GD675-3E0
Circuit diagram related to engine starting system
GD655-3E0, GD675-3E0 9
Failure code [DAQ0KK] Power source voltage of transmission

controller too low 1
Action code Failure code Power source voltage of transmission controller too low
Trouble
E03 DAQ0KK (Transmission controller system)
Contents of
• Transmission controller source voltage is below 18 V.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer
controller • All solenoids output OFF (set to Neutral)
Problem that
appears on • Stays in N
machine
Related
—
information

1) Disconnect T1,T2 and connect T-branch adapter.
2) Turn starting switch ON.
Defective lock-up clutch If voltage is normal, it is suspected that transmission controller is
1 ECMV solenoid defective.
(Internal defect)
Between T1 (female) (7), (13) and (6), (12)
Voltage 20 – 30 V
Possible causes Between T2 (female) (1), (12) and (11), (21)
and standard 1) Turn starting switch ON.
Defective contact or open
value in normal 2
circuit in wiring harness. Between T11(female)(1) and chassis ground Voltage 20 – 30 V
state
Defective contact or open 2) Disconnect T1,T2.
3
circuit in wiring harness. Between T1 (female) (6), (12), T2 (female) Resis-
Max. 1 z
(11), (21) and chassis ground tance
Defective contact or open If no problem is found in causes 1 to 3, it is suspected that there is
4
circuit in wiring harness. defective contact or open circuit in wiring harness.
Circuit diagram related to transmission controller power supply
10 GD655-3E0, GD675-3E0
Failure code [DAQSKR] Communication controller cannot recognize

S-NET 1
Action code Failure code Communication controller cannot recognize S-NET
Trouble
E03 DAQSKR (Communication controller system)
Contents of
• Communication controller cannot recognize S-NET.
trouble
Action of
controller
Problem that
• Transmission controller does not give signal to KOMNET, and machine does not allow normal opera-
appears on
tion of system.
machine
Related
• Method of reproducing error code: Turn starting switch ON.
information

ness (Disconnection in wiring without turning starting switch ON.
1
or defective contact in con- Wiring harness between TCR (female) (18) – Resis-
nector) Max. 1 z
T3 (female) (24), – T3 (female) (32) tance
Short circuit with chassis without turning starting switch ON.
2 ground in wiring harness Between chassis ground and wiring harness
Possible causes (Contact with ground circuit) between TCR (female) (18) – T3 (female) Resis-
Min. 1 Mz
and standard tance
(24), – T3 (female) (32)
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short circuit in wiring har- and carry out troubleshooting.
3 ness Between chassis ground and wiring harness
(Contact with 24V circuit) between TCR (female) (18) – T3 (female) Voltage Max. 1 V
(24), – T3 (female) (32)
Defective communication and carry out troubleshooting.
4
controller TCR Voltage
Between (18) – chassis ground 6–9V
Circuit diagram related to S-NET communication
GD655-3E0, GD675-3E0 11
Failure code [DB2RKR] Communication lost engine controller 1

Action code Failure code Communication lost engine controller
Trouble
E03 DB2RKR (Machine monitor system)
Contents of
• Communication controller cannot recognize engine controller with CAN communication circuit.
trouble
Action of
• Flashes caution lamp and turns on caution buzzer.
controller
Problem that
appears on • System may not operate normally.
machine
Related
• Method of reproducing error code: Turn starting switch ON.
information

Disconnection in wiring har- Wiring harness between FP2 (female) (1),
Resis-
ness (Disconnection in wiring (6) – EC2 (female) (46) – TCR (female) (28) Max. 1 z
1 tance
or defective contact in con- – CAN1 (female) (A) – CAN (female) (3)
nector) Wiring harness between FP2 (female) (3) –
Resis-
EC2 (female) (47) – TCR (female) (38) – Max. 1 z
tance
CAN1 (female) (B) – CAN (female) (10)
Short circuit of wiring harness between FP2
(female) (1), (6) – EC2 (female) (46) – TCR Resis-
Short circuit with chassis Min. 1 Mz
(female) (28) – CAN1 (female) (A) – CAN tance
2 ground in wiring harness
(female) (3) and chassis ground
(Contact with ground circuit)
(female) (3) – EC2 (female) (47) – TCR Resis-
Possible causes Min. 1 Mz
(female) (38) – CAN1 (female) (B) – CAN tance
and standard (female) (10) and chassis ground
value in normal
(female) (1), (6) – EC2 (female) (46) – TCR
Hot short circuit in wiring har- Voltage Max. 1V
(female) (28) – CAN1 (female) (A) – CAN
3 ness
(Contact with 24V circuit)
(female) (3) – EC2 (female) (47) – TCR
Voltage Max. 1V
(female) (38) – CAN1 (female) (B) – CAN
Defective CAN terminal without turning starting switch ON.
4
resistance Between CAN (male) (3) and (10) Resistance
Between CAN1 (male) (A) and (B) 40 – 80 z
Defective engine controller,
If no problem is found in causes 1 to 4, it is suspected that engine
defective transmission con-
5 controller, transmission controller, or steering controller is defective.
troller, or defective steering
(Troubleshooting cannot be carried out since it is internal defect.)
controller
12 GD655-3E0, GD675-3E0
Circuit diagram related to CAN communication
GD655-3E0, GD675-3E0 13
Failure code [DBF0KK] Power source voltage of communication

controller too low 1
Action code Failure code Power source voltage of communication controller too low
Trouble
E03 DBF0KK (Communication controller system)
Contents of
• C-terminal signal is OFF and battery direct voltage is below 16 V.
trouble
• Flashes warning lamp and turns on alarm buzzer.
Action of • Fixes accelerator position output sent to value for transmission controller to 0%.
controller • Sets RPM set function in OFF mode.
• Fixes VHPC control to standard side.
Problem that • gear shift points in auto-shift mode are limited.
appears on • RPM set function cannot be used.
machine • VHPC is not set to high output side.
Related
—
information

2) Disconnect battery, T11 and B12.
3) Connect T-adapter.
1 Resis-
circuit in wiring harness. Between T11 (female) (3) and B12 (male) Max. 1 z
tance
Between T11 (female) (5), (6), (7) and chassis Resis-
Max. 1 z
ground tance
Possible causes
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect battery, T11 and B12.
Grounding fault in wiring 3) Connect T-adapter.
state 2
harness
Between wiring harness between T11 (female) Resis-
Min. 1 Mz
(3) – B12 (male) and chassis ground tance
2) Disconnect V1.
Defective communication 3) Connect T-adapter.
3 4) Turn starting switch ON.
controller
Between T11 (female) (3) and T11 (female)
Voltage 20 – 30 V
(5), (6), (8)
14 GD655-3E0, GD675-3E0
Circuit diagram related to power source of communication controller
GD655-3E0, GD675-3E0 15
Failure code [DBF2KK] Voltage of 24 V solenoid power supply

system too low 1
Action code Failure code Voltage of 24 V solenoid power supply system too low
Trouble
E01 DBF2KK (Communication controller system)
Contents of
• C-terminal signal is OFF, battery direct voltage is below 20 V, and solenoid source voltage is below 16 V
trouble
Action of
• None in particular.
controller
Problem that
appears on • System may not operate normally.
machine
Related
• Reduction of this voltage does not directly affect functions of controller.
information

1 Resis-
circuit in wiring harness. Between T11 (female) (2) and B11 (male) Max. 1 z
tance
Between T11 (female) (5), (6), (7) and chassis Resis-
Max. 1 z
ground tance
Possible causes
value in normal 2) Disconnect battery, T11 and B12.
Grounding fault in wiring 3) Connect T-adapter.
state 2
harness
Between wiring harness between T11 (female) Resis-
Min. 1 Mz
(2) – B11 (male) and chassis ground tance
2) Disconnect V1.
Defective communication 3) Connect T-adapter.
controller
Between T11 (female) (2) and T11 (female)
Voltage 20 – 30 V
(5), (6), (8)
16 GD655-3E0, GD675-3E0
Circuit diagram related to 24 V solenoid power supply system
GD655-3E0, GD675-3E0 17
Failure code [DBFRKR] Communication lost communication

controller 1
Action code Failure code Communication lost communication controller
Trouble
E03 DBFRKR (Machine monitor system)
Contents of
• Machine monitor cannot check communication controller in CAN communication circuit.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer.
controller • Fixes communication values sent through CAN to communication controller to value just before trouble
Problem that • gear shift points in auto-shift mode are limited.
appears on • Articulate gauge and accumulator pressure reduction alarm do not operate.
machine • VHPC is not set to high output side.
Related
—
information

Defective contact or open Between FP2 (female) (1) and TCR (female) Resis-
1 Max. 1 z
circuit in wiring harness. (28) tance
Between FP2 (female) (3) and TCR (female) Resis-
Max. 1 z
(38) tance
Between wiring harness between FP2
Grounding fault in wiring Resis-
2 (female) (1) – TCR (female) (28) and chassis Min. 1 Mz
harness tance
ground
Possible causes
and standard Between wiring harness between FP2
Resis-
value in normal (female) (3) – TCR (female) (38) and chassis Min. 1 Mz
tance
state ground
2) Disconnect FP2 and TCR.
(female) (1) – TCR (female) (28) and chassis Voltage Max. 1 V
ground
(female) (3) – TCR (female) (38) and chassis Voltage Max. 1 V
ground
If no problem is found in causes 1 to 3, it is suspected that commu-
Defective communication
4 nication controller or machine monitor is defective. (Troubleshooting
controller or machine monitor
cannot be carried out since it is internal defect.)
18 GD655-3E0, GD675-3E0
Circuit diagram related to CAN communication system
GD655-3E0, GD675-3E0 19
Failure code [DD1PKB] Power supply line short in RPM set switch 1
Action code Failure code Power supply line short in RPM set switch
Trouble
E03 DD1PKB (Communication controller system)
Contents of • "SET" and "RESUME" of set switch are turned ON simultaneously.
trouble • During setting operation, either or both of "SET" and "RESUME" of set switch are kept ON.
Action of • Flashes warning lamp and turns on alarm buzzer
Problem that
appears on • If RPM set is being used, "SET" is cancelled and it cannot be used any more.
machine
Related
• Check in advance that set switch operates normally.
information

2) Disconnect TCR.
Short circuit in wiring harness a When measuring, operate switch and check that value does not
1
(With another wiring harness) change.
Resis-
Between TCR (female) (15) and (25) Min. 1 Mz
Possible causes tance
value in normal 2) Disconnect SH2 and TCR.
state 3) Connect T-adapter.
Hot short in wiring harness 4) Turn starting switch ON.
2
(Contact with 24 V circuit)
Between wiring harness between TCR
(female) (15) – SH2 (female) (3), TCR (female) Voltage Max. 1 V
(25) – SH2 (female) (1) and chassis ground
If no problem is found in causes 1, 2, it is suspected that communi-
3 cation controller is defective. (Troubleshooting cannot be carried out
controller
20 GD655-3E0, GD675-3E0
Circuit diagram related to RPM set switch
GD655-3E0, GD675-3E0 21
Failure code [DD1QKB] Short circuit in RPM set mode switch 1

Action code Failure code Short circuit in RPM set mode switch
Trouble
E03 DD1QKB (Communication controller system)
Contents of
• "SET" and "RESUME" of set switch are turned ON simultaneously.
trouble
Problem that
appears on • If RPM set is cancelled and it cannot be used any more.
machine
Related
• Check in advance that set switch operates normally.
information

2) Disconnect TCR.
Short circuit in wiring harness a When measuring, operate switch and check that value does not
1
(With another wiring harness) change.
Resis-
Between TCR (female) (5) and (34) Min. 1 Mz
tance
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect SH1 and TCR.
value in normal 3) Connect T-adapter.
state 4) Turn starting switch ON.
Hot short in wiring harness
2 Between wiring harness between TCR
(Contact with 24 V circuit)
(female) (5) – SH1 (female) (3), (4),
TCR (female) (34) – SH1 (female) (1), (6), Voltage Max. 1 V
TCR (female) (5) – TCR (female) (34) and
chassis ground
If no problem is found in causes 1, 2, it is suspected that communi-
3 cation controller is defective. (Troubleshooting cannot be carried out
controller
22 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 23
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch 1

Action code Failure code Disconnection in lock-up clutch fill switch
Trouble
E03 DDTGKA (Transmission controller system)
Contents of
• While controller sends solenoid output to lock-up clutch ECMV, there is not fill switch signal.
trouble
controller • Selects sudden rise mode.
Problem that
• Gear shift shock is made.
appears on
• Gear shift time lag is made.
machine
Related
• System does not reset itself until starting switch is turned OFF.
information

Defective contact or open 2) Disconnect T3, T43.
1
circuit in wiring harness. Between T3 (female) (36) and T43 (female) Resis-
Max. 1 z
(1) tance
Possible causes
value in normal 2) Disconnect T43.
Defective 2nd clutch fill switch 3) Start engine.
state 2
(Internal defect) 4) Set TM mode switch in "Manual"
While T43 (female) (1) is grounded, [DDTGKA] is displayed.
If no problem is found in causes 1, 2, it is suspected that transmis-
controller
24 GD655-3E0, GD675-3E0
Failure code [DDTGKB] Fill signal is ON when command current is

OFF (lock-up clutch fill switch) 1
Action code Failure code Fill signal is ON when command current is OFF
Trouble (lock-up clutch fill switch)
E03 DDTGKB (Transmission controller system)
Contents of
• While there is another clutch pressure switch signal, there are double signals.
trouble
controller • Sets to Neutral.
Problem that
appears on • Machine stops.
machine
Related
• System resets itself immediately after signal becomes normal.
information

Defective lock-up clutch fill 2) Disconnect T43.
1 switch
(Internal defect) Resis-
Between T43 (male) (1) and chassis ground. Min. 1 Mz
value in normal Grounding fault in wiring 2) Disconnect T3, T43.
state 2
harness Between T3 (female) (36) and chassis Resis-
Min. 1 Mz
ground. tance
controller
Circuit diagram related to clutch fill switches
GD655-3E0, GD675-3E0 25
Failure code [DDTHKA] Disconnection in FH clutch fill switch 1

Action code Failure code Disconnection in FH clutch fill switch
Trouble
E03 DDTHKA (Transmission controller system)
Contents of
• While controller sends solenoid output to FH clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective FH clutch fill switch 3) Start engine.
state 2
(Internal defect) 4) Shift gears in "F2", "F4", "F6", "F8".
While T37 (female) (1) is grounded, [DDTHKA] is displayed.
controller
26 GD655-3E0, GD675-3E0
Failure code [DDTHKB] Fill signal is ON when command current is

OFF (FH clutch fill switch) 1
Trouble (FH clutch fill switch)
E03 DDTHKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective FH clutch fill switch 2) Disconnect T37.
1
Between T37 (male) (1) and chassis ground Min. 1 Mz
state 2
Min. 1 Mz
ground tance
controller
GD655-3E0, GD675-3E0 27
Failure code [DDTJKA] Disconnection in FL clutch fill switch 1

Action code Failure code Disconnection in FL clutch fill switch
Trouble
E03 DDTJKA (Transmission controller system)
Contents of
• While controller sends solenoid output to FL clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective FL clutch fill switch 3) Start engine.
state 2
(Internal defect) 4) Shift gears in "F1", "F3", "F5", "F7".
While T36 (female) (1) is grounded, [DDTJKA] is displayed.
controller
28 GD655-3E0, GD675-3E0
Failure code [DDTJKB] Fill signal is ON when command current is

OFF (FL clutch fill switch) 1
Trouble (FL clutch fill switch)
E03 DDTJKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective FL clutch fill switch 2) Disconnect T36.
1
Between T36 (male) (1) and chassis ground. Min. 1 Mz
state 2
Min. 1 Mz
ground. tance
controller
GD655-3E0, GD675-3E0 29
Failure code [DDTKKA] Disconnection in 1st clutch fill switch 1

Action code Failure code Disconnection in 1st clutch fill switch
Trouble
E03 DDTKKA (Transmission controller system)
Contents of
• While controller sends solenoid output to 1st clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective 1st clutch fill switch 3) Start engine.
state 2
(Internal defect) 4) Shift gears in "F1", "F2", "R1".
While T39 (female) (1) is grounded, [DDTKKA] is displayed.
controller
30 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 31
Failure code [DDTKKB] Fill signal is ON when command current is

OFF (1st clutch fill switch) 1
Trouble (1st clutch fill switch)
E03 DDTKKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective 1st clutch fill switch 2) Disconnect T39.
1
state 2
Min. 1 Mz
ground tance
controller
32 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 33
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch 1

Action code Failure code Disconnection in 2nd clutch fill switch
Trouble
E03 DDTLKA (Transmission controller system)
Contents of
• While controller sends solenoid output to 2nd clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective 2nd clutch fill switch 3) Start engine.
state 2
While T40 (female) (1) is grounded, [DDTLKA] is displayed.
controller
34 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 35
Failure code [DDTLKB] Fill signal is ON when command current is

OFF (2nd clutch fill switch) 1
Trouble (2nd clutch fill switch)
E03 DDTLKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective 2nd clutch fill switch 2) Disconnect T40.
1
state 2
Min. 1 Mz
ground tance
controller
36 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 37
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch 1

Action code Failure code Disconnection in 3rd clutch fill switch
Trouble
E03 DDTMKA (Transmission controller system)
Contents of
• While controller sends solenoid output to 3rd clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective 3rd clutch fill switch 3) Start engine.
state 2
While T41 (female) (1) is grounded, [DDTMKA] is displayed.
controller
38 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 39
Failure code [DDTMKB] Fill signal is ON when command current is

OFF (3rd clutch fill switch) 1
Trouble (3rd clutch fill switch)
E03 DDTMKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective 3rd clutch fill switch 2) Disconnect T41.
1
state 2
Min. 1 Mz
ground tance
controller
40 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 41
Failure code [DDTNKA] Disconnection in R clutch fill switch 1

Action code Failure code Disconnection in R clutch fill switch
Trouble
E03 DDTNKA (Transmission controller system)
Contents of
• While controller sends solenoid output to R clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective R clutch fill switch 3) Start engine.
state 2
(Internal defect) 4) Shift gears in "F2" – "F4".
While T38 (female) (1) is grounded, [DDTNKA] is displayed.
controller
42 GD655-3E0, GD675-3E0
Failure code [DDTNKB] Fill signal is ON when command current is

OFF (R clutch fill switch) 1
Trouble (R clutch fill switch)
E03 DDTNKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective R clutch fill switch 2) Disconnect T38.
1
state 2
Min. 1 Mz
ground tance
controller
GD655-3E0, GD675-3E0 43
Failure code [DDTPKA] Disconnection in 4th clutch fill switch 1

Action code Failure code Disconnection in 4th clutch fill switch
Trouble
E03 DDTPKA (Transmission controller system)
Contents of
• While controller sends solenoid output to 4th clutch ECMV, there is not fill switch signal.
trouble
Problem that
appears on
machine
Related
information

1
Max. 1 z
(1) tance
Possible causes
Defective 4th clutch fill switch 3) Start engine.
state 2
While T42 (female) (1) is grounded, [DDTPKA] is displayed.
controller
44 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 45
Failure code [DDTPKB] Fill signal is ON when command current is

OFF (4th clutch fill switch) 1
Trouble (4th clutch fill switch)
E03 DDTPKB (Transmission controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective 4th clutch fill switch 2) Disconnect T42.
1
state 2
Min. 1 Mz
ground tance
controller
46 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 47
Failure code [DF10KA] Disconnection in transmission shift lever

switch 1
Action code Failure code Disconnection in transmission shift lever switch
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• All shift lever switch signals are not input.
trouble
controller • No F, R, N signals o N
Problem that
appears on • Cannot travel.
machine
Related
—
information

2) Disconnect T5 and T13.
Disconnection in wiring Wiring harness between T5 (female) (6) – T13 Resis-
1 Max. 1 z
harness (female) (7), T5 (female) (14) – T13 (female) (13) tance
Wiring harness between T5 (female) (14) – Resis-
Max. 1 z
T13 (female) (13) tance
2) Shift gears in "R1" – "R4".
2 Defective shift lever
Wiring harness between T13 (female) (7) –
Voltage 20 – 30 V
(19), (20), (23)
2) Shift gears in "R1" – "R4".
Voltage 20 – 30 V
(19), (20), (23)
Disconnection in wiring 2) Disconnect T3 and T13.
4
harness Wiring harness between T3 (female) – T13 Resis-
Possible causes Max. 1 z
(female) (2) tance
and standard
value in normal 1) Turn starting switch OFF.
state 2) In shift range "N".
Voltage 20 – 30 V
(19), (20), (23)
Disconnection in wiring 2) Disconnect T3 and T13.
6
harness Wiring harness between T3 (female) (8) – Resis-
Max. 1 z
2) Shift gears in "F1" – "F8", "R1" – "R4".
Voltage 20 – 30 V
(19), (20), (23)
Disconnection in wiring 2) Disconnect T5, T13.
8
Max. 1 z
2) Shift gears in "F1", "F5" – "F7".
Wiring harness between T13 (female)(5) –
Voltage 20 – 30 V
(19), (20), (23)
48 GD655-3E0, GD675-3E0

10
Max. 1 z
2) Disconnect T5, T13.
Voltage 20 – 30 V
(19), (20), (23)
Disconnection in wiring 2) Shift gears in "F1" – "F8", "R1" – "R4".
12
Max. 1 z
Possible causes T13 (female) (18) tance
value in normal 2) Shift gears in "F1" – "F3".
state 13 Defective shift lever
Voltage 20 – 30 V
(19), (20), (23)
14
Max. 1 z
(19), (20), (23) tance
2) Shift gears in "F1" – "F3".
Voltage 20 – 30 V
(19), (20), (23)
If no problem is found in causes 1 to 15, it is suspected that transmission
16 controller is defective. (Troubleshooting cannot be carried out since it is
controller
internal defect.)
GD655-3E0, GD675-3E0 49
Circuit diagram related to transmission shift lever switch
50 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 51
Failure code [DF10KB] Short circuit in transmission shift lever

switch 1
Action code Failure code Short circuit in transmission shift lever switch
Trouble
E03 DF10KB (Transmission controller system)
Contents of
• Multiple gear shift lever signals are input simultaneously.
trouble
Action of • Does not update lever signal but keeps gear speed just before trouble.
controller • Sets gear speed to N, F1 or R2, depending on direction of lever, and continues control after N signal
is input.
Problem that
appears on • Travel is limited.
machine
Related
—
information

Between T5 (female) (6), (14) and chassis
Voltage Max. 1 V
ground
Between T3 (female) (8) and chassis ground Voltage Max. 1 V
Between T3 (female) (18) and chassis
Voltage Max. 1 V
ground
Possible causes 4 Hot short in wiring harness 3) Turn starting switch ON.
and standard
value in normal
state 1) Turn starting switch OFF.
Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
2) Shift gears in "N", "P", "R1" – "R4".
Voltage Max. 1 V
(19), (20), (23)
52 GD655-3E0, GD675-3E0

2) Shift gears in "F1" – "F8", "N", "P".
Voltage Max. 1 V
(19), (20), (23)
2) Shift gears in "F1" – "F8", "R1" – "R4".
Voltage Max. 1 V
(19), (20), (23)
2) Shift gears in "N", "P".
Voltage Max. 1 V
(19), (20), (23)
Defective contact or open 2) Shift gears in "N", "P", "F2" – "F4", "F8" – "R4".
12
circuit in wiring harness Wiring harness between T13 (female) (5) –
Voltage Max. 1 V
Possible causes (19), (20), (23)
value in normal 2) Shift gears in "N", "P", "F6" – "F8", "R2" – "R4".
state 13 Defective shift lever
Voltage Max. 1 V
(19), (20), (23)
2) Shift gears in "N", "P", "F4" – "F8", "R1" – "R4".
Voltage Max. 1 V
(19), (20), (23)
2) Shift gears in "F1" – "F3".
Voltage Max. 1 V
(19), (20), (23)
2) Shift gears in "N", "P", "F1", "F2", "F7", "F8", "R3", "R4".
Voltage Max. 1 V
(19), (20), (23)
If no problem is found in causes 1 to 16, it is suspected that trans-
17 mission controller is defective. (Troubleshooting cannot be carried
controller
out since it is internal defect.)
GD655-3E0, GD675-3E0 53
Circuit diagram related to transmission shift lever switch
54 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 55
Failure code [DGF1KX] Transmission oil temperature out of range 1

Action code Failure code Transmission oil temperature out of range
Trouble
E03 DGF1KX (Transmission controller system)
Contents of
• Input voltage of transmission oil temperature sensor is below 0.5 V.
trouble
controller • Outputs with oil temperature map for less than 20°C.
Problem that
appears on • Normal operation.
machine
Related
—
information

2) Disconnect T35.
Resis-
tance
3.5 –
(normal
Defective transmission oil 4.0 kz
temp.
1 temperature sensor Between T35 (male) (1) and (2) 25°C)
(Internal defect)
Resis-
38.5 –
tance
47.0 kz
(100°C)
Between T35 (female) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes Grounding fault in wiring 2) Disconnect T3, T35.
and standard 2
harness Resis-
value in normal Between T3 (female) (1) and chassis ground Min. 1 Mz
tance
state
3 Hot short in wiring harness 2) Disconnect T3, T35.
4
circuit in wiring harness Between T3 (female) (1) and T35 (female) Resis-
Max. 1 z
(1) tance
Defective contact or open 2) Disconnect T35.
5
circuit in wiring harness Resis-
Between T3 (female) (1) and chassis ground Max. 1 z
tance
controller
56 GD655-3E0, GD675-3E0
Circuit diagram related to transmission oil temperature sensor
GD655-3E0, GD675-3E0 57
Failure code [DGT1KX] Torque converter oil temperature out of

range 1
Action code Failure code Torque converter oil temperature out of range
Trouble
E01 DGT1KX (Transmission controller system)
Contents of
• Input voltage of torque converter oil temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (voltage) from torque converter oil temperature sensor can be checked with the mon-
information itoring function (Code: 30100 TC OIL TEMP).

2) Disconnect T34.
Resis-
tance
3.5 –
(normal
Defective torque converter 4.0 kz
temp.
1 oil temperature sensor Between T34 (male) (1) and (2) 25°C)
(Internal defect)
Resis-
38.5 –
tance
47.0 kz
(100°C)
Between T34 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect T3, T34.
Possible causes 2
and standard harness Resis-
Between T3 (female) (11) and chassis ground Min. 1 Mz
value in normal tance
state 1) Turn starting switch ON.
Voltage Max. 1 V
ground
4
Between T3 (female) (11) – T34 (female) (1) Max. 1 z
tance
Defective contact or open 2) Disconnect T34.
5
circuit in wiring harness Between T34 (female) (2) and chassis Resis-
Max. 1 z
ground tance
controller
58 GD655-3E0, GD675-3E0
Circuit diagram related to torque converter oil temperature sensor
GD655-3E0, GD675-3E0 59
Failure code [DJF1KA] Disconnection in fuel level sensor 1

Action code Failure code Disconnection in fuel level sensor
Trouble
E01 DJF1KA (Machine monitor system)
Contents of
• The signal circuit of fuel level sensor is disconnected and signal is not input.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The fuel level gauge does not indicate normally.
machine
• Signal from the fuel level sensor (resistance, voltage) can be checked with monitoring function
Related
(Code: 04201-FUEL SENSOR, 04200-FUEL SENSOR)
information
• Method of reproducing failure code: Start engine

ET39 (male) Fuel level Resistance
Defective fuel level sensor FULL Max. 13 z

1
(Internal disconnection) 3/4 (18 z)
Between (1) – chassis
1/2 25.5 – 28.8 z
ground
1/4 (46.6 z)
EMPTY Min. 69.9 z
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between FP2 (female) (10) and Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective ET39 (female) (1) tance
and standard contact) Wiring harness between fuel sensor ground Resis-
value in normal Max. 1 z
state terminal – chassis ground tance
Hot short in wiring harness and carry out troubleshooting.
3
(Contact with 24V circuit) Between chassis ground and wiring harness
Voltage Max. 1 V
between FP2 (female) (10) – ET39 (female) (1)
FP2 (male) Fuel level Resistance
FULL Max. 13 z
4 Defective machine monitor
3/4 (18 z)
Between (10) –
1/2 25.5 – 28.8 z
chassis ground
1/4 (46.6 z)
EMPTY Min. 69.9 z
60 GD655-3E0, GD675-3E0
Circuit diagram related to fuel level sensor
GD655-3E0, GD675-3E0 61
Failure code [DK10KX] Input of accelerator pedal potentiometer out

of normal range 1
Action code Failure code Input of accelerator pedal potentiometer out of normal range
Trouble
E01 DK10KX (Transmission controller system)
Contents of
• Input voltage of accelerator pedal position sensor is above 4.5 V or below 0.4 V.
trouble
controller • Uses low throttle position map instead of standard set.
Problem that
appears on • No action.
machine
• The input state (voltage) from accelerator pedal potentiometer can be checked with the monitoring
Related
function (Code: 31707 THROTTLE POS).
information
• The controller interpret the specified potentiometer voltage as the throttle angle.

Defective accelerator pedal 1) Turn starting switch OFF.
1 potentiometer 2) Disconnect T3, TCR.
(Internal defect) Between T3 (female) (3) – TCR (8) Voltage 20 – 30 V
Possible causes 0.5 –

Voltage
and standard 4.75 V
value in normal Defective communication Voltage
2 1.0 – 2.0 V
state controller Between T3 (male) (3) – T2 (male) (21) (at low idle)
Voltage
(at low idle 2.1 – 4.3 V
to high idle)
controller
Circuit diagram related to accelerator pedal potentiometer
62 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 63
Failure code [DK70KX] Input of inching pedal potentiometer out of

normal range 1
Action code Failure code Input of inching pedal potentiometer out of normal range
Trouble
E03 DK70KX (Transmission controller system)
Contents of
• Signal voltage of inching angle sensor of inching pedal is out of normal range.
trouble
controller • No inching output.
Problem that
appears on • Inching is not available.
machine
• The controller interpret the specified potentiometer voltage as the pedal angle.
Related
• When adjusting the potentiometer, leave the margin for error judgement field. At low idle, adjust the
information
potentiometer so that voltage is from 1.3 to 1.6 V.

1
circuit in wiring harness Between T3 (female) (7), T8 (female) (A) and Resis-
Min. 1 Mz
chassis ground tance
3) Ground T8 (female) (B) to the chassis.
Grounding fault in wiring
2 Resis-
harness Between T3 (female) (7) and chassis ground Max. 1 z
tance
Resis-
Between T3 (female) (13) and chassis ground Max. 1 z
tance
Possible causes 0.5 –
and standard Voltage
4.75 V
value in normal
state Voltage
(Inching pedal not 0.8 – 1.6 V
Defective inching pedal Wiring harness between T3 depressed)
3 potentiometer (female) (13) – (16) Voltage
(Internal defect) (When inching pedal
not depressed to inch- 2.1 – 4.3 V
ing pedal fully
depressed)
Wiring harness between T3 4.75 –
Voltage
(female) (7) – (16) 5.25 V
Defective contact or open 3) Ground T8 (female) (C) to the chassis.
4
circuit in wiring harness
Resis-
Between T3 (16) and chassis ground Max. 1 z
tance
64 GD655-3E0, GD675-3E0

If voltage is normal, it is suspected that transmission controller is
defective.
0.5 –
Voltage
4.75 V
Voltage
Defective transmission (Inching pedal not 0.8 – 1.6 V
5 controller Wiring harness between T3 depressed)
Possible causes (Internal defect) (male) (13) – (16) Voltage
and standard (When inching pedal
value in normal not depressed to inch- 2.1 – 4.0 V
state ing pedal fully
depressed)
Wiring harness between T3 4.75 –
Voltage
(male) (7) – (16) 5.25 V
1) Disconnect T8.
Between T3 (male) (13) and (16) Voltage Max. 0.5 V
Defective inching pedal If no problem is found in causes 1 to 6, it is suspected that inching
7 potentiometer pedal potentiometer is defective. (Troubleshooting cannot be car-
(Internal defect) ried out since it is internal defect.)
Circuit diagram related to inching pedal potentiometer
GD655-3E0, GD675-3E0 65
Failure code [DKD0KA] Disconnection in articulate sensor 1

Action code Failure code Disconnection in articulate sensor
Trouble
E01 DKD0KA (Communication controller system)
Contents of
• The signal circuit of articulate sensor is disconnected and signal is not input.
trouble
Action of
• If cause of failure disappears and gear shift lever position is N, system resets itself.
controller
Problem that
appears on • The articulate gauge does not indicate normally.
machine
• Signal from the articulate sensor (resistance, voltage) can be checked with monitoring function
Related
(Code: 43905-ARTICULATE, 43904-ARTICULATE).
information
• Method of reproducing failure code: Start engine and operate the articulated section.

Defective articulate sensor FL6 (male) Articulate angle Resistance

1
(Internal disconnection) Center 96.5 – 106.5 z
Between (1) – (2) Left end (23°) 163.8 – 180 z
Right end (23°) 17.7 – 37.7 z
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between TCR (female) (24) Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective and FL6 (female) (2) tance
and standard contact) Wiring harness between TCR (female) (32) Resis-
value in normal Max. 1 z
state and FL6 (female) (1) tance
3
(Contact with 24 V) Between chassis ground and wiring harness
Voltage Max. 1 V
between TCR (female) (24) – FL6 (female) (2)
Defective communication TCR (male) Articulate angle Resistance

4
controller Center 96.5 – 106.5 z
Right end (23°) 17.7 – 37.7 z
66 GD655-3E0, GD675-3E0
Circuit diagram related to articulate sensor
GD655-3E0, GD675-3E0 67
Failure code [DLE2KA] Disconnection in engine speed sensor 1

Action code Failure code Disconnection in engine speed sensor
Trouble
E03 DLE2KA (Transmission controller system)
Contents of
• There is disconnection in engine speed sensor circuit and engine speed signal is not input.
trouble
controller • Engine speed not displayed on panel.
Problem that
appears on • No action.
machine
Related
information

2) Disconnect T46.
Defective engine speed
Resis- 500 –
Possible causes 1 sensor Between T46 (male) (1) and (2)
tance 1000 z
and standard (Internal defect)
value in normal Between T46 (male) (1), (2) and chassis Resis-
Min. 1 Mz
state ground tance
2
harness Between T4 (female) (7) – T46 (female) (1) Resis-
Max. 1 z
Between T5 (female) (10) – T46 (female) (2) tance
Circuit diagram related to engine reverse sensor
68 GD655-3E0, GD675-3E0
Failure code [DLF1KA] Disconnection in transmission input speed

sensor 1
Action code Failure code Disconnection in transmission input speed sensor
Trouble
E03 DLF1KA (Transmission controller system)
Contents of • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not
trouble input.
Action of
controller
Problem that
machine
Related
information

2) Disconnect T32.
Defective transmission input
Resis- 500 –
1 speed sensor Between T32 (male) (1) and (2)
tance 1000 z
(Internal defect)
Min. 1 Mz
ground tance
and standard Defective contact or open 2) Disconnect T5, T32.
value in normal 2
state Between T5 (female) (2) and T32 (female) (1) Max. 1 z
tance
3
Between T5 (female) (1) and T32 (female) (2) Max. 1 z
tance
controller
internal defect.)
Circuit diagram related to transmission input speed sensor
GD655-3E0, GD675-3E0 69
Failure code [DLT3KA] Disconnection in transmission output speed

sensor 1
Action code Failure code Disconnection in transmission output speed sensor
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
trouble input.
Action of
• When starting switch is ON and gear shift lever kept at N, possible up to 2nd; when traveling, taken
controller
as N until starting switch turned OFF
Problem that
appears on • Travel is impossible after stopping the machine.
machine
• The input state (voltage) from transmission output speed sensor can be checked with the monitoring
Related
function (Code: 31400 T/M SPEED: OUT).
information

2) Disconnect T33.
Defective transmission output
Resis- 500 –
1 speed sensor Between T33 (male) (1) and (2)
tance 1000 z
(Internal defect)
Min. 1 Mz
ground tance
and standard Defective contact or open 2) Disconnect T4, T33.
value in normal 2
state Between T4 (female) (1) and T33 (female) (1) Max. 1 z
tance
3
tance
controller
internal defect.)
Circuit diagram related to transmission output speed sensor
70 GD655-3E0, GD675-3E0
Failure code [DV00KB] Short circuit in caution buzzer 1

Action code Failure code Short circuit in caution buzzer
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of
• Stops caution buzzer circuit from outputting ground signal.
controller
Problem that
appears on • Caution buzzer does not sound.
machine
Related • Method of reproducing failure code: Turn starting switch ON (When it is turned ON, buzzer sounds
information for 2 second).

Defective caution buzzer a Internal defect of caution buzzer is suspected.
1
(Internal short circuit) (It cannot be diagnosed.)
Short circuit with power and carry out troubleshooting.
Possible causes 2 source in wiring harness
(Contact with 24 V circuit) Wiring harness between FP1 (female) (18) –
and standard Voltage Max. 1 V
SP26 (female)
value in normal
FP1 (male) Caution buzzer Voltage
When turned OFF 20 – 30 V
Between (18) –
chassis ground When turned ON
Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
GD655-3E0, GD675-3E0 71
Failure code [DW4BKA] Disconnection in parking brake relay 1

Action code Failure code Disconnection in parking brake relay
Trouble
E03 DW4BKA (Transmission controller system)
Contents of
• Short circuit with power source or open circuit in the parking signal circuit.
trouble
Action of
—
controller
Problem that
appears on —
machine
Related
—
information

1) Replace BR11 with a known good one.
1 Defective parking brake relay
If the condition becomes normal, parking brake relay has a defect.
Grounding fault in wiring 2) Disconnect T2 and BR11.
harness
Possible causes Short circuit in wiring 2) Disconnect T2 and BR11.
and standard 3 harness
value in normal Resis-
(with another wiring harness) Between T2 (female) (6) and BR11 (female) (2) Max. 1 z
state tance
2) Disconnect BR11.
4 Defective Fuse I-10 3) Turn starting switch ON.
Between BR11 (female) (1) and chassis
Voltage 20 – 30 V
ground
controller
internal defect.)
72 GD655-3E0, GD675-3E0
Circuit diagram related to parking brake relay
GD655-3E0, GD675-3E0 73
Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid 1

Action code Failure code Disconnection in lock-up ECMV solenoid
Trouble
E03 DXH1KA (Transmission controller system)
Contents of
• When output to lock-up ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
• Torque converter always drived
appears on
(Lock-up is not applied).
machine
Related
—
information

2) Disconnect T31.
Defective lock-up clutch
Resis-
1 ECMV solenoid Between T31 (male) (1) and (2) 5 – 15 z
tance
(Internal defect)
Min. 1 Mz
ground tance
2
Possible causes circuit in wiring harness. Resis-
and standard tance
state 2) Disconnect T2,T31.
3
harness Resis-
Between T2 (female) (20) and chassis ground. Min. 1 Mz
tance
4
tance
controller
internal defect.)
Circuit diagram related to lock-up ECMV solenoid
74 GD655-3E0, GD675-3E0
Failure code [DXH1KY] Power supply line short in lock-up ECMV

solenoid 1
Action code Failure code Power supply line short in lock-up ECMV solenoid
Trouble
E03 DXH1KY (Transmission controller system)
Contents of
• When output to lock-up ECMV is OFF, current flows to circuit.
trouble
Action of • Turns lock-up solenoid output OFF.
controller • Flashes warning lamp and turns on alarm buzzer.
Problem that
appears on • Lock-up is always applied.
machine
Related
information

2) Disconnect T31.
Defective lock-up ECMV
Resis-
1 solenoid Between T31 (male) (1) and (2) 5 – 15 z
tance
(Internal defect)
Min. 1 Mz
ground tance
2
Possible causes harness Between T2 (female) (10) and chassis Resis-
Min. 1 Mz
and standard ground tance
state Short circuit in wiring 2) Disconnect T2.
3 harness
Resis-
(With another wiring harness) Between T2 (female) (10) and (20) 5 – 15 z
tance
controller
internal defect.)
GD655-3E0, GD675-3E0 75
Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid 1

Action code Failure code Disconnection in FH clutch ECMV solenoid
Trouble
Contents of
• When output to FH clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
appears on • Can not travel in F2, F4, F6, F8.
machine
Related
—
information

2) Disconnect T25.
Defective FH clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
Possible causes circuit in wiring harness Resis-
and standard tance
state 2) Disconnect T2, T25.
3
harness Resis-
tance
4
tance
controller
internal defect.)
Circuit diagram related to FH clutch ECMV solenoid
76 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 77
Failure code [DXH2KY] Power supply line short in FH clutch ECMV

solenoid 1
Action code Failure code Power supply line short in FH clutch ECMV solenoid
Trouble
Contents of
• When output to FH clutch ECMV is OFF, current flows to circuit.
trouble
• Turns FL, FH, R solenoid outputs OFF.
• When lever position at:
N, F1: can not run (1st – 4th solenoids turns OFF)
F2, F3: F2
Action of
F4, F5: F4
controller
F6, F7: F6
F8: F8
R: 1st thru 4th
Problem that
appears on • Possible to travel in F2, F4, F6, F8, but will occur some shift shock.
machine
Related
information

2) Disconnect T25.
Defective FH clutch solenoid Resis-
1 Between T25 (male) (1) and (2) 5 – 15 z
(Internal defect) tance
Min. 1 Mz
ground tance
2
Possible causes harness Resis-
and standard tance
state Short circuit in wiring harness 2) Disconnect T2.
3
(With another wiring harness) Resis-
Between T2 (female) (8) and (18) Min. 1 Mz
tance
controller
internal defect.)
78 GD655-3E0, GD675-3E0
Circuit diagram related to FH clutch ECMV solenoid
GD655-3E0, GD675-3E0 79
Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid 1

Action code Failure code Disconnection in FL clutch ECMV solenoid
Trouble
Contents of
• When output to FL clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
appears on • Can not travel in F1, F3, F5, F7.
machine
Related
—
information

2) Disconnect T24.
Defective FL clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
Between T2 (female) (17) – T24 (female) (2) Min. 1 Mz
and standard tance
state 2) Disconnect T2,T24.
3
harness Resis-
Between T2 (female) (7) and chassis ground 5 – 15 z
tance
4
tance
controller
internal defect.)
Circuit diagram related to FL clutch ECMV solenoid
80 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 81
Failure code [DXH3KY] Power supply line short in FL clutch ECMV

solenoid 1
Action code Failure code Power supply line short in FL clutch ECMV solenoid
Trouble
Contents of
• When output to FL clutch ECMV is OFF, current flows to circuit.
trouble
• Turns FL, FH, R solenoid outputs OFF.
N: 1st – 4th solenoids OFF
F1, F2: F1
Action of
F3, F4: F3
controller
F5, F6: F5
F7, F8: F7
R: 1st thru 4th solenoids OFF
Problem that
appears on • Possible to travel in F1, F3, F5, F7, but will occur some shift shock.
machine
Related
—
information

2) Disconnect T24.
Defective FL clutch solenoid Resis-
1 Between T24 (male) (1) and (2) 5 – 15 z
(Internal defect) tance
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect T2.
2
Possible causes harness Resis-
and standard tance
3
Between T2 (female) (7) and (17) 5 – 15 z
tance
2) Disconnect T2 and T24.
controller
internal defect.)
82 GD655-3E0, GD675-3E0
Circuit diagram related to FL clutch ECMV solenoid
GD655-3E0, GD675-3E0 83
Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid 1

Action code Failure code Disconnection in 1st clutch ECMV solenoid
Trouble
Contents of
• When output to 1st clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
appears on • Can not travel in F1, F2, R1.
machine
Related
—
information

2) Disconnect T27.
Defective 1st clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
and standard tance
3
harness Resis-
tance
4
tance
controller
internal defect.)
Circuit diagram related to clutch ECMV solenoids
84 GD655-3E0, GD675-3E0
Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch
ECMV solenoid 1
Action code Failure code Power supply line short in 1st, 3rd clutch ECMV solenoid
Trouble
Contents of
• When output to 1st, 3rd clutch ECMV is OFF, current flows to circuit.
trouble
Action of • Turns 1st thru 4th solenoid outputs OFF.
Problem that
appears on • Possible to travel in F1, F2, F5, F6, R1, R3, but will occur some shift shock.
machine
Related
information

2) Disconnect T2, T27, T29.
Defective 1st, 3rd clutch
Between T27 (male) (1) and (2), between T29 Resis-
1 ECMV solenoid 5 – 15 z
(male) (1) and (2) tance
(Internal defect)
Between T27 (male) (1), (2), T29 (male) (1), (2) Resis-
Min. 1 Mz
and chassis ground tance
Grounding fault in wiring 2) Disconnect T2, T27, T29.
2
harness Between T2 (female) (2), (3) and chassis Resis-
Min. 1 Mz
Possible causes ground tance
value in normal Short circuit in wiring harness 2) Disconnect T2.
state 3
(With another wiring harness) Between T2 (female) (2) and (13), T2 (female) Resis-
5 – 15 z
(3) and (14) tance
4 Hot short in wiring harness Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
controller
internal defect.)
GD655-3E0, GD675-3E0 85
Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid1

Action code Failure code Disconnection in 2nd clutch ECMV solenoid
Trouble
Contents of
• When output to 2nd clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
machine
Related
—
information

2) Disconnect T28.
Defective 2nd clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
and standard tance
3
harness Resis-
tance
4
tance
controller
internal defect.)
86 GD655-3E0, GD675-3E0
Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch
ECMV solenoid 1
Action code Failure code Power supply line short in 2nd, 4th clutch ECMV solenoid
Trouble
Contents of
• When output to 2nd, 4th clutch ECMV is OFF, current flows to circuit.
trouble
Action of • Turns 1st thru 4th solenoid outputs OFF.
Problem that
appears on • Possible to travel in F3, F4, F7, F8, R2, R4. But will occur some shift shock.
machine
Related
information

Defective 1st, 3rd clutch
Between T28 (male) (1) and (2), T30 (male) (1) Resis-
1 ECMV solenoid 5 – 15 z
and (2) tance
(Internal defect)
Between T28 (male) (1), (2), T30 (male) (1), (2) Resis-
Min. 1 Mz
and chassis ground tance
Grounding fault in wiring 2) Disconnect T2, T28, T30.
2
harness Between T2 (female) (4), (5) and chassis Resis-
Min. 1 Mz
Possible causes ground tance
value in normal Short circuit in wiring harness 2) Disconnect T2.
state 3
(With another wiring harness) Between T2 (female) (4) and (15), T2 (female) Resis-
5 – 15 z
(5) and (16) tance
4 Hot short in wiring harness Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
controller
internal defect.)
GD655-3E0, GD675-3E0 87
Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid 1

Action code Failure code Disconnection in 3rd clutch ECMV solenoid
Trouble
Contents of
• When output to 3rd clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
machine
Related
—
information

2) Disconnect T29.
Defective 3rd clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
and standard tance
3
harness Resis-
tance
4
tance
controller
internal defect.)
88 GD655-3E0, GD675-3E0
Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid 1

Action code Failure code Disconnection in R clutch ECMV solenoid
Trouble
Contents of
• When output to R clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
appears on • Can not travel in reverse.
machine
Related
—
information

2) Disconnect T26.
Defective R clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
and standard tance
3
harness Resis-
tance
4
tance
controller
internal defect.)
Circuit diagram related to R clutch ECMV solenoid
GD655-3E0, GD675-3E0 89
Failure code [DXH7KY] Power supply line short in R clutch ECMV

solenoid 1
Action code Failure code Power supply line short in R clutch ECMV solenoid
Trouble
Contents of
• When output to R clutch ECMV is OFF, current flows to circuit.
trouble
• Turns FL,FH,R solenoid outputs OFF.
N, F1-F8: can not run (1st-4th solenoids turns OFF)
Action of R1: R1
controller R2: R2
R3: R3
R4: R4
Problem that
appears on • Possible to travel in R1, R2, R3, R4.
machine
Related
information

2) Disconnect T26.
Defective R clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
Possible causes harness Between wiring harness T2 (female) (9) – Resis-
Min. 1 Mz
and standard T26 (female) (1) and chassis ground tance
3
Between T2 (female) (9) and (19) 5 – 15 z
tance
controller
internal defect.)
90 GD655-3E0, GD675-3E0
Circuit diagram related to R clutch ECMV solenoid
GD655-3E0, GD675-3E0 91
Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid 1

Action code Failure code Disconnection in 4th clutch ECMV solenoid
Trouble
E03 DXHHKA (Transmission controller system)
Contents of
• When output to 4thd clutch ECMV is OFF, current flows to circuit.
trouble
Action of
controller
Problem that
machine
Related
—
information

2) Disconnect T30.
Defective 4th clutch ECMV
Resis-
tance
(Internal defect)
Min. 1 Mz
ground tance
2
and standard tance
3
harness Resis-
tance
4
tance
controller
internal defect.)
92 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 93
SEN01965-01

© 2009 KOMATSU
All Rights Reserved
94
SEN01841-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Contents of troubleshooting table......................................................................................................... 3
E-1 Engine does not start at all or does not start easily ....................................................................... 4
E-2 Transmission mode does not change.......................................................................................... 12
E-3 Differential lock function does not work or is not reset [Differential lock specification] ................ 14
E-4 Wheel brake does not work normally .......................................................................................... 18
E-5 Parking brake does not work or is not reset ................................................................................ 20
E-6 Lift arm lock pin is not locked or reset [Lift arm specification]...................................................... 22
E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification] 25
E-8 Blade float function does not work or is not reset [Blade accumulator and float specification] ... 28
E-9 When starting switch is turned ON, machine monitor does not operate normally ....................... 36
E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display ............... 38
E-11 When starting switch is turned ON, caution item lights up......................................................... 39
E-12 While engine is running, emergency stop item lights up ........................................................... 40
GD655-3E0, GD675-3E0 1
E-13 Indication of speedometer and engine tachometer is abnormal ................................................ 49

E-14 Indication of engine coolant temperature gauge is abnormal .................................................... 50
E-15 Indication of articulate gauge is abnormal ................................................................................. 52
E-16 Indication of torque converter oil temperature gauge is abnormal............................................. 53
E-17 Indication of fuel level gauge is abnormal.................................................................................. 54
E-18 Display of character display is abnormal ................................................................................... 56
E-19 Centralized warning lamp does not light up or go off................................................................. 57
E-20 Alarm buzzer does not sound or stop ........................................................................................ 58
E-21 Machine monitor mode selector switch does not function ......................................................... 60
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off ............................................. 63
E-23 Working lamp does not light up or go off ................................................................................... 68
E-24 Turn signal lamp and hazard lamp do not blink or go off ........................................................... 72
E-25 Brake lamp does not light up or go off ....................................................................................... 78
E-26 Backup lamp does not light up or go off .................................................................................... 80
E-27 Backup buzzer does not sound or stop ..................................................................................... 81
E-28 Air conditioner does not work or stop ........................................................................................ 82
E-29 KOMTRAX system does not operate normally .......................................................................... 86
2 GD655-3E0, GD675-3E0
Troubleshooting of electrical system (E-mode) 1

Contents of troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Symptom of Symptom of
failure failure that has appeared in the machine
General
Information related to troubles occurred or troubleshooting
information
<Described contents>
• Standard value when normal required to judge the possible cause
• Remarks required to judge whether the cause is right or not
1
<Symptoms of defective harness>
• Disconnection in wiring
The connector contact is defective or the wiring harness is dis-
connected.
• Defective grounding
A harness not connected to GND (ground) circuit comes into con-
tact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply (24 V) circuit
2 comes into contact with the electric power supply (24 V) circuit.
• Short circuit
A harness abnormally comes into contact with a harness of sepa-
Possible Cause by which a trouble rate circuit.
causes and the is assumed to be caused
standard values (The order number indi-
when normal cates a serial number, not <Points to remember when troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling T-
adapter
For troubleshooting, insert or connect the T- adapter as
3 described below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapter in both the male and female.
• When “male”or “female” is indicated for a connector num-
ber, disconnect the connector, and insert the T-adapter in
only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads of the tester as described below unless especially
4 specified.
• Connect the plus (+) lead to a pin number or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin number or harness
indicated in the rear.
Related circuit diagram
• This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Indication of “Connector No. and Pin No.” from the branch or junction point:
Indicates the branch destination or the splice location in the same harness
• Arrow ( ): Indicates the approximate mounting place on machine
GD655-3E0, GD675-3E0 3
E-1 Engine does not start at all or does not start easily 1
Symptom of
(1) When starting switch is turned to START, starting motor does not rotate.
failure
• Since engine start circuit has neutral safety function, engine cannot be started if gear shift lever is not
General in P position.
information • Before starting troubleshooting, check that error indicator of gear shift lever is not blinking.
(If error indicator is blinking, carry out troubleshooting for failure code [DF10KA] or [DF10KB] first.)

Battery voltage Electrolyte specific gravity
1 Insufficient battery charge
Min. 24 V Min. 1.26
a Prepare with starting switch OFF, then keep starting switch OFF
and start engine and carry out troubleshooting in each case.
Defective starting switch Starting switch Switch position Resistance
2
Between OFF Min. 1 Mz
terminals B – C START Max. 1 z
troubleshooting.
Defective safety relay
3 Replace safety relay (Right No.) with another relay (5-
(Internal defect)
pin type). If condition becomes normal at this time, SP13
safety relay is defective.
troubleshooting.
Defective cold start aid
4
switch relay (Internal defect) Replace cold start aid switch relay (Right No.) with
another relay (5-pin type). If condition becomes normal at SP14
this time, cold start aid switch relay is defective.
Defective diode without turning starting switch ON.
5
(Internal disconnection) R28 (male), R29 (male) Continuity
Possible
causes and the Between (2) – (1) There is continuity
standard values a Prepare with starting switch OFF, then turn starting switch ON
when normal Defective alternator and carry out troubleshooting.
6 (Internal short circuit)
R30 (female) Voltage
[75 A alternator specification]
Between 2 – ground Max. 1 V
a Prepare with starting switch OFF (with wiring harness con-
nected), then start engine and carry out troubleshooting.
Starting motor Voltage
Defective starting motor Between B – E Power supply input 20 – 30 V
7
(Internal defect) Between R – E Charge input Max. 1 V
Between C – E Start input 20 – 30 V
If power supply input, charge input and start input are normal but
starting motor does not rotate, starting motor is defective.
Wiring harness between ET49 – starting Resis-
Max. 1 z
motor terminal B tance
Wiring harness between starting motor termi- Resis-
8 (Disconnection in wiring or Max. 1 z
nal E – ground tance
defective contact in connector)
Wiring harness between ST8 – SP13 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
SP14 (female) (5) tance
4 GD655-3E0, GD675-3E0

Max. 1 z
R28 (female) (2), R29 (female) (2) tance
Wiring harness between R28 (female) (1), Resis-
Disconnection in wiring harness R29 (female) (1) – starting motor terminal S Max. 1 z
tance
8 (Disconnection in wiring or
defective contact in connector) Wiring harness between T13 (female) (6) – Resis-
Max. 1 z
Max. 1 z
ground (FT01) tance
Wiring harness between ET49 – starting Resis-
Min. 1 Mz
motor terminal B tance
Possible
causes and the Wiring harness between ST8 – SP13 Resis-
Min. 1 Mz
standard values (female) (3) or circuit branch end tance
when normal Wiring harness between SP13 (female) (5) – Resis-
Ground fault in wiring harness Min. 1 Mz
9 SP14 (female) (5) tance
(Contact with GND circuit)
Wiring harness between SP13 (female) (5) –
Resis-
R28 (female) (2), R29 (female) (2) or circuit Min. 1 Mz
tance
branch end
Wiring harness between R28 (female) (1), Resis-
Min. 1 Mz
R29 (female) (1) – starting motor terminal S tance
Min. 1 Mz
Hot short (Contact with 24V
10 Wiring harness between R30 (female) (2) –
circuit) in wiring harness
alternator terminal R, R19 (female) (2), FP2 Voltage Max. 1 V
(female) (9) or circuit branch end
GD655-3E0, GD675-3E0 5
Circuit diagram related to auto-preheating, starting, start aid, and charging of engine
6 GD655-3E0, GD675-3E0
Symptom of
(2) When starting switch is turned to START, starting motor does not rotate.
failure
• Engine has auto preheater function. If temperature is low (Engine coolant temperature: Below –3°C),
engine controller drives preheater relay automatically to preheat engine (Preheating time is 5 – 45 sec-
General
onds and preheater pilot lamp lights up during that time).
information
• State (Temperature) of engine coolant can be checked with monitoring function (Code: ENGINE-
04105-COOLANT TEMP).

If slow blow fuse is broken, circuit probably has ground fault etc.
1 Defective slow blow fuse 2
(See cause 7.)
Defective preheater relay and carry out troubleshooting.
2
(Internal defect) Replace preheater relay with normal relay. If condition becomes nor-
mal at this time, preheater relay is defective.
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch ON and carry out troubleshooting.
Heater relay Voltage
Defective heater relay Between B – E Power supply input 20 – 30 V
3
(Internal defect) Between 5 – E Coil drive input 20 – 30 V
Between A – E Heater drive output 20 – 30 V
If power supply input and coil drive input are normal but heater drive
output is abnormal, heater relay is defective.
Defective intake air heater without turning starting switch ON.
4
(Internal disconnection) Intake air heater Continuity
Between terminals There is continuity
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and the without turning starting switch ON.
standard values Disconnection in wiring har- Wiring harness between ET53 – heater relay Resis-
Max. 1 z
when normal ness (Disconnection in wiring terminal B tance
5
or defective contact in con- Wiring harness between heater relay termi- Resis-
nector) Max. 1 z
nal A – intake air heater tance
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal 5 – EC2 (female) (40) tance
Wiring harness between ET53 – heater relay Resis-
Min. 1 Mz
terminal B tance
Ground fault in wiring harness Wiring harness between heater relay termi- Resis-
6 Min. 1 Mz
(Contact with GND circuit) nal A – intake air heater tance
Wiring harness between heater relay termi- Resis-
Min. 1 Mz
nal 5 – EC2 (female) (40) tance
Min. 1 Mz
heater relay terminal 5 or R31 (female) (1) tance
Engine coolant
7 Defective engine controller EC2 Voltage
temperature
Between (40) – Min. –5°C 20 – 30 V
ground Below –5°C Max. 1 V
8 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 9
Symptom of
(3) Even if start aid switch is pressed when ambient temperature is low, engine does not start easily.
failure
General • If start aid switch is used, load on hydraulic pump is decreased when engine is started so that engine
information can be started easily.

Defective fuse A10 of fuse If fuse is broken, circuit probably has ground fault etc.
1
box I (FB1) (See causes 5 and 7.)
troubleshooting.
Defective start aid switch
2 Replace neutral relay (Right No.) with another relay (6-
relay (Internal defect)
pin type). If condition becomes normal at this time, neu- SP14
tral relay is defective.
Defective start aid switch FR19 (male) Start aid switch Resistance
3
Q Min. 1 Mz
Between (1) – (2)
I Max. 1 z
4
(Internal disconnection) L2 (male) Continuity
Between (2) – (1) There is continuity
Possible without turning starting switch ON.
Defective start aid solenoid
causes and the 5 valve (Internal disconnection L3 (male) Between (1) – (2)
standard values or short circuit) Between (1) – (2) 0.5 – 1.0 z
when normal
Between (1) – ground Min. 1 Mz
Wiring harness between fuse A10 of fuse Resis-
Max. 1 z
Disconnection in wiring har- box I (FB1) – FP19 (female) (1) tance
ness (Disconnection in wiring Wiring harness between FP19 (female) (2) – Resis-
6 Max. 1 z
or defective contact in con- SP14 (female) (3) tance
nector) Wiring harness between SP14 (female) (5) – Resis-
Max. 1 z
L3 (female) (1) tance
Wiring harness between L3 (female) (2) – Resis-
Max. 1 z
ground (FT01) tance
Wiring harness between fuse A10 of fuse Resis-
Min. 1 Mz
Ground fault in wiring harness box I (FB1) – FP19 (female) (1) tance
7
(Contact with GND circuit) Wiring harness between FP19 (female) (2) – Resis-
Min. 1 Mz
Min. 1 Mz
L3 (female) (1) or L2 (female) (1) tance
10 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 11
E-2 Transmission mode does not change 1

Symptom of
• Transmission mode does not change.
failure
• Mode 1: Direct power shift (HYDROSHIFT) mode
General Mode 2: Torque converter mode
information • Input state (ON/OFF) from transmission mode selector switch can be checked with monitoring mode
(Code: TRANSMISSION-41700-SHIFT MODE SW).

Defective transmission mode Transmission mode
1 selector switch (Internal dis- SP29 (male) Resistance
selector switch
connection or short circuit)
Mode 1 Min. 1 Mz
Between (1) – (2)
Mode 2 Max. 1 z
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between T5 (female) (17) – Resis-
2 Max. 1 z
or defective contact in con- SP29 (female) (2) tance
nector) Wiring harness between SP29 (female) (1) – Resis-
Possible Max. 1 z
TCR (female) (2), (12) tance
causes and the
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal Ground fault in wiring harness without turning starting switch ON.
3
(Contact with GND circuit) Wiring harness between T5 (female) (17) – Resis-
Max. 1 z
Hot short (Contact with 24 V and carry out troubleshooting.
4
circuit) in wiring harness Wiring harness between T5 (female) (17) –
Voltage Max. 1 V
SP29 (female) (2)
Defective transmission con- Transmission mode
5 T5 Voltage
troller selector switch
Between (17) – Mode 1 20 – 30 V
ground Mode 2 Max. 1 V
12 GD655-3E0, GD675-3E0
Circuit diagram related to transmission mode selector switch
GD655-3E0, GD675-3E0 13
E-3 Differential lock function does not work or is not reset [Differential
lock specification] 1
Symptom of
(1) Differential lock function does not work or is not reset.
failure
• Transmission controller checks coil circuit (primary circuit) of differential lock relay for trouble.
(If disconnection, short circuit, etc. occur, failure code [D19CKZ] is displayed.)
General • Input state (ON/OFF) from differential lock switch can be checked with monitoring function
information (Code: TRANSMISSION1-31904-DIFF LOCK SW).
• Drive state (ON/OFF) of differential lock relay can be checked with monitoring function
(Code: TRANSMISSION1-31903-DIFF RELAY).

Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See causes
1
(FB1) 4 and 6.)
Defective differential lock Differential lock
2 switch (Internal disconnec- FP13 (male) Resistance
switch
tion or short circuit)
ON Min. 1 Mz
Between (1) – (2)
OFF Max. 1 z
troubleshooting.
Defective differential lock
3 Replace differential lock relay (Right No.) with another
relay (5-pin type). If condition becomes normal at this BR7
time, differential lock relay is defective.
Prepare with starting switch OFF, then carry out troubleshooting
Defective differential lock without turning starting switch ON.
4 solenoid valve (Internal dis- R44 (male) Resistance
connection or short circuit) Between (1) – (2) Max. 1 z
Possible
causes and the Max. 1 z
standard values FP13 (female) (2) tance
when normal Disconnection in wiring har- Wiring harness between FP13 (female) (1) – Resis-
Max. 1 z
ness (Disconnection in wiring A10 of fuse box I (FB1) tance
5
or defective contact in con- Wiring harness between A6 of fuse box I Resis-
nector) Max. 1 z
(FB1) – BR7 (female) (3) tance
Wiring harness between BR7 (female) (6) – Resis-
Max. 1 z
R44 (female) (1) tance
Wiring harness between R44 (female) (2) – Resis-
Max. 1 z
ground (ET77) tance
Ground fault in wiring har- Min. 1 Mz
FP13 (female) (2) tance
6 ness
(Contact with GND circuit) Wiring harness between A6 of fuse box I Resis-
Min. 1 Mz
(FB1) – BR7 (female) (3) tance
Wiring harness between BR7 (female) (6) – Resis-
Min. 1 Mz
Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Contact with 24 V Wiring harness between T5 (female) (9) –
7 Voltage Max. 1 V
circuit) in wiring harness FP13 (female) (2)
Wiring harness between BR7 (female) (6) –
Voltage Max. 1 V
R44 (female) (1)
14 GD655-3E0, GD675-3E0

Possible and carry out troubleshooting.
causes and the
Defective transmission con- Differential lock
standard values 8 T5 Voltage
troller switch
when normal
OFF 20 – 30 V
Between (9) – ground
ON Max. 1 V
Symptom of
(2) Only display of differential lock pilot lamp is abnormal (Function is normal).
failure
• When differential lock is operated: Pilot lamp lights up
General When differential lock is reset: Pilot lamp goes off
information • Operation signal of differential lock pilot lamp is received from transmission controller by communica-
tion.

Possible
Machine monitor may be defective. (Since trouble is in system,
causes and the 1 Defective machine monitor
troubleshooting cannot be carried out.)
standard values
when normal Defective transmission con- Transmission controller may be defective. (Since trouble is in sys-
2
troller tem, troubleshooting cannot be carried out.)
GD655-3E0, GD675-3E0 15
Circuit diagram related to differential lock switch and solenoid valve
16 GD655-3E0, GD675-3E0
E-4 Wheel brake does not work normally 1

Symptom of
• Wheel brake does not work normally.
failure
General • If engine startup solenoid valve operates (turned ON) continuously, brake accumulator is not
information charged with air.

Defective start aid switch FP19 (male) Start aid switch Resistance
1
(Internal short circuit)
Q Min. 1 Mz
Between (1) – (2)
I Max. 1 z
Possible Defective engine startup without turning starting switch ON.
causes and the 2 solenoid valve
L3 (male) Resistance
standard values (Internal defect)
Between (1) – (2) 0.5 – 1.0 z
when normal
Wiring harness between FP19 (female) (2) –
Voltage Max. 1 V
Hot short (Contact with 24 V SP14 (female) (3)
3
circuit) in wiring harness Wiring harness between SP14 (female) (2) –
Voltage Max. 1 V
L2 (female) (2) or circuit branch end
Wiring harness between L3 (female) (1) – L2
Voltage Max. 1 V
(female) (1)
18 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 19
E-5 Parking brake does not work or is not reset 1

Symptom of
(1) Parking brake does not work or is not reset.
failure
• Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If discon-
General nection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.)
information • Before starting troubleshooting, check that wheel brake operates normally. (If wheel brake does not
operate normally, carry out troubleshooting for wheel brake first.)

Defective parking brake sole-
1 noid valve (Internal discon- FL8 (male) Resistance
Possible nection or short circuit) Between (1) – (2) 40 – 60 z
causes and the Between (1) – ground Min. 1 Mz
standard values
when normal
ness (Disconnection in wiring Wiring harness between FL8 (female) (1) – Resis-
2 Max. 1 z
or defective contact in con- circuit branch end tance
nector) Wiring harness between FL8 (female) (2) – Resis-
Max. 1 z
ground (FT01) tance
Symptom of
(2) Only display of parking brake pilot lamp is abnormal (Function is normal).
failure
• When parking brake is operated: Pilot lamp lights up
General When parking brake is reset: Pilot lamp goes off
information • Operation signal of parking brake pilot lamp is received from transmission controller by communica-
tion.

Possible
Machine monitor may be defective. (Since trouble is in system,
causes and the 1 Defective machine monitor
troubleshooting cannot be carried out.)
standard values
when normal Defective transmission con- Transmission controller may be defective. (Since trouble is in sys-
2
troller tem, troubleshooting cannot be carried out.)
20 GD655-3E0, GD675-3E0
Circuit diagram related to parking brake solenoid valve
GD655-3E0, GD675-3E0 21
E-6 Lift arm lock pin is not locked or reset [Lift arm specification] 1
Symptom of
(1) Lift arm lock pin is not locked or reset.
failure
General • Lift arm lock switch is turned ON (Pin is reset) when pushed in, and turned OFF (Pin is locked) when
information pushed back.

Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc.
1
(FB1) (See causes 3 and 5.)
Defective lift arm lock switch a Prepare with starting switch OFF, then carry out troubleshooting
2 (Internal disconnection or without turning starting switch ON.
short circuit) SP30 (male) Lift arm lock switch Resistance
OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
Defective lift arm lock sole-
3 noid valve (Internal discon- FL7 (male) Resistance
nection or short circuit) Between (1) – (2) 40 – 60 z
Possible
causes and the
standard values
when normal Disconnection in wiring har- Wiring harness between fuse A6 of fuse box I Resis-
Max. 1 z
ness (Disconnection in wiring (FB1) – SP30 (female) (1) tance
4
or defective contact in con- Wiring harness between SP30 (female) (2) – Resis-
nector) Max. 1 z
FL7 (female) (1) tance
Max. 1 z
ground (FT01) tance
Wiring harness between fuse A6 of fuse box I
Ground fault in wiring harness Resis-
5 (FB1) – SP30 (female) (1) or circuit branch Min. 1 Mz
(Contact with GND circuit) tance
end
Min. 1 Mz
FL7 (female) (1) or FP3 (female) (9) tance
6
Voltage Max. 1 V
FL7 (female) (1) or FP3 (female) (9)
22 GD655-3E0, GD675-3E0
Symptom of
(2) Only display of lift arm lock pin pilot lamp is abnormal (Function is normal).
failure
General • When lift arm pin is locked: Pilot lamp goes off
information When lift arm pin is reset: Pilot lamp lights up

Lift arm lock pin pilot lamp bulb may be broken or may have defec-
1 Broken bulb
tive contact. Check it directly.
Defective lamp assembly Lamp assembly may have defect (disconnection or short circuit) in
2
(Internal defect) it. Check it directly.
Possible 3 Max. 1 z
causes and the nector) Wiring harness between FP3 (female) (12) – Resis-
standard values Max. 1 z
when normal ground (FT01) tance
Ground fault in wiring harness without turning starting switch ON.
4
Min. 1 Mz
5
circuit) in wiring harness Wiring harness between FP3 (female) (9) –
Voltage Max. 1 V
circuit branch end
GD655-3E0, GD675-3E0 23
Circuit diagram related to lift arm lock switch and solenoid valve
24 GD655-3E0, GD675-3E0
E-7 Blade accumulator function does not work or is not reset

[Blade accumulator and float specification] 1
Symptom of
(1) Blade accumulator function of both right and left sides does not work or is not reset.
failure
General
information

Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc.
1
(FB1) (See causes 3, 4, 5 and 7.)
Defective blade accumulator/ Blade accumulator/
2 float switch (Internal discon- SP18 (male) Resistance
float switch
nection or short circuit)
OFF Min. 1 Mz
Between (B) – (A)
Accumulator Max. 1 z
Defective left blade accumu- without turning starting switch ON.
3 lator solenoid valve (Internal
FL10 (male) Resistance
short circuit)
Defective right blade accu- without turning starting switch ON.
4 mulator solenoid valve (Inter-
nal short circuit)
Defective diode (Internal without turning starting switch ON.
Possible 5
causes and the short circuit) FL15 (male), FL16 (male) Continuity (Resistance)
standard values Between (1) – (2) There is no continuity (Min. 1 Mz)
when normal
ness (Disconnection in wiring Wiring harness between fuse A6 of fuse box I Resis-
6 Max. 1 z
or defective contact in con- (FB1) – SP18 (female) (B) tance
nector) Wiring harness between SP18 (female) (A) – Resis-
Max. 1 z
Resis-
(FB1) -– SP18 (female) (B), L4 (female) (B), Min. 1 Mz
Ground fault in wiring harness tance
7 or L5 (female) (B)
Wiring harness between SP18 (female) (A) –
FL9 (female) (1), FL10 (female) (1), FL15 Resis-
Min. 1 Mz
(female) (1), FL16 (female) (1), or FP3 tance
(female) (7)
Hot short (Contact with 24 V Wiring harness between SP18 (female) (A) –
8
circuit) in wiring harness FL9 (female) (1), FL10 (female) (1), FL15
Voltage Max. 1 V
(female) (1), FL16 (female) (1), or FP3
(female) (7)
GD655-3E0, GD675-3E0 25
Symptom of
(2) Blade accumulator function of only left side does not work or is not reset.
failure
General
information

Defective left blade accumu- without turning starting switch ON.
1 lator solenoid valve (Internal
Possible disconnection)
Between (1) – (2) 20 – 30 z
causes and the
when normal Disconnection in wiring har- without turning starting switch ON.
2 Max. 1 z
Max. 1 z
ground (FT01) tance
Symptom of
(3) Blade accumulator function of only right side does not work or is not reset.
failure
General
information

Defective right blade accu- without turning starting switch ON.
1 mulator solenoid valve (Inter-
Possible nal disconnection)
Between (1) – (2) 20 – 30 z
causes and the
when normal without turning starting switch ON.
Disconnection in wiring har-
2 Max. 1 z
Max. 1 z
ground (FT01) tance
Symptom of
(4) Only display of blade accumulator pilot lamp is abnormal (Function is normal).
failure
General • When blade accumulator is operated: Pilot lamp lights up
information When blade accumulator is reset: Pilot lamp goes off

Blade accumulator pilot lamp bulb may be broken or may have
1 Broken bulb
defective contact. Check it directly.
2
Possible 3 Max. 1 z
4
Min. 1 Mz
5
Voltage Max. 1 V
circuit branch end
26 GD655-3E0, GD675-3E0
Circuit diagram related to blade accumulator and float switch and solenoid valve
GD655-3E0, GD675-3E0 27
E-8 Blade float function does not work or is not reset

Symptom of
(1) Blade float function of both right and left sides does not work or is not reset.
failure
General
information

Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See causes
1
(FB1) 3, 4, 5, 6, 7 and 9.)
Defective blade accumulator/ Blade accumulator/
2 float switch (Internal discon- SP18 (male) Resistance
float switch
nection or short circuit)
OFF Min. 1 Mz
Between (B) – (C)
Float Max. 1 z
Defective left blade float without turning starting switch ON.
3 solenoid valve 1 (Internal
short circuit)
short circuit)
Possible Between (1) – ground Min. 1 Mz
causes and the a Prepare with starting switch OFF, then carry out troubleshooting
standard values Defective right blade float without turning starting switch ON.
when normal 5 solenoid valve 1 (Internal
short circuit)
Defective right blade float without turning starting switch ON.
short circuit)
Defective diode (Internal
7 FL17 (male), LF18 (male),
short circuit) Continuity (Resistance)
FL19 (male), FL20 (male)
Between (1) – (2) There is no continuity (Min. 1 Mz)
ness (Disconnection in wiring Wiring harness between fuse A6 of fuse box I Resis-
8 Max. 1 z
or defective contact in con- (FB1) – SP18 (female) (B) tance
nector) Wiring harness between SP18 (female) (C) – Resis-
Min. 1 Mz
28 GD655-3E0, GD675-3E0

Resis-
(FB1) – SP18 (female) (B), L4 (female) (B), or Min. 1 Mz
tance
L5 (female) (B)
Wiring harness between SP18 (female) (C) –
Resis-
Ground fault in wiring harness SP7 (female) (1), (2), SP8 (female) (1), (2), Min. 1 Mz
9 tance
Possible (Contact with GND circuit) or FP3 (female) (8)
causes and the Wiring harness between SP7 (female) (5) –
standard values Resis-
FL13 (female) (1), LF14 (female) (1), FL19 Min. 1 Mz
when normal tance
(female) (1), or FL20 (female) (1)
Resis-
FL11 (female) (1), FL12 (female) (1), FL17 Min. 1 Mz
tance
Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Contact with 24 V
10 Wiring harness between SP18 (female) (C) –
SP7 (female) (1), (2), SP8 (female) (1), (2), Voltage Max. 1 V
or FP3 (female) (8)
GD655-3E0, GD675-3E0 29
Symptom of
(2) Blade float function of only left side does not work or is not reset.
failure
General
information

troubleshooting.
Defective left blade float
1 Replace left blade float relay (Right No.) with another
relay (5-pin type). If condition becomes normal at this SP7
time, left blade float relay is defective.
2
(Internal disconnection) SP33 (male) Continuity
Left blade lift cylinder
L5 Voltage
control lever
Between (B) – (C) All range 20 – 30 V
Defective left float cancel
3 Neutral 20 – 30 V
switch (Internal defect)
Between (B) – (A) Raise operation
Max. 1 V
Lower operation
Left float cancel switch voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring har-
ness, too, for another cause of trouble, and then judge.
causes and the Defective left blade float without turning starting switch ON.
standard values 4 solenoid valve 1
when normal FL13 (male) Resistance
Between (1) – (2) 20 – 30 z
5 solenoid valve 2
Between (1) – (2) 20 – 30 z
Resis-
Wiring harness between SP7 (female) (1) – (3) Max. 1 z
tance
Max. 1 z
Disconnection in wiring har- Wiring harness between SP33 (female) (1) – Resis-
Max. 1 z
ness (Disconnection in wiring L5 (female) (A) tance
6
or defective contact in con- Wiring harness between L5 (female) (B) – Resis-
nector) Max. 1 z
Wiring harness between L5 (female) (C) – Resis-
Max. 1 z
ground (FT01) tance
Max. 1 z
FL13 (female) (1) or FL14 (female) (1) tance
Wiring harness between FL13 (female) (2), Resis-
Max. 1 z
FL14 (female) (2) – ground (FT01) tance
30 GD655-3E0, GD675-3E0

Min. 1 Mz
Ground fault in wiring harness
7 Wiring harness between SP33 (female) (1) – Resis-
Possible (Contact with GND circuit) Min. 1 Mz
L5 (female) (A) or circuit branch end tance
causes and the
standard values Wiring harness between SP7 (female) (5) –
Resis-
when normal FL13 (female) (1), FL14 (female) (1), FL19 Min. 1 Mz
tance
8 Wiring harness between SP7 (female) (5) –
FL13 (female) (1), FL14 (female) (1), FL19 Voltage Max. 1 V
GD655-3E0, GD675-3E0 31
Symptom of
(3) Blade float function of only right side does not work or is not reset.
failure
General
information

troubleshooting.
Defective right blade float
1 Replace right blade float relay (Right No.) with another
relay (5-pin type). If condition becomes normal at this SP8
time, right blade float relay is defective.
2
(Internal disconnection) SP32 (male) Continuity
Right blade lift cylin-
L5 Voltage
der control lever
Between (B) – (C) All range 20 – 30 V
Defective right float cancel
3 Neutral 20 – 30 V
switch (Internal defect)
Between (B) – (A) Raise operation
Max. 1 V
Lower operation
Right float cancel switch voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring har-
ness, too, for another cause of trouble, and then judge.
causes and the Defective right blade float without turning starting switch ON.
standard values 4 solenoid valve 1 (Internal dis-
when normal FL11 (male) Resistance
connection)
Between (1) – (2) 20 – 30 z
Defective right blade float without turning starting switch ON.
5 solenoid valve 2 (Internal dis-
connection)
Between (1) – (2) 20 – 30 z
Max. 1 z
SP8 (female) (1), (3) tance
Max. 1 z
Max. 1 z
ness (Disconnection in wiring L4 (female) (A) tance
6
or defective contact in con- Wiring harness between L4 (female) (B) – Resis-
nector) Max. 1 z
Wiring harness between L4 (female) (C) – Resis-
Max. 1 z
ground (FT01) tance
Max. 1 z
FL11 (female) (1) or FL12 (female) (1) tance
Max. 1 z
32 GD655-3E0, GD675-3E0

Min. 1 Mz
7 Wiring harness between SP32 (female) (1) – Resis-
Possible (Contact with GND circuit) Min. 1 Mz
L4 (female) (A) or circuit branch end tance
causes and the
standard values Wiring harness between SP8 (female) (5) –
Resis-
when normal FL11 (female) (1), FL12 (female) (1), FL17 Min. 1 Mz
tance
8 Wiring harness between SP8 (female) (5) –
FL11 (female) (1), FL12 (female) (1), FL17 Voltage Max. 1 V
Symptom of
(4) Only display of blade float pilot lamp is abnormal (Function is normal).
failure
General • When blade float is operated: Pilot lamp lights up
information When blade float is reset: Pilot lamp goes off

Blade float pilot lamp bulb may be broken or may have defective
1 Broken bulb
contact. Check it directly.
2
Possible 3 Max. 1 z
4
Min. 1 Mz
5
Voltage Max. 1 V
circuit branch end
GD655-3E0, GD675-3E0 33
Circuit diagram related to blade accumulator and float switch and solenoid valve
34 GD655-3E0, GD675-3E0
E-9 When starting switch is turned ON, machine monitor does not
operate normally 1
Symptom of
• When starting switch is turned ON, machine monitor does not operate normally.
failure
• When starting switch is turned ON, machine monitor displays as follows.
1) Centralized warning lamp is turned ON for 2 seconds, then turned OFF.
2) Monitor lamp is turned ON for 2 seconds, then turned OFF for 1 second and displayed normally.
General
3) Speedometer displays “88” for 2 seconds, then is turned OFF for 1 second and displayed normally.
information
4) Meter section performs system check for 3 seconds, then is displayed normally.
5) Character display displays “KOMATSU” for 3 seconds, then is displayed normally.
• When starting switch is turned ON, machine monitor sounds alarm buzzer for 2 seconds, then stops.

Defective fuses No. 12 or 14
1 If fuse is broken, circuit probably has ground fault etc. (See cause 4.)
of fuse box III
and OFF and carry out troubleshooting in each case.
Defective starting switch Starting switch Switch position Resistance
2
(Internal defect)
Between terminals OFF Min. 1 Mz
B – ACC ON Max. 1 z
Wiring harness between fuse A3 of fuse box I Resis-
Max. 1 z
Disconnection in wiring har- (FB1) – ST6 tance
ness (Disconnection in wiring Wiring harness between ST9 – FP1 (female) Resis-
3 Max. 1 z
or defective contact in con- (1), (2) tance
Possible nector) Wiring harness between fuse A1 of fuse box I Resis-
Max. 1 z
causes and the (FB1) – FP1 (female) (5), (6) tance
standard values Wiring harness between FP1 (female) (3), Resis-
when normal Max. 1 z
(4) – TCR (21), (31) tance
Min. 1 Mz
(FB1) – ST6 or circuit branch end tance
4 Wiring harness between ST9 – FP1 (female) Resis-
(Contact with GND circuit) Min. 1 Mz
(1), (2) or circuit branch end tance
Resis-
(FB1) – FP1 (female) (5), (6) or circuit branch Min. 1 Mz
tance
end
5 Defective machine monitor FP1 Voltage
Between (1), (2) – (3), (4) 20 – 30 V
Between (5), (6) – (3), (4) 20 – 30 V
36 GD655-3E0, GD675-3E0
Circuit diagram related to machine monitor power supply
GD655-3E0, GD675-3E0 37
E-10 When starting switch is turned ON, machine monitor is not reset to
ordinary display 1
Symptom of
• When starting switch is turned ON, machine monitor is not reset to ordinary display
failure
• When starting switch is turned ON, machine monitor displays as follows.
1) Centralized warning lamp is turned ON for 2 seconds, then turned OFF.
2) Monitor lamp is turned ON for 2 seconds, then turned OFF for 1 second and displayed normally.
General
3) Speedometer displays “88” for 2 seconds, then is turned OFF for 1 second and displayed normally.
information
4) Meter section performs system check for 3 seconds, then is displayed normally.
5) Character display displays “KOMATSU” for 3 seconds, then is displayed normally.
• When starting switch is turned ON, machine monitor sounds alarm buzzer for 2 seconds, then stops.
Possible Cause Standard value when normal and remarks for troubleshooting
causes and the
standard values Machine monitor may be defective.
when normal (Since trouble is in system, troubleshooting cannot be carried out.)
38 GD655-3E0, GD675-3E0
E-11 When starting switch is turned ON, caution item lights up 1

Symptom of
(1) Parking brake pilot lamp does not display normally.
failure
General • When parking brake is operated: Pilot lamp lights up
information When parking brake is reset: Pilot lamp goes off
causes and the
standard values 1 Carry out troubleshooting “E-5 Parking brake does not work or is not reset”.
when normal
Symptom of
(2) Maintenance caution monitor blinks or lights up.
failure
General • Maintenance caution lamp blinks in 30 hours before replacement time and lights up after replace-
information ment time (for 30 seconds after starting switch is turned ON).

Possible An item is near or after main-
Check character display. If any item needs maintenance, carry out
causes and the 1 tenance time
maintenance.
standard values (When system is normal)
when normal If cause 1 is not detected, machine monitor may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
GD655-3E0, GD675-3E0 39
E-12 While engine is running, emergency stop item lights up 1

Symptom of
(1) While engine is running, battery charge circuit caution lamp lights up.
failure
• If battery charge circuit has trouble while engine is running, battery charge circuit caution lamp lights
up and alarm buzzer sounds.
General
• Generation signal of alternator is received from transmission controller by communication.
information
• Generation state (ON/OFF) of alternator can be checked with monitoring function
(Code: TRANSMISSION-04301-ALTERNATOR R).

Defective alternator troubleshooting.
(Defective generation)
R30 (female) Engine speed Voltage
[75 A alternator specification]
Between (2) – ground Min. medium (half) 20 – 30 V
1
Defective alternator or regu- a Prepare with starting switch OFF, then start engine and carry out
lator troubleshooting.
(Defective generation) R30 (female) Engine speed Voltage
[140 A alternator specification] Between (2) – ground Min. medium (half) 20 – 30 V
Possible ness (Disconnection in wiring without turning starting switch ON.
causes and the 2
or defective contact in con- Wiring harness between FP2 (female) (9) – Resis-
standard values nector) Max. 1 z
R30 (male) (2) tance
when normal
3
Min. 1 Mz
R30 (male) (2) or circuit branch end tance
troubleshooting.
Defective transmission con-
4 FP2 Engine speed Voltage
troller
Between
Min. medium (half) 20 – 30 V
(9) – ground
If causes 1 – 4 are not detected, machine monitor may be defective.
40 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 41
Symptom of
(2) Engine oil pressure caution lamp lights up.
failure
• If engine oil pressure is abnormal while engine is running, engine oil pressure caution lamp lights up
General
and alarm buzzer sounds.
information
• Signal of engine oil pressure switch is received from engine controller by communication.

Engine oil pressure reduction Engine oil pressure reduction is detected. Check engine oil pres-
1
(When system is normal) sure.
a Prepare with starting switch OFF, then keep starting switch OFF
Defective engine oil pressure C2 Engine Resistance
2
switch (Internal short circuit)
Between terminal – Stopped Max. 1 z
ground Min. 600 rpm Min. 1 Mz
causes and the Ground fault in wiring harness without turning starting switch ON.
standard values 3
(Contact with GND circuit) Wiring harness between EC1 (female) (17) – Resis-
C2 (1) tance
Prepare with starting switch OFF, then turn starting switch ON (with
engine stopped) and start engine and carry out troubleshooting in
each case.
4 Defective engine controller EC1 Engine Voltage
Between (17) – Stopped Max. 1 V
ground Min. 600 rpm 20 – 30 V
42 GD655-3E0, GD675-3E0
Circuit diagram related to engine oil pressure switch
GD655-3E0, GD675-3E0 43
Symptom of
(3) Brake oil pressure caution lamp lights up.
failure
• If brake oil pressure is abnormal while engine is running, brake oil pressure caution lamp lights up
and alarm buzzer sounds.
General • Signal of brake oil pressure switch (Front/Rear) is received from communication controller by com-
information munication.
• Input state (ON/OFF) from brake oil pressure switch (Front/Rear) can be checked with monitoring func-
tion (Code: TRANSMISSION1-35500-ACC OIL PRE F, TRANSMISSION1-35501-ACC OIL PRE R).

Brake oil pressure reduction
1 Brake oil pressure reduction is detected. Check brake oil pressure.
(When system is normal)
Defective fuse A12 of fuse
box I (FB1)
Accumulator oil
R15 Voltage
pressure
Between (A) – (C) All range 20 – 30 V
Below approx. 4.2 MPa
Defective front brake oil
{Below approx. Max. 1 V
3 pressure switch (Internal
defect) 42.5 kg/cm2}
Between (B) – (C)
Above approx. 4.2 MPa
{Above approx. 20 – 30 V
42.5 kg/cm2}
Front brake oil pressure switch voltage is measured with wiring har-
ness connected. Accordingly, if voltage is abnormal, check wiring har-
ness and controller, too, for another cause of trouble, and then judge.
Possible troubleshooting.
causes and the
standard values Accumulator oil
R16 Voltage
when normal pressure
Between (A) – (C) All range 20 – 30 V
Defective rear brake oil pres- {Below approx. Max. 1 V
4
sure switch (Internal defect) 42.5 kg/cm2}
Between (B) – (C)
Above approx. 4.2 MPa
42.5 kg/cm2}
Rear brake oil pressure switch voltage is measured with wiring har-
ness connected. Accordingly, if voltage is abnormal, check wiring har-
ness and controller, too, for another cause of trouble, and then judge.
Max. 1 z
Disconnection in wiring har- (FB1) – R15 (female) (A) or R16 (female) (A) tance
ness (Disconnection in wiring Wiring harness between R15 (female) (C), Resis-
5 Max. 1 z
or defective contact in con- R16 (female) (C) – ground (ET89) tance
nector) Wiring harness between R15 (female) (B) – Resis-
Max. 1 z
Wiring harness between R16 (female) (B) – Resis-
Max. 1 z
44 GD655-3E0, GD675-3E0

Min. 1 Mz
Ground fault in wiring harness (FB1) – R15 (female) (A) or R16 (female) (A) tance
6
(Contact with GND circuit) Wiring harness between R15 (female) (B) – Resis-
Min. 1 Mz
Wiring harness between R16 (female) (B) – Resis-
Min. 1 Mz
Possible TCR Engine Voltage
causes and the Below approx. 4.2 MPa
standard values {Below approx. Max. 1 V
when normal
Between (35) – 42.5 kg/cm2}
ground Above approx. 4.2 MPa
7 {Above approx. 20 – 30 V
controller
42.5 kg/cm2}
{Below approx. Max. 1 V
Between (26) – 42.5 kg/cm2}
ground Above approx. 4.2 MPa
42.5 kg/cm2}
GD655-3E0, GD675-3E0 45
Circuit diagram related to front brake oil pressure switch and rear brake oil pressure switch
46 GD655-3E0, GD675-3E0
Symptom of
(4) Torque converter oil temperature caution lamp lights up.
failure
• If torque converter oil temperature is abnormal while engine is running, torque converter oil tempera-
ture caution lamp lights up and alarm buzzer sounds.
• Torque converter oil temperature caution lamp lights up and goes off according to the display of
General torque converter oil temperature gauge.
information • Signal of torque converter oil temperature sensor is received from transmission controller by commu-
nication.
• State (Temperature) of torque converter oil can be checked with monitoring function
(Code: TRANSMISSION1-30100-T/C OIL TEMP).

Torque converter oil overheat Torque converter oil overheat is detected. Check torque converter
1
(When system is normal) oil temperature.
If indication of torque converter oil temperature gauge is abnormal,
Possible carry out troubleshooting for “E-18 Indication of torque converter oil
causes and the temperature gauge is abnormal”.
standard values Defective torque converter Oil temperature
2 See following figure
when normal oil temperature system gauge
White range Red range
Oil temperature lamp
OFF ON
If causes 1 and 2 are not detected, machine monitor may be defective.
Torque converter oil temperature gauge
GD655-3E0, GD675-3E0 47
Symptom of
(5) Differential oil temperature caution lamp lights up.
failure
• If differential oil temperature is abnormal while engine is running, differential oil temperature caution
General
lamp lights up and alarm buzzer sounds.
information
• Signal of differential oil temperature sensor is received from transmission controller by communication.

Differential oil overheat Differential oil overheat is detected. Check differential oil tempera-
1
(When system is normal) ture.
Defective differential oil tem- Differential oil
2 perature switch (Internal R43 (male) Resistance
temperature
short circuit)
Below 120 °C Min. 1 Mz
Between (1) – (2)
Above 120 °C Max. 1 z
Possible
causes and the
standard values 3
when normal (Contact with GND circuit) Wiring harness between T3-2 (female) (10) – Resis-
Min. 1 Mz
Defective transmission con- Differential oil
4 T3-2 Voltage
troller temperature
Between (10) – Below 120 °C 20 – 30 V
ground Above 120 °C Max. 1 V
Circuit diagram related to differential oil temperature switch
48 GD655-3E0, GD675-3E0
E-13 Indication of speedometer and engine tachometer is abnormal 1

Symptom of
(1) Indication of speedometer is abnormal.
failure
General • Speedometer signal (transmission output shaft speed sensor signal) is received from transmission
information controller by communication.

Abnormality in transmission
Check occurrence record of failure code [DLT3KA]. If it is dis-
Possible 1 output shaft speed sensor
played, carry out troubleshooting for it.
causes and the system
standard values If cause 1 is not detected, machine monitor may be defective.
when normal 2 Defective machine monitor
Defective transmission con- If cause 1 is not detected, transmission controller may be defective.
3
troller (Since trouble is in system, troubleshooting cannot be carried out.)
Symptom of
(2) Display of speedometer display pilot lamp is abnormal.
failure
General • Speedometer pilot lamp lights up when km/h is selected and goes off when MPH is selected.
information • Speedometer pilot lamp signal is processed in machine monitor.
causes and the
standard values Machine monitor may be defective. (Since trouble is in system,
when normal troubleshooting cannot be carried out.)
Symptom of
(3) Indication of engine tachometer is abnormal.
failure
General • Engine tachometer signal (Engine Ne speed sensor signal) is received from transmission controller
information by communication.

Abnormality in engine Ne Check occurrence record of failure code [DLE3LC]. If it is dis-
Possible 1
speed sensor system played, carry out troubleshooting for it.
causes and the
when normal (Since trouble is in system, troubleshooting cannot be carried out.)
If cause 1 is not detected, transmission controller may be defective.
GD655-3E0, GD675-3E0 49
E-14 Indication of engine coolant temperature gauge is abnormal 1

Symptom of
• Indication of engine coolant temperature gauge is abnormal.
failure
• If engine coolant high temperature sensor system has abnormality, failure code [B@BCNS] may be
displayed and recorded.
General • Engine coolant temperature gauge signal (Engine coolant high temperature sensor signal) is
information received from engine controller by communication.
• State (Temperature) of engine coolant can be checked with monitoring function
(Code: MONITOR PANEL-04104-COOLANT TEMP).

Defective engine coolant without turning starting switch ON.
high temperature sensor C3 (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) – (2) 3.5 k – 90 kz
Between (1), (2) – ground Min. 1 Mz
ness (Disconnection in wiring Wiring harness between EC1 (female) (15) – Resis-
2 Max. 1 z
or defective contact in con- C3 (female) (1) tance
nector) Wiring harness between EC1 (female) (38) – Resis-
Max. 1 z
Possible
causes and the
standard values 3
when normal (Contact with GND circuit) Wiring harness between EC1 (female) (15) – Resis-
Min. 1 Mz
4
(Contact with 24 V circuit) Wiring harness between EC1 (female) (15) –
Voltage Max. 1 V
C3 (female) (1)
Between (15) – (38) 3.5 k – 90 kz
Between (15), (38) – ground Min. 1 Mz
50 GD655-3E0, GD675-3E0
Circuit diagram related to engine coolant high temperature sensor
GD655-3E0, GD675-3E0 51
E-15 Indication of articulate gauge is abnormal 1

Symptom of
• Indication of articulate gauge is abnormal.
failure
• If articulate angle sensor system has abnormality, failure code [DKD0KA] may be displayed and
recorded.
General • Articulate gauge signal (Articulate angle sensor signal) is received from transmission controller by
information communication.
• Input state (Resistance/Voltage) from articulate angle sensor can be checked with monitoring function
(Code: TRANSMISSION1-43905-ARTICULATE, TRANSMSSION1-43904-ARTICULATE).

Abnormality in articulate Check occurrence record of failure code [DKD0KA]. If it is dis-
1
angle sensor system played, carry out troubleshooting for it.
Defective articulate angle FL6 (male) Articulate Resistance

2
sensor (Internal short circuit) Center 96.5 – 106.5 z
Right end (23°) 17.7 – 37.7 z
Possible
causes and the
standard values 3
when normal (Contact with GND circuit) Wiring harness between TCR (female) (24) – Resis-
Min. 1 Mz
FL6 (female) (2) tance
Defective communication TCR (male) Articulate Resistance

4
controller Center 96.5 – 106.5 z
Between (24) –
Left end (23°) 163.8 – 180 z
ground
Right end (23°) 17.7 – 37.7 z
Circuit diagram related to articulate angle sensor
52 GD655-3E0, GD675-3E0
E-16 Indication of torque converter oil temperature gauge is abnormal 1

Symptom of
• Indication of torque converter oil temperature gauge is abnormal.
failure
• If torque converter oil temperature sensor system has abnormality, failure code [DGT1KX] may be
displayed and recorded.
General • Torque converter oil temperature gauge signal (Torque converter oil temperature sensor signal) is
information received from transmission controller by communication.
• Input state (Voltage) from torque converter oil temperature sensor can be checked with monitoring
function (Code: TRANSMISSION1-30101-T/C OIL TEMP.)

Abnormality in torque con-
Check occurrence record of failure code [DGT1KX]. If it is dis-
Possible 1 verter oil temperature sen-
played, carry out troubleshooting for it.
causes and the sor system
when normal 2 Defective machine monitor
Defective transmission con- If cause 1 is not detected, transmission controller may be defective.
3
troller (Since trouble is in system, troubleshooting cannot be carried out.)
GD655-3E0, GD675-3E0 53
E-17 Indication of fuel level gauge is abnormal 1

Symptom of
• Indication of fuel level gauge is abnormal.
failure
• If fuel level sensor system has abnormality, failure code [DJF1KA] may be displayed and recorded.
General
information • Input state (Resistance/Voltage) from fuel level sensor can be checked with monitoring function
(Code: MONITOR PANEL-04201-FUEL SENSOR, MONITOR PANEL-04200-FUEL SENSOR).

Abnormality in fuel level sen- Check occurrence record of failure code [DJF1KA]. If it is displayed,
1
sor system carry out troubleshooting for it.
ET39 (male) Fuel level Resistance
Defective fuel level sensor FULL 10 ± 5 z

2
(Internal short circuit) 3/4 (19 z)
Between (1) – 011 1/2 32 ± 0.5 z
1/4 (49.5 z)
Possible EMPTY 80 ± 0.5 z
causes and the
when normal Ground fault in wiring harness without turning starting switch ON.
3
Min. 1 Mz
ET39 (female) (1) tance
FP2 (female) Fuel level Resistance
FULL 10 ± 5 z
3/4 (19 z)
Between (10) –
1/2 32 ± 0.5 z
ground
1/4 (49.5 z)
EMPTY 80 ± 0.5 z
54 GD655-3E0, GD675-3E0
Circuit diagram related to fuel level sensor
GD655-3E0, GD675-3E0 55
E-18 Display of character display is abnormal 1

(1) Service meter does not operate while engine is running.
Symptom of
(2) Trip odometer does not operate while machine is traveling.
failure
(3) Character display displays nothing.
• Service meter measures time by engine Ne speed sensor signal. While it is in operation, hourglass
General
mark blinks.
information
• Trip odometer integrates travel distance by transmission output shaft speed sensor signal.
causes and the
standard values Machine monitor may be defective. (Since trouble is in system,
when normal troubleshooting cannot be carried out.)
56 GD655-3E0, GD675-3E0
E-19 Centralized warning lamp does not light up or go off 1

Symptom of
• Centralized warning lamp does not light up or go off.
failure
• Centralized warning lamp lights up under following conditions.
1) When emergency stop item has abnormality
General
2) When character display displays action code [E02] or [E03]
information
3) When machine overruns
• If centralized warning lamp lights up, alarm buzzer sounds intermittently.

Defective fuse A10 of fuse
box I (FB1)
Centralized warning lamp bulb may be broken or may have defec-
2 Broken bulb
tive contact. Check it directly.
3
ness (Disconnection in wiring Wiring harness between fuse A10 of fuse Resis-
4 Max. 1 z
or defective contact in con- box I (FB1) – FP3 (female) (1) tance
Possible
nector) Wiring harness between FP3 (female) (11) – Resis-
standard values FP1 (female) (19) tance
when normal a Prepare with starting switch OFF, then carry out troubleshooting
Wiring harness between fuse A10 of fuse
5 box I (FB1) – FP3 (female) (1) or circuit Min. 1 Mz
branch end
Wiring harness between FP3 (female) (11) – Resis-
Min. 1 Mz
a Prepare with starting switch OFF.
FP1 Starting switch Voltage
Between (19) – ON (for 2 sec after ON) Max. 1 V
ground ON (after 2 sec after ON) 20 – 30 V
Circuit diagram related to centralized warning lamp
GD655-3E0, GD675-3E0 57
E-20 Alarm buzzer does not sound or stop 1

Symptom of
• Alarm buzzer does not sound or stop.
failure
General
• If alarm buzzer system has abnormality, failure code [DV00KB] may be displayed and recorded.
information

Abnormality in alarm buzzer Check occurrence record of failure code [DV00KB]. If it is dis-
1
system played, carry out troubleshooting for it.
Defective fuse A10 of fuse If fuse is broken, circuit probably has ground fault etc.
2
box I (FB1) (See causes 3 and 5.)
SP26 Starting switch Voltage
Defective alarm buzzer
3 ON (for 2 sec after ON) 20 – 30 V
(Internal defect) Between (1) – (2)
ON (after 2 sec after ON) Max. 3 V
If voltage is normal but alarm buzzer does not sound, alarm buzzer
is defective.
Possible Disconnection in wiring har- without turning starting switch ON.
causes and the ness (Disconnection in wiring Wiring harness between fuse A10 of fuse Resis-
standard values 4 Max. 1 z
or defective contact in con- box I (FB1) – SP26 (female) (1) tance
when normal nector) Wiring harness between SP26 (female) (2) – Resis-
Max. 1 z
5 box I (FB1) – SP26 (female) (1) or circuit Min. 1 Mz
branch end
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and
6 Defective machine monitor FP1 Starting switch Voltage
Between (18) – ON (for 2 sec after ON) Max. 3 V
ground ON (after 2 sec after ON) 20 – 30 V
58 GD655-3E0, GD675-3E0
Circuit diagram related to alarm buzzer
GD655-3E0, GD675-3E0 59
E-21 Machine monitor mode selector switch does not function 1

Symptom of
(1) Machine monitor mode selector switch 1 does not function
failure
General • t (Left) position: Used to cancel various modes and operations
information • U(Right) position: Used to select (enter) various modes and operations

Defective fuse A1 of fuse box I
(FB1)
Machine monitor
Defective machine monitor FP15 (male) Resistance
mode selector switch 1
2 Neutral Min. 1 Mz
Between (2) – (3)
short circuit) t (Left) Max. 1 z
Neutral Min. 1 Mz
Between (2) – (1)
U (Right) Max. 1 z
Disconnection in wiring har- Wiring harness between fuse A1 of fuse box I Resis-
Max. 1 z
ness (Disconnection in wiring (FB1) – FP15 (female) (2) tance
3
nector) Max. 1 z
Max. 1 z
causes and the without turning starting switch ON.
standard values Wiring harness between fuse A1 of fuse box I
when normal Resis-
(FB1) – FP15 (female) (2) or circuit branch Min. 1 Mz
Ground fault in wiring harness end tance
4
Min. 1 Mz
Min. 1 Mz
Hot short (Contact with 24 V Wiring harness between FP15 (female) (3) –
5 Voltage Max. 1 V
Voltage Max. 1 V
FP1 (female) (16)
Machine monitor
FP1 Voltage
6 Defective machine monitor Neutral Max. 1 V
Between (17) –
ground t (Left) 20 – 30 V
Between (16) – Neutral Max. 1 V
ground U (Right) 20 – 30 V
60 GD655-3E0, GD675-3E0
Symptom of
(2) Machine monitor mode selector switch 2 does not function
failure
General • > (Left) position : Used to display next screen or increase number to be input
information • < (Right) position : Used to display previous page or decrease number to be input

Machine monitor
Defective machine monitor FP14 (male) Resistance
1 Neutral Min. 1 Mz
Between (2) – (1)
short circuit) > (Left) Max. 1 z
Neutral Min. 1 Mz
Between (2) – (3)
< (Right) Max. 1 z
Disconnection in wiring har- Wiring harness between FP14 (female) (2) – Resis-
Max. 1 z
ness (Disconnection in wiring ground (FT01) tance
2
nector) Max. 1 z
Max. 1 z
Possible
causes and the
standard values
when normal Ground fault in wiring harness Wiring harness between FP14 (female) (1) – Resis-
3 Min. 1 Mz
(Contact with GND circuit) FP1 (female) (15) tance
Min. 1 Mz
4 Voltage Max. 1 V
Voltage Max. 1 V
FP1 (female) (14)
Machine monitor
FP1 Voltage
5 Defective machine monitor Neutral Max. 1 V
Between (15) –
ground > (Left) 20 – 30 V
Between (14) – Neutral Max. 1 V

ground < (Right) 20 – 30 V
GD655-3E0, GD675-3E0 61
Circuit diagram related to machine monitor mode selector switches 1 and 2
62 GD655-3E0, GD675-3E0
E-22 Headlamp, clearance lamp and tail lamp do not light up or go off 1
Symptom of (1) None of headlamp, clearance lamp, tail lamp, machine monitor night lamp and switch panel lamp
failure [Cabless specification] lights up or goes off.
• Clearance lamp ON position: Clearance lamp, tail lamp, machine monitor night lamp and switch
General
panel lamp [Cabless specification] light up.
information
• Headlamp ON position: Above lamps and headlamp light up.

Defective fuse A11 of fuse If fuse is broken, circuit probably has ground fault etc. (See cause 4
1
box I (FB1) and troubles (2), (3) and (5).)
SP19 (female) Headlamp switch Resistance
Defective headlamp switch
2 (Internal disconnection or OFF Min. 1 Mz
Between (2) – (3)
Possible short circuit) Clearance lamp ON Max. 1 z
causes and the OFF Min. 1 Mz
standard values Between (5) – (6)
Headlamp ON Max. 1 z
when normal
ness (Disconnection in wiring without turning starting switch ON.
3
or defective contact in con- Wiring harness between fuse A11 of fuse Resis-
nector) Max. 1 z
box I (FB1) – SP19 (female) (2), (5) tance
4
(Contact with GND circuit) Wiring harness between fuse A11 of fuse Resis-
Min. 1 Mz
box I (FB1) – SP19 (female) (2), (5) tance
GD655-3E0, GD675-3E0 63
Symptom of (2) Headlamp does not light up or go off.

failure (3) High beam or low beam of headlamp cannot be selected.
General
information

If only specific headlamp does not light up, that lamp bulb may be
1 Broken bulb
broken or may have defective contact. Check it directly.
Dimmer switch FP12 (male) Resistance
Defective dimmer switch Between (A) – (B) Max. 1 z
2
(Internal disconnection) Low
Between (A) – (C) Min. 1 Mz
Between (A) – (B) Max. 1 z
High
Between (A) – (C) Min. 1 Mz
Max. 1 z
FP12 (female) (A) tance
Wiring harness between FP12 (female) (B) –
Resis-
Disconnection in wiring har- FL1 (female) (1), FL2 (female) (1), C27 Max. 1 z
tance
ness (Disconnection in wiring (female) (1), or C28 (female) (1)
3
or defective contact in con- Wiring harness between FP12 (female) (C) –
Resis-
nector) FL1 (female) (3), FL2 (female) (3), C27 Max. 1 z
tance
(female) (3), or C28 (female) (3)
Possible Max. 1 z
causes and the
standard values Wiring harness between C27 (female) (2), Resis-
Max. 1 z
when normal C28 (female) (2) – ground (CT41) tance
Min. 1 Mz
FP12 (female) (A) tance
Ground fault in wiring harness Wiring harness between FP12 (female) (B) – Resis-
4 FL1 (female) (1), FL2 (female) (1), C27 Min. 1 Mz
Wiring harness between FP12 (female) (C) –
FL1 (female) (3), FL2 (female) (3), C27 Resis-
Min. 1 Mz
(female) (3), C28 (female) (3), or FP3 tance
(female) (3)
Voltage Max. 1 V
FP12 (female) (A)
Hot short (Contact with 24 V Wiring harness between FP12 (female) (B) –
5 FL1 (female) (1), FL2 (female) (1), C27 Voltage Max. 1 V
FL1 (female) (3), FL2 (female) (3), C27
Voltage Max. 1 V
(female) (3), C28 (female) (3), or FP3
(female) (3)
64 GD655-3E0, GD675-3E0
Symptom of
(4) High beam pilot lamp does not light up or go off.
failure
General
information

High beam pilot lamp bulb may be broken or may have defective
1 Broken bulb
2
Possible 3 Max. 1 z
or defective contact in con- circuit branch point tance
4
Min. 1 Mz
circuit branch point tance
5
Voltage Max. 1 V
circuit branch point
GD655-3E0, GD675-3E0 65
Symptom of (5) Clearance lamp, tail lamp, machine monitor night lamp and switch panel lamp [Cabless specifica-
failure tion] do not light up or go off.
General
information

If only specific clearance lamp does not light up, that lamp bulb may
1 Broken clearance lamp bulb
be broken or may have defective contact. Check it directly.
If only specific tail lamp does not light up, that lamp bulb may be
2 Broken tail lamp bulb
Defective machine monitor FP1 Headlamp switch Voltage
3
(Internal defect)
OFF Max. 1 V
Between (8) – ground
Clearance lamp ON 20 – 30 V
Broken switch panel lamp If only switch panel lamp does not light up, its bulb may be broken or
4
bulb [Cabless specification] may have defective contact. Check it directly.
Possible
Disconnection in wiring har- FL22 (female) (1), FL23 (female) (1), RL2 Resis-
ness (Disconnection in wiring (female) (4), RL3 (female) (4), FP1 (female) tance
standard values 5
or defective contact in con- (8), or ST10 (female)
when normal
nector) Wiring harness between FL22 (female) (2), Resis-
Max. 1 z
Wiring harness between RL2 (female) (6), Resis-
Max. 1 z
RL3 (female) (6) – ground (ET77) tance
Ground fault in wiring harness Wiring harness between SP19 (female) (3) –
6
(Contact with GND circuit) FL22 (female) (1), FL23 (female) (1), RL2 Resis-
Min. 1 Mz
(female) (4), RL3 (female) (4), FP1 (female) tance
(8), ST10 (female), or SP9 (female) (1)
Hot short (Contact with 24 V Wiring harness between SP19 (female) (3) –
7
circuit) in wiring harness FL22 (female) (1), FL23 (female) (1), RL2
Voltage Max. 1 V
(female) (4), RL3 (female) (4), FP1 (female)
(8), ST10 (female), or SP20 (female) (8)
66 GD655-3E0, GD675-3E0
Circuit diagram related to headlamp, clearance lamp, tail lamp
GD655-3E0, GD675-3E0 67
E-23 Working lamp does not light up or go off 1

Symptom of
(1) None of front working lamps and rear working lamps lights up or goes off.
failure
General
information

Defective fuse A9 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See cause 4
1
(FB1) and troubles (2) and (3).)
Defective working lamp
2 switch (Internal disconnec- SP23 (male) Working lamp switch Resistance
tion or short circuit) Between (A) – (B) OFF Min. 1 Mz
Between (C) – (B) ON Max. 1 z
causes and the Wiring harness between fuse A8 of fuse box I Resis-
Disconnection in wiring har- Max. 1 z
standard values (FB1) – SP23 (female) (B) or SP10 (female) (1) tance
ness (Disconnection in wiring
when normal 3
or defective contact in con- Wiring harness between SP23 (female) (B) – Resis-
nector) Max. 1 z
Max. 1 z
ground (FT01) tance
Ground fault in wiring harness Wiring harness between fuse A9 of fuse box I Resis-
4 Min. 1 Mz
(Contact with GND circuit) (FB1) – SP23 (female) (C) or SP11 (female) (5) tance
Wiring harness between SP23 (female) (C) – Resis-
Min. 1 Mz
68 GD655-3E0, GD675-3E0
Symptom of
(2) Front working lamps do not light up or go off
failure
General
information

If only specific front working lamp does not light up, that lamp bulb
1 Broken bulb
may be broken or may have defective contact. Check it directly.
Defective front working lamp
2 Replace front working lamp relay (Right No.) with
another relay (6-pin type). If condition becomes normal SP10
at this time, front working lamp relay is defective.
Resis-
Wiring harness between SP10 (female) (3) – (1) Max. 1 z
Disconnection in wiring har- tance
ness (Disconnection in wiring Wiring harness between SP10 (female) (2) – Resis-
3 Max. 1 z
Possible or defective contact in con- FL26 (female) (1) tance
causes and the nector) Wiring harness between SP10 (female) (4) – Resis-
Max. 1 z
standard values FL27 (female) (1) tance
when normal Wiring harness between FL26 (female) (2), Resis-
Max. 1 z
Ground fault in wiring harness Wiring harness between SP10 (female) (2) – Resis-
4 Min. 1 Mz
(Contact with GND circuit) FL26 (female) (1) tance
Min. 1 Mz
FL27 (female) (1) or FP3 (female) (5) tance
Hot short (Contact with 24 V Wiring harness between SP10 (female) (2) –
5 Voltage Max. 1 V
circuit) in wiring harness FL26 (female) (1)
Voltage Max. 1 V
FL27 (female) (1) or FP3 (female) (5)
GD655-3E0, GD675-3E0 69
Symptom of
(3) Rear working lamps do not light up or go off
failure
General
information

Rear working lamp bulbs may be broken or may have defective con-
1 Broken bulb
tact. Check them directly.
Defective rear working lamp
2 Replace rear working lamp relay (Right No.) with
another relay (6-pin type). If condition becomes normal SP11
at this time, rear working lamp relay is defective.
Max. 1 z
Possible Disconnection in wiring har- SP11 (female) (1) tance
causes and the ness (Disconnection in wiring Wiring harness between SP11 (female) (6) – Resis-
3 Max. 1 z
standard values or defective contact in con- SP10 (6) tance
when normal nector) Wiring harness between SP11 (female) (4) – Resis-
Max. 1 z
RL4 (female) (1) or RL5 (female) (1) tance
Max. 1 z
4
(Contact with GND circuit) Wiring harness between SP11 (female) (4) – Resis-
Min. 1 Mz
5
Voltage Max. 1 V
RL4 (female) (1) or RL5 (female) (1)
Symptom of
(4) Working lamp pilot lamp does not light up or go off.
failure
General
information

Working lamp pilot lamp bulb may be broken or may have defective
1 Broken bulb
2
Possible 3 Max. 1 z
or defective contact in con- circuit branch point tance
4
Min. 1 Mz
5
Voltage Max. 1 V
70 GD655-3E0, GD675-3E0
Circuit diagram related to working lamp
GD655-3E0, GD675-3E0 71
E-24 Turn signal lamp and hazard lamp do not blink or go off 1
Symptom of
(1) None of turn signal lamp and hazard lamp blinks or goes off.
failure
General
information

Defective fuse A2 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See cause 4
1
(FB1) and troubles (2) and (3).)
SP22 Voltage
Between (3) – (1) 20 – 30 V
Defective flasher
2 20 – 30 V Max. 1 V
(Internal defect) Between (4) – (1)
(Approx. 85 Hz)
Flasher voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness, too, for
another cause of trouble, and then judge.
causes and the Disconnection in wiring har- Wiring harness between fuse A2 of fuse box I Resis-
ness (Disconnection in wiring (FB1) – SP22 (female) (3) tance
when normal 3
nector) Max. 1 z
ground (FT01) tance
Max. 1 z
Ground fault in wiring harness Wiring harness between fuse A2 of fuse box I Resis-
4 Min. 1 Mz
(Contact with GND circuit) (FB1) – SP22 (female) (3) tance
Min. 1 Mz
SP20 (female) (2), (5) or FP11 (female) (A) tance
5
Voltage Max. 1 V
SP20 (female) (2), (5) or FP11 (female) (A)
72 GD655-3E0, GD675-3E0
Symptom of
(2) Turn signal lamp does not blink or go off.
failure
General
information

If only specific turn signal lamp or hazard lamp does not light up,
1 Broken bulb that lamp bulb may be broken or may have defective contact.
Check it directly.
FP11 (male) Turn signal lever Resistance
Defective turn signal lever
2 (Internal disconnection or Neutral Min. 1 Mz
Between (A) – (B)
short circuit) Left turn (Upper side) Max. 1 z
Neutral Min. 1 Mz
Between (A) – (C)
Right turn (Lower side) Max. 1 z
Wiring harness between FP11 (female) (A) – Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between FP11 (female) (B) – Resis-
Max. 1 z
ness (Disconnection in wiring FL23 (female) (3) or RL3 (female) (1) tance
3
Possible or defective contact in con- Wiring harness between FP11 (female) (C) – Resis-
nector) Max. 1 z
causes and the FL22 (female) (3) or RL2 (female) (1) tance
standard values Wiring harness between FL23 (female) (2), Resis-
Max. 1 z
Resis-
Ground fault in wiring harness FL23 (female) (3), RL3 (female) (1), FP3 Min. 1 Mz
4 tance
(Contact with GND circuit) (female) (4), or SP20 (female) (6)
Resis-
FL22 (female) (3), RL2 (female) (1), FP3 Min. 1 Mz
tance
(female) (2), or SP20 (female) (3)
Hot short (Contact with 24 V FL23 (female) (3), RL3 (female) (1), FP3 Voltage Max. 1 V
5
circuit) in wiring harness (female) (4), or SP20 (female) (6)
FL22 (female) (3), RL2 (female) (1), FP3 Voltage Max. 1 V
(female) (2), or SP20 (female) (3)
GD655-3E0, GD675-3E0 73
Symptom of
(3) Hazard lamp does not blink or go off.
failure
General
information

If only specific turn signal lamp or hazard lamp does not light up,
1 Broken bulb that lamp bulb may be broken or may have defective contact.
Check it directly.
Defective hazard lamp
2 switch (Internal disconnec- SP20 (male) Hazard lamp switch Resistance
tion or short circuit) Between (2) – (3) OFF Min. 1 Mz
Between (5) – (6) ON Max. 1 z
Wiring harness between SP20 (female) (2), Resis-
Max. 1 z
(5) – circuit branch point tance
Max. 1 z
ness (Disconnection in wiring FL23 (female) (3) or RL3 (female) (1) tance
3
nector) Max. 1 z
Possible FL22 (female) (3) or RL2 (female) (1) tance
causes and the Wiring harness between FL23 (female) (2), Resis-
Max. 1 z
standard values FL22 (female) (2) or ground (FT01) tance
when normal
Max. 1 z
RL2 (female) (6) or ground (ET77) tance
Resis-
Ground fault in wiring harness FL23 (female) (3), RL3 (female) (1), FP3 Min. 1 Mz
4 tance
(Contact with GND circuit) (female) (4), or FP11 (female) (B)
Resis-
FL22 (female) (3), RL2 (female) (1), FP3 Min. 1 Mz
tance
(female) (2), or FP11 (female) (C)
Hot short (Contact with 24 V FL23 (female) (3), RL3 (female) (1), FP3 Voltage Max. 1 V
5
circuit) in wiring harness (female) (4), or FP11 (female) (B)
FL22 (female) (3), RL2 (female) (1), FP3 Voltage Max. 1 V
(female) (2), or FP11 (female) (C)
74 GD655-3E0, GD675-3E0
Symptom of
(4) Turn signal pilot lamp does not light up or go off.
failure
General
information

Turn signal pilot lamp bulb which does not light up may be broken or
1 Broken bulb
may have defective contact. Check it directly.
2
Disconnection in wiring har- Wiring harness between FP3 (female) (4) – Resis-
Max. 1 z
ness (Disconnection in wiring circuit branch point tance
3
nector) Max. 1 z
Possible
ground (FT01) tance
standard values
Ground fault in wiring harness Wiring harness between FP3 (female) (4) – Resis-
4 Min. 1 Mz
(Contact with GND circuit) circuit branch point tance
Min. 1 Mz
5 Voltage Max. 1 V
circuit) in wiring harness circuit branch point
Voltage Max. 1 V
GD655-3E0, GD675-3E0 75
Circuit diagram related to turn signal lamp and hazard lamp
76 GD655-3E0, GD675-3E0
E-25 Brake lamp does not light up or go off 1

Symptom of
• Brake lamp does not light up or go off.
failure
General
information

Defective fuse A12 of fuse If fuse is broken, circuit probably has ground fault etc. (See causes
1
box I (FB1) 4 and 6.)
If only specific brake lamp does not light up, that lamp bulb may be
2 Broken brake lamp bulb
troubleshooting.
Defective brake lamp switch
3 (Internal disconnection or B13 (male) Brake pedal Resistance
short circuit) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
troubleshooting.
Defective stop lamp relay
4 Replace stop lamp relay (Right No.) with another relay
(Internal defect)
(5-pin type). If condition becomes normal at this time, SP12
stop lamp relay is defective.
Resis-
box I (FB1) – B13 (female) (1) or SP12 Max. 1 z
tance
(female) (3)
Possible Disconnection in wiring har- Wiring harness between B13 (female) (2) – Resis-
causes and the ness (Disconnection in wiring SP12 (female) (1) Max. 1 z
standard values 5 tance
or defective contact in con-
when normal Wiring harness between SP12 (female) (2) – Resis-
nector) Max. 1 z
ground (FT01) tance
Max. 1 z
Max. 1 z
Resis-
box I (FB1) – B13 (female) (1) or SP12 Min. 1 Mz
Ground fault in wiring harness (female) (3) tance
6
Wiring harness between B13 (female) (2) – Resis-
Min. 1 Mz
Min. 1 Mz
Hot short (Contact with 24 V Wiring harness between B13 (female) (2) –
7 Voltage Max. 1 V
circuit) in wiring harness SP12 (female) (1)
Voltage Max. 1 V
RL3 (female) (5) or RL2 (female) (6)
78 GD655-3E0, GD675-3E0
Circuit diagram related to brake lamp
GD655-3E0, GD675-3E0 79
E-26 Backup lamp does not light up or go off 1

Symptom of
• Backup lamp does not light up or go off.
failure
General • Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If discon-
information nection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.)

If only specific backup lamp does not light up, that lamp bulb may be
1 Broken brake lamp bulb
ness (Disconnection in wiring Wiring harness between RL3 (female) (2), Resis-
2 Max. 1 z
or defective contact in con- RL2 (female) (2) – circuit branch point tance
Possible nector) Wiring harness between RL3 (female) (6), Resis-
standard values
3
(Contact with GND circuit) Wiring harness between RL3 (female) (2), Resis-
Min. 1Mz
RL2 (female) (2) – circuit branch point tance
4
circuit) in wiring harness Wiring harness between RL3 (female) (2),
Voltage Max. 1 V
RL2 (female) (2) – circuit branch point
Circuit diagram related to backup lamp and backup buzzer
80 GD655-3E0, GD675-3E0
E-27 Backup buzzer does not sound or stop 1

Symptom of
• Backup buzzer does not sound or stop.
failure
General • Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If discon-
information nection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.)

RT3, RT2 Gear shift lever Voltage
Defective backup buzzer R1 – R4 Max. 1 V
1
(Internal defect) Between terminals Other than between
20 – 30 V
R1 – R4
If voltage is normal but backup buzzer does not sound, backup
buzzer is defective.
Possible
causes and the
standard values ness (Disconnection in wiring Wiring harness between RT3 – circuit branch Resis-
2 Max. 1 z
when normal or defective contact in con- point tance
nector) Resis-
Wiring harness between RT2 – ground (ET77) Max. 1 z
tance
3
(Contact with GND circuit) Wiring harness between RT3 – circuit branch Resis-
Min. 1 Mz
point tance
4
circuit) in wiring harness Wiring harness between RT3 – circuit branch Resis-
Min. 1 Mz
point tance
Circuit diagram related to backup lamp and backup buzzer
GD655-3E0, GD675-3E0 81
E-28 Air conditioner does not work or stop 1

Symptom of
• Air conditioner does not work or stop.
failure
General • Following is troubleshooting for only power supply circuit and ground circuit between air conditioner
information and operator’s cab. For troubleshooting for air conditioner unit, see Shop Manual for air conditioner.

Defective fuse No. 3 or No. 4
of fuse box A or 5A or 15A
fuse of main circuit in air con-
ditioner
• When fuse No. 8 of fuse box A is broken
Wiring harness between fuse No. 8 of fuse
Resis-
box A – 5A fuse of main circuit in air condi- Min. 1 Mz
tance
tioner unit or 15A fuse in air conditioner unit
• When fuse No. 7 of fuse box A is broken
Wiring harness between fuse No. 7 of fuse Resis-
Min. 1 Mz
box A – compressor clutch relay tance
2
(Contact with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Possible • When 5A fuse of main circuit in air conditioner unit is broken
causes and the Wiring harness between 5A fuse of main cir-
standard values cuit in air conditioner unit – C48 (female) (7), Resis-
when normal Min. 1 Mz
pressure switch, or primary side of blower tance
OFF relay
• When 15A fuse in air conditioner unit is broken
Wiring harness between 15A fuse in air con- Resis-
Min. 1 Mz
ditioner unit – blower OFF relay tance
C48 Starting switch Voltage
Disconnection in air condi- ON 20 – 30 V
tioner control panel power Between (7) – (1)
OFF Max. 1 V
supply or ground wiring har-
3 a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring
or defective contact in con- without turning starting switch ON.
nector) Wiring harness between fuse No. 8 of fuse Resis-
Max. 1 z
box A – C48 (female) (7) tance
Wiring harness between C48 (female) (1) – Resis-
Max. 1 z
ground tance
82 GD655-3E0, GD675-3E0

Blower OFF relay and
Starting switch Voltage
pressure switch
Between blower OFF ON 20 – 30 V
relay (15A fuse line) –
ground OFF Max. 1 V
Between blower OFF ON 20 – 30 V

relay (5A fuse line of
main circuit) – ground OFF Max. 1 V
Possible Pressure switch ON 20 – 30 V

causes and the Disconnection in relay power (5A fuse line of main
standard values supply wiring harness (Dis- circuit) – ground OFF Max. 1 V
4
when normal connection in wiring or defec-
tive contact in connector) a Prepare with starting switch OFF, then carry out troubleshooting
Wiring harness between fuse No. 8 of fuse Resis-
Max. 1 z
box A – blower OFF relay (15A fuse line side) tance
Resis-
box A – blower OFF relay (5A fuse line side Max. 1 z
tance
of main circuit)
Resis-
box A – pressure switch (5A fuse line side of Max. 1 z
tance
main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
GD655-3E0, GD675-3E0 83
Circuit diagram related to air conditioner
84 GD655-3E0, GD675-3E0
E-29 KOMTRAX system does not operate normally 1

Symptom of
• KOMTRAX system does not operate normally.
failure
• If KOMTRAX system administrator asks if there is trouble in system on machine side, carry out trou-
General
bleshooting.
information
• Even if KOMTRAX system has trouble, it does not appear on machine.

a Prepare with starting switch OFF.
LED (1) Normal condition
LED-A1 ON
1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshooting
G01 Signal Voltage
Between (39), (40) – Unswitched
20 – 30 V
(37), (38) power supply
a Prepare with starting switch ON.
2 LED (6) Normal condition
environment
LED-A2 ON
a Prepare with engine started.
LED-C1 ON
Starting switch signal ACC or troubleshooting.
3
Possible alternator signal R C01 Signal Voltage
causes and the Between (36) –
standard values Starting switch ACC 20 – 30 V
(37), (38)
when normal
Between (28) –
Alternator R 20 – 30 V
(37), (38)
LED-C3 OFF
a Turn starting switch to START and carry out troubleshooting.
LED-C3 Fast blink (Period: 1 sec)
Defective network type or without turning starting switch ON.
4
starting switch signal C
G01 Signal Continuity
Between (24), (25) –
Network type There is continuity
(37), (38)
troubleshooting.
G01 Signal Voltage
Between (27) –
Starting switch C 20 – 30 V
(37), (38)
86 GD655-3E0, GD675-3E0

LED-C4 Slow blink (Period: 4 sec)
Defective fuel sensor con- and carry out troubleshooting.
5
nection or pattern G01 Signal Voltage
Between (32) –
Fuel sensor Max. 5 V
(37), (38)
Between (17) – Fuel sensor pattern
Possible 20 – 30 V
(37), (38) selection
causes and the
standard values a Prepare with starting switch ON.
when normal LED (12) Normal condition
Defective transmission of
6 If letters at right are
data
7-segment not displayed, condi- [–] [C] [H]
tion is normal.
Defective GPS measuring Dot ON (See *)
7
condition
*: Even in place where radio waves are strong enough, it may take
more than 1 minute to complete measurement after the starting
switch is turned ON.
LED display section G01 connector
GD655-3E0, GD675-3E0 87
SEN01841-00

© 2006 KOMATSU
All Rights Reserved
88
SEN01842-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Contents of troubleshooting table......................................................................................................... 3
H-1 Excessive drop in engine speed, or engine stalls ......................................................................... 4
H-2 Machine does not move in either forward or reverse direction...................................................... 5
H-3 Transmission does not shift up or shift down ................................................................................ 6
H-4 Machine is slow or lacks power when traveling............................................................................. 7
H-5 Torque converter lockup function cannot be actuated or canceled ............................................... 9
H-6 Excessive time lag when starting or shifting gear........................................................................ 10
H-7 Torque converter oil temperature is high ......................................................................................11
H-8 Differential lock function is not operated or reset [Differential lock specification] ........................ 13
H-9 Machine is slow or lacks power when steering ........................................................................... 14
H-10 Wheel brake does not work normally ........................................................................................ 15
H-11 Parking brake is not applied or released ................................................................................... 16
H-12 All work equipment is slow or lacks power ................................................................................ 17
GD655-3E0, GD675-3E0 1
H-13 No work equipment moves ........................................................................................................ 18

H-14 Abnormal noise generated around pump .................................................................................. 19
H-15 Blade is slow or lacks power in lifting ........................................................................................ 20
H-16 Excessive blade drift.................................................................................................................. 21
H-17 Drawbar side shift operation is slow or lacks power .................................................................. 22
H-18 Blade side shift operation is slow or lacks power ...................................................................... 23
H-19 Power tilt operation is slow or lacks power................................................................................ 24
H-20 Articulate operation is slow or lacks power................................................................................ 25
H-21 Leaning operation is slow or lacks power.................................................................................. 26
H-22 Excessive drift of leaning........................................................................................................... 27
H-23 Blade does not rotate ................................................................................................................ 28
H-24 Lift arm lock pin is not locked or reset [Lift arm specification].................................................... 29
[Blade accumulator and float specification] ............................................................................... 30
H-26 Blade float function is not operated or reset [Blade accumulator and float specification].......... 31
2 GD655-3E0, GD675-3E0
Troubleshooting of hydraulic and mechanical system (H-mode)1

Contents of troubleshooting table 1
a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
2
Possible causes Cause for presumed failure
and standard <Contents>
(The attached No. is for fil-
value in normal • The standard values in normalcy by which to judge "Good" or "No
ing and reference purpose
state Good" about presumed causes.
only. It does not stand for
• References for making judgement of "Good" or "No Good"
any priority.)
3
GD655-3E0, GD675-3E0 3
H-1 Excessive drop in engine speed, or engine stalls 1

Trouble • Excessive drop in engine speed, or engine stalls
Related
• Before starting troubleshooting, check that oil level in hydraulic tank is normal.
information

a Prepare with engine stopped, then run engine at high idle and
Malfunction or improper carry out troubleshooting.
1 adjustment of piston pump If condition does not become normal after adjustment, PC valve of
(PC valve) piston pump may be malfunctioning or may have defect in it. Check
Possible causes piston pump directly.
and standard Clogged piston pump (orifice
2 Orifice plug of piston pump may be clogged. Check it directly.
value in normal plug)
state Malfunction of piston pump Servo piston of piston pump may be malfunctioning. Check it
3
(servo piston) directly.
Defect in piston pump (pump
4 Piston pump may have defect in it. Check it directly.
unit)
Engine may be defective. Carry out troubleshooting for engine
5 Defective engine
(S mode).
4 GD655-3E0, GD675-3E0
H-2 Machine does not move in either forward or reverse direction 1

Trouble • Machine does not move in either forward or reverse direction
Related • Before starting troubleshooting, check that oil level in transmission case is normal.
information • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C.

Power train pump may not be rotating because of defect in PTO.
1 Defect in PTO
Check PTO directly.
Defective coupling of power Power train pump may not be rotating because of defective coupling
2
train pump (drive system) of its drive system. Check drive system directly.
Clogged suction strainer of Suction strainer of transmission case may be clogged. Check it
3
transmission case directly.
Air in suction circuit of power Suction circuit of power train pump may have sucked air. Check it
4
train pump directly.
Defect in power train pump
5 Power train pump may have defect in it. Check it directly.
(pump unit)
a Prepare with engine stopped, then start engine and carry out
troubleshooting.
Power train main
Gear shift lever Engine
Malfunction of power train relief pressure
6
Possible causes main relief valve 2.4 ± 0.1 MPa
and standard Low idle
{24.5 ± 1.0 kg/cm2}
value in normal P position
2.46 ± 0.2 MPa
state High idle
{25.1 ± 2.0 kg/cm2}
Malfunction of torque con-
7 Gear shift lever Torque converter inlet pressure
verter main relief valve
0.88 ± 0.05 MPa
P position
{9.0 ± 0.5 kg/cm2}
Gear shift lever Torque converter outlet pressure
8 Defect in torque converter 0.59 ± 0.05 MPa

P position
{6.0 ± 0.5 kg/cm2}
If torque converter inlet pressure is normal and outlet pressure is
abnormal, torque converter may have defect in it. Check torque
converter directly.
9 Defect in transmission Transmission may have defect in it. Check it directly.
GD655-3E0, GD675-3E0 5
H-3 Transmission does not shift up or shift down 1

Trouble (1) Machine does not move in forward or reverse direction
• Before starting troubleshooting, check that oil level in transmission case is normal.
Related • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C.
information • Before starting troubleshooting, set gear shift lever in each gear speed and check that machine does
not move in only forward or reverse direction.

a Prepare with engine stopped, then run engine at high idle (no-
load travel) and carry out troubleshooting.
Measured clutch Clutch pressure
1.96 – 2.45 MPa
Malfunction of transmission FL, FH
Possible causes 1 {20 – 25 kg/cm2}
clutch valve (ECMV)
and standard 2.25 ± 0.2 MPa
value in normal R
{23.0 ± 2.0 kg/cm2}
state
If oil pressure is abnormal, replace clutch valve (ECMV) with one of
normal side and check again, then judge.
Defective transmission clutch
2 Transmission clutch piston seal may be defective. Check it directly.
piston seal
Worn or broken transmis- Transmission clutch disc/plate may be worn or broken. Check it
3
sion clutch disc/plate directly.
Trouble (2) Transmission does not shift up or shift down

information • Before starting troubleshooting, set gear shift lever in each gear speed and check that machine does
not move in only specific gear speed.

Malfunction of transmission
Possible causes 1 1.96 – 2.45 MPa
clutch valve (ECMV) FL, FH, 1st, 2nd, 3rd, 4th
and standard {20 – 25 kg/cm2}
value in normal
state
same set pressure and check again, then judge.
piston seal
3
6 GD655-3E0, GD675-3E0
H-4 Machine is slow or lacks power when traveling 1

Trouble (1) Machine is slow or lacks power in all gear speeds
information • Before starting troubleshooting, check that wheel brake and parking brake are not dragging (If
machine starts moving when engine speed is low idle and gear speed is F4, brakes are normal).

Clogged suction strainer of Suction strainer of transmission case may be clogged. Check it
1
transmission case directly.
Air in suction circuit of power Suction circuit of power train pump may have sucked air. Check it
2
train pump directly.
Defect in power train pump
3 Power train pump may have defect in it. Check it directly.
(pump unit)
troubleshooting.
Power train main
4
main relief valve 2.4 ± 0.1 MPa
Low idle
{24.5 ± 1.0 kg/cm2}
P position
2.46 ± 0.2 MPa
Possible causes High idle
and standard {25.1 ± 2.0 kg/cm2}
value in normal a Prepare with engine stopped, then run engine at high idle and
state carry out troubleshooting.
verter main relief valve
0.88 ± 0.05 MPa
P position
{9.0 ± 0.5 kg/cm2}

P position
{6.0 ± 0.5 kg/cm2}
abnormal, torque converter may have defect in it. Check torque con-
verter directly.
7 Defect in transmission Transmission may have defect in it. Check it directly.
8 Defect in final drive Final drive may have defect in it. Check it directly.
GD655-3E0, GD675-3E0 7
Trouble (2) Machine is slow or lacks power in specific gear speed

• Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C.
Related
• Torque converter lockup clutch operates in specific gear speed according to position of transmission
information
mode selector switch (See table of "Transmission mode selector switch and torque converter lockup
function").

Transmission mode
1 verter lockup clutch valve Gear shift lever Clutch pressure
selector switch
(ECMV)
2.01 ± 0.15 MPa
Mode 1 F1 position
{20.5 ± 1.5 kg/cm2}
Defective torque converter Torque converter lockup clutch piston seal may be defective. Check
2
lockup clutch piston seal it directly.
Worn or broken torque con-
Torque converter lockup clutch disc/plate may be worn or broken.
3 verter lockup clutch disc/
Check it directly.
Possible causes plate
and standard
value in normal
state
1.96 – 2.45 MPa
Malfunction of transmission FL, FH, 1st, 2nd, 3rd, 4th
4 {20 – 25 kg/cm2}
clutch valve (ECMV)
2.06 – 2.45 MPa
R
{21 – 25 kg/cm2}
piston seal
6
Transmission mode selector switch and torque converter lockup function

Gear shift lever F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
Gear speed F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
Transmission mode Mode 1 D D D D D D D D D D TC TC
selector switch Mode 2 TC TC TC TC AT AT AT AT TC TC TC TC
D: Lockup clutch is kept in operation (Direct drive, manual shift).

TC: Lockup clutch is kept reset (Torque converter drive, manual shift).
AT: Lockup clutch is operated and reset automatically according to slipping condition of torque converter
(Torque converter drive, automatic shift).
8 GD655-3E0, GD675-3E0
H-5 Torque converter lockup function cannot be actuated or canceled1

Trouble • Torque converter lockup function cannot be actuated or canceled
Related
• Torque converter lockup clutch operates in specific gear speed according to position of transmission
information
mode selector switch (See table of "Transmission mode selector switch and torque converter lockup
function").

Transmission mode
1 verter lockup clutch valve Gear shift lever Clutch pressure
Possible causes selector switch
(ECMV)
and standard 2.01 ± 0.15 MPa
value in normal Mode 1 F1 position
{20.5 ± 1.5 kg/cm2}
state
2
Worn or broken torque con-
3 verter lockup clutch disc/
Check it directly.
plate
Transmission mode selector switch and torque converter lockup function

Gear shift lever F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
Gear speed F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
Transmission mode Mode 1 D D D D D D D D D D TC TC
selector switch Mode 2 TC TC TC TC AT AT AT AT TC TC TC TC
D: Lockup clutch is kept in operation (Direct drive, manual shift).

TC: Lockup clutch is kept reset (Torque converter drive, manual shift).
AT: Lockup clutch is operated and reset automatically according to slipping condition of torque converter
(Torque converter drive, automatic shift).
GD655-3E0, GD675-3E0 9
H-6 Excessive time lag when starting or shifting gear 1

Trouble • Excessive time lag when starting or shifting gear
Related • Before starting troubleshooting, set gear shift lever in each gear speed and check which gear speed
information or travel direction has excessive time lag.
• Before starting troubleshooting, check that travel speed is normal. (If abnormal, carry out trouble-
shooting for "H-4 Machine is slow or lacks power when traveling" first.)

1.96 – 2.45 MPa
Possible causes 1 {20 – 25 kg/cm2}
clutch valve (ECMV)
and standard 2.06 – 2.45 MPa
value in normal R
{21 – 25 kg/cm2}
state
piston seal
3
10 GD655-3E0, GD675-3E0
H-7 Torque converter oil temperature is high 1

Trouble • Torque converter oil temperature is high
information • Before starting troubleshooting, check that wheel brake and parking brake are not dragging (If
machine starts moving when engine speed is low idle and gear speed is F4, brakes are normal).

troubleshooting.
Power train main
1
main relief valve 2.4 ± 0.1 MPa
Low idle
{24.5 ± 1.0 kg/cm2}
P position
2.46 ± 0.2 MPa
High idle
{25.1 ± 2.0 kg/cm2}
Malfunction of torque
converter main relief valve
0.88 ± 0.05 MPa
P position
{9.0 ± 0.5 kg/cm2}

P position
{6.0 ± 0.5 kg/cm2}
Possible causes abnormal, torque converter may have defect in it. Check torque
and standard converter directly.
value in normal
state
Malfunction of torque
Transmission mode
4 converter lockup clutch valve Gear shift lever Clutch pressure
selector switch
(ECMV)
2.01 ± 0.15 MPa
Mode 1 F1 position
{20.5 ± 1.5 kg/cm2}
5
Worn or broken torque
6 converter lockup clutch disc/
Check it directly.
plate
1.96 – 2.45 MPa
7 {20 – 25 kg/cm2}
clutch valve (ECMV)
2.06 – 2.45 MPa
R
{21 – 25 kg/cm2}
piston seal
GD655-3E0, GD675-3E0 11
and standard Worn or broken transmission Transmission clutch disc/plate may be worn or broken. Check it
9
value in normal clutch disc/plate directly.
state 10 Defect in transmission Transmission may have defect in it. Check it directly.
12 GD655-3E0, GD675-3E0
H-8 Differential lock function is not operated or reset [Differential lock

specification] 1
Trouble • Differential lock function does not work or is not reset
Related • Before starting troubleshooting, check that oil level in final drive case is normal.
information • Check oil pressure while final drive case oil temperature gauge is reading 45 – 55°C.

Defective coupling of
Differential lock pump may not be rotating because of defective cou-
1 differential lock pump
pling of its drive system. Check drive system directly.
(drive system)
Clogged suction strainer of
2 Suction strainer of final drive case may be clogged. Check it directly.
final drive case
Air in suction circuit of Suction circuit of differential lock pump may have sucked air. Check
3
differential lock pump it directly.
Defect in differential lock
4 Differential lock pump may have defect in it. Check it directly.
pump (pump unit)
Possible causes carry out troubleshooting.
and standard
Differential lock pressure
value in normal Differential lock switch
(Pump outlet, valve outlet)
state
Malfunction or improper Approx. 0 MPa
OFF
5 adjustment of differential lock {Approx. 0 kg/cm2}
valve Max. 2.84 MPa
ON
{Max. 29.0 kg/cm2}
If oil pressure does not become normal after adjustment, differential
lock valve may be malfunctioning or may have defect in it. Check
differential lock valve directly.
Defective differential lock Differential lock clutch piston seal may be defective. Check it
6
clutch piston seal directly.
Worn or broken differential Differential lock clutch disc/plate may be worn or broken. Check it
7
lock clutch disc/plate directly.
GD655-3E0, GD675-3E0 13
H-9 Machine is slow or lacks power when steering 1

Trouble • Machine is slow or lacks power when steering
• Check oil pressure and cylinder leakage while hydraulic oil temperature is 45 – 55°C.
Related • Before starting troubleshooting, check that work equipment operates normally (If not, carry out trou-
information bleshooting for "H-12 All work equipment is slow or lacks power" first).
• Since steering valve (Orbit-roll) is variable ratio type, steering speed changes according to rotating
speed of steering wheel.

Malfunction of priority valve Steering cylinder Steering oil pressure
1
(relief valve)
Possible causes 18.1 +0.7
+0 MPa
When relieved
and standard {185 +0 kg/cm2}
+7
value in normal 2 Malfunction of steering valve Steering valve (Orbit-roll) may be malfunctioning. Check it directly.
state
Defective steering cylinder
3 Steering cylinder Cylinder leakage
seal
When relieved in
0 cc/min
extending operation
14 GD655-3E0, GD675-3E0
H-10 Wheel brake does not work normally 1

Trouble • Wheel brake does not work normally
Related • Check oil pressure while hydraulic oil temperature is 45 – 55°C.
information • Before starting troubleshooting, check that work equipment operates normally (If not, carry out trou-
bleshooting for "H-13 No work equipment moves" first).

9.36 +0.2
+0 MPa
Cut-in pressure 2
Malfunction or improper {95.5 +2
+0 kg/cm }
adjustment of brake 12.26 +0.98 MPa

1 Cut-out pressure +0
accumulator charge valve 2
{125 +10
+10 kg/cm }
(pressure governor valve)
If oil pressure does not become normal after adjustment, pressure
governor valve of brake accumulator charge valve may be malfunc-
tioning or may have defect in it. Check pressure governor valve
directly.
Malfunction of brake
LS relief valve of brake accumulator charge valve may be malfunc-
2 accumulator charge valve
tioning. Check it directly.
(LS relief valve)
Gas pressure in brake accumulator (2 units of front and rear) may
Gas pressure reduction in be low. Check it directly.
3
brake accumulator Accumulator gas pressure 3.4 ± 0.1 MPa
Possible causes (Nitrogen gas) {35 ± 1 kg/cm2}
and standard
value in normal
state
Brake pedal Wheel brake actuating pressure
4 Malfunction of brake valve 3.9 +0.10
–0.31 MPa
Pressed (to stroke end) 2
{40 +1
–3 kg/cm }
If oil pressure is abnormal, block hose outlet on slack adjuster side

and check again, then judge.
5 Malfunction of slack adjuster Slack adjuster may be malfunctioning. Check it directly.
a Prepare with engine stopped, then carry out troubleshooting with-
out starting engine (Increase accumulator pressure before start-
ing check).
6 Defective brake piston seal Wheel brake actuating pressure
Brake pedal
reduction (in 5 min)
98 kPa
Pressed (to stroke end)
{1.0 kg/cm2}
Worn or broken brake disc/
7 Brake disc/plate may be worn or broken. Check it directly.
plate
Defective air bleeding from Air may not be bled from brake circuit normally. Bleed air (Slack
8
brake circuit adjuster section and wheel brake section).
GD655-3E0, GD675-3E0 15
H-11 Parking brake is not applied or released 1

Trouble • Parking brake is not applied or released
Related • Check oil pressure while hydraulic oil temperature is 45 – 55°C.
information • Before starting troubleshooting, check that wheel brake operates normally (If not, carry out trouble-
shooting for "H-10 Wheel brake does not work normally" first).

Clogged parking brake bank
1 Parking brake bank valve filter may be clogged. Check it directly.
valve (filter)
Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of parking brake Gear shift lever Parking brake actuating pressure
Possible causes 2 bank valve (parking solenoid 0 MPa
and standard valve) P position
{0 kg/cm2}
value in normal
state 9.36 – 13.24 MPa
Position other than P
{95.5 – 135 kg/cm2}
3 Clogged elbow filter Elbow filter may be clogged. Check it directly.
Malfunction of parking brake
4 Parking brake calipers may be malfunctioning. Check it directly.
calipers
Improper adjustment of
5 Parking brake may be adjusted improperly. Check it directly.
parking brake
16 GD655-3E0, GD675-3E0
H-12 All work equipment is slow or lacks power 1

Trouble • All work equipment is slow or lacks power
Related • Before starting troubleshooting, check that oil level in hydraulic tank is normal.
information • Check oil pressure while hydraulic oil temperature is 45 – 55°C.

Clogged suction strainer of
1 Suction strainer of hydraulic tank may be clogged. Check it directly.
hydraulic tank
Loosened joint or cracked
Joint of piston pump suction piping may be loosened or hose is
2 hose of piston pump suction
cracked. Check them directly.
piping
a Adjust with engine stopped, then run engine at high idle and carry
Malfunction or improper out troubleshooting.
3 adjustment of piston pump If condition does not become normal after adjustment, PC valve of
(PC valve) piston pump may be malfunctioning or may have defect in it. Check
piston pump directly.
Work equipment LS differential pressure
2.8 ± 0.98 MPa
Malfunction or improper All work equipment in neutral
{29 ± 10 kg/cm2}
4 adjustment of piston pump
(LS valve) While blade is turning 2.35 ± 0.1 MPa
(Lever at stroke end) {24 ± 1 kg/cm2}
If differential pressure does not become normal after adjustment, LS
Possible causes valve of piston pump may be malfunctioning or may have defect in
and standard it. Check LS valve directly.
value in normal
state Clogged piston pump
5 Orifice plug of piston pump may be clogged. Check it directly.
(orifice plug)
Malfunction of piston pump Servo piston of piston pump may be malfunctioning. Check it
6
(servo piston) directly.
Defect in piston pump
(pump unit)
Malfunction of left 5-spool
8 Work equipment Unload pressure
control valve (unload valve)
2.8 ± 0.98 MPa
All work equipment in neutral
{29 ± 10 kg/cm2}
Work equipment circuit relief
Malfunction or improper Work equipment
pressure
adjustment of right 4-spool
9 When relieved 20.6 ± 1 MPa
control valve (main relief
valve/LS relief valve) (Check each actuator singly) {210 ± 10 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve or LS relief valve of right 4-spool control valve may be mal-
functioning or may have defect in it. Check them directly.
GD655-3E0, GD675-3E0 17
H-13 No work equipment moves 1

Trouble • No work equipment moves
information • Check oil pressure while hydraulic oil temperature is 45 – 55°C.

Piston pump may not be rotating because of defect in PTO. Check
1 Defect in PTO
PTO directly.
Defective piston pump Piston pump may not be rotating because of defective coupling of its
2
(drive system) drive system. Check drive system directly.
Defect in piston pump
(pump unit)
Possible causes Malfunction of left 5-spool
4 Work equipment Unload pressure
and standard control valve (unload valve)
value in normal 2.8 ± 0.98 MPa
All work equipment in neutral
state {29 ± 10 kg/cm2}
Malfunction or improper Work equipment
pressure
adjustment of right 4-spool
5 When relieved 20.6 ± 1 MPa
control valve (main relief
valve/LS relief valve) (Check each actuator singly) {210 ± 10 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve or LS relief valve of right 4-spool control valve may be mal-
functioning or may have defect in it. Check them directly.
18 GD655-3E0, GD675-3E0
H-14 Abnormal noise generated around pump 1

Trouble • Abnormal noise generated around pump
Related
• Causes 1 – 5 are in piston pump system and causes 6 – 9 are in power train pump system.
information

Oil level reduction in hydraulic
1 Oil level in hydraulic tank may be low. Check it directly.
tank
2 Air in hydraulic oil Hydraulic oil may contain air. Check it directly.
Hydraulic tank cap may be clogged and pressure in tank may be
3 Clogged hydraulic tank cap
negative. Check tank cap directly.
Clogged hydraulic tank Hydraulic tank strainer may be clogged and pressure in suction cir-
Possible causes 4
strainer cuit may be negative. Check tank strainer directly.
and standard
5 Defect in piston pump Piston pump may have defect in it. Check it directly.
value in normal
state Oil level reduction in
6 Oil level in transmission case may be low. Check it directly.
transmission case
7 Air in transmission oil Transmission oil may contain air. Check it directly.
Clogged transmission case Transmission case strainer may be clogged and pressure in suction
8
strainer circuit may be negative. Check case strainer directly.
9 Defect in power train pump Power train pump may have defect in it. Check it directly.
If causes 1 – 9 are not detected, operate machine for a while to see
– When cause cannot be found
if condition changes.
GD655-3E0, GD675-3E0 19
H-15 Blade is slow or lacks power in lifting 1

Trouble • Blade is slow or lacks power in lifting
information • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C.

Insufficient stroke of blade lift a Carry out troubleshooting with engine stopped.
1
control valve (spool) Spool stroke (Each side) 6 mm
Malfunction of pilot check Check valve of pilot check valve may be malfunctioning. Check it
2
valve (check valve) directly.
Possible causes Malfunction of pilot check
and standard 3 valve (relief valve) Right blade lift cylinder
pressure
value in normal [Only right blade lift]
state When relieved in 20.6 ± 1 MPa
raising operation {210 ± 10 kg/cm2}
Defective blade lift cylinder
4 Blade lift cylinder Cylinder oil leakage
seal
When relieved in
0 cc/min
lowering operation
5 Deformed blade lift cylinder Blade lift cylinder may be deformed. Check it directly.
20 GD655-3E0, GD675-3E0
H-16 Excessive blade drift 1

Trouble • Excessive blade drift

1
Malfunction of pilot check
Possible causes Work equipment circuit relief
2 valve (relief valve) Right blade lift cylinder
and standard pressure
[Only right blade lift]
value in normal When relieved in 20.6 ± 1 MPa
state raising operation {210 ± 10 kg/cm2}
Defective blade lift cylinder
3 Blade lift cylinder Cylinder oil leakage
seal
When relieved in
0 cc/min
lowering operation
GD655-3E0, GD675-3E0 21
H-17 Drawbar side shift operation is slow or lacks power 1

Trouble • Drawbar side shift operation is slow or lacks power

Insufficient stroke of drawbar a Carry out troubleshooting with engine stopped.
1
side shift control valve (spool) Spool stroke (Each side) 6 mm
2 Pilot check valve may be malfunctioning. Check it directly.
Possible causes valve
and standard a Prepare with engine stopped, then run engine at high idle and
value in normal carry out troubleshooting.
state Defective drawbar side shift
3 Drawbar side shift cylinder Cylinder oil leakage
cylinder seal
When relieved in
0 cc/min
right shift operation
Deformed drawbar side shift
4 Drawbar side shift cylinder may be deformed. Check it directly.
cylinder
22 GD655-3E0, GD675-3E0
H-18 Blade side shift operation is slow or lacks power 1

Trouble • Blade side shift operation is slow or lacks power

Insufficient stroke of blade a Carry out troubleshooting with engine stopped.
1
side shift control valve (spool) Spool stroke (Each side) 6 mm
2 Defective swivel joint seal Swivel joint seal may be defective. Check it directly.
Possible causes
Defective blade side shift
state 3 Blade side shift cylinder Cylinder oil leakage
cylinder seal
When relieved in
0 cc/min
left shift operation
Deformed blade side shift
4 Blade side shift cylinder may be deformed. Check it directly.
cylinder
GD655-3E0, GD675-3E0 23
H-19 Power tilt operation is slow or lacks power 1

Trouble • Power tilt operation is slow or lacks power

Insufficient stroke of power a Carry out troubleshooting with engine stopped.
1
tilt control valve (spool) Spool stroke (Each side) 6 mm
2
Possible causes Malfunction of pilot check Work equipment circuit relief
3 Power tilt cylinder
and standard valve (relief valve) pressure
value in normal When relieved in cutting angle 20.6 ± 1 MPa
state reducing operation {210 ± 10 kg/cm2}
4 Defective swivel joint seal Swivel joint seal may be defective. Check it directly.
Defective power tilt cylinder
5 Power tilt cylinder Cylinder oil leakage
seal
When relieved in cutting angle
0 cc/min
increasing operation
6 Deformed power tilt cylinder Power tilt cylinder may be deformed. Check it directly.
24 GD655-3E0, GD675-3E0
H-20 Articulate operation is slow or lacks power 1

Trouble • Articulate operation is slow or lacks power

Insufficient stroke of articulate a Carry out troubleshooting with engine stopped.
1
Possible causes 2 Pilot check valve may be malfunctioning. Check it directly.
valve
and standard
Defective articulate cylinder
3 Articulate cylinder Cylinder oil leakage
seal
When relieved in
0 cc/min
extension operation
4 Deformed articulate cylinder Articulate cylinder may be deformed. Check it directly.
GD655-3E0, GD675-3E0 25
H-21 Leaning operation is slow or lacks power 1

Trouble • Leaning operation is slow or lacks power

Insufficient stroke of leaning a Carry out troubleshooting with engine stopped.
1
Possible causes 2 Pilot check valve may be malfunctioning. Check it directly.
valve
and standard
Defective leaning cylinder
3 Leaning cylinder Cylinder oil leakage
seal
When relieved in
0 cc/min
right leaning operation
4 Deformed leaning cylinder Leaning cylinder may be deformed. Check it directly.
26 GD655-3E0, GD675-3E0
H-22 Excessive drift of leaning 1

Trouble • Excessive drift of leaning

1 Pilot check valve may be malfunctioning. Check it directly.
Possible causes valve
state Defective leaning cylinder
2 Leaning cylinder Cylinder oil leakage
seal
When relieved in
0 cc/min
right leaning operation
GD655-3E0, GD675-3E0 27
H-23 Blade does not rotate 1

Trouble • Blade does not rotate
information • Before starting troubleshooting, check that oil level in circle rotation gear case is normal.

Insufficient stroke of blade a Carry out troubleshooting with engine stopped.
1
rotation control valve (spool) Spool stroke (Each side) 5 mm
Broken circle rotation gear
2 Shear pin of circle rotation gear may be broken. Check it directly.
Possible causes (shear pin) [Shear pin type]
and standard Improper adjustment of circle
value in normal Clutch of circle rotation gear may be adjusted improperly. Check it
3 rotation gear (clutch)
state directly.
[Clutch type]
Defect in circle rotation gear
4 Gear of circle rotation gear may have defect in it. Check it directly.
(gear)
Malfunction or internal defect Circle rotation motor may be malfunctioning or may have defect in it.
5
of circle rotation motor Check it directly.
28 GD655-3E0, GD675-3E0
H-24 Lift arm lock pin is not locked or reset [Lift arm specification] 1
Trouble • Lift arm lock pin is not locked or reset
Related
• Check oil pressure while hydraulic oil temperature is 45 – 55°C.
information

Misalignment of lift arm and
1 Lift arm and lock pin may be misaligned. Align them.
lock pin
Clogged parking brake bank
2 Parking brake valve filter may be clogged. Check it directly.
valve (filter)
Possible causes a Prepare with engine stopped, then run engine at high idle and
and standard carry out troubleshooting.
value in normal Malfunction of parking brake Lift arm lock pin lamp Cylinder head Cylinder bottom
state 3 bank valve (bank solenoid pressure pressure
valve) 9.36 – 13.24 MPa
When OFF
{95.5 – 135 kg/cm2}
When ON Same as above Lower than above
Malfunction or internal defect Lift arm lock cylinder may be malfunctioning or may have defect in it.
4
of lift arm lock cylinder Check it directly.
GD655-3E0, GD675-3E0 29

Trouble • Blade accumulator function is not operated or reset
Related
—
information

Malfunction or internal defect
Blade accumulator solenoid valves (2 units of right and left) may be
Possible causes 1 of blade accumulator solenoid
malfunctioning or may have defect in them. Check them directly.
and standard valve
value in normal Gas pressure in blade accumulators (2 units of right and left) may
state Gas pressure reduction in be low. Check it directly.
2
blade accumulator Accumulator gas pressure 2.0 ± 0.1 MPa
(Nitrogen gas) {20 ± 1 kg/cm2}
30 GD655-3E0, GD675-3E0
H-26 Blade float function is not operated or reset

Trouble • Blade float function is not operated or reset
Related
—
information
and standard
value in normal Malfunction or internal defect Blade float solenoid valves (4 units of right and left) may be malfunc-
1
state of blade float solenoid valve tioning or may have defect in them. Check them directly.
GD655-3E0, GD675-3E0 31
SEN01842-00

© 2006 KOMATSU
All Rights Reserved
32
SEN01843-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting charts ............................................................................................... 3
S-1 Starting performance is poor.......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 7
S-3 Engine does not pick up smoothly............................................................................................... 10
S-4 Engine stops during operations ....................................................................................................11
S-5 Engine does not rotate smoothly ................................................................................................. 12
S-6 Engine lacks output (or lacks power)........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 15
S-9 Oil becomes contaminated quickly .............................................................................................. 16
S-10 Fuel consumption is excessive.................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ....................................... 18
S-12 Oil pressure drops ..................................................................................................................... 19
S-13 Oil level rises (water, fuel in oil) ................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) .............................................................. 21
GD655-3E0, GD675-3E0 1
S-15 Abnormal noise is made ............................................................................................................ 22

S-16 Vibration is excessive ................................................................................................................ 23
2 GD655-3E0, GD675-3E0
Troubleshooting of engine (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E.
(If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
GD655-3E0, GD675-3E0 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
4 GD655-3E0, GD675-3E0
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
GD655-3E0, GD675-3E0 5
S-1 Starting performance is poor. 1
General causes why starting performance is poor Cause
Stuck and seized fuel supply pump plunger

Clogged air breather hole in fuel tank cap
• Defective electrical system
• Insufficient supply of fuel
Defective contact of valve, valve seat
Defective alternator (generator unit)

Leakage, clogging, air in fuel piping
Defective alternator (regulator unit)

Defective intake air heater system
• Insufficient intake of air
Defective or deteriorated battery

• Improper selection of fuel
Clogged air cleaner element
Clogged fuel filter, element
Defective electric lift pump

Worn piston ring, cylinder
a With the common rail fuel injection system (CRI), the fuel injec-
tion timing is recognized electrically, so even when the starting
Defective injector
operation is carried out, the engine may not start until the
crankshaft has completed two rotations. However, this does
not indicate any abnormality.
Confirm recent repair history

Degree of use of
Operated for long period E E E
machine
Gradually became worse Q w w Q
Ease of starting
Starts when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation & Maintenance Manual w w Q Q
Engine oil must be added more frequently w
Preheating monitor does not work normally during preheating or in low temperatures
w
(when monitor is installed)
Charging monitor shows abnormality in charging while driving (when monitor is installed) w w
Dust indicator lamp is red (when indicator is installed) w
Air breather hole in fuel tank cap is clogged w
Leakage of fuel from fuel piping w Q
Starting motor cranks engine slowly w
When engine is No fuel comes out even when fuel filter air bleed plug is removed w Q
cranked with starting When hose at collection portion for spill flow from fuel injector is
motor w
disconnected, spill flow is small
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
w
ders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Check air cleaner directly q

When compression pressure is measured, it is found to be low q q
Check fuel filter, strainer directly q
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q
Troubleshooting
Carry out troubleshooting for code display “Defective electric lift pump (*2)“ q
Engine speed does not change when operation of certain cylinders is stopped in reduced cylin-
q
der mode
Intake air heater mount does not become warm during operation of preheating q
Is voltage between alternator terminal B and terminal E with engine at low idle? Yes q
(20 – 30V) No q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Action
*1: Failure code of code display [CA559] and [CA2249]

6 GD655-3E0, GD675-3E0
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
• Seized parts inside engine:

See "S-4 Engine stops during operations"
Defective steering circuit wiring

• Defective electrical system
• Problem in drive devices on applicable machine side:
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Carry out troubleshooting for devices on applicable machine
Defective safety relay

Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w

Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch Makes grating noise w w
is turned to START, start-
ing pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Carry out troubleshooting on applicable machine

Inspect flywheel ring gear directly
When specific gravity of electrolyte and voltage of battery are measured, they are low q
There is not voltage (20 – 30 V) between battery relay terminal B and ter-
q
minal E
When terminal B and terminal C of starting switch are connected, engine
q
Troubleshooting
starts
When terminal B and terminal C at safety relay outlet are connected,
Turn starting switch OFF, q
engine starts
connect cord, and carry
Even if terminal B and terminal C at safety relay outlet are connected,
out troubleshooting at ON q
engine does not start
When terminal at safety switch and terminal B at starting motor are con-
q
nected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
GD655-3E0, GD675-3E0 7
b) Engine turns but no exhaust smoke comes out Cause
Defective actuation of fuel overflow valve (does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Defective fuel supply pump IMV solenoid

Seized, abnormally worn fuel feed pump
Stuck, seized fuel supply pump plunger
Defective common rail pressure limiter

Broken fuel supply pump shaft

Clogged fuel filter, element

Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of use of
Questions
Operated for long period E E

machine
Exhaust smoke suddenly stops coming out (when starting again) w Q w w E
Replacement of filters has not been carried out according to Operation & Mainte-
w E Q
nance 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 E E
When fuel filter is removed, there is no fuel in filter w w Q
Check items
There is a leakage from fuel piping w
When engine is No fuel comes out even when fuel filter air bleed plug is removed Q Q w Q Q
cranked with start- When hose at collection portion for spill flow from fuel injector is
ing motor Q w w w Q
disconnected, spill flow is small
Check fuel filter directly q

Check fuel feed pump directly q
Troubleshooting
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q q
Carry out troubleshooting for code display “Abnormality in IMV solenoid (*2)“ q
Check fuel overflow valve directly q
Possible to start in reduced cylinder mode q
When pressure limiter return pipe is removed, fuel comes out q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add

*2: Failure code of code display [CA2311]
8 GD655-3E0, GD675-3E0
c) Exhaust smoke comes out but engine does not start Cause
(Fuel is being injected)
Defective coolant temperature sensor, defective wiring harness

General causes why exhaust smoke comes out but engine does not
start
Worn dynamic valve system (valve, rocker lever, etc.)

• Lack of rotating force due to defective electrical system


Leakage, clogging, air in fuel system
Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner

Improper fuel used
Clogged fuel filter

Degree of use of
Operated for long period E E E
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used w Q Q

Replacement of filters has not been carried out according to Operation & Maintenance Manual w w
Preheating monitor does not work normally during preheating or in low temperatures
w
(when monitor is installed)
Air breather hole in fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is no fuel in filter w Q
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Q w Q
Check items
When engine is No fuel comes out even when fuel filter air bleed plug is removed
cranked with starting When hose at collection portion for spill flow from fuel injector is dis-
motor w
connected, spill flow is small
w
ders is low

Check dynamic valve system directly q
When compression pressure is measured, it is found to be low q
When air is bled from fuel line, air comes out q
Troubleshooting
Check fuel filter directly q

Possible to start in reduced cylinder mode q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low. q
Defective coolant temperature gauge display (when coolant temperature gauge is installed) q
Intake air heater mount does not become warm during preheating q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Action

GD655-3E0, GD675-3E0 9
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Cause

Defective contact of valve and valve seat


Seized turbocharger, interference
• Abnormal fuel injection condition
Clogged injector, defective spray


• Controller controlled by derate mode
Improper valve clearance

(The injection amount (output) is limited because a failure has occurred in
the electrical system.)
Clogged fuel filter

Degree of use of
Operated for long period E E E E
machine
Questions
Engine pick-up suddenly becomes poor w Q Q Q

Non-specified fuel is being used w w w
Rust and water are found when fuel in fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some cyl-
Q w
inders is low
Color of exhaust Blue under light load w

Check items
gas Black w Q w w
When engine is running, abnormal noise is heard from around cylinder head w
When engine is running, noise of interference is heard from around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Check valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

When air is bled from fuel line, air comes out q
q
der mode
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Action
10 GD655-3E0, GD675-3E0
S-4 Engine stops during operations 1

General causes why engine stops Cause
Broken dynamic valve system (valve, rocker lever, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

• Internal part of engine seized
Failure in power train mounted on the machine

• Engine overheating
• Failure in power train on the machine:

Carry out troubleshooting on the machine.
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Broken, seized fuel feed pump

Broken fuel supply pump shaft
Clogged, leaking fuel piping
Broken, seized gear train
Clogged fuel filter

Degree of use of machine Operated for long period E
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w w
Engine overheated and stopped w Q Q
Questions
Condition when engine

stopped Engine stopped slowly w Q
There was hunting and engine stopped w Q Q Q
Replacement of filters has not been carried out according to Operation & Maintenance Manual w
Fuel level monitor indicates low fuel remaining (when monitor is installed) w
Rust and water are found when fuel in fuel tank is drained w
Metal particles are found when oil in oil pan is drained w w w Q
Check items
Does not turn at all w w
When it is attempted to turn Turns in opposite direction w

engine by hand Moves amount of backlash w w
Fuel supply pump shaft does not run w
Engine rotates but stops when load is applied to machine w
q
Carry out troubleshooting on the machine
Check dynamic valve system directly
Check piston and connecting rod directly q
Check crankshaft bearing directly q
q
Troubleshooting
Check gear train directly

Check fuel feed pump directly q
When auxiliary equipment (pump, air compressor, etc.) is removed, engine turns q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add
GD655-3E0, GD675-3E0 11
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Cause
Defective Bkup speed sensor, defective wiring harness

• Air in fuel system
Defective Ne speed sensor, defective wiring harness

• Speed sensor is not normal (abnormality not big enough to generate failure display
Clogged fuel injector, defective spray (dirt caught)

Clogged fuel filter

Degree of use of
Operated for long period E
machine
Questions
Occurs at a certain speed range Q Q

Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Check items

Rust and water are found when fuel in fuel tank is drained Q
q
Troubleshooting
Check fuel filter, strainer directly

Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode q
Carry out troubleshooting for code display “Abnormality in Ne speed sensor (*1)“ q
Carry out troubleshooting for code display “Abnormality in Bkup speed sensor (*2)“ q
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add

12 GD655-3E0, GD675-3E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Defective boost pressure sensor, defective wiring harness

Defective mount of boost pressure sensor (air leakage)
Clogged fuel injector, defective spray (dirt caught)


Defective contact of valve and valve seat
Defective injector drive (signal, solenoid)

• Engine overheating:

See “S-14 Coolant temperature becomes too high (over-

heating)“
Clogged, leaking fuel piping

Leakage in air intake piping

Clogged fuel spill piping

(The injection amount (output) is limited because a failure
Clogged fuel filter

has occurred in the electrical system.)
Degree of use of
machine
Questions
Suddenly Q w Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q
Engine oil must be added more frequently Q Q
Dust indicator lamp is red (when indicator is installed) w w
Power is lacking after short stop in operations w

Black w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
w w
low

Check items
High idle speed of engine is 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
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w
Check air intake piping directly q
When boost pressure is measured, it is found to be low q q q

Troubleshooting
Check fuel piping q
Check spill port check valve directly q
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder
q q
mode
Check mounting of boost pressure sensor directly q
Carry out troubleshooting for code display “Abnormality in boost pressure sensor (*2)“ q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Action

GD655-3E0, GD675-3E0 13
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Cause
Leakage of air between turbocharger and cylinder head

• Engine overheating:
Defective coolant temperature sensor,

See “S-14 Coolant temperature becomes too high
Defective contact of valve, valve seat

(overheating)“
Defective fuel injection pressure

Defective fuel injection timing

Clogged, seized fuel injector
(The injection amount (output) is limited because a failure has
Crushed, clogged muffler
defective wiring harness

occurred in the electrical system.)
Worn fuel injector

Degree of use of
machine
Suddenly became black w w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q

Non-specified fuel is being used Q Q
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operates in low-temperature mode even at normal temperatures Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cyl-
Q w
inders is low
Check items
Rotation speed of torque converter stall and pump relief is high (excessive injection of fuel) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When hose from injector to spill collection portion is disconnected, spill flow is found to be
w
abnormally high

Troubleshooting

When muffler is removed, exhaust color returns to normal q
q
der mode
Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)“ q
Confirm with monitoring function of INSITE or on the machine q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Action
*1:Failure code of code display [CA559] and [CA2249]

*2:Failure code of code display [CA114] and [CA145]
14 GD655-3E0, GD675-3E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Cause
Turbocharger
• Abnormal combustion of oil
Leakage from oil pan, cylinder head, etc.

• The engine has been run at low or high idle for a long time
Worn, broken valve (stem, guide, seal)

continuously
(more than 20 minutes continuous operation is not allowed)
Clogged breather, breather hose

Dust stuck in from intake system
Worn seal at the side of turbine

• External leakage of oil
Worn seal at the side of blower

• Wear of lubrication system
Leakage from oil drain plug

Worn, broken rear oil seal
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Degree of use of
E E E E
Questions
Operated for long period

machine
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Oil gets contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Loose piping clamp in air intake system w
Inside of turbocharger air supply pipe is dirty with oil w
Inside of turbocharger exhaust pipe is dirty with oil Q w
Check items
There is oil in engine coolant w

Oil level in clutch or damper chamber rises w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be extremely dirty q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather, breather hose directly q
Check rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Action
GD655-3E0, GD675-3E0 15
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Cause
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
Clogged breather, breather hose

• Improper oil used
Defective oil filter safety valve

• Operation under excessive load
Exhaust smoke color is poor

Worn valve, valve guide
Clogged oil cooler

Clogged oil filter
Questions
Degree of use of machine Operated for long period E E E

Non-specified fuel is being used Q Q
Metal particles are found when oil inside oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather, breather hose directly q
See S-7
Check oil cooler directly q
Check oil filter directly q
Spring of oil filter safety valve catching or broken q
Check turbocharger drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Action
16 GD655-3E0, GD675-3E0
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause
Defective coolant temperature sensor, defective wiring harness

• Leakage of fuel
• Improper condition of fuel injection (injection pressure, injection timing)
• Excessive injection of fuel
External leakage from fuel piping, fuel filter
Defective common rail fuel pressure
Defective actuation of fuel injector

Leakage of fuel inside head cover
Defective fuel feed pump oil seal

Defective supply pump plunger
Defective fuel injection timing

Defective fuel injector spray
Degree of use of
E E E
Questions

machine
Is more than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
There is irregular combustion w
Engine oil level rises and smells of diesel fuel w w
w
ders is low
Check items
Low idle speed is high Q

Rotation speed of torque converter stall and pump relief is high Q
Color of exhaust Black Q Q Q Q

gas White Q
Remove head cover and check directly q

Check fuel feed pump oil seal directly q
q
Troubleshooting
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder
q
mode
When flow of oil from fuel injector at spill return collection portion is measured, it is found to be
q
excessive
Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)” q
Confirm with monitoring function of INSITE or on the machine q q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Action

GD655-3E0, GD675-3E0 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)1
General causes why oil is in coolant Causes
Broken hydraulic oil cooler or power train

• Internal leakage in lubrication system
oil cooler on applicable machine side

• Internal leakage in cooling system
Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
Holes caused by pitting
Degree of use of
E E
Questions

machine
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
w
Check items
There are excessive air bubbles in radiator, coolant spurts back

Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water is found w
Carry out troubleshooting

q
on applicable machine
Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect cylinder block, liner directly q q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Remedy
18 GD655-3E0, GD675-3E0
S-12 Oil pressure drops 1
General causes why oil pressure drops Cause
Defective oil level sensor, defective wiring harness

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
Leaking, crushed, clogged hydraulic piping

• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Clogged, broken pipe inside oil pan

Clogged strainer inside oil pan
Defective regulator valve

Worn bearing journal
Defective oil pump

Lack oil in oil pan
Clogged oil filter

Water, fuel in oil
Degree of use of
E E E
Questions

machine
Oil level monitor indicates drop in oil pressure (when monitor is installed) Q w
Non-specified oil is being used Q Q
indicates oil pressure drop at low idle w
Oil pressure moni- indicates oil pressure drop at low idle and high idle Q w w w Q
tor (when monitor
is installed) indicates oil pressure drop on slopes w
sometimes indicates oil pressure drop w Q
Oil level monitor indicates low amount of oil (when monitor is installed) w w
Oil level in oil pan is low w
There is crushing, external leakage from hydraulic piping w
Check items
Oil is cloudy white and smells of diesel oil w

Metal particles are found when oil in oil pan is drained w
Metal particles are found when oil inside oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Check oil pan strainer and pipe directly q q

See S-13
Oil pump rotation is heavy, there is play q

Deterioration, damage of valve, spring in regulator valve q
Check oil filter directly q
When oil level sensor is replaced, oil level monitor displays normally q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
—
Action
Add
GD655-3E0, GD675-3E0 19
S-13 Oil level rises (water, fuel in oil) 1
General causes why oil level rises Cause
Defective auxiliary equipment seal (pump, air compressor)

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the coolant, carry out troubleshooting for “S-11 Oil is in coolant“.
Defective part inside fuel supply pump

Broken oil cooler core, O-ring

Cracks inside cylinder block
Worn, broken rear oil seal

Broken injector O-ring
Holes made by pitting

Questions
Degree of use of
machine
Fuel consumption has increased w w
Coolant must be added more frequently Q Q
There is oil in engine coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is cloudy white Q Q
After engine is started, drops of water come from muffler Q
When radiator cap is left open and engine is running at low idle, an abnormal number of bubbles
w Q
Check items
appear, or water spurts back

Exhaust smoke is white Q
Oil level goes down in clutch chamber or damper chamber w
Oil level goes down in hydraulic tank w

Remove injector and check O-ring q
Troubleshooting
Check cylinder block, liner directly q q

Check rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove supply pump and check directly q
Check auxiliary equipment seal directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Action
20 GD655-3E0, GD675-3E0
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Cause
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

• Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature

• Drop in heat dissipation efficiency
Defective actuation of thermostat
Fan belt slipping, worn fan pulley

• Defective cooling circulation system
Clogged, crushed radiator fins

• Rise in oil temperature in power train:
Clogged, broken oil cooler

Carry out troubleshooting on the machine.
Clogged radiator core

Holes made by pitting
Broken water pump

Lack of coolant
Degree of use of
machine
Condition of over- Suddenly overheated Q w Q

Questions
heating Always tends to overheat Q w w Q

Coolant tempera- Rises quickly Q w
ture gauge
(when coolant
temperature Does not go down from red range w
gauge is installed)
Radiator coolant level monitor indicates low coolant level (when monitor is installed) w
Engine oil level has risen, oil is cloudy white w Q
Fan belt tension is loose w
There is play when fan pulley is rotated w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, water spurts back w
When light bulb is held behind radiator, no light passes through w
Check items
Radiator shroud, inside of underguard are clogged with dirt or mud w w

Water is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than coolant temperature (when oil
w
and coolant temperature gauges are installed)
q
Carry out troubleshooting on the machine
When compression pressure is measured, it is found to be low

Check cylinder liner directly q
Check oil cooler directly q
Temperature difference between top and bottom radiator tanks is excessive q
Troubleshooting
When function test is carried out on thermostat, it does not open even at cracking tem-
q
perature
Temperature difference between top and bottom radiator tanks is small q
Check radiator core directly q
When function test is carried out on radiator cap, cracking pressure is found to be low q
Check fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Action
Add
GD655-3E0, GD675-3E0 21
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Cause
Defective fuel injection timing (abnormal coolant temperature

• Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head

• Abnormal combustion
Broken dynamic valve system (valve, rocker lever, etc.)

• Air sucked in from intake system
Defect inside muffler (dividing board out of position)
low temperature sensor, boost temperature sensor)

a Judge if the noise is an internal one or an external one.
Excessive wear of piston ring, cylinder liner

a
Deformed fan, loose fan belt, interference

If the engine is not thoroughly warmed up, the engine sound
becomes slightly louder because it is operated in the low tem-
perature mode, but this is not an abnormality.

a When the engine is accelerated, it enters the acceleration
Improper gear train backlash
Clogged, seized fuel injector

mode and the engine noise is a little bit higher for 3 seconds at
Dirt caught in fuel injector

Missing, seized bushing

a maximum, but this is not an abnormality.

Degree of use of
Operated for long period E
machine
Questions
Condition of abnor- Gradually occurred Q Q

mal noise Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil inside oil filter is drained w w
Leakage of air between turbocharger and cylinder head w
When engine is running, abnormal noise is heard from around cylinder head w w
When engine is running, vibrating noise is heard from around muffler w
Check items
w Q
ders is low
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when accelerating Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Check gear train directly q q
Check fan, fan belt directly q
q q
der mode
Abnormal noise is made only when starting q
Confirm with monitoring function of INSITE or on the machine q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Action
22 GD655-3E0, GD675-3E0
S-16 Vibration is excessive 1
General causes why vibration is excessive Cause
Misalignment between engine and equipment on the machine

Defective fuel injection timing (abnormal coolant temperature,
• Defective parts (abnormal wear, breakage, etc,)
Broken part inside output shaft and damper on the machine

• Improper alignment with machine
• Abnormal combustion
Stuck dynamic valve system (valve, rocker lever, etc.)

a If there is abnormal noise together with the vibration, carry out troubleshoot-
Loose engine mounting bolts, broken cushion

ing also for “S-15 Abnormal noise is made“.
Worn main bearing, connecting rod

Improper gear train backlash
boost temperature sensor)

Worn cam bushing
Degree of use of
E E E
Questions

machine
Condition of vibra- Suddenly increased Q Q

tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil inside oil filter is drained w w
Metal particles are found when oil in oil pan is drained 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 main bearing, connecting rod bearing directly q
Troubleshooting
Check gear train directly q

Check camshaft bushing directly q
Confirm with monitoring function of INSITE or on the machine q
Check engine mounting bolts, cushions directly q
When face runout and radial runout are inspected, they are found to be incorrect q
Check inside of output shaft and damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Action
GD655-3E0, GD675-3E0 23
SEN01843-00

© 2006 KOMATSU
All Rights Reserved
24
SEN01914-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tool list ..................................................................................................................................... 7
Sketches of special tools.................................................................................................................... 12
GD655-3E0, GD675-3E0 1
SEN01914-01 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools [*1] : This mark shows that instructions or precau-
N: Tools newly developed for this tions for parts installation work are given in
model. They have a new part num- "Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were 4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] ••• etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
k
from Komatsu Ltd. (i.e. tools to be
made locally).
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 GD655-3E0, GD675-3E0
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] ••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be : Amount of oil or coolant to be replenished
made locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
GD655-3E0, GD675-3E0 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
Gasket sealant
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 GD655-3E0, GD675-3E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
SYG2-400T-A • Seizure resistance, heat resistance and water

Hyper White
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
GD655-3E0, GD675-3E0 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 GD655-3E0, GD675-3E0
Special tool list 1

(Rev. 2009.01)
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a 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 avail-
able on the market
a New/Remodel: 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 developed 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 modifi-
cation.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools")
Necessity
Sketch
Sym-
Q'ty
N/R
Work item Part number Part name Work content
bol
Removal and installa-

tion of fuel supply pump, 1 795-799-1131 Gear t 1 Setting of 1.6TOP
fuel injector and cylinder
head assembly
Removal and installa- Removal and installation of
tion of fuel supply pump 2 795-799-1390 Remover t 1 fuel supply pump assembly
assembly
Removal and installa- 3 795-799-6700 Puller t 1 Removal of fuel injector

tion of fuel injector 4 795-799-8150 Remover q 1 assembly
A
5 795-931-1100 Seal puller q 1 Removal of engine rear seal
Removal and installa-
tion of engine rear seal 795-799-1150 Repair stand q 1
7 Fixing of engine assembly
795-799-2280 Adapter q 1
Removal and installa- Press fitting of engine front
6 795-799-8120 Oil seal driver q 1 N
tion of engine front seal seal
Removal and installa- Tightening of cylinder head
tion of cylinder head 8 790-331-1120 Wrench (angle) q 1 bolt
assembly
790-501-5000 Repair stand (AC100 V) q 1
Repair stand (AC110 V,
790-501-5200 q 1
220 V)
Disassembly, assembly of
1 790-901-2110 Bracket q 1 torque converter
793-310-2131 Plate q 1
Disassembly and
assembly of torque con- C 793-310-2141 Plate q 1
verter Removal, installation of stator
2 792-390-1210 Wrench t 1
shaft round nut
790-201-2740 Spacer t 1
3 Press fitting of bearing
790-201-2750 Spacer t 1
Removal, installation of PTO
4 790-102-1871 Wrench t 1 bearing locknut
GD655-3E0, GD675-3E0 7
Necessity
Sketch
Sym-
Q'ty
N/R
bol
790-201-2740 Spacer t 1
Press fitting of 4th clutch
1 790-201-2750 Spacer t 1 bearing
790-101-5201 Push tool kit t 1
Disassembly and
assembly of transmis- D 790-201-2740 Spacer t 1 Press fitting of FH, 1st, 2nd
sion assembly 2
790-101-5201 Push tool kit t 1 and 3rd clutch bearings
797T-423-1320 Push tool t 1 Q Press fitting of FL and R

3
790-101-5201 Push tool kit t 1 clutch bearings
794T-423-1130 Push tool t 1 N Q
Press fitting of case oil seal
4 790-101-5221 Grip t 1 on pulley side
01010-51225 Bolt t 1
794T-423-1130 Push tool t 1 Q
794T-423-1140 Spacer t 1 N Q Press fitting of case dust
5
790-101-5221 Grip t 1 seal on pulley side
01010-51225 Bolt t 1
794T-423-1110 Push tool t 1 N Q
Press fitting of coupling cage
6 790-101-5221 Grip t 1 oil seal
Disassembly and 01010-51225 Bolt t 1
assembly of transmis- D 794T-423-1110 Push tool t 1 Q
sion assembly
794T-423-1120 Spacer t 1 N Q Press fitting of coupling cage
7
790-101-5221 Grip t 1 dust seal
01010-51225 Bolt t 1
794T-423-1180 Push tool t 1 N Q
Press fitting of coupling
8 790-101-5221 Grip 1 cover
01010-51225 Bolt 1
9 793-310-2100 Lifting tool t 1 Lifting of clutch assembly
Centering of transmission
10 792-271-2000 Centering tool t 1
and final drive
11 799-301-1600 Oil leak tester t 1 Operation check of piston
793T-659-1110 Push tool t 1 Q Press fitting of shaft bearing
1
790-201-2240 Plate t 1 inner race
Disassembly and 790-101-5401 Push tool kit t 1
assembly of axle H
assembly 790-101-5531 • Plate 1 Press fitting of housing oil
2
790-101-5421 • Grip 1 seal
01010-51240 • Bolt 1
8 GD655-3E0, GD675-3E0
Necessity
Sketch
Sym-
Q'ty
N/R
bol
Disassembly and Removal and installation of

assembly of final drive 1 792-571-1600 Chain puller t 1 chain
assembly
790-101-5551 • Plate 1
2 Press fitting of cage oil seal
790-101-5421 • Grip 1
Disassembly and
assembly of final brake 01010-51240 • Bolt 1
case assembly J
794T-425-1110 Push tool t 1 N Q Press fitting of drive shaft
3
793T-659-1110 Push tool t 1 Q bearing inner race
4 799-301-1600 Oil leak tester t 1 Operation check of piston
790-201-2850 Spacer t 1
Disassembly and Press fitting of bevel pinion
assembly of bevel pin- 5 790-201-2230 Plate t 1 bearing inner race
ion assembly
790-201-2740 Spacer t 1
Removal and installa- 796-460-1210 Oil stopper t 1
tion of work equipment S Stopping of hydraulic oil
pump assembly 23B-60-32121 Rod t 1
GD655-3E0, GD675-3E0 9
Necessity
Sketch
Sym-
Q'ty
N/R
bol
790-502-1003 Cylinder repair stand t 1 Removal and installation of

1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder assembly

2 790-330-1100 Wrench assembly t 1 cylinder head
Commercially Socket (Width across flats: t 1 For steering
available 30 mm)
For blade lift,
blade side
Commercially Socket (Width across flats: t 1 shift, power
available 41 mm) tilt, drawbar
shift and Removal and
3 leaning installation of
nut
Commercially Socket (Width across flats: t 1 For scarifier
available 46 mm)
Socket (Width across flats: t 1
790-302-1280 For articulate
55 mm)
Socket (Width across flats: t 1
790-302-1290 For ripper
60 mm)
Press fitting of cylinder head
790-101-5021 • Grip 1 bushing
01010-50816 • Bolt 1
790-201-1731 • Push tool 1 For steering
4 790-201-1751 • Push tool 1 For leaning
Disassembly and For blade lift,
assembly of hydraulic U blade side
cylinder assembly 790-201-1771 • Push tool 1 shift, draw-
bar shift and
articulate
790-201-1761 • Push tool 1 For power tilt
Press fitting of cylinder head
790-101-5021 • Grip 1 dust seal
01010-50816 • Bolt 1
790-201-1540 • Plate 1 For steering
5 790-201-1560 • Plate 1 For leaning
For blade lift,
blade side
790-201-1580 • Plate 1 shift, draw-
bar shift and
articulate
790-201-1570 • Plate 1 For power tilt
6 790-720-1000 Expander t 1 Installation of piston ring
796-720-1620 Ring t 1
For steering
07281-00609 Clamp t 1
796-720-1650 Ring t 1 For leaning,
7 blade lift,
blade side
shift, draw-
07281-01029 Clamp q 1 bar shift,
articulate and
power tilt
10 GD655-3E0, GD675-3E0
Necessity
Sketch
Sym-
Q'ty
N/R
bol

1 791-342-1310 Wrench t 1 cover
Disassembly and
assembly of bank pin 790-720-1000 Expander t 1
assembly 2 790-720-1740 Ring t 1 Installation of piston ring
07281-00809 Clamp t 1
V
Press fitting of worm bearing
3 796-460-1110 Push tool t 1 inner race
Disassembly and
assembly of circle rota- 794T-470-1110 Push tool t 1 N Q
tion gear assembly Press fitting of hosing oil
4 790-101-5221 Grip t 1 seal
01010-51225 Bolt t 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1
Collection and addition Collection and addition of air
X 799-703-1110 Vacuum pump (220 V) t 1
of refrigerant conditioner refrigerant
799-703-1120 Vacuum pump (240 V) t 1
799-703-1400 Gas leak tester t 1
GD655-3E0, GD675-3E0 11
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D3 Push tool
D4, D5 Push tool
12 GD655-3E0, GD675-3E0
D5 Spacer
D6, D7 Push tool
GD655-3E0, GD675-3E0 13
D7 Spacer
D8 Push tool
14 GD655-3E0, GD675-3E0
J3 Push tool
J3, H1 Push tool
GD655-3E0, GD675-3E0 15
V4 Push tool
16 GD655-3E0, GD675-3E0
GD655-3E0, GD675-3E0 17

© 2009 KOMATSU
All Rights Reserved
18 GD655-3E0, GD675-3E0
SEN01915-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
50 Disassembly and assembly

Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Removal and installation of fuel supply pump assembly...................................................................... 2
Removal and installation of fuel injector assembly .............................................................................. 5
Removal and installation of cylinder head assembly ......................................................................... 10
Removal and installation of engine front seal .................................................................................... 22
Removal and installation of engine rear seal ..................................................................................... 26
Removal and installation of engine assembly .................................................................................... 32
Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly ....................... 36
Removal and installation of air conditioner condenser....................................................................... 40
Removal and installation of oil cooler assembly ................................................................................ 43
Removal and installation of aftercooler assembly .............................................................................. 45
Removal and installation of radiator assembly................................................................................... 48
Removal and installation of engine hood ........................................................................................... 51
GD655-3E0, GD675-3E0 1
Engine and cooling system 1

Removal and installation of fuel 3. Front engine hood cover
supply pump assembly 1 1) Remove the rubber cap and remove 4
mounting bolts (3).
Special tools 2) Remove front cover (4) of the engine
hood.
Necessity
a Remove the front cover to remove the
Symbol
Sketch
Part number Part name mounting bolts of the fuel supply
Q’ty
N/R
pump bracket from the front of the
2 795-799-1390 Remover t 1 engine.
A 3 795-799-6700 Puller t 1
4 795-799-8150 Remover q 1
Removal
k Stop the machine on a level ground, apply
the parking brake, and lock the tires with
chocks.
k Disconnect the cable from the negative (–)
terminal of the battery.
k Close the fuel stop valve.
1. Set lock pin (1) to the frame.
4. Pipings and wiring harnesses

1) Disconnect connector (5).
2) Remove bracket (6).
3) Disconnect fuel tube (7) from the fuel sup-
ply pump.
4) Disconnect fuel pipes (8), (9), (10) and
(11) from the fuel supply pump.
a Low-pressure pipes (9), (10) and (11)
cannot be reused. Replace them with
new ones.
2. Open engine left side cover (2).
2 GD655-3E0, GD675-3E0
5. Fuel supply pump assembly Installation

1) Remove cap (14). q Install the fuel supply pump assembly accord-
a Use a filter wrench to remove the cap. ing to the following procedure.
2) Remove nut (15) and washer (16) from 1. Install fuel supply pump assembly (19), setting
the shaft (SH) of the fuel supply pump. projection (P) of its shaft (SH) to the groove (G)
a Take care not to drop the nut and of the gear (GY).
washer into the case.
3) Tighten tool A2 evenly to disconnect the 2. Install bracket (17) to fuel supply pump assem-
shaft (SH) of the fuel supply pump from bly (19).
the drive gear (GY).
3. Tighten 4 nuts (18).
2 Mounting nut (18): Adhesive (LT-2)
3 Mounting nut (18):
43 ± 6 Nm {4.4 ± 0.6 kgm}
3 Mounting bolt (20):
43 ± 6 Nm {4.4 ± 0.6 kgm}
77 ± 12 Nm {7.8 ± 1.2 kgm}
4. Install washer (16) and tighten nut (15).

a Take care not to drop the nut and washer
into the case.
3 Nut: 180 ± 12.7 Nm {18.2 ± 1.3 kgm}

5) Remove 4 nuts (18) and fuel supply pump
assembly (19).
GD655-3E0, GD675-3E0 3
q Carry out the following installation in the

reverse order to removal.
4 GD655-3E0, GD675-3E0
Removal and installation of fuel 2) Using a sling, lift up muffler assembly (3)
injector assembly 1 temporarily and remove 4 mounting bolts
(4) and 3 mounting bolts (5).
Special tools
Necessity
Symbol
Sketch
Part number Part name
Q’ty
N/R
1 795-799-1131 Gear t 1
2 795-799-1390 Remover t 1
A
3 795-799-6700 Puller t 1
4 795-799-8150 Remover q 1
Removal
chocks. 3) Using sling [1], remove muffler assembly
k Disconnect the cable from the negative (–) (3). [*1]
terminal of the battery. 4 Muffler assembly: 35 kg
4. Air conditioner compressor [*2]

1) Loosen 4 bolts (4), bolt (5) and bolt (6).
2. Remove the engine hood assembly. 2) Loosen adjustment nut (7) and remove air
For details, see "Removal and installation of conditioner compressor drive belt.
engine hood assembly". 3) Remove air conditioner compressor (8)
and fix it with ropes to a place where it will
3. Muffler assembly not be an obstacle.
1) Remove muffler drain tube (2).
GD655-3E0, GD675-3E0 5
5. Adjusting valve timing

1) Remove bracket (9) and cap (10) together
and install cranking tool A1 (See the tool
table).
a See Testing and adjusting volume,
"Testing and adjusting valve clear-
ance".
7. Rocker arm and crosshead

1) Remove wiring harness nut (14) from the
injector.
a Wiring harness locations
Wiring harness color Cylinder No.
Yellow, orange (Exchangeable) 1, 3, 5
2) Remove cap (11). Red, brown (Exchangeable) 2, 4, 6
a Use a filter wrench to remove the cap.
3) Crank the engine to set stamp (M) of the 2) Loosen locknut (15) and then loosen
drive gear (GY) to the TDC position. adjustment screw (16) 2 – 3 turns.
a Use a mirror to set the stamp. a Loosen the adjustment screw so that
a See Testing and adjusting volume, excessive force will not be applied to
"Testing and adjusting valve clear- the push rod when the rocker arm is
ance". installed.
3) Remove mounting bolts (17), rocker arm
and crosshead assembly (18).
a Record the position and direction
(shapes of holes (a) and (b)) of each
crosshead.
(When reinstalling the crosshead, set
it in the same direction.)
6. Cylinder head cover

2) Remove the 2 mounting bolts and then
remove blow-by duct cover (13) and fix it
to the engine with ropes.
a Check that the No. 1 cylinder is at the
top position. For details, see Testing
and adjusting volume, "Testing and
adjusting valve clearance".
6 GD655-3E0, GD675-3E0
Installation
q Fuel injector assembly
a Check that the fuel injector sleeve is free from
flaws and foreign matter.
1. Fit gasket (23) and O-ring (24) to fuel injector
(22).
2 O-ring (24) of fuel injector (22) and cyl-
inder head surface:
Engine oil (EO15W-40)
2. Install holder (25) to fuel injector (22).

a Match the projection and concave (B) and
(A).
8. Fuel injector 3. Insert fuel injector (22) in the cylinder head

1) Remove retainer (19) and inlet connector with the fuel inlet hole on the air intake mani-
(20). fold side.
a Before removing retainer (19), clean it
and around it thoroughly. 4. Tighten mounting bolts (21) of holder (25) by 3
a Tool A4 (Remover) is set for removal – 4 threads with the fingers.
of inlet connector (20). (See the tool
table.)
5. Fit O-ring (26) to inlet connector (20).

2 O-ring (26) of inlet connector (20) and
2) Remove 2 fuel injector assembly mount- cylinder head surface:
ing bolts (21). Engine oil (EO15W-40)
3) Using tool A3, remove fuel injector assem-
bly (22). 6. Install inlet connector (20) temporarily with nut
a Take care that foreign matter will not (19).
enter the mounting part of the fuel (Set the projection (C) and insert the inlet con-
injector assembly. nector in the fuel injector hole.)
3 Nut: 14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}
GD655-3E0, GD675-3E0 7
7. Tighten mounting bolts (21) of holder (25) 3. Check the inlet connector visually. If it has any
alternately. of the following faults, replace it and fuel injec-
3 Mounting bolt: tor assembly together.
9.8 ± 2.0 Nm {1.0 ± 0.2 kgm} q There is a worn part or an uneven seat
a The top of holder (25) must be in parallel contact mark on sealing face (e) at the
with the top of the cylinder head. front end of the inlet connector.
Allowable inclination: 2.4° a If high-pressure fuel leaks through the
inlet connector, the seal surface has
8. Tighten nut (19) of inlet connector (20) perma- fine streaks or cracks.
nently.
3 Nut: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm}
q Precautions for installing inlet connector

1. When replacing the fuel injector assembly with
new one, be sure to replace inlet connector
(20), too.
q Rocker arm and crosshead

a The shapes of holes (a) and (b) of each
crosshead are different. Accordingly,
when reusing the crossheads, install each
of them to the same intake/exhaust valve
in the same direction as it has been
installed. (A new crosshead may be
2. Check the inlet connector visually. If it has any installed in either direction.)
of the following faults, replace it. a Check that 2 valves are inserted in holes
1) There is a bur or a worn part at front end (a) and (b).
(a) or rear end (b) of the inlet connector.
2) There is foreign matter in the edge filter at
rear end (c) of the inlet connector.
3) The O-ring at upper part (d) of the inlet
connector is cracked or deteriorated.

8 GD655-3E0, GD675-3E0
[*1]
Tighten the muffler-related bolts according to the 4) Tighten bolts (37) – (39) to the specified
following procedure. torque (3 places marked with *5).
1) Tighten bolts (1) – (4) and (5) – (14) to the 5) Tighten bolts (15) – (22) to the specified
specified torque (4 places marked with *1). torque (5 places marked with *6).
2) Temporarily tighten bolts (15) – (22), (23) 6) Tighten bolts (23) – (25) to the specified
– (25) and (26) – (28) (5 places marked torque (2 places marked with *7).
with *2 and 2 places marked with *3). a When tightening the bolts in steps 5) and
3) Tighten bolts (29) – (32) and (33) – (36) to 6), adjust the muffler, exhaust elbow, etc.
the specified torque (2 places marked with so that they will not be installed forcibly.
*4).
[*2]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting volume,
"Testing and adjusting air conditioner compressor
belt tension".
GD655-3E0, GD675-3E0 9
Removal and installation of 2) Using a sling, lift up muffler assembly (3)

cylinder head assembly 1 temporarily and remove 4 mounting bolts
(4) and 3 mounting bolts (5).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
A 8 790-331-1120 Wrench (angle) q 1
Removal
chocks.
3) Using sling [1], remove muffler assembly
1. Set lock pin (1) to the frame. (3). [*1]
4 Muffler assembly: 35 kg
2. Remove the engine hood assembly.

For details, see "Removal and installation of 4. Air conditioner compressor [*2]
engine hood assembly". 1) Loosen 4 bolts (4), bolt (5) and bolt (6).
2) Loosen adjustment nut (7) and remove air
3. Muffler assembly conditioner compressor drive belt.
1) Remove muffler drain tube (2). 3) Remove air conditioner compressor (8)
and fix it with ropes to a place where it will
not be an obstacle.
10 GD655-3E0, GD675-3E0
5. Air intake connector and electrical intake 7. Heater hose

air heater Disconnect heater hose (31).
1) Remove electrical intake air heater con-
nector (9) and clamp (10).
2) Disconnect air hose (11). [*3]
3) Remove 4 mounting bolts (12), air intake
connector and electrical intake air heater
assembly (13). [*4]
8. Blow-by duct cover

2) Remove the 2 mounting bolts and blow-by
duct cover (33) and fix it to the engine with
ropes.
a Check that the No. 1 cylinder is at the
6. Pipings, hoses and connectors [*5] top position. For details, see Testing
1) Remove high-pressure pipe clamp (14). and adjusting volume, "Testing and
2) Remove bellows (15). (Remove both bel- adjusting valve clearance".
lows on the fuel supply pump side and
common rail side.)
3) Remove high-pressure pipe (16) (between
the fuel supply pump and common rail).
4) Disconnect connectors (17), (18), (19),
(20) and (21).
5) Disconnect clamps (22) and (23).
7) Remove fuel return tube (25).
8) Remove 12 bellows (26) of each high-
pressure pipe.
9) Remove 6 high-pressure pipes (27)
(between the common rail and cylinder
head).
10) Remove common rail (28). 9. Turbocharger and exhaust manifold assem-
11) Remove clamp (29). bly
12) Remove bracket (30). 1) Remove cover (34).
2) Disconnect lubrication inlet tube (35) and
outlet tube (36). [*6]
3) Sling turbocharger and exhaust manifold
assembly (37) temporarily and remove the
muffler mounting bolts. [*7]
GD655-3E0, GD675-3E0 11
11. Adjusting valve timing

1) Remove bracket (40) and cap (41)
together and install cranking tool A1 (See
the tool table).
ance".
4) Using sling [1], remove turbocharger and

exhaust manifold assembly (37).
4 Turbocharger and exhaust manifold
assembly: 38 kg
2) Remove cap (42).

a Use a filter wrench to remove the cap.
3) Crank the engine to set stamp (M) of the
drive gear (GY) to the TDC position.
a Use a mirror to set the stamp.
ance".
10. Alternator assembly [*8]

Loosen V-belt (38) and disconnect alternator
assembly (39).
a Fix the alternator assembly to the engine
with ropes.
12. Remove cylinder head cover (43). [*9]
12 GD655-3E0, GD675-3E0
13. Rocker arm and crosshead 14. Fuel injector

1) Remove wiring harness nut (44) from the 1) Remove retainer (49) and inlet connector
injector. (50).
a Wiring harness locations a Before removing retainer (49), clean it
Wiring harness color Cylinder No. and around it thoroughly.
a Tool A4 (Remover) is set for removal
Yellow, orange (Exchangeable) 1, 3, 5
of inlet connector (50). (See the tool
Red, brown (Exchangeable) 2, 4, 6 table.)
2) Loosen locknut (45) and then loosen

adjustment screw (46) 2 – 3 turns.
a Loosen the adjustment screw so that
excessive force will not be applied to
the push rod when the rocker arm is
installed.
3) Remove mounting bolts (47), rocker arm
and crosshead assembly (48).
a Record the position and direction
(shapes of holes (a) and (b)) of each
crosshead. (When reinstalling the
crosshead, set it in the same direc-
tion.)
2) Remove 2 fuel injector assembly mount-
ing bolts (51).
3) Using tool A3, remove fuel injector assem-
bly (52).
a Take care that foreign matter will not
enter the mounting part of the fuel
injector assembly.
GD655-3E0, GD675-3E0 13
15. Rocker housing Installation

1) Remove push rod (53). q Cylinder head assembly
2) Remove spacer (54). a Check that there is not foreign matter on the
a Remove the spacers of other cylin- cylinder head mounting face and inside the cyl-
ders, too. inders.
3) Remove rocker housing assembly (55). 1. Set cylinder head gasket (57) to the cylinder
block.
a Set the holes of cylinder head gasket (57)
to those of the cylinder block.
16. Cylinder head

1) Remove the 26 mounting bolts and lift off
cylinder head assembly (56).
4 Cylinder head assembly: 85 kg 2. Sling cylinder head assembly (56) and set it to
the cylinder block.
2) Remove cylinder head gasket (57).
a Hit the valve stem lightly with a plastic
hammer to check that the collet is fitted to
the valve stem groove securely.
a Check that the holes of cylinder head gas-
ket (57) are set to those of the cylinder
block.
4 Cylinder head assembly: 85 kg
14 GD655-3E0, GD675-3E0
3. Before tightening the cylinder head mounting 3) Tool A8 (See the tool table) is set for angle
bolts, check the following. tightening.
1) Measure stem length (a) of every bolt and 4) When not using angle tightening tool A8
check that it is less than the using limit. Make marks on the cylinder head and each
2) Using limit of length bolt stem: 162.6 mm bolt and then tighten the bolt 120 ± 5°.
a If a bolt is longer than the using limit,
do not reuse it but replace it.
2 Apply engine oil (SAE15W-40) to
the threads and seat of each
mounting bolt.
q Rocker housing
1. Install push rod (53).
a Check that the push rod is set in the tap-
pet securely.
2 Apply engine oil (SAE15W-40) to the
4. Method of tightening cylinder head mounting push rod socket.
bolts
1) Tighten each cylinder head mounting bolt 2. Fit the gasket and install rocker housing
2 – 3 turns with the fingers. assembly (55).
2) Tighten the cylinder head mounting bolts
according to the following procedure in the 3. Tighten the mounting bolts in the order shown
order shown in the figure. in the following figure. ([1] o [7])
1] 150 ± 9.8 Nm {15.3 ± 1.0 kgm} 3 Mounting bolt:
2] Return all the bolts 360°. 24 ± 4 Nm {2.4 ± 0.4 kgm}
3] 115 ± 4.9 Nm {11.7 ± 0.5 kgm}
4] Check the tightening torque of 115 ± 4. Install spacer (54).
4.9 Nm {11.7 ± 0.5 kgm}.
5] 120 ± 5°
GD655-3E0, GD675-3E0 15
5. Fit O-ring (56) to inlet connector (50).

2 O-ring (56) of inlet connector (50) and
cylinder head surface:
6. Install inlet connector (50) temporarily with nut

(49).
(Set the projection (C) and insert the inlet con-
nector in the fuel injector hole.)
3 Nut: 14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}
q Fuel injector assembly

a Check that the fuel injector sleeve is free from
flaws and foreign matter.
1. Fit gasket (53) and O-ring (54) to fuel injector
(52).
2 O-ring (54) of fuel injector (52) and cyl-
inder head surface:
2. Install holder (55) to fuel injector (52).

a Match the projection and concave (B) and 7. Tighten mounting bolts (51) of holder (55)
(A). alternately.
3 Mounting bolt:
3. Insert fuel injector (52) in the cylinder head 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
with the fuel inlet hole on the air intake mani- a The top of holder (55) must be in parallel
fold side. with the top of the cylinder head.
Allowable inclination: 2.4°
4. Tighten mounting bolts (51) of holder (55) by 3
– 4 threads with the fingers. 8. Tighten nut (49) of inlet connector (50) perma-
nently.
3 Nut: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm}
q Precautions for installing inlet connector

1. When replacing the fuel injector assembly with
new one, be sure to replace inlet connector
(50), too.
16 GD655-3E0, GD675-3E0
2. Check the inlet connector visually. If it has any q Rocker arm and crosshead
of the following faults, replace it. a The shapes of holes (a) and (b) of each
1) There is a bur or a worn part at front end crosshead are different. Accordingly,
(a) or rear end (b) of the inlet connector. when reusing the crossheads, install each
2) There is foreign matter in the edge filter at of them to the same intake/exhaust valve
rear end (c) of the inlet connector. in the same direction as it has been
3) The O-ring at upper part (d) of the inlet installed. (A new crosshead may be
connector is cracked or deteriorated. installed in either direction.)
a Check that 2 valves are inserted in holes
(a) and (b).
3. Check the inlet connector visually. If it has any

of the following faults, replace it and fuel injec-
tor assembly together. 1. Install rocker arm and crosshead assembly
q There is a worn part or an uneven seat (48) and tighten mounting bolts (47) with the
contact mark on sealing face (e) at the fingers.
front end of the inlet connector. a Check that the ball of adjustment screw
a If high-pressure fuel leaks through the ( 44) is fitted in the push rod socket
inlet connector, the seal surface has securely.
fine streaks or cracks. a Check that the cap on the crosshead side
of the rocker arm is in contact with a plane
of the crosshead (that the cap is not in
contact diagonally).
2 Apply engine oil (SAE15W-40) to the
threads and seat of the mounting bolt.
2. Tighten mounting bolt (47) permanently.

3 Mounting bolt:
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
a Adjust the valve clearance.
For details, see Testing and adjusting,
Testing and adjusting valve clearance.
3 Locknut (45):
24 ± 4 Nm {2.45 ± 0.41 kgm}
GD655-3E0, GD675-3E0 17
3. Install wiring harness (44).

a Install wiring harness (44) so that it will not
touch the inside wall of rocker housing
assembly (55) strongly or come off guide
(a) or bend sharply.
a When installing wiring harness (44), make
a clearance at part (f) on rocker arm (48a).
Install wiring harness (44) as shown in the
figure so that the rocker arm will not inter-
fere with it when the rocker arm vibrates.
3 Mounting nut:
1.25 ± 0.25 Nm {0.10 ± 0.03 kgm}
a Installed position of wiring harnesses
Color of wiring harness Cylinder No.
Yellow, orange (Exchangeable) 1, 3, 5 q Carry out the following installation in the
Red, brown (Exchangeable) 2, 4, 6
18 GD655-3E0, GD675-3E0
[*1]
Tighten the muffler-related bolts according to the 4) Tighten bolts (37) – (39) to the specified
following procedure. torque (3 places marked with *5).
1) Tighten bolts (1) – (4) and (5) – (14) to the 5) Tighten bolts (15) – (22) to the specified
specified torque (4 places marked with *1). torque (5 places marked with *6).
2) Temporarily tighten bolts (15) – (22), (23) 6) Tighten bolts (23) – (25) to the specified
– (25) and (26) – (28) (5 places marked torque (2 places marked with *7).
with *2 and 2 places marked with *3). a When tightening the bolts in steps 5) and
3) Tighten bolts (29) – (32) and (33) – (36) to 6), adjust the muffler, exhaust elbow, etc.
the specified torque (2 places marked with so that they will not be installed forcibly.
*4).
[*2] [*3]
Adjust the air conditioner compressor belt tension. 3 Clamp of air hose (11):
For details, see Testing and adjusting volume, 24 ± 4 Nm {2.45 ± 0.41 kgm}
belt tension".
GD655-3E0, GD675-3E0 19
[*4] 5. Install 6 high-pressure pipes (27) between the

q Air intake connector common rail and fuel injector.
Fit the gasket and install air intake connector 3 Nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm}
(13).
2 Both sides of gasket: 6. Tighten fuel return tube (25) permanently.
Gasket sealant (LG-7) 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
24 ± 4 Nm {2.4 ± 0.41 kgm} 7. Tighten common rail (28) permanently.
3 Joint bolt:
[*5] 43.1 ± 4.0 Nm {4.4 ± 0.4 kgm}
q High-pressure pipe and common rail
k Do not bend the high-pressure pipe to col- 8. Tighten clamp (14) and bracket (24) perma-
lect before installing. nently.
k Be sure to use the genuine high-pressure
pipe clamps and observe the tightening
torque.
k Install each high-pressure pipe and wiring
harness at least 10 mm apart from each
other.
a When installing each high-pressure pipe,
check the taper seal of its joint (Part (a): Part of
2 mm from the end) for the following visible
defects. If there are any of these defects, they
can cause fuel leakage. In this case, replace
the high-pressure pipe.
q Lengthwise slit (b)
q Spot (c)
q Level difference (d) at end of taper seal 9. Apply caulking material (e) (hatched part) to
(part at 2 mm from end) caused by fatigue nut (49) of inlet connector (50) and cylinder
which your nail can feel head.
2 Caulking material:
GE TOSHIBA SILICONE TOSSEAL 381
1. Install common rail (28) lightly with the fingers.
2. Tighten fuel return tube (25) lightly with the fin-

gers.
3. Install high-pressure pipe (16) between the

supply pump and common rail.
3 Nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm}
4. Install bracket (24) and tighten clamp (14)

lightly with the fingers.
20 GD655-3E0, GD675-3E0
10. Install 12 bellows (26). [*7]

q Exhaust manifold and turbocharger
11. Install right and left bellows (15). 3 Tightening procedure for mounting bolts:
a Install each bellows with the slits out and 1) Tighten all the bolts to 24 ± 4 Nm {2.4 ±
down. 0.4 kgm} in the order of [1] – [12] shown in
a The bellows are installed so that fuel will the figure.
not spout over the hot parts of the engine 2) Tighten only bolts [1] – [4] to 24 ± 4 Nm
and catch fire when it leaks for some rea- {2.4 ± 0.4 kgm} in order.
son. 3) Tighten all the bolts to 43 ± 6 Nm {4.4 ±
0.6 kgm} in the order of [1] – [12] shown in
the figure.
4) Tighten only bolts [1] – [4] to 43 ± 6 Nm
{4.4 ± 0.6 kgm} in order.
[*6]
3 Mounting bolt of turbocharger lubrication
hose (35): 35 ± 5 Nm {3.6 ± 0.5 kgm}
3 Mounting bolt of turbocharger lubrication
tube (36): 24 ± 4 Nm {2.4 ± 0.4 kgm} [*8]
Adjust the alternator belt tension. For details, see
Testing and adjusting volume, "Testing and adjust-
ing alternator belt tension".
[*9]
3 Cylinder head cover mounting bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 39.5 l
GD655-3E0, GD675-3E0 21
Removal and installation of 3. Remove the engine hood assembly. For

engine front seal 1 details, see "Removal and installation of
engine hood assembly".
Special tools
4. Remove the hydraulic tank, fuel tank and res-
Necessity
Symbol
erv o i r tan k as s e m bl y. F or d etai l s , s e e
Sketch
Part number Part name "Removal and installation of hydraulic tank,
Q’ty
N/R
fuel tank and reservoir tank assembly".
A 6 795-799-8120 Oil seal driver q 1 N
5. Remove the engine assembly. For details, see
"Removal and installation of engine assembly".
Removal
k Stop the machine on a level place and
6. Insert a wrench to the portion (A) (width across
apply the parking brake.
flaats T 12.7 mm) of tensioner (2) and loosen
k Lower the work equipment to the ground,
and remove alternator belt (3).
stop the engine, and loosen the hydraulic
k Take care not catch your fingers
tank cap gradually to release the pressure
between the tensioner and pulley.
inside the hydraulic tank.
k If the radiator coolant temperature is high,
wait until it decreases to avoid getting
scalded and then drain the coolant.
1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
a Ask professional traders for collecting and
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec- 7. Remove 4 mounting bolts (4) and crankshaft
tive glasses when collecting or filling pulley/damper (5). [*2]
the refrigerant. Collecting and filling a Make a match mark on the crankshaft pul-
work must be conducted by a qualified ley and front cover (since the stamp of
person. 1.6TOP is made on the crankshaft pulley).
a Quantity of refrigerant: 1,050 ± 50 g
22 GD655-3E0, GD675-3E0
8. Remove the 5 mounting bolts and seal carrier Installation

(6).
1. Wipe off foreign matter from the crankshaft
9. Remove dust seal (7) and engine front seal flange portion (A) with clean cloths.
from seal carrier (6).
a Since plastic part (P) on the inside of the

engine front seal is a pilot (guide tool) for
installation of the crankshaft, do not
remove it from the engine front seal.
2. Set tool A6 to engine front seal (8) from pilot

(P) side.
3. Install engine front seal (8) from inside of seal

carrier (6).
a Set the seal flush with the inside wall of
the seal carrier.
4. Set pilot (P) to the crankshaft and push it and

seal carrier (6) together into the crankshaft
with the hands.
GD655-3E0, GD675-3E0 23
5. Remove pilot (P).
a Install the crankshaft pulley/damper tem-

6. Install seal carrier (6). porarily and install the alternator belt, and
2 Apply gasket sealant to the following then tighten to the specified torque.
parts.: Gasket sealant (Threebond
1207D or equivalent) q Carry out the following installation in the
1) All inside surface (a) of seal carrier (6) reverse order to removal.
2) Threaded part (b) and periphery (c)
of bolt (10) [*1]
3) Threaded part (d) of nut (11) a When installing the air conditioner hoses, take
q Tighten the mounting bolts in the order [1] care that dirt, dust, water, etc. will not enter
o [5] shown in the figure. them.
3 Seal carrier mounting bolt: a When installing each joint of the air conditioner
9.8 ± 2 Nm {1 ± 0.2 kgm} hose, check that O-ring (70) is fitted to it.
a Check the installed dimension of 0.5 – 1 a Check that O-ring (70) is free from flaw and
mm. deterioration.
a When connecting the refrigerant piping, apply
7. Install dust seal (7). compressor oil for new refrigerant (R134a)
a Push in the dust seal until it touches the oil (DENSO: ND-OIL8) to O-ring (70).
seal. 3 Thread size (M16 x 1.5) (Width across flats:
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
3 Thread size (M22 x 1.5) (Width across flats:
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3 Receiver tank refrigerant tube mounting bolt
(M6 x 1.0) (Width across flats: 10 mm):
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
3 Air conditioner compressor refrigerant tube
mounting bolt (M6 x 1.0) (Width across flats:
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
24 GD655-3E0, GD675-3E0
[*2]
3 Mounting bolt of crankshaft pulley/damper:
200 ± 10 Nm {20.4 ± 1 kgm}
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
6 Hydraulic tank: 45 l

Close the radiator cap and add coolant through
the coolant filler of the reservoir tank to the full
level of the coolant level gauge. Run the
engine to increase the coolant temperature.
Then, check the coolant level again.
6 Coolant: 39.5 l
GD655-3E0, GD675-3E0 25
Removal and installation of 3. Remove the engine hood assembly. For details,
engine rear seal 1 see "Removal and installation of engine hood
assembly".
Special tools
Necessity
Symbol
er v o i r tan k as s e m bl y. F or d etai l s , s e e
Sketch
Part number Part name "Removal and installation of hydraulic tank,
Q’ty
N/R
fuel tank and reservoir tank assembly".
5 795-931-1100 Seal puller q 1
5. Remove the engine assembly. For details, see
A 795-799-1150 Repair stand q 1
7 "Removal and installation of engine assembly".
795-799-2280 Adapter q 1
6. Place the engine assembly on block [1].
Removal a The repair stand and adapter A7 are set
k Stop the machine on a level place and (See tool table).
apply the parking brake.
k Lower the work equipment to the ground, 7. Remove mounting bolts (2), set guide bolts,
stop the engine, and loosen the hydraulic and lift off flywheel (3). [*2]
4 Flywheel assembly: 45 kg

the atmosphere.
Therefore, make sure to wear protec- 8. Sling flywheel housing (5), remove mounting
tive glasses when collecting or filling bolts (4), and lift off the flywheel housing (5).
the refrigerant. Collecting and filling 4 Flywheel housing (5): 70 kg
work must be conducted by a qualified
person.
26 GD655-3E0, GD675-3E0
9. Remove rear cover (6). Installation

10. Remove rear seal (7) from rear cover (6). 1. Clean, degrease, and dry the faces of the gas-
a Take care not to scratch the seal fitting ket between the rear cover and cylinder block.
face of the flywheel housing and seal con-
tact face of the crankshaft. 2. Clean, degrease, and dry the seal lip face
(periphery of the crankshaft).
a If engine rear seal (7) is stuck to the

crankshaft and cannot be removed, make 3. Apply neutral detergent to the periphery of the
holes (about 3 mm in diameter) on its right engine rear seal.
and left sides with a drill. Then, using seal a Since plastic part (P) on the inside of the
puller A5, remove the seal with impacts of engine rear seal is a pilot (guide tool) for
slide hammer (SH). installation of the crankshaft, do not
remove it from the engine rear seal.
4. Install engine rear seal (7) to rear cover (6).
GD655-3E0, GD675-3E0 27
5. Using alignment tool (A) attached to the engine 8. Set pilot (P) to the crankshaft and push it and
rear seal, push rear seal (7) into rear cover (6). rear cover (6) together into the crankshaft with
the hands.
6. Remove alignment tool (A). a Do not forget gasket (G).
a Use guide pin [2].
9. Remove pilot (P).
7. Apply gasket sealant according to the following

procedure.
1) Apply gasket sealant to thick line on the
underside of rear cover (6) shown below. 10. Install alignment tool (A) again and check that
2 Apply string 3 mm in diameter to rear seal (7) is inserted to a proper depth.
thick line: Gasket sealant (LG-7) a Evenly set the heights of rear cover (6)
and both sides (B) of the oil pan rail.
a Keep alignment tool (A) installed.
11. Remove guide pin [2] and tighten the 8 rear

cover mounting bolts in the following order.
3 Rear cover mounting bolt:
12.7 ± 2.0 Nm {1.3 ± 0.2 kgm}
12. Remove alignment tool (A).
2) Apply gasket sealant thickly to 2 hatched

parts (a) shown below.
2 Hatched part (a):
Gasket sealant (LG-7)
28 GD655-3E0, GD675-3E0
[*1]
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
a When installing each joint of the air conditioner
hose, check that O-ring (70) is fitted to it.
a Check that O-ring (70) is free from flaw and
deterioration.
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) to O-ring (70).
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
13. Cut off gasket (G). (Right and left) 24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
a Take care that the cut gasket will not fall in 3 Thread size (M24 x 1.5) (Width across flats:
the engine. 27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}

3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
14. Install the flywheel housing.

2 String 1 – 3 mm in diameter around
mounting bolt hole on cylinder block
face side and flange face:
Gasket sealant (LG-6)
a Tighten the mounting bolts in the order
shown in the following figure.
3 Flywheel housing mounting bolt:
77 ± 12 Nm {7.9 ± 1.2 kgm}

GD655-3E0, GD675-3E0 29
[*2] q Measuring radial runout

a Fix the flywheel to the flywheel housing with 1) Install dial gauge [4] to the end of the
ring wrench [3]. crankshaft.
2) Set the probe of the dial gauge perpendic-
ular to the socket of the flywheel housing.
3) Set the dial gauge to "0", rotate the crank-
shaft 1 turn, and measure the difference
between the lowest and highest values.
a After the flywheel is rotated 1 turn,
check that the dial gauge indicates
the value at the start of rotation.
aTighten the mounting bolts in the order shown

in the following figure.
3 Flywheel mounting bolt:
137 ± 7 Nm {14.0 ± 0.7 kgm}
q Measuring facial runout

1) Similarly to measurement of the radial
runout, set the probe of the dial gauge
perpendicular to end face of the flywheel.
a When measuring, bring the crank-
shaft to the front or rear side so that
an error will not be caused by the end
play.
2) Set the dial gauge to "0", rotate the crank-
shaft 1 turn, and measure the difference
a Measure the facial runout and radial runout of between the lowest and highest values.
the flywheel housing.
(Check with dial gauge [4].)
q Facial runout: Max. 0.20 mm
q Radial runout: Max. 0.20 mm
30 GD655-3E0, GD675-3E0

again.

6 Coolant: 39.5 l
GD655-3E0, GD675-3E0 31
Removal and installation of 5. Air conditioner compressor [*2]

engine assembly 1 1) Loosen 4 bolts (2), bolt (3) and bolt (4).
2) Loosen adjustment nut (5) and remove air
Removal conditioner compressor drive belt.
3) Remove air conditioner compressor (6)
k Stop the machine on a level place and and fix it with ropes to a place where it will
apply the parking brake. not be an obstacle.
k Lower the work equipment to the ground,
stop the engine, and loosen the hydraulic

a Never release the refrigerant (R134a) to 6. Hoses and pipings
the atmosphere. 1) Disconnect radiator hose (7).
2) Disconnect heater hose (8).
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
7. Air intake connector

1) Disconnect air hose (9). [*3]
2) Remove fuel prefilter assembly (10) and
its bracket together.
3. Remove the engine hood assembly. For

details, see "Removal and installation of
4. Remove the fuel tank, hydraulic tank and cool-

ant reservoir tank assembly. For details, see
"Removal and installation of fuel tank, hydrau-
lic tank and reservoir tank assembly".
32 GD655-3E0, GD675-3E0
8. Disconnect engine oil drain hose (11) from the 2) Disconnect 2 wiring harnesses (14).
drain valve at lower part.
11. Engine mounting bolts [*4]

9. Remove hose (12) from the flywheel housing 1) Using the sling, lift up the engine assembly
bottom. temporarily.
2) Loosen 2 mounting bolts (15) on the
mounting bar at the engine block bottom.
3) Remove left engine mounting bolt (16).
10. Relay wiring harness on right side of engine

1) Remove cover (13).
4) Remove right engine mounting bolt (17).
GD655-3E0, GD675-3E0 33
12. Engine assembly Installation

1) Using the sling, lift up the engine assem-
bly and remove 12 mounting bolts (18). q Carry out installation in the reverse order to
2) Move engine assembly (19) forward to removal.
disconnect it from the transmission. [*5]
a Using a forcing screw (M10, P1.5 mm), [*1]
disconnect the engine from the trans- a When installing the air conditioner hoses, take
mission. care that dirt, dust, water, etc. will not enter
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3) Using sling [1], remove engine assembly
(20).
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
4 Engine assembly: 850 kg 3 Air conditioner compressor refrigerant tube
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
34 GD655-3E0, GD675-3E0
[*2]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting volume,
belt".
[*3]
3 Clamp of air hose (9):
8 ± 1.0 Nm {0.8 ± 0.1 kgm}
[*4]
2 Engine mounting bolt: Adhesive (LT-2)
3 Engine mounting bolt:
610 – 765 Nm {62.5 – 78 kgm}
[*5]
3 Engine and transmission case mounting bolt:
54 – 74 Nm {6 – 7.5 kgm}
a Take care not to damage the O-ring between the

engine assembly and transmission assembly.

again.

engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
6 Coolant: 39.5 l
GD655-3E0, GD675-3E0 35
Removal and installation of fuel 4) Loosen the clamp on the tank side and
tank, hydraulic tank and coolant disconnect air intake connector hose (5).
[*1]
sub tank assembly 1
Removal
chocks.
k Drain the coolant, hydraulic oil and fuel.
4. Hoses and tubes on radiator side

1) Loosen the clamp on the tank side and
disconnect aftercooler hose (6).
2) Remove tube (7) between aftercooler and
turbocharger.
disconnect radiator hose (8).

For details, see "Removal and installation of
3. Hoses and tubes on engine side

disconnect turbocharger outlet hose (2).
2) Disconnect heater hose (3) from the tank.
disconnect radiator hose (4).
4) Disconnect hose (9) between the radiator

and coolant sub tank.
36 GD655-3E0, GD675-3E0
5. Upper hoses and tubes 4) Disconnect connectors (18), (19), (20) and
1) Loosen the clamp on the tank side and (21).
disconnect aftercooler outlet hose (10). 5) Disconnect wiring harness clamps (22),
2) Remove 2 coolant return hose clamps (11). (23) and (24).
3) Remove air intake tube (12).
4) Disconnect radiator sub tank overflow
hose (13).
5) Disconnect hydraulic tank overflow hose
(13a).
6) Disconnect connector (25).

7) Disconnect wiring harness clamps (26)
and (27).
6. Wires and connectors on right side

1) Disconnect ground wire D11 (14).
2) Disconnect connector ET39 (15).
and (17).
8) Disconnect connectors (28).

and (30).
GD655-3E0, GD675-3E0 37
7. Corrosion resistor 3) Disconnect work equipment pump speed

Disconnect the related hoses and remove cor- sensor wiring connector (35).
rosion resistor (31) and its bracket together.
9. Related hoses and clamps

8. Hoses and wiring connectors at tank bottom 1) Disconnect oil cooler hose clamps (36)
1) Disconnect connectors T32 (32) and T34 and (37).
(33). 2) Disconnect coolant sub tank drain hose
(38).
3) Disconnect hydraulic tank outlet hose
(39).
4) Disconnect hydraulic tank return hose
(40).
2) Disconnect 2 fuel tube clamps (34).
5) Disconnect fuel hose (41).

6) Disconnect 2 hydraulic oil return hoses
(42).
7) Disconnect hydraulic tube (43).
38 GD655-3E0, GD675-3E0
8) Disconnect breather hose (44). 11. Using sling [1], remove fuel tank, hydraulic
tank and coolant sub tank assembly (47).
4 Fuel tank, hydraulic tank and coolant
sub tank assembly: 310 kg
9) Disconnect hydraulic hose (45).
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Air intake connector hose clamp
8 ± 1.0 Nm {0.82 ± 0.1 kgm}
[*2]
2 Tank mount bolt: Adhesive (LT-2)
10. Tank assembly mount 3 Tank mount bolt:
Remove 4 mount bolts (46). [*2] 245 – 309 Nm {25 – 31.5 kgm}

again.

engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
5 Coolant: 39.5 l
GD655-3E0, GD675-3E0 39
Removal and installation of air 2. Set lock pin (1) to the frame.
conditioner condenser 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Vacuum pump
799-703-1100 (100 V) t 1
Vacuum pump
X 799-703-1110 (220 V) t 1
Vacuum pump
799-703-1120 (240 V) t 1
799-703-1400 Gas leak tester t 1 3. Engine hood and radiator guard

1) Remove the engine hood assembly. For
Removal engine hood assembly".
k Stop the machine on a level place and 2) Disconnect rear light connector (2).
apply the parking brake. 3) Disconnect air conditioner condenser pip-
k Lower the work equipment to the ground, ing (3).
stop the engine, and loosen the hydraulic a Since the air conditioner condenser piping
tank cap gradually to release the pressure is installed through the right lower part of
inside the hydraulic tank. the shroud, disconnect it.

the atmosphere.
Therefore, make sure to wear protec- 4) Remove 3 radiator guard mounting bolts
tive glasses when collecting or filling (4).
the refrigerant. Collecting and filling a Mounting bolt (4a) is used to secure
work must be conducted by a qualified the engine hood, too.
person. a Work on the right side similarly.
40 GD655-3E0, GD675-3E0
5) Using sling [1], remove radiator guard (5). 5. Air conditioner condenser
4 Radiator guard: 75 kg 1) Disconnect 2 air conditioner condenser
pipings (8).
2) Remove 4 mounting bolts (9) and air con-
ditioner condenser (10).
4. Fan
1) Remove fan guard (6).
2) Remove the 6 mounting bolts and fan (7).

[*2]
GD655-3E0, GD675-3E0 41
Installation
removal.
[*1]
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
3 Fan mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
42 GD655-3E0, GD675-3E0
Removal and installation of oil 3) Remove 3 radiator guard mounting bolts

cooler assembly 1 (4).
a Mounting bolt (4a) is used to secure
Removal the engine hood, too.
a Work on the right side similarly.
chocks.
4) Using sling [1], remove radiator guard (5).

4 Radiator guard: 75 kg
2. Engine hood and radiator guard

2) Disconnect rear light connector (2).
3. Oil cooler hoses

1) Disconnect upper hose (6) from the oil
cooler.
GD655-3E0, GD675-3E0 43
2) Disconnect lower hose (7) from the oil 4) Remove left radiator mount (10).
cooler. a The radiator mount must be removed
since it is an obstacle to removal of
mounting bolt (11) on the lower left
side.
5) Remove 2 mounting bolts (11) from the
lower left side.
6) Remove mounting bolt (12) from the lower
left rear side.
4. Oil cooler
1) Remove 2 mounting bolts (8) from the
upper left side.
2) Remove mounting bolt (9) from the upper
left rear side.
7) Using sling [3], remove oil cooler (13).

4 Oil cooler: 17 kg
3) Set a jack [2] under the left part of the radi-

ator to support the radiator.
a Set the jack to remove the left radia-
tor mount.
Installation
Carry out installation in the reverse order to
removal.

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
44 GD655-3E0, GD675-3E0
Removal and installation of 3) Using sling [1], remove radiator guard (5).
aftercooler assembly 1 4 Radiator guard: 75 kg
Removal
chocks.
k Drain the coolant and hydraulic oil.
3. Fan
1) Remove fan guard (6).

2) Remove 3 radiator guard mounting bolts
(4).
a Mounting bolt (4a) is used to secure 2) Remove the 6 mounting bolts and fan (7).
the engine hood, too.
GD655-3E0, GD675-3E0 45
4. Upper piping 7. Disconnect rear light connector (17) and

1) Remove air hoses (8) and (9). remove bracket (18).
2) Remove radiator upper hose (10).
3) Disconnect overflow tube (11).
4) Disconnect oil cooler hose (12).
8. Aftercooler
1) Remove 6 aftercooler mounting bolts (19).
5. Shroud
1) Remove upper mounting bolt (13a) of stay
(13) and fold down the stay to the left.
2) Remove 10 shroud mounting bolts (14).
2) Using sling [1], remove aftercooler assem-

bly (20).
a When slinging the aftercooler, take care
not to break the sponge around it.
4 Aftercooler assembly: 28 kg
6. Air conditioner condenser
Remove the 4 air conditioner condenser bolts
(15) and move air conditioner condenser (16)
toward the fan.
46 GD655-3E0, GD675-3E0
Installation
removal.

again.

5 Coolant: 39.5 l
GD655-3E0, GD675-3E0 47
Removal and installation of 3) Using sling [1], remove radiator guard (5).
radiator assembly 1 4 Radiator guard: 75 kg
Removal
chocks.
k Drain the coolant.
3. Piping
1) Remove radiator upper hose (6).
2) Disconnect overflow tube (7).

1) Remove the engine hood assembly.
For details, see "Removal and installation
of engine hood assembly".
2) Remove 3 radiator guard mounting bolts
(4).
the engine hood, too. 3) Disconnect radiator lower hose (8).
48 GD655-3E0, GD675-3E0
4. Fan 7. Disconnect rear light connector (15) and

1) Remove fan guard (9). remove bracket (16).
2) Remove 6 mounting bolts and fan (10). 8. Radiator

1) Remove 2 radiator mounting bolts (17).
5. Shroud
1) Remove upper mounting bolt (11a) of stay
(11) and fold down the stay to the left.
2) Remove 10 shroud mounting bolts (12).
2) Using sling [1], remove radiator assembly

(18).
a When slinging the radiator, take care not
to damage the sponge around it.
6. Air conditioner condenser
4 Radiator assembly: 22 kg
Remove 4 air conditioner condenser mounting
bolts (13) and move air conditioner condenser
(14) toward the transmission.
GD655-3E0, GD675-3E0 49
Installation
removal.

6 Coolant: 39.5 l
50 GD655-3E0, GD675-3E0

engine hood 1
Removal
chocks.
4) Remove air conditioner compressor wiring

harness clamp (7).
5) Loosen the V-belt, remove the air condi-

tioner compressor mounting bracket, and
move air conditioner compressor (8) back
and fix it. [*1]
a The air conditioner compressor must be
removed back since it interferes with the
engine hood.
3. Front engine hood cover

1) Remove the rubber cap and remove 4
mounting bolts (3).
2) Remove front cover (4) of the engine
hood.
3) Remove 4 mounting bolts (5) and front
lower cover (6) of the engine hood.
a This cover must be removed since it
interferes with the air conditioner pip-
ing.
GD655-3E0, GD675-3E0 51
4. Left engine hood cover 5. Remove the 2 mounting bolts (13) from the
1) Remove the rubber cap and 6 mounting front lower part of the engine hood.
bolts (9). a Work on the right side similarly.
2) Remove engine hood left cover (10).
6. Remove the 2 mounting bolts (14) from the

lower part of the engine hood.
3) Remove 3 mounting bolts (11) on the radi- a Work on the right side similarly.
ator guard.
7. Engine hood top cover

1) Remove the rubber cap and 6 mounting
4) Remove wiring harness clamp (12) from bolts (15).
the right rear part. 2) Remove cover (16).
52 GD655-3E0, GD675-3E0
3) Remove 3 mounting bolts (17) on the radi- Installation

ator cover. Carry out installation in the reverse order to
removal.
8. Remove the clamp and air duct (18). [*2]
9. Using sling [1], lift off engine hood (19).

4 Engine hood: 240 kg
a Lift up the engine hood with a chain block,
adjusting the slinging position so that the
rear part of the engine hood will be lower.
GD655-3E0, GD675-3E0 53
SEN01915-01

© 2009 KOMATSU
All Rights Reserved
54
SEN01916-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Removal and installation of engine and transmission assembly .......................................................... 2
Removal and installation of transmission assembly............................................................................. 8
Disassembly and assembly of torque converter assembly ................................................................ 14
Disassembly and assembly of transmission assembly ...................................................................... 21
GD655-3E0, GD675-3E0 1
Power train, Part 1 1

Removal and installation of 3) Disconnect air conditioner condenser pip-
engine and transmission ing (3).
assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
799-703-1100 Vacuum pump t 1

(100 V)
X 799-703-1110 Vacuum pump t 1

(220 V)
799-703-1120 Vacuum pump t 1

(240 V)
er v o i r tan k as s e m bl y. F or d etai l s , s e e
"Removal and installation of hydraulic tank,
Removal fuel tank and reservoir tank assembly".
the parking brake, and lock the tires with 4. Fan
chocks. 1) Remove fan guard (4).
k Drain the coolant, hydraulic oil, fuel and
transmission oil.
(R134a).
k If the refrigerant gets in your eyes, you may
lose your sight. Accordingly, when collect-
ing or adding it, you must be qualified for
handling the refrigerant and put on protec-
tive goggles.
2) Loosen and remove fan belt (5). [*1]

"Testing and adjusting fan belt tension".
3) Remove the 6 mounting bolts and fan (6).
2. Engine hood
2 GD655-3E0, GD675-3E0
5. Cooler hoses 7. Disconnect the clamp of hydraulic tank drain

1) Disconnect lower hose (7) from the radia- valve hose (12) from the transmission and fix it
tor bottom. to the frame.
2) Disconnect hose (8) from the oil cooler
bottom.
8. Transmission control wiring harness

1) Disconnect connectors (13), (14) and (15).
3) Disconnect hose (9) from the oil cooler 2) Remove bracket (16).
top.
3) Disconnect connectors CN-T31 (17) and

6. Work equipment pump piping CN-T43 (18) and remove clamp (19).
1) Disconnect outlet hose (10) from the work
equipment pump.
2) Disconnect 2 LS pressure hoses (11) from
the work equipment pump.
GD655-3E0, GD675-3E0 3
9. Transmission pump 11. Transmission lower piping

1) Remove outlet hose elbow (20) from the 1) Disconnect hose (28) from the transmis-
transmission pump. sion filter.
2) Disconnect hoses (21) and (22) from the 2) Remove clamp (29) and disconnect hose
transmission pump. (30).
a Stop the disconnected hoes and
elbow with plugs.
4) Remove elbow (24) and suction hose (25).
5) Remove 3 mounting bolts and transmis-
sion pump (26).
a The transmission pump must be
removed since it is an obstacle to
removal of the transmission mounting
bolts.
12. Remove universal joint (31) from the lower

part. [*2]
10. Remove oil feed pipe (27).
13. Remove hose (32) from the flywheel housing

bottom.
4 GD655-3E0, GD675-3E0
14. Relay wiring harness on right side of 16. Transmission mounting bolts [*3]
engine 1) Remove 2 left transmission mounting bolts
1) Remove cover (33). (36).
2) Disconnect 2 wiring harnesses (34). 2) Remove 2 right transmission mounting

bolts (37).
15. Remove the upper mounting nut of the sole-

noid cover and 2 stud bolts (35). 17. Engine mounting bolts [*4]
a These parts must be removed since they 1) Using the sling, lift up the transmission
interfere with the shroud when the trans- assembly temporarily.
mission is removed. 2) Loosen 2 mounting bolts (38) on the
mounting bar at the engine block bottom.
3) Remove left engine mounting bolt (39).
GD655-3E0, GD675-3E0 5
4) Remove right engine mounting bolt (40). 19. Disconnection of engine and transmission
assembly
1) Using sling [4], lift up engine assembly
(42) temporarily.
2) Remove the 12 transmission mounting
bolts.
3) While lifting up engine assembly (42) with
sling [4], disconnect it from the transmis-
sion with a forcing screw (M10, P1.5 mm).
[*5]
4 Engine assembly: 840 kg
18. Engine and transmission assembly

1) Using sling [3], remove engine and trans-
mission assembly (41).
a Check that all the hydraulic pipes and
electric wires are disconnected.
4 Engine and transmission assembly:
1,840 kg
6 GD655-3E0, GD675-3E0
Installation
removal.
[*1]
a Adjust the fan belt tension. For details, see
Testing and adjusting volume, "Testing and
adjusting fan belt".
[*2]
3 Universal joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
2 Transmission mounting bolt:
Adhesive (LT-2)
3 Transmission mounting bolt:
610 – 765 Nm {62.5 – 78 kgm}
[*4]
2 Engine mounting bolt: Adhesive (LT-2)
3 Engine mounting bolt:
610 – 765 Nm {62.5 – 78 kgm}
[*5]
a Take care not to damage the O-ring between the
engine assembly and transmission assembly.
54 – 74 Nm {6 – 7.5 kgm}
q Refilling with oil (Hydraulic tank and trans-

mission case)
again.

5 Coolant: 39.5 l
q Charging air conditioner with refrigerant
Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
GD655-3E0, GD675-3E0 7
Removal and installation of 4. Fan

transmission assembly 1 1) Remove fan guard (2).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Vacuum pump
799-703-1100 (100 V) t 1
Vacuum pump
X 799-703-1110 (220 V) t 1
Vacuum pump
799-703-1120 (240 V) t 1

2) Loosen and remove fan belt (3). [*1]
Removal "Testing and adjusting fan belt tension".
k Stop the machine on a level ground, apply 3) Remove the 6 mounting bolts and fan (4).
chocks.
k Drain the coolant, hydraulic oil, fuel and
transmission oil.
(R134a).
tive goggles.
1. Set lock pin (1) to the frame. 5. Radiator and cooler assembly
a Remove the radiator assembly to secure a
"space" to move and disconnect the trans-
mission assembly backward.
2) Disconnect air conditioner condenser pip-
ing (6).
a Disconnect the air conditioner condenser
piping since it is installed through the right
bottom of the shroud.

For details, see "Removal and installation of
3. Remove the hydraulic tank, fuel tank and reser-

voir tank assembly. For details, see "Removal
and installation of hydraulic tank, fuel tank and
reservoir tank assembly".
8 GD655-3E0, GD675-3E0
3) Remove 3 radiator guard mounting bolts 7) Disconnect hose (11) from the oil cooler
(7). top.
the engine hood, too.
8) Remove radiator mount bolt (12).

9) Remove stay mounting bolt (13).
4) Using sling [1], remove radiator guard (8).

4 Radiator guard: 75 kg
10) Using sling [2], remove radiator and cooler

assembly (14).
4 Radiator and cooler assembly:
5) Disconnect lower hose (9) from the radia- 130 kg
tor bottom.
6) Disconnect hose (10) from the oil cooler
bottom.
GD655-3E0, GD675-3E0 9
6. Work equipment pump piping 3) Disconnect connectors CN-T31 (22) and

1) Disconnect outlet hose (15) from the work CN-T43 (23) and remove clamp (24).
equipment pump.
2) Disconnect 2 LS pressure hoses (16) from
the work equipment pump.
1) Remove outlet hose elbow (25) from the
transmission pump.
7. Disconnect the clamp of hydraulic tank drain 2) Disconnect hoses (26) and (27) from the
valve hose (17) from the transmission and fix it transmission pump.
to the frame. a Stop the disconnected hoes and
elbow with plugs.
4) Remove elbow (29) and suction hose (30).
5) Remove 3 mounting bolts and transmis-
sion pump (31).
a The transmission pump must be
removed since it is an obstacle to
removal of the transmission mounting
bolts.
8. Transmission control wiring harness

1) Disconnect connectors (18), (19) and (20).
10 GD655-3E0, GD675-3E0
10. Remove oil feed pipe (32). 13. Transmission mounting bolts [*3]
1) Remove 2 left transmission mounting bolts
(37).
11. Transmission lower piping

1) Disconnect hose (33) from the transmis-
sion filter. 2) Remove 2 right transmission mounting
2) Remove clamp (34) and disconnect hose bolts (38).
(35).
14. Transmission assembly

12. Remove universal joint (36) from the lower 1) Using sling [3], lift up transmission assem-
part. [*2] bly (39) temporarily.
GD655-3E0, GD675-3E0 11
2) Support the flywheel housing with jack [4]. 15. Related components
1) Using sling [5], remove fan pulley assem-
bly (42).
4 Fan pulley assembly: 34 kg
3) Using the sling, lift up the transmission

assembly temporarily and remove 12
mounting bolts (40).
4) Move and disconnect transmission assem- 2) Remove the 2 mounting bolts. Using sling
bly (41) backward. [*4] [6], remove work equipment pump assem-
a Using a forcing screw (M10, P1.5 mm), bly (43).
4
disconnect the transmission assembly
from the engine. Work equipment pump assembly:
57 kg
5) Using sling [3], lift off transmission assem-

bly (39). 3) Remove right and left transmission
4
mounts (44).
Transmission assembly: 1,000 kg 4) Remove pulley (45).
12 GD655-3E0, GD675-3E0
Installation
removal.
[*1]
Adjust the fan belt tension. For details, see Testing
and adjusting volume, "Testing and adjusting fan
belt tension".
[*2]
3 Universal joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
2 Transmission mount bolt: Adhesive (LT-2)
3 Transmission mount bolt:
610 – 765 Nm {62.5 – 78 kgm}
[*4]
a Take care not to damage the O-ring between
the engine assembly and transmission assem-
bly.
54 – 74 Nm {6 – 7.5 kgm}
q Refilling with oil (Hydraulic tank and trans-
mission case)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.

6 Coolant: 39.5 l

GD655-3E0, GD675-3E0 13
Disassembly and assembly of 2. Torque converter lock-up housing

torque converter assembly 1 1) Remove snap ring (4), then remove
spacer (5).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Repair stand
790-501-5000 (AC100 V) q 1
Repair stand
790-501-5200 (AC110 V, 220 V) q 1
1
790-901-2110 Bracket q 1
793-310-2131 Plate q 1
C
793-310-2141 Plate q 1
2 792-390-1210 Wrench t 1
790-201-2740 Spacer t 1 2) Remove housing mounting bolts (6).
3
790-201-2750 Spacer t 1
4 790-102-1871 Wrench t 1
Disassembly
1. Pilot
1) Set torque converter assembly (1) on work
stand with pilot side at the top.
2) Remove mounting bolts (2), and using
forcing screws, remove pilot (3).
3) Using puller [1], remove torque converter

lock-up housing (7).
14 GD655-3E0, GD675-3E0
4) Remove bearing (8) from housing (7). 4. Turbine assembly

5) Remove piston (9) from housing (7). Remove turbine assembly (24).
6) Remove seal ring (10) from piston (9). 5. Stator assembly

7) Remove seal ring (11) from housing (7). 1) Remove stator assembly (13).
a Rotate to the right as seen from the
top and pull up.
2) Disassembly of stator assembly
1] Remove snap ring (14), then remove
race and free wheel assembly (15)
from stator (16).
3. Drive case
1) Remove disc (12).
2) Remove mounting bolts (22), then using
eyebolts [2], remove drive case (23).
2] Remove snap ring (17) from stator

(16).
3] Remove bushings (18) and (19), then
remove free wheel (20) from race
(21).
GD655-3E0, GD675-3E0 15
6. Stator shaft 7. Disassembly of pump assembly

1) Using tool C2, remove nut (25). 1) Remove mounting bolts (31), then push
bearing (32) from opposite side, and
remove together with gear (27) from pump
assembly (35).
2) Remove spacer (29).

3) Turn over pump and stator shaft assembly
(26), support gear (27) with block [3], then
remove stator shaft (28) with push tool [4]. 2) Remove bearing (32) from gear (27).
3) Using forcing screws [5], remove collar
(34) from gear (27).
4) Remove seal ring (30) from stator shaft

(28).
16 GD655-3E0, GD675-3E0
Assembly 2. Stator shaft

a Wash all the parts clean and check that there 1) Install seal ring (30) to stator shaft (28).
is no dirt or damage before assembling. 2 Outside circumference of seal ring:
a Check that the snap ring is securely fitted in Grease (G2-LI)

the groove.
1. Pump assembly
1) Install collar (34) to gear (27).
a Align the bolt holes.
2) Install bearing (32) to collar (34).
2) Set stator shaft (28) on work stand, and

install to pump assembly (35).
a Press fit the inner race end of the
bearing.
3) Install spacer (29).
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}
4) Using tool C2, tighten nut (25).

2 Nut: Thread tightener (LT-2)
3 Nut:
161.8 ± 14.7 Nm {16.5 ± 1.5 kgm}
GD655-3E0, GD675-3E0 17
3. Stator assembly 2) Rotate stator assembly (13) to right (clock-

1) Assembly of stator assembly wise) to install.
1] Assemble free wheel (20) to race a Check the direction of rotation of the
(21), then expand fit bushings (18) stator from the turbine end (input
and (19). end).
a Coat the sliding surface of the bush- q Clockwise: Free
ing and free wheel with engine oil. q Counterclockwise: Locked
a Be careful not to damage the sprag of a If the direction of rotation of the stator
the free wheel. is not as given above, reverse the
race and freewheel assembly, reas-
semble the stator assembly, then
check the direction of rotation again.
2] Install snap ring (17) to stator (16).
4. Turbine assembly
Install turbine assembly (24).
3] Fit race and free wheel assembly (15)

to stator (16), then install snap ring
(14).
18 GD655-3E0, GD675-3E0
5. Drive case 5) Install bearing (8) with push tool [6].

1) Using eyebolt [2], install drive case (23). a Press fit the outer race and inner race
2) Tighten mounting bolts (22). at the same time.
2 Mounting bolt: a Take care that push tool [6] will not
Thread tightener (LT-2) touch cage groove (a) of bearing (8).
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
3) Install disc (12).
6) Fit spacer (5) and install snap ring (4).

a Check that the snap ring is securely
fitted in the groove.
6. Torque converter lock-up housing
1) Install seal ring (11) to housing (7) and
install seal ring (10) to piston (9).
2 Outside circumference of seal ring:
Grease (G2-LI)
7) Tighten mounting bolts (6).

2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
2) Install piston (9) to housing (7).
3) Using eyebolts [2], install housing (7).
4) Temporarily assemble several mounting
bolts (6).
GD655-3E0, GD675-3E0 19
7. Pilot
Install pilot (3), then tighten mounting bolts (2).
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
20 GD655-3E0, GD675-3E0
Disassembly and assembly of Disassembly

transmission assembly 1 k Set blocks securely to transmission assem-
bly (1), then sling the assembly to prevent it
Special tools from falling over.
Necessity
Symbol
Sketch
Q’ty
N/R
790-201-2740 Spacer t 1
1 790-201-2750 Spacer t 1
790-201-2740 Spacer t 1
2
797T-423-1320 Push tool t 1 Q
3
794T-423-1130 Push tool t 1 N Q
4 790-101-5221 Grip t 1 1. Fan bracket assembly
01010-51225 Bolt t 1 Sling fan bracket, remove mounting bolts, then
794T-423-1130 Push tool t 1 Q remove fan bracket assembly (2).
794T-423-1140 Spacer t 1 N Q
5
790-101-5221 Grip t 1
D 01010-51225 Bolt t 1
794T-423-1110 Push tool t 1 N Q
6 790-101-5221 Grip t 1
01010-51225 Bolt t 1
794T-423-1110 Push tool t 1 Q
794T-423-1120 Spacer t 1 N Q
7
790-101-5221 Grip t 1
01010-51225 Bolt t 1
794T-423-1180 Push tool t 1 N Q
8 790-101-5221 Grip 1 2. Piston pump assembly
01010-51225 Bolt 1 Sling pump assembly (5), then remove mount-
ing bolts and lift off.
9 793-310-2100 Lifting tool t 1
10 792-271-2000 Centering tool t 1
11 799-301-1600 Oil leak tester t 1
GD655-3E0, GD675-3E0 21
3. Gear pump assembly

1) Remove outlet tube (6).
2) Sling gear pump assembly (7), remove
mounting bolts, then remove.
10. Oil lubrication tubes, wiring harness

1) Remove tubes (17), (18), (19), (20), (21),
(22), and (27), then remove block (23).
2) Remove wiring harness (24).
4. Oil lubrication hoses, tube
1) Remove hoses (8) and (9). 11. Oil temperature sensor (for transmission
2) Remove tube (10). oil)
Remove oil temperature sensor (25).
5. Transmission mount (right)
Remove transmission mount (right) (11). 12. Strainer
Remove strainer (26).
6. Speed sensor (for detection of transmis-
sion output shaft speed)
Remove speed sensor (12).
13. Lubrication tube, block assembly

Remove lubrication tube and block assembly
(28).
7. Fan pulley
Remove fan pulley (13).
8. Transmission mount (left)

Remove transmission mount (left) (14).
9. Return hose, valve cover

1) Remove hose (15).
2) Remove valve cover (16).
22 GD655-3E0, GD675-3E0
14. Coupling, retainer 16. Torque converter lock-up valve assembly,

1) Remove coupling (31). oil pressure tube
2) Remove mounting bolts, then using forc- 1) Remove oil pressure tube (36).
ing screws, remove retainer (32). 2) Remove mounting bolts at valve seat end,
then remove valve assembly (37) together
with seat (38).
3) Remove valve assembly (37) from valve
seat (38).
3) Remove dust seal (33) and oil seal (29)

from retainer (32).
15. Torque converter relief valve assembly

1) Remove 4 mounting bolts, then remove
torque converter relief valve assembly 17. Oil lubrication tubes
(34). Remove tubes (39) and (40).
GD655-3E0, GD675-3E0 23
18. Cover, breather 2) Remove filter (47) and case (48).

1) Remove cover (41). a Use forcing screws when removing
2) Remove breather (42). case (48).
19. Speed sensor

(for detection of engine speed)
3) Remove mounting bolts of valve seat,

then using eyebolts [3], remove valve
assembly (50).
20. Oil block (torque converter oil outlet)

Remove oil block (44).

sion input shaft speed)
4) Remove ECMV (51) from valve seat.
22. Transmission control valve assembly

1) Face transmission assembly (46) to side
so that valve assembly is at the top, then
set on block [2].
24 GD655-3E0, GD675-3E0
23. Transmission cover assembly 24. Fan drive shaft

1) Remove mounting bolts of cover assembly 1) Remove bolt (56), then remove plate (49).
(52), then using forcing screws [4], discon- 2) Remove flange (57).
nect from transmission case. 3) Knock out shaft (58) and remove.
2) Using eyebolts [5], remove cover assem- 4) Remove dust seal (59) and oil seal (35).
bly (52). 5) Remove snap ring (60), then remove
a Using lever block, adjust so that bearing (61) from cover.
clearance from transmission case is
uniform.
25. Idler gear (for REVERSE)

1) Remove bolt (62), then remove plate (63).
3) Remove outer races (53) and (54) and 2) Using gear puller [6], remove bearing (64)
bearing (55) from cover (52). together with gear (65).
GD655-3E0, GD675-3E0 25
3) Remove bearing (64) from gear (65). 3) Disassembly of 4th speed clutch assem-
4) Remove spacer (66), bearing (64), and bly
spacer (97) from shaft. 1] Remove seal ring (70).
a There is a collar under the bearing. 2] Using press, remove bearing (71) and
gear (72).
a Hold the gear and push shaft (73).
a The clutch assembly will fall, so use
cushioning material to catch it.
26. 4th speed clutch assembly

1) Remove oil guides (67) and (68).
3] Remove snap ring (74) from shaft

(73).
2) Using 2 wire ropes, remove 4th speed

clutch assembly (69).
4] Using press, remove bearing (75) at

clutch end, spacer (76), thrust washer
(77), and clutch assembly (78) from
shaft (73).
26 GD655-3E0, GD675-3E0
a Hold the drum end of clutch assembly 9] Remove 7 plates (83), 6 springs (84),
(78) and push shaft (73). and 6 discs (85) in turn.
a The shaft will fall, so use cushioning a Store the discs and plates in a flat
material to catch it. place to prevent them from warping.
5] Remove thrust washer (77) and seal 10] Remove piston assembly (86).
ring (79) from shaft (73). a The piston cannot be removed if it is
6] Remove needle bearing (80) from 4th at an angle, so set it horizontal to
speed clutch gear (137). remove it.
a Be careful not to use force when
removing. This will scratch the inside
surface of the cylinder.
11] Remove seal rings (87) and (88) from
piston assembly (86).
7] Push in end plate (81) with bar handle

[7], and remove snap ring (82).
8] Remove bar handle, then remove end
plate (81).
GD655-3E0, GD675-3E0 27
27. 2nd, 3rd speed clutch assembly 4] Remove 3rd speed clutch gear (96).
1) Using gear puller [8], remove bearing (90) 5] Remove needle bearing (80) from 3rd
and gear (91) of 1st speed shaft. speed clutch gear (96).
a Remove this because the 2nd speed
clutch gear is in contact with gear (91)
and cannot be removed.
2) Using 2 wire ropes, remove 2nd and 3rd
speed clutch assemblies (92).
6] Push in end plate (81) with push tool

[10], and remove snap ring (82).
7] Remove end plate (81).
3) Disassembly of 2nd, 3rd speed clutch

assembly
1] Remove seal ring (70).
8] Remove 8 plates (83), 7 springs (84),

and 7 discs (85) in turn.
a Store the discs and plates in a flat
place to prevent them from warping.
2] Using bearing race puller [9], remove
bearing (95) at 3rd speed end.
3] Remove spacer (76) and thrust
washer (77).
28 GD655-3E0, GD675-3E0
9] Remove thrust washer (77). 13] Remove thrust washer (77) and 2nd
10] Remove piston assembly (86). speed clutch gear (100).
a The piston cannot be removed if it is 14] Remove needle bearing (80) from
at an angle, so set it horizontal to 2nd speed clutch gear (100).
remove it.
15] Push in end plate (81) with bearing

race puller [12] and forcing screws
[13], then remove snap ring (82) and
end plate (81).
12] Using gear puller [11], remove 2nd

speed inner race (98) and intermedi-
ate gear (99), then remove snap ring
(89) from gear (99).
16] Remove 15 plates (83), 14 springs

(84), and 14 discs (85) in turn.
GD655-3E0, GD675-3E0 29
17] Remove thrust washer (77) and pis- 2) Disassembly of 1st, FH clutch assembly
ton assembly (101). a The intermediate gear and bearing at
a If the piston is at an angle, it will not the tip of the 1st gear shaft were
come out, so set it horizontally and removed in Step 28, 1).
remove it. 1] Remove seal ring (70).
a Do not use force to remove it. The 2] Remove snap ring (104) and thrust
inside surface of the cylinder will be washer (77).
damaged. 3] Remove 1st speed clutch gear (105).
4] Remove bushing (80) from 1st speed

clutch gear (105).
28. 1st, FH clutch assembly, REVERSE, FL
clutch assembly
1) Using eyebolt [14], remove 1st, FH clutch
assembly (102) and REVERSE, FL clutch
assembly (103) at the same time.
a The gears of the two sets of clutch assem-
blies cross, so both sets must be raised at
the same time in order to remove them.
a Raise both types of clutch assemblies per-
pendicularly.
30 GD655-3E0, GD675-3E0
5] Push in end plate (81) with push tool 11] Pull out FH gear (106) with forcing
[10], and remove snap ring (82). screws [15], then remove together
6] Remove end plate (81). with bearing (107), spacer (108), and
7] Remove 6 plates (83), 5 springs (84), thrust washer (77).
12] Remove thrust bearing (109) and

needle bearing (80) from FH clutch
gear (106).
8] Remove thrust washer (77). 13] Push in end plate (81) with bar handle
9] Remove piston assembly (86). [7 ], a nd re mov e sn ap ri ng (8 2) .
a The piston cannot be removed if it is Remove bar handle, then remove end
at an angle, so set it horizontal to plate (81).
remove it.
GD655-3E0, GD675-3E0 31
14] Remove 13 plates (83), 12 springs 3) Disassembly of R, FL clutch assembly

(84), and 12 discs (85) in turn. 1] Remove seal rings (70) and (113).
2] Remove bearing (114) and gear (115)

at FL clutch end with bearing race
15] Remove piston assembly (110). puller [16].
a There is a sleeve on the inside, so it 3] Remove snap ring (116), then remove
can be removed smoothly. thrust washer (77).
16] Remove seal rings (112) and (88)

from piston assembly (110). 4] Remove FL clutch gear (117).
17] Remove snap ring (111), then remove 5] Remove needle bearing (80) from
sleeve (137) from piston assembly. gear (117).
32 GD655-3E0, GD675-3E0
6] Remove thrust bearing (109). 9] Remove piston assembly (118).

a There is a sleeve on the inside, so it
can be removed smoothly.

[7 ], a nd r emov e sn ap ri ng ( 82) .
Remove handle, then remove end 10] Remove seal rings (120) and (88)
plate (81). from piston assembly.
sleeve (119).

a Store the discs and plates in a flat 12] Using bearing race puller [17],
place to prevent them from warping. remove R clutch gear (121), bearing
( 1 2 2 ) , s pa c e r ( 10 8 ) , a n d t hr u s t
washer (123).
13] Remove needle bearing (124) from R
clutch gear (121).
GD655-3E0, GD675-3E0 33

14] Remove thrust bearing (109).

[7 ], and r emov e sn ap ri ng ( 82) .
Remove handle, then remove end
plate (81). 17] Remove piston assembly (118).
a There is a sleeve on the inside, so it
can be removed smoothly.
18] Remove seal rings (120) and (88)

from piston assembly.
sleeve (119).
34 GD655-3E0, GD675-3E0
29. Torque converter assembly 3) To remove, knock out gear (129) from end
1) Set transmission case (126) securely on where nut is fitted.
block [18] (height: Min. 400 mm).
4) Remove snap ring (125), then remove

2) Remove 8 torque converter assembly spacer (146), bearing (131), and outer
mounting bolts (123) from under case. race (132).
3) Using eyebolts [19], remove torque con-
verter assembly (127) from transmission
case.
5) Remove bearing (136) and spacer (139)

from gear (129).
30. Idler gear (procedure is same for both sets,

procedure given below is for fan drive shaft
end)
1) Turn over transmission case and set
securely on block.
2) Use wrench [21] with claw to remove nut
(128).
a Hold it at the gear end to prevent it
from rotating.
GD655-3E0, GD675-3E0 35
31. Hydraulic pump drive gear (procedure is 5) Remove bearing (143), then remove outer
same for both sets, procedure given below race (144).
is for piston pump end)
1) Remove snap ring (138).
2) Using puller [20], pull out shaft (140).
a Support the shaft to prevent the
spacer and gear from falling when the
shaft comes out.
32. Outer race (for FH clutch shaft)

Remove outer race (145) from transmission
case.
3) Remove gear (135) and spacer (142).
4) Remove bearing (137) from shaft (140).
36 GD655-3E0, GD675-3E0
Assembly 3) Install snap ring (138).

a Wash all the parts clean and check that there a Check that the snap ring is fitted
is no dirt or damage before assembling. securely in the groove.
1. Outer race
Install outer race (145) to transmission case.
4) Install bearing (143) and outer race (144)

in order.
2. Hydraulic pump drive gear (procedure is

same for both sets, procedure given below
is for piston pump end)
1) Install bearing (137) to shaft (140).
3. Idler gear (procedure is same for both sets,

procedure given below is for fan drive shaft
end)
a Match the production No. of the inner and
outer races and the spacer, and assemble
2) Assemble gear (135) and spacer (142) in the bearing as a set.
case, then install shaft (140). 1) Using push tool, press fit bearing (136) to
a Tap the tip of the shaft. gear (129), then install spacer (139).
GD655-3E0, GD675-3E0 37
2) Install outer race (132) to case. 4. Torque converter assembly

1) Set transmission case (126) on block [18]
with torque converter side at the top.
a The mounting bolts for the torque
converter assembly are tightened
temporarily from below, so use a
block at least 400 mm in height.
3) Assemble gear (124) to outer race of

case.
4) Install bearing (126) to gear (124).
a Hold at the gear end.
5) Fit spacer (146) and install snap ring
(125).
a Check that the snap ring is fitted 2) Check position of oil hole and fit guide bolt
securely in the groove. [22] to stator shaft.
a Make a mark by the hole where the
guide bolt is inserted.
3) Using eyebolts [19], install torque con-
verter assembly (127).
a Mesh the torque converter PTO gear
and idler gear.
4) Install 2 – 3 mounting bolts temporarily
from below.
6) Use wrench [21] with claw to tighten nut

(128).
2 Nut: Thread tightener (LT-2)
3 Nut: 353 ± 39 Nm {36 ± 4 kgm}
a After tightening the nut, drop 6 cc of
engine oil (TO-30) on the nut, rotate
about 10 times, then check the tight-
ening torque again.
38 GD655-3E0, GD675-3E0
5) Turn over transmission case (121) and set 2] Assemble seal rings (120) and (88) to
to block [18]. piston.
a Be careful to assemble the seal ring
with the side receiving the pressure
facing in the correct direction.
a Replace the seal ring with a new part.
6) Tighten mounting bolts (123).

2 Mounting bolt:
3 Mounting bolt:
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm} 3] Install piston assembly (118) to cylin-
der portion.
a When installing the piston assembly,
coat the contact surface and the
inside and outside circumference of
the seal ring with transmission oil.
5. R.FL clutch assembly, 1st. FH clutch

assembly
1) Assembly of R.FL clutch assembly
1] Set sleeve (119) to piston, then install
snap ring (111).
a Check that the snap ring is fitted
securely in the groove.
GD655-3E0, GD675-3E0 39
4] Assemble 9 plates (83), 8 springs 8] Align inner teeth of discs and install R
(84), and 8 discs (85) in turn. clutch gear (121).
a Soak the discs for at least 2 minutes a Move the gear carefully a little at a
i n clean transmi ssion oi l befor e time to the left, right, up, and down to
assembling. align the teeth of the gear and discs
a Be careful not to let the springs and when installing.
discs overlap. 9] Install thrust washer (123) and spacer
(108).
5] Assemble end plate (81), then push in

with bar handle [7] and install snap 10] Using push tool [23], press fit bearing
ring (82). (122) to shaft.
a Check that the snap ring is fitted a After press fitting the bearing, check
securely in the groove. that there is no clearance between
the end face of the bearing and the
spacer.
a After press fitting the bearing, check
clearance (e) between the thrust
washer and the spacer.
a Clearance (e): 0.29 – 0.69 mm
6] Install thrust bearing (109).

a Insert the thick race to the clutch end.
7] Assemble needle bearing (124) to R
clutch gear (121).
40 GD655-3E0, GD675-3E0
11] Set sleeve (119) to piston, then install 14] Assemble 9 plates (83), 8 springs
snap ring (111). (84), and 8 discs (85) in turn.
a Check that the snap ring is fitted a Soak the discs for at least 2 minutes
securely in the groove. in c lean transmis sion oil befor e
assembling.
a Be careful not to let the springs and
discs overlap.
12] Assemble seal rings (120) and (88) to

piston.
with the side receiving the pressure 15] Assemble end plate (81), then push in
facing in the correct direction. with bar handle [7] and install snap
a Replace the seal ring with a new part. ring (82).
securely into the groove.
13] Install piston assembly (118) to cylin-

der portion.
a When installing the piston assembly, 16] Install thrust bearing (109).
coat the contact surface and the a Insert the thick race to the clutch end.
inside and outside circumference of 17] Assemble needle bearing (80) to FL
the seal ring with transmission oil. clutch gear (117).
GD655-3E0, GD675-3E0 41
18] Align inner teeth of disc and install FL 21] Install seal rings (70) and (113) to
clutch gear (117). shaft.
a Move the gear carefully a little at a a Coat the outer circumference of the
time to the left, right, up, and down to seal ring with grease (G2-LI), and be
align the teeth of the gear and discs careful to install it uniformly.
when installing.
22] Using tool D11, pump in air through

19] Install thrust washer (77) and snap oil hole in shaft and check operation
ring (116). of clutch.
20] Install gear (115), and using push a If the gear at the end where the air is
tool, press fit bearing (114) to shaft. pumped in is held in position, the
a After press fitting the bearing, check clutch is working normally.
that there is no clearance between a Air pressure:
the end face of the gear and the bear- 0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
ing.
washer and the gear.
2) Assembly of 1st. FH clutch assembly

1] Set sleeve (137) to piston, then install
snap ring (111).
42 GD655-3E0, GD675-3E0
4] Assemble 13 plates (83), 12 springs

a Soak the discs for at least 2 minutes
in c lean transmis sion oil befor e
assembling.
discs overlap.
2] Install seal rings (112) and (88) to pis-

ton assembly (110).
with the side receiving the pressure
facing in the correct direction.

with bar handle [7] and install snap
ring (82).

der portion.
6] Install thrust bearing (109).
a Insert the thick race to the clutch end.
7] Assemble needle bearing (80) to FH
clutch gear (106).
GD655-3E0, GD675-3E0 43
8] Align inner teeth of disc and install FH

clutch gear (106).
a Move the gear carefully a little at a
time to the left, right, up, and down to
align the teeth of the gear and discs
when installing.

der portion.
9] Install thrust washer (77) and spacer 13] Install thrust washer (77).
(108).
10] Using push tool, install bearing (107).
that there is no clearance between
spacer.
the clearance (e) between the thrust

in c lean transmis sion oil befor e
assembling.
discs overlap.

a Be careful to assemble the piston with
the side receiving the pressure facing
in the correct direction.
44 GD655-3E0, GD675-3E0
15] Assemble end plate (81).

16] Push end plate with push tool [10],
then install snap ring (82).

oil hole in shaft and check operation
of clutch.
a If the gear at the end where the air is
pumped in is held in position, the
17] Assemble bushing (80) to 1st speed clutch is working normally.
clutch gear (105). a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
18] Align inner teeth of disc and install 1st

speed clutch gear (105).
a Move the gear carefully a little at a
time to the left, right, up, and down to
align the teeth of the gear and discs
when installing.
a When installing 1st gear (105) to the
shaft, take care not to damage the
bushing.
19] Fit thrust washer (77) and install snap
ring (104).
20] Install seal ring (70) to shaft.
a Coat the outer circumference of the
seal ring with grease (G2-LI), and be
careful to install it uniformly.
GD655-3E0, GD675-3E0 45
3) Using eyebolts [14], install 1st. FH clutch 2] Install piston assembly (101) to cylin-
assembly (102) and REVERSE. FL clutch der portion.
assembly (103) at same time. a When installing the piston assembly,
a Raise both clutch assemblies perpen- coat the contact surface and the
dicularly. inside and outside circumference of
a If it is difficult to insert the 1st. FH the seal ring with transmission oil.
clutch assembly, remove the outer 3] Install thrust washer (77).
race from the transmission case end,
then assemble to the shaft bearing
and install.

6. 2nd, 3rd speed clutch assembly in c lean transmis sion oil befor e
1) Assembly of 2nd, 3rd speed clutch assem- assembling.
bly a Be careful not to let the springs and
1] Assemble seal rings (88) and (87) to discs overlap.
46 GD655-3E0, GD675-3E0
5] Assemble end plate (81). 10] Fit snap ring (89) to intermediate gear
6] Push in with bearing race puller [12] (99), then install to shaft.
and forcing screws [13], and install 11] Using press, install inner race (98).
snap ring (82). a After press fitting the inner race,
a Check that the snap ring is fitted check that there is no clearance
between the end face of the gear and
the inner race.
7] Install needle bearing (80) to 2nd a After press fitting the inner race,
speed clutch gear (100). check clearance (e) between the gear
and the thrust washer.
8] Align inner teeth of disc and install

2nd speed clutch gear (100).
a Move the gear carefully a little at a 12] Assemble seal rings (88) and (87) to
time to the left, right, up, and down to piston assembly (86).
align the teeth of the gear and discs a Be careful to assemble the piston with
when installing. the side receiving the pressure facing
9] Install thrust washer (77). in the correct direction.
GD655-3E0, GD675-3E0 47
13] Install piston assembly (86) to cylin- 16] Install end plate (81).
der portion. 17] Push in end plate with push tool [10],
a When installing the piston assembly, and install snap ring (82).
coat the contact surface and the a Check that the snap ring is fitted
inside and outside circumference of securely in the groove.
the seal ring with transmission oil. 18] Assemble needle bearing (80) to 3rd
14] Install thrust washer (77). speed clutch gear (96).
15] Assemble 8 plates (83), 7 springs 19] Align inner teeth of disc and install
(84), and 7 discs (85) in turn. 3rd speed clutch gear (96).
a Soak the discs for at least 2 minutes a Move the gear carefully a little at a
i n clean transmi ssion oi l befor e time to the left, right, up, and down to
assembling. align the teeth of the gear and discs
a Be careful not to let the springs and when installing.
discs overlap. 20] Install thrust washer (77) and spacer
(76).
48 GD655-3E0, GD675-3E0
21] Using press, install bearing (95).

the end face of the spacer and the
bearing.
the clearance (e) between the thrust
2) Using 2 wire ropes, install 2nd, 3rd speed

22] Install seal ring (70) to shaft.
3) Install gear (91) to 1st speed clutch shaft.

4) Using push tool [24], install bearing (90).
spacer.
23] Using tool D11, pump in air through washer and the spacer.
oil hole in shaft and check operation a Clearance (e): 0.26 – 0.74 mm
of clutch.
clutch is working normally.
a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
GD655-3E0, GD675-3E0 49
7. 4th speed clutch assembly 7] Install thrust washer (77) and spacer
1) Assembly of 4th speed clutch assembly (76).
8] Press fit bearing (75) to shaft.

the end face of the spacer and the
bearing.
2] Assemble piston assembly (86) to clearance (e) between the spacer and
cylinder portion of 4th speed clutch the bearing.
gear. a Clearance (e): 0.3 – 0.7 mm
3] Install needle bearing (80) to 4th
speed clutch gear (78).
9] Turn over 4th speed clutch and shaft

assembly, and assemble 7 plates
(83), 6 springs (84), and 6 discs (85)
in turn.
a It is unstable, so support by hand.
4] Install thrust washer (77) and seal a Soak the discs for at least 2 minutes
ring (79) to shaft (73). in c lean transmis sion oil befor e
a Coat the outer circumference of the assembling.
seal ring with grease (G2-LI), and be a Be careful not to let the springs and
careful to install it uniformly. discs overlap.
5] Set with spline of shaft (73) at the top
and support with block.
a It is unstable, so support it by hand.
6] Install 4th speed clutch gear (137) to
shaft (73).
a The piston assembly will fall out, so
be careful.
50 GD655-3E0, GD675-3E0
13] Using press, press fit bearing (71).

gear.
14] Install seal ring (70).
a Coat the outer circumference of the
seal ring with grease (G2-LI), and be
careful to install it uniformly.

end plate with bar handle [7] and
install snap ring (82).

oil hole in shaft and check operation
of clutch.
clutch is working normally.
a Air pressure:
0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}
11] Install snap ring (74) to tip of shaft

(73) on opposite side from clutch.
12] Install gear (72).
GD655-3E0, GD675-3E0 51
2) Using 2 wire ropes, install 4th speed

4) Align the match marks and install gear

(65), then install bearing (64) with the
3) Install oil guides (68) and (67). push tool.
8. Idler gear (for REVERSE) 5) Check that there is clearance (a) of 0.15 –
1) Using the push tool, install outer race 0.91 mm between the end face of bearing
(64a) to gear (65). (64) and that of the shaft.
a Check the manufacturer numbers and 6) Install plate (63) and tighten bolts (62).
match symbols of the inner and outer 2 Bolt: Thread tightener (LT-2)
races of the bearing and make 3 Bolt:
"match marks". 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
2) Install spacer (97) to the shaft.
a Install the spacer with the largely cut
inside down.
3) Push bearing (64) with spacer (66) and
the push tool to install it to the shaft.
a Align the match mark on the bearing
with that on the outer race installed to
the gear.
52 GD655-3E0, GD675-3E0
9. Fan drive shaft 5) Install flange (57).

1) Using push tool [28], press fit bearing (61) 6) Fit plate (49) and tighten bolts (56).
to shaft (58). 2 Bolt: Thread tightener (LT-2)
3 Bolt:
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}
2) Install shaft (58) to cover.

3) Install snap ring (60).
a Check that the snap ring is fitted 10. Transmission cover assembly
securely in the groove. 1) Install bearing (55) and outer races (54)
and (53) to transmission cover (52) with
push tool.
4) Install oil seal (35) and dust seal (59).

a Coat the area between the oil seal lip
surface and oil seal and dust seal 2) See diagram below and coat transmission
with silicon grease. case with gasket sealant.
(Three Bond 1855 or equivalent) 2 Mating face of front cover:
Gasket sealant (Three Bond
1207B or equivalent)
a Be careful not to let the gasket seal-
ant be squeezed inside the case; be
careful not to coat with too much gas-
ket sealant.
a Check that there are no scratches or
damage to the front cover.
GD655-3E0, GD675-3E0 53
2) Using eyebolts [3] and guide bolt [21], set

control valve assembly (50) to transmis-
sion case, and tighten temporarily with
mounting bolts.
3) Using eyebolts [5] and lever block, raise

transmission assembly (52) horizontally.
4) Align outer race and bearing of cover with
each clutch shaft, align spline of fan drive
shaft at same time, then lower cover 3) Install case (48) and filter (47) for 2nd, 3rd
assembly (52) slowly and install. speed clutch, then tighten mounting bolts.
5) Tighten mounting bolts of cover assembly a The bolts are of different lengths, so
(52). be careful to install at the correct
3 Mounting bolt: place.
110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}

11. Transmission control valve assembly sion input shaft speed)
1) Install ECMV (51) to valve seat. 1) Set transmission assembly (46) securely
on blocks [2] with torque converter side at
top.
54 GD655-3E0, GD675-3E0
2) Install speed sensor (45). 16. Oil lubrication tubes

a Screw it in until it contacts the gear Install tubes (40) and (39).
lightly, then turn it back 1/2 – 1 turn 3 Joint bolt:
and tighten with the locknut. 11.25 ± 1.45 Nm {1.15 ± 0.15 kgm}
3 Locknut:
58.8 ± 9.8 Nm {6.0 ± 1.0 kgm}
13. Oil block (torque converter oil outlet)

Install oil block (44).
17. Torque converter lock-up valve, oil pres-

sure tube
1) Install valve (37) to valve seat (38).
14. Speed sensor (for detection of engine speed)

Install speed sensor (43).
a Screw it in until it contacts the gear lightly,
then turn it back 1/2 – 1 turn and tighten
with the locknut.
3 Locknut: 58.8 ± 9.8 Nm {6.0 ± 1.0 kgm}
15. Cover, breather

1) Install breather (42).
2) Install cover (41).
2) Install lock-up valve (37) and seat as one

unit.
3) Install oil pressure tube (36).
GD655-3E0, GD675-3E0 55
18. Torque converter relief valve 20. Oil lubrication tube, block assembly
1) Install torque converter relief valve assem- Install oil lubrication tube and block assembly
bly (34), then tighten 4 mounting bolts. (28).
3 Mounting bolt:
49 ± 4.9 Nm {5.0 ± 0.5 kgm}
21. Strainer
Install strainer (26).
19. Coupling, retainer
1) Install oil seal (29) and dust seal (33) to 22. Oil temperature sensor (for transmission
retainer (32). oil)
a Coat the area between the oil seal lip Install oil temperature sensor (25).
surface and oil seal and dust seal
with silicon grease. 23. Oil lubrication tube, wiring harness
(Three Bond 1855 or equivalent) 1) Install wiring harness (24).
2) Install block (23).
3) Install tubes (22), (21), (20), (19), (18),
(17), and (27).
3 Joint bolt:
49 ± 4.9 Nm {5.0 ± 0.5 kgm}
2) Install retainer (32) to case.

3) Install coupling (31).
24. Valve cover, return hose

1) Install valve cover (16).
2) Install hose (15).
25. Transmission mount (left)

Install transmission mount (left) (14).
56 GD655-3E0, GD675-3E0
26. Fan pulley 30. Gear pump assembly

Install fan pulley (13). 1) Install gear pump assembly (7), then
tighten mounting bolts.
2) Install outlet tube (6).

sion output shaft speed)
Install speed sensor (12). 31. Piston pump assembly
a Screw it in until it contacts the gear lightly, 1) Sling piston pump assembly (5) with wire
then turn it back 1/2 – 1 turn and tighten rope and install, then tighten mounting
with the locknut. bolts.
3 Locknut: 58.8 ± 9.8 Nm {6.0 ± 1.0 kgm}
28. Transmission mount (right)
Install transmission mount (right) (11).
32. Fan bracket assembly

1) Sling bracket portion of fan assembly (2),
set to transmission case, then tighten
29. Lubrication tube, lubrication hoses mounting bolts.
1) Install hoses (9) and (8).
2) Install tube (10).
3 Joint bolt:
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
GD655-3E0, GD675-3E0 57
SEN01916-00

© 2006 KOMATSU
All Rights Reserved
58
SEN01917-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Removal and installation of final drive assembly ................................................................................. 2
Disassembly and assembly of final drive assembly ............................................................................. 7
Disassembly and assembly of final brake case assembly ................................................................. 12
Disassembly and assembly of side case assembly (For standard final drive) ................................... 16
Disassembly and assembly of bevel gear assembly.......................................................................... 19
Disassembly and assembly of bevel gear shaft ................................................................................. 23
Disassembly and assembly of bevel pinion assembly ....................................................................... 25
GD655-3E0, GD675-3E0 1
Power train, Part 2 1

Removal and installation of final
drive assembly 1 4. Lower work equipment (1) to ground.
Removal
a To prepare for disassembly and assembly of
the final drive assembly, jack up the machine
and support it with strong, stable stands.
a The height of the bottom surface of the main
frame must be approx. 1,000 mm.
1. Set stand [1] to front of front frame.
5. Set blocks [5] under 4 rear wheels.
2. Set blocks [2] to center of main frame.
6. Remove left and right engine side covers (1a).
3. Set blocks [3] to rear of frame.

a Lower ripper to ground.
2 GD655-3E0, GD675-3E0
7. Drain differential oil. (Limited slip differential type) a When lifting the wheel, use a sling and fit it
1) Loosen drain plug (2) and drain oil into to the center of the tire so that the tire
container. does not come out, then lift the wheel.
2) Remove breather hose (4), then remove
oil filler tube (9).
6 TO30: 14 l
9. Loosen mounting bolts of universal joint (6)

between transmission and differential. Remove
universal joint (6), then remove brake hose (7).
7. Drain differential oil. (With differential lock type)
1) Loosen drain plug (2) and drain oil into
container.
2) Remove differential lock and 2 temperature
connectors (3), then remove 2 hoses (4).
3) Remove oil filler tube (9).
6 TO30: 17 l
10. Disconnect brake hoses (8) (front, rear, left,

right: 4).
a Fit male and female plugs into the hoses.
8. Sling wheel (5), loosen 2 wheel nuts and 8

bolts, then lift off wheel, and place it in a stable
posture where there is no danger. (Remove 4
rear wheels.)
a When the wheel is removed, the tandem
case will tilt, so insert a stand of a height
equal to the bottom surface of the case
before removing the wheel.
GD655-3E0, GD675-3E0 3
11. Remove oil filler tube of differential from inter- 13. After raising final drive assembly (13), use a
mediate thread portion (9). (With differential crane and forklift truck together. Insert forks of
lock type) lift truck from right side (or left side) of final
drive and remove lifting tool from fork. With left
side of final drive raised, operate crane slowly
and drive lift truck in reverse. When tip of forks
is holding tandem case on left side, check that
forks can support final drive, then remove lift-
ing tool on left side and use lift truck to remove
to outside of machine. Then raise with crane
and set on stable stand.
12. Raise final drive assembly, remove bolts (12)

mounting assembly to main frame (2 each at
left, right, front, rear: total 8), then lower.
4 Final drive assembly: 2,750 kg
4 GD655-3E0, GD675-3E0
Installation 4. Install breather hose (4) and drain plug (2). Install
1. Raise final drive assembly (13), bring as close oil filler tube of differential to intermediate thread
as possible to frame at side of machine (on portion (9), then remove oil filler cap (17) and fill
either left or right side), then remove lifting tool with oil. (Limited slip differential type)
at frame side. Use lift truck from opposite side 5 TO30: 14 l
of machine to support tandem case on side
where lifting tool has been removed, then
operate crane and lift truck together to place at
specified position.
4 Final drive assembly: 2,750 kg
2. Raise final drive assembly (13), and align posi-

tion of mounting bolt holes.
a To ensure safety during the operation, set
a stand of a height equal to the bottom
surface of the case.
4. Install 2 differential lock solenoid connectors

and 2 oil temperature sensor connectors (3).
Install other 2 hoses (4) and oil filler tube (9).
Tighten drain plug (2). (With differential lock
type)
3. Keep raised with crane, tighten mounting bolts

(12) and nuts (14) (2 each at left, right, front,
rear: total 8), and install final drive assembly to
main frame.
a Insert the bolts from below, install the nuts
from above, then tighten the bolts from
below.
2 Mounting bolt:
3 Mounting bolt:
5. Install universal joint (6) between differential
and transmission. Install parking brake hose
927 – 1133 Nm {94.5 – 115.5 kgm}
(7).
a Install the hoses without twisting or inter-
ference.
GD655-3E0, GD675-3E0 5
6. Install hoses (8) to front, rear, left, and right of 9. Install left and right engine side covers (1a).
final brake.
7. Install oil filler tube of differential to intermedi-

ate thread portion (9), then remove oil filler cap
(17) and fill with oil.
5 TO30: 17 l
8. Sling wheel (5) and install to final case, then

tighten 2 nuts and 8 bolts.
a When lifting the wheel, use a sling and fit it
to the center of the tire so that the tire
does not come out, then lift the wheel.
3 Mounting bolt:
392 – 490 Nm {40 – 50 kgm}
Target: 441 Nm {45 kgm}
6 GD655-3E0, GD675-3E0
Disassembly and assembly of 3) Using tool J1, shorten chain (9).

final drive assembly 1 4) Using tool J1, remove spring pin (8) from
chain (9), then remove plate (11) and con-
Special tools necting link (10).
Necessity
Symbol
Sketch
Q’ty
N/R
J 1 792-571-1600 Chain puller t 1
Disassembly
1. Draining oil
Remove drain plug (1) and drain the tandem
case oil.
6 Tandem drive case: 83 l
2. Step nonskid plate and covers

1) Remove step nonskid plate (2). 5) Pull and remove chain (9) from the
2) Remove 2 top covers (3) and 4 side cov- sprocket.
ers (4) for removal and installation of the
chain.
4. Final brake case

Sling final brake case assembly (12) tempo-
3. Chain rarily, remove the mounting bolts on the tan-
1) Using hand pump [1], release parking dem case assembly, and lift off the final brake
brake (5). case assembly.
2) While turning disc (6), set connecting link
assembly (7) to the removal/installation 4 Final brake case assembly: 230 kg
hole.
GD655-3E0, GD675-3E0 7
5. Tandem case assembly 7. Final drive assembly

Sling tandem case assembly (13) temporarily, Sling final drive assembly (15) temporarily,
remove the mounting bolts on side case (14), remove the mounting bolts on side case (14),
and lift off the tandem case assembly. and lift off the final drive assembly.
4 Tandem case assembly: 400 kg 4 Final drive assembly: 300 kg
6. Side case assembly

Sling side case assembly (14) temporarily,
remove the mounting bolts on final drive
assembly (15), and lift off the side case assem-
bly.
4 Side case assembly: 230 kg
8 GD655-3E0, GD675-3E0
Assembly 3. Final drive assembly

a Clean all the parts and check them for dirt or 1) Install the shaft to final drive assembly
damage before installing. (15).
a If the shaft spline does not fit the
1. Final brake case assembly assembly, adjust it by turning the
Sling final brake case assembly (12) and install parking brake disc.
it to the 4 places of the front, rear, right, and left 2) Sling final drive assembly (15) and install it
parts of the tandem case. to side case (14).
2 Mounting bolt: Gasket sealant (LG-1) 2 Fitting face of side case:
3 Mounting bolt: Adhesive (LOCTITE 515)
245 – 309 Nm {25 – 31.5 kgm} 3 Mounting bolt:
(Target: 277 Nm {28.2 kgm}) 245 – 309 Nm {25 – 31.5 kgm}

4
(Target: 277 Nm {28.2 kgm})
Final brake case assembly: 230 kg
4 Final drive assembly: 320 kg
2. Right side case assembly

Sling right side case assembly (14) and install 4. Left side case assembly
it to tandem case assembly (13). Sling left side case assembly (14) and install it
2 Mounting bolt: Gasket sealant (LG-1) to final drive assembly (15), fitting it to shaft
3 Mounting bolt: (16).
245 – 309 Nm {25 – 31.5 kgm} a If the shaft spline does not fit the assem-
(Target: 277 Nm {28.2 kgm}) bly, adjust it by turning the parking brake
4
disc.
2 Fitting face of side case:
Side case assembly: 230 kg
Adhesive (LOCTITE 515)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
(Target: 277 Nm {28.2 kgm})
4 Side case assembly: 310 kg
GD655-3E0, GD675-3E0 9
5. Tandem case assembly 3) Using tool J1, shorten the chain and install
Sling tandem case assembly (13) and install it connecting link (10).
to side case (14). 4) Install plate (11) and spring pin (8) to con-
2 Mounting bolt: Gasket sealant (LG-1) nect the chain.
3 Mounting bolt: a Installed positions of plate (11) and
245 – 309 Nm {25 – 31.5 kgm} spring pin (8)
(Target: 277 Nm {28.2 kgm}) Chain at front of machine:
4 Tandem case assembly: 850 kg Outside of machine
Chain at rear of machine:
Inside of machine
6. Chain
1) Insert chain (9) in tandem case assembly
(13) and mesh its end with the sprocket. 7. Parking brake
2) Rotate the parking brake disc to wind up the 1) Release parking brake (5) with hand pump
chain and set it to the connecting link [1].
assembly mounting hole. 2) Install parking brake (5).
a For the method of installing and
adjusting the parking brake, see Test-
ing and adjusting volume, "Testing
and adjusting parking brake pad
clearance".
10 GD655-3E0, GD675-3E0
8. Refilling with oil

1) Tighten tandem case drain plug (1) and
add oil through (18).
a After adding oil, rotate the final input
coupling 7 turns to rotate the disc a
half turn and soak it in the oil.
3 Drain plug:
58.8 – 78.4 Nm {6.0 – 8.0 kgm}
5 Tandem case: 83 l (each side)
9. Covers
1) Install covers (3) and gaskets (19) to the
top, front, rear, right and left chain installa-
tion holes.
2 Cover: Gasket sealant (Threebond 1207B)
2 Bolt: Gasket sealant (LG-1)
2) Install cover (20).
2 Cover: Gasket sealant (Threebond 1207B)
2 Bolt: Gasket sealant (LG-1)
a For details of procedure for adjusting park-

ing brake mount, see Testing and adjusting.
GD655-3E0, GD675-3E0 11
Disassembly and assembly of 3. Gear and shaft

final brake case assembly 1 1) Remove gear (8).
2) Remove shaft (9) from cage (10).
Special tools 3) Remove seal (17) from cage (10).
4) Remove bearing (11) and spacer (13)
Necessity
Symbol
from shaft (9).
Sketch
Q’ty
N/R
790-101-5551 • Plate 1
2
790-101-5421 • Grip 1
J 01010-51240 • Bolt 1
794T-425-1110 Push tool t 1 N Q
3
793T-659-1110 Push tool t 1 Q
4 799-301-1600 Oil leak tester t 1
Disassembly
1. Sprocket and cage
1) Remove mounting bolts (1). 4. Guide and spring
2) Remove holder (2), shim (3), sprocket (4) Remove guide (14) and spring (15).
and cage (5).
5. Piston
Remove piston (16).
2. Brake plate and brake disc

Remove 5 brake plates (6) and 4 brake discs
(7).
12 GD655-3E0, GD675-3E0
Assembly 4. Brake piston

a Clean all the parts and check them for dirt or 1) Install O-ring (19) to brake piston (16).
damage before installing. 2 O-ring and piston groove:
Grease (G2-LI)
1. Shaft
Press fit spacer (13) and bearing (11) to shaft
(9).
2 Bearing: Engine oil (TO30)
2) Install brake piston (16) to cage (10).

2 Piston insertion part in cage:
Grease (G2-LI)
2. Disc wear gauge

Place cage (10) on a stable stand and install
disc wear gauge (18).
3. Seal
Press fit seal (17).
2 Space in oil seal lip (Fill 80%):
Grease (G2-LI)
2 Between bearing and oil seal:
Grease (G2-LI)
5. Guide and brake spring

1) Install guide (14) and brake spring (15).
q Installed height of brake spring:
60.5 mm
q Free height of brake spring:
76.5 mm
q Installed load of brake spring:
735 N {75 kg}
GD655-3E0, GD675-3E0 13
2) Tighten guide with torque wrench [1]. 9. Brake plate and brake disc
2 Threads of guide: Adhesive (LT-2) Install 5 brake plates (6) and 4 brake discs (7)
3 Guide: 49 Nm {5 kgm} alternately.
6. Cage 10. Cage

Install cage (10) to shaft (9). 1) Fit O-rings (23) to the inside and outside
of cage (5) and install cage (5) to cage
7. Bleeder and plug (10).
Install bleeder (20) and plug (21).
a Before installing the bleeder, insert mount-
ing bolt (22) on the tandem drive.
3 Plug: 68.7 ± 9.8 Nm {7 ± 1 kgm}
2) Set the collar and press fit bearing (24).

2 Bearing: Engine oil (EO30)
8. Gear
Install the collar and gear (8).
14 GD655-3E0, GD675-3E0
11. Sprocket
1) Set the collar and install sprocket (4).
2) Install shim (3) and holder (2) and tighten
mounting bolts (1).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a After adjusting the bearing pre-load,
apply adhesive (LT-2) to the mounting
bolts and tighten them again.
12. Plate
Install plate (12).
13. Adjusting pre-load

1) Using push-pull gauge [2], measure the
drag torque (A) of the shaft.
Adjust the pre-load on the bearings to the
value of above drag force (A) + 44 to 63 N
{4.5 to 6.4 kg} with shim (3).
q Standard shim thickness: 2 mm
q Kinds of shim thickness: 0.1 mm, 0.2
mm, 0.5 mm
2) After adjusting the pre-load, tighten holder
mounting bolts (1) again.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
GD655-3E0, GD675-3E0 15
Disassembly and assembly of 3) Remove bearing (9) and collar (10) from
side case assembly shaft (8).
(For standard final drive) 1
Disassembly
1. Sprocket
1) Place side case assembly (1) on a stable
stand with the sprocket side up.
2) Remove bolt (2) and plate (3).
a Check the thickness and quantity of
the shims.
3) Remove sprocket (4) and collars (5) and
(6).
3. Case
1) Turn over the side case assembly and
remove bolts (11) and holder (12).
2) Sling cage (13) and remove it from flange
(14).
2. Shaft
1) Remove snap ring (7).
2) Turn over the side case assembly. Using a
press, remover shaft (8).
4. Flange
Remove bushing (15), oil seals (16) and (17),
and thrust washer (18) from flange (14).
16 GD655-3E0, GD675-3E0
Assembly 2. Cage
a Clean the all parts and check them for dirt or 1) Sling cage (13) and install it to flange (14).
damage before installing. 2 Bushing contact surface:
Lubricant containing molybdenum
1. Flange disulfide (LM-P)
1) Install thrust washer (18) to flange (14). 2) Install holder (12) with 10 mounting bolts
2 Both sides of thrust washer: (11).
Lubricant containing molybdenum 3 Mounting bolt:
disulfide (LM-P) 98 – 123 Nm {10 – 12.5 kgm}

2) Using push tool [1], press fit oil seal (17).
2 Circumference of seal :
Gasket sealant (LG1 or LG5)
2 Space of oil seal lip (To be filled up to 50%):
Grease (G2-LI)
3. Shaft
Using push tool [2], install collar (10) to shaft
(8).
Using push tool [3], install bearing (9) to shaft
(8).
3) Similarly to step 2), press fit oil seal (16).
2 Space of oil seal lip (To be filled up to 50%):
Grease (G2-LI)
4) Press fit flange (14) to bushing (15).
2 Bushing contact surface:
disulfide (LM-P)
GD655-3E0, GD675-3E0 17
3) Press fit shaft (8) to flange (14).

4) Install snap ring (7).
4. Sprocket
1) Install collars (6) and (5) and sprocket (4)
to the shaft.
2) Insert a shim so that clearance (a)
between the sprocket and plate will be
0.03 – 0.25 mm, and then install plate (3)
and mounting bolt (2).
2 Bearing roller: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
18 GD655-3E0, GD675-3E0
Disassembly and assembly of Assembly

bevel gear assembly 1 1. Bevel gear assembly
1) Sling bevel gear assembly (5) by the shaft
Disassembly and set it to the installation position in the
1. Bevel pinion assembly case.
1) Set bevel gear assembly (3) on the block 2) Install the removed shims and cages (7)
with the bevel pinion side up. and (6).
2) Remove 6 mounting bolts (2) and sling a This work is necessary for adjustment
bevel pinion assembly (3). of the pre-load on the side bearing of
a Check the thickness and quantity of the bevel gear assembly after installa-
the shims. tion of the bevel pinion assembly.
2. Bevel gear assembly 2. Bevel pinion assembly

1) Set the bevel gear assembly on the block 1) Set case (1) on the block with the bevel
with the bevel pinion side down. pinion assembly side up.
k Set the block securely. 2) Install the removed shims and bevel pin-
2) Remove cover (4). ion assembly (3) and tighten mounting
3) Sling bevel gear assembly (5) by the bolts (2).
shaft. 3 Mounting bolt:
4) Remove right and left cages (6) and (7) 98 – 123 Nm {10 – 12.5 kgm}
and bevel gear assembly (5).
the shims.
GD655-3E0, GD675-3E0 19
3. Adjusting backlash, tooth contact and pre- 2) Measuring pre-load

load Using torque wrench [3], measure the
Adjust the pre-load on the tapered roller bear- starting torque of the bevel pinion.
ing and the bac klas h and tooth contact a Adjust the shims of the right and left
between the bevel gear and bevel pinion. cages so that the starting torque of
a Adjust the starting torque of the bevel pin- the bevel pinion will be increased by
ion assembly to (8.7 – 11.7 Nm {0.89 – (0.7 – 1.5 Nm {0.07 – 0.15 kgm}) from
1.19 kgm}) in advance. the basic starting torque of (8.7 – 11.7
q Standard shim thickness: 2 mm Nm {0.89 – 1.19 kgm}).
q Kinds of shim thickness: 0.1 mm, 0.2 q Standard shim thickness: 1.5 mm
mm, 0.5 mm (each side)
a Fit the shims removed when the bevel pin- q Kinds of shim thickness: 0.1 mm, 0.2
ion assembly was disassembled and mm, 0.5 mm
install the bevel pinion to the case.
a Adjust the pre-load, backlash and tooth
contact simultaneously.
a Adjust the pre-load, backlash and tooth
contact while the bevel gear and bevel
pinion are meshed.
1) Measuring backlash (with fuse)
Put wire fuse (1.5 mm in diameter) [1]
between the bevel gear and bevel pinion
and rotate the bevel gear, and then mea-
sure the fuse thickness with micrometer
[2].
a Put the fuse on the center of the tooth
depth of the bevel pinion (position of about
21 mm from the small end).
(Measure at 3 or more positions.)
a Backlash: 0.25 – 0.33 mm
20 GD655-3E0, GD675-3E0
3) Adjusting tooth contact 1] If the bevel pinion is too far from the
Apply red lead thinly to the surfaces of the center line of the bevel gear, the con-
bevel pinion teeth and turn the bevel gear tact is at the small end of the bevel
in the forward and reverse directions, then gear tooth faces curved outward and
check the tooth contact pattern. at the large end of the tooth faces
a The center of the tooth contact pat- curved inward.
tern should be at 28% – 40% (a) of
the face width from the bevel gear
small end. The tooth contact width
should be 46% – 58% of the face
width and tooth contact should be
made at the center of the tooth depth.
If the bevel gear and bevel pinion are
adjusted in this way, their teeth come
in contact with each other correctly
when they are loaded.
a If the tooth contact pattern is not
pr oper, adjust the tooth contact
according to the following procedure.
a In this case, decrease the thickness of

the shims at the bevel pinion assembly
mounting position to move the bevel
pinion in direction (A) and bring it near
the bevel gear. Then, adjust the shims
of the right and left cages by the
approach of the bevel pinion to move
the bevel gear in direction (B), and then
check the tooth contact pattern and
backlash again.
GD655-3E0, GD675-3E0 21
2] If the bevel pinion is too close to the

center line of the bevel gear, the con-
tact is at the large end of the bevel
gear tooth faces curved inward and
the large end of the bevel gear tooth
faces curved outward.
a In this case, increase the thickness of

the shims at the bevel pinion assembly
mounting position to move the bevel
pinion in direction (A) and bring it far
from the bevel gear. Then, adjust the
shims of the right and left cages by the
increased distance of the bevel pinion
to move the bevel gear in direction (B),
and then check the tooth contact pat-
tern and backlash again.
a If the shim of either cage is decreased

to adjust the bevel gear position,
increase the shim on the other cage by
the quantity of the decreased shim so
that the pre-load on the bearing will not
change.
22 GD655-3E0, GD675-3E0
Disassembly and assembly of

bevel gear shaft 1
Disassembly
1. Remove 12 bolts (1), tap out 4 pins (2), then 2. Remove 8 bolts (4) and disassemble case (5)
remove gear (3). and bearing (6).
3. Remove case (7) and bearing (8).
4. Remove non-spin assembly (9).
5. Disassemble the non-spin assembly into side

gear (9-1a), (9-1b), spring (9-2a), (9-2b), clutch
(9-3a), (9-3b), ring (9-4a), (9-4b), and spider
(9-5).
GD655-3E0, GD675-3E0 23
Assembly
1. Bevel gear shaft assembly 2. Assemble spider (9-5), ring (9-4a), (9-4b),
1) Using push tool [1] (Inside diameter 111 clutch (9-3a), (9-3b), spring (9-2a), (9-2b) and
mm), press fit bearing (6) to case (5). side gear (9-1a), (9-1b) each other.
3. Fit non-spin assembly (9) into cases (5) and

(7), and secure with 8 bolts (4).
2) Using push tool [2] (Inside diameter 121

mm), press fit bearing (8) to case (7).
4. Secure gear (3) with bolt (1), then knock in pin

(2) and caulk it with a caulking punch.
3 Bolt: 157 – 196 Nm {16 – 20 kgm}
24 GD655-3E0, GD675-3E0
Disassembly and assembly of 3. Bearing

bevel pinion assembly 1 Remove bearing (4) from pinion shaft (3).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
790-201-2850 Spacer t 1
J 5 790-201-2230 Plate t 1
790-201-2740 Spacer t 1
Disassembly
1. Coupling
1) Remove the coupling mounting bolt,
holder and shim.
the shims.
2) Remove coupling (1).
2. Pinion shaft
1) Set bevel pinion assembly (2) on the
press stand.
2) Using tool [1], press out pinion shaft (3)
with the press.
a If the pinion shaft is pressed out, the
bearing on the coupling side comes
off.
GD655-3E0, GD675-3E0 25
Assembly 4. Coupling
1. Bearing 1) Install coupling (1).
Using push tool [2], press fit bearing (4) to pin- 2 Contact faces of coupling and seal:
ion shaft (2) with the press. Grease (G2-LI)

2 Bearing: Engine oil (TO30) 2) Install the O-ring, shim and holder, and
then tighten coupling mounting bolt (6).
q Kinds of shim thickness: 0.1 mm, 0.2
mm, 0.5 mm
3 Coupling mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
2. Pinion shaft
1) Install cage (5) to pinion shaft (3).
2) Using push tool [3], press fit the bearing
on the coupling side with the press.
2 Bearing: Engine oil (TO30)
3. Seal 5. Starting torque

Install seal (6). Using torque wrench [4], measure the starting
2 Circumference of seal : torque with the coupling mounting bolt.
Gasket sealant (LG1 or LG5) q Starting torque: 8.7 – 11.7 Nm {0.89 – 1.19
kgm}
2 Space in seal lip (Fill 80%): a If the starting torque is out of the standard
Grease (G2-LI) range, adjust the pre-load with the shim
and then measure the starting torque
again.
26 GD655-3E0, GD675-3E0
SEN01917-00

© 2006 KOMATSU
All Rights Reserved
28
SEN01918-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Steering system
Steering system .............................................................................................................................................. 2
Removal and installation of steering valve (Orbit-roll).......................................................................... 2
Disassembly and assembly of steering valve ...................................................................................... 4
GD655-3E0, GD675-3E0 1
Steering system 1
Removal and installation of Installation
steering valve (Orbit-roll) 1 a Carry out installation of the steering valve in
the reverse order of removal.
Removal
1. Remove cover (1) of post stand, then remove
monitor mounting cover (2), and remove wiring
harness and cable of each monitor.
2. Remove 5 hoses (3) installing to Orbit-roll.
3. Remove mounting bolts of Orbit-roll (4), then

remove Orbit-roll (4) and steering shaft (5).
2 GD655-3E0, GD675-3E0
Disassembly and assembly of steering valve 1

Component parts
Tools needed for disassembly and assembly

q Torque wrench (torque capacity: 49 Nm {5 kgm}) q Plastic hammer
q 5/12 in - 12 point socket q Small amount of grease
q Flat-headed screwdriver (large) q Vise
q Flat-headed screwdriver (small) q Oil-based felt pen
q Spring insertion tool (P/N: 600057) q Tweezers
q 3/16 in hexagonal wrench
4 GD655-3E0, GD675-3E0
Parts list
Part No. Part name Q‘ty Remarks
1 Screw 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 1
Centering spring 6 For standard input torque specification
13
Centering spring 4 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 sub 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
41 Name plate 1
42 Rivet 2
Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A
GD655-3E0, GD675-3E0 5
Disassembly 3. Remove spacer (5) inside spline on inside of

a When disassembling the valve, cleanliness is star of Gerotor (4).
extremely important. Carry out the work in a Remove Gerotor (4). Be careful not to drop
clean place. star from ring of outer circumference of Gero-
a In the following explanation diagrams, it is not tor.
absolutely necessary to hold the unit in a vise, Remove O-ring (22) from Gerotor.
but it is recommended to use a vise as far as
possible.
k Be extremely careful not to injure yourself
on the edges of sleeves, spool, housing,
and other machined parts.
1. Put end cap (3) at the top, fit side face of hous-
ing between copper sheets in vise [8], and be
careful not to tighten vise too strongly.
4. Remove drive (8), then remove spacer plate

(7). Remove O-ring (23) from housing.
2. Remove 6 screws (1) and 1 retainer screw (2),

then remove end cap (3). Remove O-ring (22)
from end cap (3).
5. Using flat-headed screwdriver, remove adapter

screw (39). Remove housing from vise, set
upside down, then remove ball (40).
a Be careful not to drop or lose the ball.
6 GD655-3E0, GD675-3E0
6. Set housing upside down, remove 2 springs

(31), 2 retainer plugs (30), and 2 balls (32).
a Be careful not to drop or lose the parts.
9. Remove 2 race bearings (15) and thrust nee-

dle (16).
7. Set on clean cloth with flange surface of hous-

ing facing up to prevent damage to finished
surface. Use flat-headed screwdriver to raise
tip of retaining ring (20), then remove from
housing.
k The retaining ring may fly out from the
housing, so always wear protective
glasses.
10. Push spline portion inside spool with thumb

and remove spool and sleeve assembly from
opposite side of housing flange. When doing
this, be careful not to let outside diameter of
sleeve get caught in inside diameter of hous-
ing.
a Depending on the assembly of sleeve and
spool, it may not work properly if it is
assembled 180° from the proper direction,
8. Set housing on clean cloth with axial line of so make marks to show the position of
valve horizontal. Turn spool and sleeve assem- spool and sleeve (43). Remove pin (12).
bly to set sleeve pin in horizontal position, then k The retaining ring may fly out from the
push out spool and sleeve assembly slightly, housing, so always wear protective
and remove seal gland bushing (21) from glasses.
housing.
Remove oil seal and dust seal from gland
bushing.
a When removing the seal, be careful not to
damage the seal gland bushing.
GD655-3E0, GD675-3E0 7
11. Push out spool inside sleeve slightly, and 14. Disassembly of overload relief valve
remove centering spring (13) carefully by hand Using hexagonal wrench (width across flats:
from spool. 3/16 inch), remove plug (37) 2 places. Remove
O-ring (38) from plug. Using tweezers, remove
2 springs (36), 2 ball holders (35), and 2 balls
(34).
a The valve seat is stuck to the housing and
cannot be removed.
12. Rotate spool slowly and pull out spool (11)

from sleeve (10). Remove O-ring from hous-
ing.
13. Disassembly of steering relief valve

Using hexagonal wrench (width across flats: 3/
16 inch), remove plug (28). Remove O-ring
(29) from plug. Using tweezers, remove spring
(27) and poppet (26).
a The valve seat is stuck to the housing and
cannot be removed.
8 GD655-3E0, GD675-3E0
Assembly k The centering spring may fly out from the

spool, so always wear protective glasses.
a Check all the joining parts.
Parts with gouges or burrs will cause leakage
of oil, so replace them with new parts.
Wash all metal parts with clean solvent and
blow dry with compressed air. If they are wiped
with rags or paper, pieces of cloth or paper will
stick to the parts or get inside the valves. This
will cause the hydraulic system to become
dirty, so do not wipe with cloth or paper.
Do not polish parts with sandpaper or modify
with a file.
k Be extremely careful not to injure yourself
on the edges of sleeves, spools, housing,
and other machined parts.
a As a basic rule, assemble new O-rings and
3. Set housing on clean cloth with axial line of
seal after disassembling. Coat the O-rings with
valve horizontal. Insert spool and sleeve
a small amount of clean grease before assem-
assembly from opposite end of housing to
bling.
flange end. In this condition, check that spool
a The O-rings in front of or behind the spacer
and sleeve assembly rotates smoothly inside
plate are of very similar sizes, so check the
housing.
part number before opening the seal kit, and
a When inserting spool and sleeve assem-
be extremely careful not to mix them.
bly, be careful not to insert it at an angle
and get it caught. Keep the pin at near the
1. Turn spool (11) and insert slowly into sleeve
horizontal position, and rotate slightly to
(10). Grip spline portion of spool and check
left and right to insert.
that spool rotates smoothly inside sleeve. Align
a Insert so that the end face of the spool
mark made when disassembling.
and sleeve assembly is level with the end
face of the housing. If it is inserted further,
the pin will fall inside the housing, so stop
inserting when the end face is level.
2. Align 2 spring grooves st 180° in spool and

sleeve, then stand on a horizontal plate. Insert
spring insertion tool (Part No.: 600057) in
spring groove, then fit centering spring to
insertion tool so that notched portions at both
ends are at bottom. When doing this, it is eas-
ier to insert if spool is lifted up slightly from
sleeve. Hold centering spring at opposite end
with a finger and compress it to push it into
spool sleeve groove. When doing this, slide
insertion tool at same speed as pushing in
spring. After inserting, align end of spring with
outside diameter of sleeve. Insert sleeve pin
into hole in sleeve, and align both ends of pin
with outside diameter of sleeve.
GD655-3E0, GD675-3E0 9
4. Place housing on clean flat surface, then a The diagram below is the standard seal
assemble O-ring (17). specification drawing.
Assemble 2 race bearings (15) and thrust nee-
dle (16). Always insert thrust needle between
race bearings.
6. After assembling seals, rotate seal gland bush-

ing (21) and insert to spool. Tap with plastic
hammer to insert to specified position.
a There are two types of seal: Teflon seal Assemble retaining ring (20) to housing.
and standard seal. a Push open with a flat-headed screwdriver
so that the whole circumference of the
5. Assemble dust seal (19) to seal gland bushing retaining ring fits securely in the groove in
(21). Assemble dust seal so that flat surface is the housing.
at seal gland bushing end. Assemble oil seal k The retaining ring may fly out from the
(18) to seal gland bushing. housing, so always wear protective
a Assemble the oil seal carefully so that glasses.
there is no twisting or deformation.
a The diagram below is the Teflon seal
specification drawing; (44) is the distin-
guishing groove.
10 GD655-3E0, GD675-3E0
a Seal assembly drawing 8. Assembly of overload relief valve

Screwdriver [9], dust seal (19), retaining Assemble O-ring (38) to plug (37). Fit grease
ring (20), seal gland bushing (21), oil seal to ball holder (35) and install ball (34). Using
(18), O-ring (17). tweezers, assemble ball holder (35) and spring
(36) to housing. Using hexagonal wrench
(width across flats: 3/16 inch), assemble plug
(37) to housing.
a The size of the overload valve ball and the
anti-cavitation check valve ball is different,
so be careful not to mix them.
7. Assembly of steering relief valve

Assemble O-ring (29) to plug (28).
Using tweezers, assemble spring (27) and
poppet (26) to housing. Using hexagonal
wrench (width across flats: 3/16 inch), assem-
ble plug (28) to housing.
9. Assembly of anti-cavitation check valve
Grip the port surface and side surface of the
housing lightly in a vise. Fit copper sheets in
the vise, and be careful not to tighten the vise
too strongly.
Of the 7 bolt holes in the end face of the hous-
ing, insert 1 each of spring (31), retainer plug
(30), and ball (32) in the 2 holes shown in the
drawing.
a Be careful not to drop or lose the ball. Be
careful of the assembly direction of the
retainer plug.
GD655-3E0, GD675-3E0 11
10. Assembly of Gerotor end 12. Assemble O-ring (23) to housing.

Grip the port surface and side surface of the Set spacer plate (7) on top and align position
housing lightly in a vise. (45): 25 mm. Fit cop- of bolt holes.
per sheets in the vise, and be careful not to a The pitch diameter of the bolt holes and oil
tighten the vise too strongly. holes is different.
11. Of the 7 bolt holes in the end face of the hous- 13. Turn spool and sleeve assembly and set pin
ing, insert ball (40) in the holes shown in the (12) and port surface (46) of housing in paral-
drawing. Assemble adapter screw (39) in holes lel. Insert drive (8) into portion (47), then mate
in same drawing. drive yoke and pin (12). To carry out position-
ing exactly, use a felt pen to draw line on end
face of drive (8) parallel to pin.
14. Assemble O-ring (22) to Gerotor (4).
12 GD655-3E0, GD675-3E0
15. Set O-ring at end face of Gerotor (4) at spacer 17. Order for tightening end cap mounting screws
plate (7) side, align concave portions (48) of is as shown in diagram below.
Gerotor star teeth with pin (12), align with mark
drawn on end face of drive (8), and assemble.
When doing this, check carefully that lines (A),
(B), (C), and (D) are parallel as shown in dia-
gram below.
a Turn Gerotor ring to align bolt holes. Do
not remove mating of drive and Gerotor
star.
a The above procedure is important for
aligning the valve timing.
a After tightening to torque given below,

install handle to spool and check that
spool rotates.
Screw tightening torque
Discharge capacity Tightening torque

(cc/rev) (Nm {kgm})
51 – 230 22.6 {2.3}
16. Assemble spacer (5) to spline Gerotor star. 277 23.5 {2.4}
a Do not assemble spacers to 51 cc/rev and 369 – 737 28.4 {2.9}
69 cc/rev discharge capacity Orbit-rolls.
Assemble 2 spacers to 184 cc/rev dis-
charge capacity Orbit-roll. List of capacities and spacers
Assemble O-ring (22) to end cap (3), set
on top of Gerotor, then align bolt holes. Discharge Discharge Spacer
Coat 6 screws (1) and thread of retainer capacity symbol capacity (cc/rev) thickness (mm)
screw assembly (2) with oil, then assem-
A 51 —
ble to end cap.
Install retainer screw assemblies to bolt B 69 —
holes where adapter screws have already
been assembled. 14.7 Nm {1.5 kgm}, then C 96 3.6
tighten in order to following torque. 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
GD655-3E0, GD675-3E0 13
SEN01918-00

© 2006 KOMATSU
All Rights Reserved
14
SEN01919-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Hydraulic system
Hydraulic system............................................................................................................................................. 2
Disassembly and assembly of work equipment control valve assembly .............................................. 2
Disassembly and assembly of hydraulic cylinder assembly................................................................. 5
GD655-3E0, GD675-3E0 1
Hydraulic system 1
work equipment control valve
assembly 1
a Only precautions for assembling the work
equipment control valve are explained in this
section.
Assembly of left work equipment control

valve assembly
q Apply engine oil to the sliding surfaces of the
spools before assembling.
q Plugs
a Thoroughly degrease the plugs and valve
mounting holes with denatured alcohol
etc. and then dry them.
a Do not apply hydraulic pressure to the
plugs for 2 hours after installation.
(1): Blade tilt spool plug
(2): Circle rotation spool plug
(3): Blade shift spool plug
(4): Left blade lift spool plug
(5): Ripper (or scarifier) spool plug
(if equipped)
2 Spool plugs (1) – (5):
Adhesive (LT-2)
14.7 – 19.6 Nm {1.5 – 2 kgm}
2 GD655-3E0, GD675-3E0
q Spools Assembly of right work equipment control

a The play of spool (6) must not exceed valve assembly
0.15 mm. q Apply engine oil to the sliding surfaces of the
a If the play of spool (6) exceeds 0.15 mm, spools before assembling.
adjust it with one of the following retainers.
Retainer thickness (a): q Plugs
723-11-32810: 9.7 mm a Thoroughly degrease the plugs and valve
723-11-32820: 9.8 mm mounting holes with denatured alcohol
723-11-32830: 9.6 mm etc. and then dry them.
a Do not apply hydraulic pressure to the
plugs for 2 hours after installation.
(1): Drawbar shift spool plug
(2): Articulate spool plug
(3): Leaning spool plug
(4): Right blade lift spool plug
Adhesive (LT-2)
14.7 – 19.6 Nm {1.5 – 2 kgm}
GD655-3E0, GD675-3E0 3
q Spools
a The play of spool (5) must not exceed
0.15 mm.
a If the play of spool (5) exceeds 0.15 mm,
adjust it with one of the following retainers.
Retainer thickness (a):
723-11-32810: 9.7 mm
723-11-32820: 9.8 mm
723-11-32830: 9.6 mm
4 GD655-3E0, GD675-3E0
Disassembly and assembly of 1. Cylinder

hydraulic cylinder assembly 1 Steering cylinder and power tilt cylinder
Press fit bushing (1) and install snap ring (2).
Special tools a The steering cylinder is shown as an
example in the figure.
Necessity
Symbol
Sketch
Q’ty
N/R
Cylinder repair
790-502-1003 stand t 1
1
790-101-1102 Hydraulic pump t 1
2 790-330-1100 Wrench assembly t 1
Commercially Socket (Width
available across flats: 30 mm) t 1
available across flats: 41 mm) t 1
3 available across flats: 46 mm) t 1
Socket (Width
790-302-1280 across flats: 55 mm) t 1 Leaning cylinder, blade side shift cylinder
and articulate cylinder
Socket (Width
790-302-1290 across flats: 60 mm) t 1 Press fit bushing (3) and dust seal (4).
a The leaning cylinder is shown as an
790-101-5021 • Grip 1
01010-50816 • Bolt 1
U 4 790-201-1731 • Push tool 1
790-201-1751 • Push tool 1
790-201-1771 • Push tool 1
790-201-1761 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-201-1540 • Plate 1
790-201-1560 • Plate 1
790-201-1580 • Plate 1
Blade lift cylinder
790-201-1570 • Plate 1
Press fit bushing (5).
6 790-720-1000 Expander t 1
796-720-1620 Ring t 1
07281-00609 Clamp t 1
7
796-720-1650 Ring t 1
07281-01029 Clamp q 1
a In this section, only the assembly procedure is

explained.
Assembly
a Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean all the parts. After assembling, cover
the piping ports and pin holes to prevent dirt
from entering them.
GD655-3E0, GD675-3E0 5
2. Piston rod 3) Install snap ring (12).

Power tilt cylinder 4) Install buffer ring (13).
Press fit bushing (6) and install snap ring (7). a This work is not necessary to the
steering cylinder.
5) Install rod packing (14).
6) Install O-rings (15) and (16) and backup
ring (17).
a Do not insert the backup ring forcibly,
but warm it in water at 50 – 60°C and
then insert it.
Steering cylinder
Leaning cylinder, blade side shift cylinder

and articulate cylinder
Press fit bushing (8) and dust seal (9).
a The leaning cylinder is shown as an
Cylinders other than steering cylinder
3. Cylinder head assembly

1) Using tool U4, press fit bushing (10) to the
cylinder head.
2) Using tool U5, press fit dust seal (11).
a The leaning cylinder is shown as an 7) Install cylinder head assembly (18) to pis-
example in the figure. ton rod (19).
6 GD655-3E0, GD675-3E0
4. Piston assembly 6) Install piston assembly (24) and nut (25)

1) Install retainer (20) to piston rod (19). to piston rod (19).
a This work is necessary to the leaning
cylinder only.
7) Set piston rod assembly (26) to tool U1.

8) Using tool U3, tighten nut (25).
2) Set piston ring (21) to tool U6 and rotate a Width across flats of piston nut
the handle 8 – 10 turns to expand the pis- q Steering cylinder: 30 mm
ton ring. q Blade lift cylinder, blade side shift
cylinder, power tilt cylinder, draw-
bar shift cylinder, leaning cylin-
der: 41 mm
q Articulate cylinder: 55 mm
q Scarifier cylinder: 46 mm
q Ripper cylinder: 60 mm
2 Piston nut: Adhesive (LOCTITE
262 or equivalent)
3 Piston nut:
Steering cylinder:
392 ± 39 Nm {40 ± 4.0 kgm}
Leaning cylinder:
618 ± 62 Nm {63 ± 6.3 kgm}
Blade lift cylinder:
3) Remove piston ring (21) from tool U6 and 647 ± 64.5 Nm {66 ± 6.6 kgm}
install it to piston (22). Blade side shift cylinder:
4) Using tool U7, contract piston ring (21). 618 ± 62 Nm {63 ± 6.3 kgm}
5) Install wear ring (23). Drawbar shift cylinder:
618 ± 62 Nm {63 ± 6.3 kgm}
Articulate cylinder:
1.42 ± 0.14 kNm {145 ± 14.5 kgm}
Power tilt cylinder:
647 ± 64.5 Nm {66 ± 6.6 kgm}
Scarifier cylinder:
785 ± 78.5 Nm {80 ± 8.0 kgm}
Ripper cylinder:
1.77 ± 0.18 kNm {180 ± 18.0 kgm}
GD655-3E0, GD675-3E0 7
5. Piston rod assembly 6. Elbow

1) Remove piston rod assembly (26) from Install the hydraulic piping elbows to the cylin-
tool U1 and install it to cylinder (27). der.
a Perform this work for only the steering cyl-
inder.
3 Elbow: 46.1 – 61.8 Nm {4.7 – 6.3 kgm}
2) Set cylinder assembly (28) to tool U1.

3) Using tool U2, tighten cylinder head.
3 Cylinder head:
Steering cylinder:
245 ± 24.5 Nm {25 ± 2.5 kgm}
Leaning cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
Blade lift cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
Blade side shift cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
Drawbar shift cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
Articulate cylinder:
677 ± 67.5 Nm {69 ± 6.9 kgm}
Power tilt cylinder:
588 ± 59.0 Nm {60 ± 6.0 kgm}
Scarifier cylinder:
677 ± 67.5 Nm {69 ± 6.9 kgm}
Ripper cylinder:
981 ± 98.0 Nm {100 ± 10 kgm}
8 GD655-3E0, GD675-3E0
SEN01919-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01920-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Removal and installation of circle drawbar assembly .......................................................................... 3
Removal and installation of blade circle gear assembly ...................................................................... 5
Removal and installation of blade circle rotation gear assembly (with shear pin) ................................ 7
Disassembly and assembly of blade circle rotation gear assembly (with shear pin)............................ 9
Disassembly and assembly of circle rotation gear assembly (with slip clutch) .................................. 13
GD655-3E0, GD675-3E0 1
Work equipment 1
Removal and installation of blade Installation
assembly 1 1. Raise center of blade (1), and install right tip of
blade to adjuster. Extend blade side shift cylin-
Removal der rod fully, and move position of lifting wire
k Start the engine, operate the work equip- while pushing in blade to point where it is pos-
ment control levers, raise blade so that bot- sible to connect cylinder rod.
tom is approx. 100 mm from ground, set a Do not coat the rail at the rear of the blade
stable stand to match height under circle, with grease.
then lower. 4 Blade assembly: Approx. 755 kg
(differs according to blade)
1. Operate blade control lever and shift blade (1)
fully to left. Sling blade, remove mounting
bolts of blade side shift cylinder rod (2),
remove rod head, then operate control lever to
retract cylinder rod fully.
a After completing operation of the control
lever, stop the engine and lock the lever.
2. Install cylinder rod (2) to blade (1) and tighten

mounting bolts to specified torque. Remove
stand from under circle.
2 Cylinder rod pin hole: Coat with G2-LI
2. Sling blade (1), move position of wire to center

of blade while pushing blade out, then lift off.
4 Blade assembly: Approx. 755 kg
(differs according to blade)
2 GD655-3E0, GD675-3E0
Removal and installation of circle 7. Disconnect 2 drawbar side shift cylinder hoses
drawbar assembly 1 (9), 2 swivel joint hoses (10) and 2 circle rota-
tion motor hoses (11) from the drawbar end
side.
a Stop the disconnected hoses and nipples
Removal with plugs.
1. Remove the blade assembly. For details, see
"Removal and installation of blade assembly".
2. Operate the drawbar side shift lever to set the

drawbar to the center.
3. Operate the blade lift cylinder lever to set the

drawbar to the horizontal position and support
the blade mounting bracket with a stand.
k After stopping the engine, operate the
drawbar side shift lever and circle rota-
tion lever to release the residual pres-
sure in the piping.
4. Remove bottom cap (3) and disconnect draw- 8. Sling the circle drawbar assembly temporarily.
bar side shift cylinder (2) from drawbar (1). [*1]
9. Remove holder (13) and shim (14) and discon-
5. Remove right and left caps (5) and disconnect nect ball joint (12). [*3]
drawbar lift cylinder rod (4) from drawbar (1). a Check the thickness and quantity of the
[*2] shims.
10. Lift off the circle drawbar assembly.

4 Circle drawbar assembly:
Approx. 1,250 kg
6. Disconnect hoses (6) and (7) and clamp (8)

from the drawbar side shift cylinder.
with plugs.
GD655-3E0, GD675-3E0 3
Installation
removal.
[*1] [*2]
2 Ball joint:
Molybdenum disulfide lubricant (LM-P)
[*3]
a Insert shim (14) of the same thickness as
removed one. After installation, if the ball joint
has excessive play, adjust it by decreasing the
shim 1 piece by 1.
a If the shim is decreased too much, the ball joint
does not move smoothly and the nut will be
loosened. Take care.
q Standard shim thickness: 4 – 4.46 mm
q Kind of shim thickness: 0.29 mm
2 Ball joint (when installed):
2 Ball joint (filled after installed):
Molybdenum disulfide lubricant (LM-G)
3 Mounting nut:
588.4 – 1,029.5 {60 – 105 kgm}
4 GD655-3E0, GD675-3E0
Removal and installation of blade 10. Remove cylinder mounting bracket (12).
circle gear assembly 1
Removal
1. Remove the blade assembly. For details, see
"Removal and installation of blade assembly".
2. Operate the drawbar side shift lever to set the

drawbar to the center.
3. Operate the blade lift cylinder lever to set the

drawbar to the horizontal position and support
the blade mounting bracket with a stand.
k After stopping the engine, operate the
blade side shift lever and blade tilt
lever to release the residual pressure in 11. Remove holder (14), shim (15), joint (19) and
the piping. pinion gear (13). [*2]
a Raise the holder mounting bolt lock plate
4. Disconnect 2 hoses (3) from blade side shift and remove the mounting bolt.
cylinder (2). a When removing the bolt, hold the pinion
a Stop the disconnected hoses and nipples gear with the hand to prevent it from fall-
with plugs. ing.
a Check the thickness and quantity of the
5. Sling blade side cylinder (2) temporarily and shims.
remove the bolt on the bottom side and then lift
off the cylinder.
4 Blade side shift cylinder assembly:
50 kg
6. Remove adjuster (4), cover (5) and rod (6).
(For shear pin type)
7. Disconnect hoses (8) and (9) from blade power

tilt cylinder (7).
with plugs.
8. Sling blade power tilt cylinder assembly (7)

temporarily.
9. Remove the lock plate, pins (10) and (11) and

blade power tilt cylinder assembly (7). [*1]
4 Blade power tilt cylinder assembly:
20 kg
GD655-3E0, GD675-3E0 5
(For slip clutch type) Installation

removal.
[*1]
2 Pin:
[*2]
a When installing the pinion gear, take care not
to drop it.
2 Contact faces of pinion gear and shaft:
q Kind of shim thickness: 0.2 mm, 0.5 mm, 1.0
12. Sling circle gear (17) temporarily. mm
13. Remove 6 circle guides (16) and lift off blade [*3]
circle gear (17) below drawbar (18). [*3] a Adjust the circle guide clearance. For details,
4 Blade circle gear assembly: 140 kg see Testing and adjusting volume, "Testing and
adjusting circle guide clearance".
2 Circle teeth, guide, circle top, and guide con-
tact face:
3 Circle guide mounting bolt:
490.3 – 608 Nm {50 – 62 kgm}
6 GD655-3E0, GD675-3E0
Removal and installation of blade 4. Lift off circle gear assembly (3).
circle rotation gear assembly
(with shear pin) 1
Removal
k Stop the engine and operate the circle rota-
tion control lever to release the residual
pressure in the piping.
1. Disconnect 2 hoses (2) from circle motor (1).

a Plug the removed hoses and nipples.
2. Drive out 2 dowel pins (4) from underside and

remove the 4 mounting bolts of circle gear
assembly (3) from underside. [*1]
3. Remove holder (6) and shim (7), and then

remove joint (8) and pinion gear (9). [*2]
a Raise lock plate (5) of the mounting bolts
of holder (6) and remove the mounting
bolts.
a When removing the bolts, hold pinion gear
(9) with the hand so that it will not fall.
a Check the thickness and quantity of shims
(7).
GD655-3E0, GD675-3E0 7
Installation
[*1]
3 Mounting bolt:
911 – 1,029 Nm {93 – 105 kgm}
[*2]
1. Install pinion gear (9) and joint (8) and fix them
with holder (6) temporarily.
2. Measure clearance (b) between the ends of

shaft (10) and joint (8), and then select shims
0.1 – 0.5 mm thicker than (b).
q Kinds of shim thickness: 0.2 mm, 0.5 mm,
1.0 mm
3. Make clearance (a) of the same dimension

between plate (11) and pinion gear (9).
4. Install pinion gear (9), joint (8), and shim (7) in

order.
5. Install holder (6) with the mounting bolts and

bend lock plate (5) securely.
2 Plate (11), pinion gear (9), and contact
face of shaft (10):
disulfide (LM-P)
2 Filling for part (c) at top of pinion gear:
Grease (G2-LI)
8 GD655-3E0, GD675-3E0
Disassembly and assembly of 4. Housing

blade circle rotation gear Remove housing (7) and shim (8) from case
(6).
assembly (with shear pin) 1 a Check the thickness and quantity of shims
(8).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
3 796-460-1110 Push tool t 1
794T-470-1110 Push tool t 1 N Q
V
4 790-101-5221 Grip t 1
01010-51225 Bolt t 1
Disassembly
1. Draining oil
Remove the drain plug and drain the oil from
the circle rotation gear case.
6
5. Worm gear and bearing assembly
Circle rotation gear case: Approx. 5 l
1) Remove worm gear and bearing assembly
(9).
2. Disconnection of circle rotation gear and
motor
Remove mounting bolts (2) and disconnect cir-
cle rotation gear assembly (3) and motor
assembly (4).
a Take care not to drop or lose the motor
shaft key.
3. Cover
Remove cover (5).
2) Remove 2 bearings (11) from shaft (10).
GD655-3E0, GD675-3E0 9
6. Worm wheel shaft assembly Assembly

1) Remove worm wheel shaft assembly (12). 1. Worm gear and bearing assembly
a Remove washer (18). 1) Press fit 2 bearings (11) to worm gear
(10).
2) Remove gear (14) from shaft (13).

a Remove washer (17). 2) Install worm gear and bearing assembly
(9) to case (6).
2. Housing
1) Set the O-ring to housing (7) and install
them to the case, inserting shim (8).
a Adjust the shim so that the rotating
torque of the worm shaft will be 2.94 –
7.8 Nm {0.3 – 0.8 kgm} to give a pre-
load to the bearing.
a When measuring the rotating torque,
check that the worm gear is not
meshed with the worm wheel gear.
q Types of shim: 0.1, 0.2, 1.0 mm
2) Check the quantity of the shims, loosen
the bolts on the housing side, and pull the
housing out of the case a little.
a Remove the worm gear and bearing
assembly from the outer race of the
bearing.
10 GD655-3E0, GD675-3E0
a Install washers (17) and (18) to the

top and bottom of the worm wheel
shaft assembly.
3. Worm wheel shaft assembly

1) Using push tool kits (70 mm and 73 mm),
press fit bushing (15) to case (6).
2) Using push tool kit (85 mm), press fit oil 4. Connection of circle rotation gear and
seal (16). motor assembly
2 Oil seal lip: Grease (G2-LI) Matching circle rotation gear (3) and motor
assembly (4), install mounting bolts (2).
a Install the key to the motor assembly
shaft.
3) Install gear (14) to shaft (13).

a Install washer (17).
5. Refilling with oil

Tighten drain plug (1) and add gear oil to the
specified level.
5 Circle rotation gear case: 5 l
3 Drain plug:
32.36 – 44.13 Nm {3.3 – 4.5 kgm}
4) Install worm wheel shaft assembly (12).

a Matching the teeth of the worm wheel
gear and worm wheel, tighten the
nuts on the housing side.
GD655-3E0, GD675-3E0 11
6. Cover
Set the O-ring and install cover (5).
2 Bolts at 2 through parts of case tap on
worm gear side: Adhesive (LT-2)
aInstall cover (5) so that oil filler plug (19)

will be positioned as shown in the illustra-
tion.
3 Oil filler plug:
73.55 – 122.58 Nm {7.5 – 12.5 kgm}
12 GD655-3E0, GD675-3E0

circle rotation gear assembly
(with slip clutch) 1
Disassembly
1. Remove 2 hoses (2) of circle motor (1). Knock
out 2 dowel pins (4) of circle rotation gear from
bottom. Remove 6 mounting bolts of circle
rotation gear from bottom.
a Fit male and female plugs into the hoses
and nipples.
3. Install eyebolt to circle rotation gear assembly

(3), then raise and set on strong, stable stand.
Loosen 4 mounting bolts of circle motor (1) and
remove motor. Loosen 8 mounting bolts of
cover (8) of circle rotation gear assembly (3),
then remove cover.
4 Circle rotation gear assembly:
Approx. 125 kg
2. Raise lock plate (7) for mounting bolts of

holder (6) and pinion gear, then remove bolts.
Remove holder (6) and take out pinion gear
(5). It will fall out, so remove it quickly.
a When raising the lock plate, support the
pinion gear by hand to prevent it from fall-
ing out when it is removed.
4. Pull out 8 mounting bolts of housing (9), then

using 2 forcing screws (10), remove housing.
GD655-3E0, GD675-3E0 13
5. Remove 3 bolts of circle gear shaft, then 8. Separate circle gear (17) and shaft (14).
remove plate (11) and collar (12). Remove 4 Remove spacer (18) under shaft.
mounting nuts of worm gear bearing cage (13),
then remove cage together with shim.
9. Remove worm gear (19) from gear case, then

remove 2 left and right bearings (20). Turn
6. Install eyebolts to circle gear shaft (14), and lift over gear case, remove oil seal (21), then
off gear assembly. Remove belleville spring remove bushing (22).
(15) and collar (16).
7. Remove 5 plates (18) and 6 discs (19) from cir-

cle gear (17) in order.
14 GD655-3E0, GD675-3E0
Assembly 4. Press fit bearing (20) to worm gear (19).

1. Press fit bushing (22) to circle gear insertion
portion of gear case. Turn over gear case and
press fit oil seal (21).
a Coat the shaft seal surface of seal (21)
with G2-LI and bushing (22) with LM-P.
5. Assemble worm gear (19) to gear case.
2. Assemble circle gear (17), shaft (14), and

spacer (18).
6. Install bearing cage (13) to gear case.
3. Assemble plates (18) and discs (19) to circle

gear (17) in order.
a NOTICE: When assembling, coat the
whole surface of the discs (front and rear
faces) with GO#90 oil.
GD655-3E0, GD675-3E0 15
7. Install nuts to mounting bolts of bearing cage 9. Install collar (12), then install bolts to housing
(13), set to condition where shim (23) adjust- (9), and tighten to specified torque. Assemble
ment is possible, then adjust shim and tighten shim (25).
nut. a Types of shim: 0.2, 0.5 mm
a To apply the preload to the bearing, adjust
with shims so that the friction torque of the
worm shaft is 2.9 – 7.85 Nm {0.3 – 0.8
kgm}.
When measuring the rotating torque, the
wo r m an d w o r m w h ee l mu s t n o t b e
meshed (measure before assembling
worm and worm wheel).
a Types of shim: 0.1, 0.2, 1.0 mm
(Shim adjustment: 1.65 mm)
10. Install lock plate (11) to gear shaft, and tighten

3 bolts to specified torque. Install gear case
cover (8), then install bolt and tighten to speci-
fied torque.
a When installing cover (8), set position of
oil filler plug (26) at oil level gauge side of
gear case (rear of machine), then install.
Make sure that oval hole in housing (9) is
aligned. If it is not aligned, change mount-
ing position of cage (9).
8. Install plate (18) and belleville spring (15) to
circle gear (17), then install lifting tool to shaft,
raise gear assembly, and assemble to gear
case. Using forcing screws, hold housing (9),
and install to gear case.
a When installing housing (9), set with oval
hole (24) in housing facing oil level gauge
side of gear case (rear of machine), then
install. (Relationship with oil filler plug)
2 Only 2 mounting bolts of cover at
case tap hole:
Coat with thread tightener (LT-2)
16 GD655-3E0, GD675-3E0
11. Assemble circle motor (1) to worm gear, and

tighten 4 mounting bolts to specified torque.
a Install the gear case securely to the motor
before installing.
13. Knock in 2 dowel pins (4), and install 2 hoses

(2) to circle motor (1). Tighten drain plug,
remove oil filler plug (26), then fill with oil. After
filling with oil, tighten fully.
12. Raise circle gear assembly and install to draw- a After knocking in the dowel pin, caulk the
bar, then install pinion gear (5) from bottom, circumference at 2 places.
install shim (27) and holder (6) with 2 bolts, a When adding oil, set the rotating gear hor-
install lock plate (7) to bolt, then tighten to izontal, and add oil until oil comes out from
specified torque. level plug hole.
a Bend lock plate (7) fully to lock in position, 3 Drain plug:
then tighten mounting bolts of rotation 32.36 – 44.13 Nm {3.3 – 4.5 kgm}
assembly to specified tightening torque. 3 Oil filler plug:
a When installing the pinion gear, be careful 73.5 – 122.6 Nm {7.5 – 12.5 kgm}
5
not to drop it. Circle rotation gear case:
a Types of shim at pinion gear portion: 0.2, GO #90, approx. 7 l
0.5, 1.0 mm (Standard: 3.0 mm).
3 4 bolts at dowel pin mounts at front
and rear of machine:
911.4 – 1029 Nm {93 – 105 kgm}
3 2 bolts at left and right of machine:
490.3 – 608 Nm {50 – 62 kgm}
a For details of the procedure for adjusting

the slip clutch, see Testing and adjusting.
GD655-3E0, GD675-3E0 17
SEN01920-00

© 2006 KOMATSU
All Rights Reserved
18
SEN01921-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Removal and installation of operator's cab assembly .......................................................................... 2
Removal and installation of floor frame assembly................................................................................ 4
Disassembly and assembly of operator’s seat assembly..................................................................... 7
Removal and installation of operator's cab glass (stuck glass).......................................................... 16
Removal and installation of air conditioner unit assembly ................................................................. 22
GD655-3E0, GD675-3E0 1
Cab and its attachments 1

Removal and installation of 3. Remove operator's cab right cover (3) and left
operator's cab assembly 1 cover (4).
Removal
chocks.
a When removing the left rear cover, discon-

nect washing tank (5) and hose (6).
2. Disconnect right working lamp wiring harness

connector (2).
4. Remove cover (7).
2 GD655-3E0, GD675-3E0
5. Disconnect air conditioner air outlet duct (8). 10. Remove 4 operator's cab mount bolts (15). [*1]
a Remove the operator's cab mount bolts on
6. Disconnect connector (10) from wiring harness the right side similarly.
(9).
11. Using sling [1], remove operator's cab (16).

4
7. Remove the mounting bolts of left cover (11) Operator's cab assembly: 880 kg
and right cover (12) of the work equipment
control lever and move the covers up.
Installation
8. Disconnect sensor bracket (13). Carry out installation in the reverse order to
removal.
9. Remove 4 operator's cab mounting bolts (14).
a Remove the sensor bracket mounting [*1]
3
bolts and operator's cab mounting bolts on Mount bolt (15):
the right side similarly. 883 – 1,001 Nm {90 – 102 kgm}
GD655-3E0, GD675-3E0 3
Removal and installation of floor 4. Disconnect all linkage (5) from right control
frame assembly 1 valve (4).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Vacuum pump
799-703-1100 (100 V) t 1
Vacuum pump
X 799-703-1111 (220 V) t 1
Vacuum pump
799-703-1121 (240 V) t 1
799-703-1401 Gas leak detector t 1

5. Disconnect wiring harness connectors (6), (7)
and (8).
Removal
k
q Connector (6): T16, T17, T18
Stop the machine on a level ground, apply q Connector (7): B8, B9, B10
the parking brake, and lock the tires with q Connector (8): FL4, FL5
chocks.
k Disconnect the cable from the negative (–) 6. Remove clamp (10) of connector (8).
k Collect the air conditioner refrigerant 7. Remove mounting bolts (11) and disconnect
(R134a).
k
bracket (12) from the machine.
If the refrigerant gets in your eyes, you may
tive goggles.
8. Disconnect steering hoses (13) and (14).
2. Remove the operator's cab assembly. For

details, see "Removal and installation of opera-
tor's cab assembly".
3. Disconnect all linkage (3) from left control

valve (2).
4 GD655-3E0, GD675-3E0
9. Remove steering return hoses (15), (16) and 11. Disconnect air conditioner piping (19).
(17). a Disconnect the clamp installed to the back
side of the floor, too.
12. Remove air conditioner water drain hose

clamps (20) and (21).
10. Remove the clamp and disconnect 2 heater

hoses (18).
13. Disconnect solenoid valve connector (22).
GD655-3E0, GD675-3E0 5
14. Disconnect control valve sensor connector Installation

(23). Carry out installation in the reverse order to
a Disconnect the clamp installed to the back removal.
side of the floor, too.
15. Disconnect ground wire (24).
16. Remove 2 mount bolts (25).
17. Using sling [1], remove floor frame assembly

(26).
4 Floor frame assembly: 300 kg
6 GD655-3E0, GD675-3E0
Disassembly and assembly of operator’s seat assembly 1

a The procedure for disassembling and assembling the operator's seat assembly [with air suspension
(manufactured by ISRING HAUSEN)] is shown below.
a If this operator’s seat is equipped.
A: Headrest E: Left-hand armrest

B: Seatback F: Suspension cover
C: Seat cushion G: Sliderails
D: Right-hand armrest
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of the 2 clips (2) of headrest stay (1) on
both sides.
GD655-3E0, GD675-3E0 7
2) Apply force (b) to part (a) of each clip (2) 2. Seatback

in the direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear
Release headrest stay (1) from part (d) of left of seatback (4).
the clip and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simulta-

neously, remove headrest (3).
3) Bring seatback (4) down forward.
8 GD655-3E0, GD675-3E0
4) Apply force (E) to the right side of seat- 2) Push cushion stopper wire (9) down with
back (4) in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and
right side up. remove it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion q The procedure for disassembling right-
1) Push cushion adjuster lever (7) inward hand armrest (10) is shown below.
and slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) simi-
larly.)
GD655-3E0, GD675-3E0 9
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment wash-
a Use a flat-head screwdriver, etc. to ers (16) installed to each bolt between
remove the cap. the armrest and seatback. Take care
2) Loosen armrest hinge mounting bolt (13). not to lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of 1) Remove right-hand hinge cover (17).
right-hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
4) Turn right-hand armrest (10) up by 180°.

a If the armrest is not turned, you can-
not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B).
10 GD655-3E0, GD675-3E0
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part;2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
GD655-3E0, GD675-3E0 11
2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part 1. Rails
of each rail. 1) Put height adjustment washers (31)
between rails (28) and suspension, and
then set rails (28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part 2) Set rails (28) to the front end and install 1
of each rail, and then remove rails (28). lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
3) Set rails (28) to the rear end and install 1
lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
12 GD655-3E0, GD675-3E0
2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails

1) Set suspension cover (27) in position and (22), and then install cushion rear fixing
install 6 plastic suspension cover clips plate (21), and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension 3 Cushion rail mounting bolt:
cover clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Clips (small) (25):
Front upper part;2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
2) Install 3 metallic suspension cover clips

(24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
GD655-3E0, GD675-3E0 13
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

q The procedure for assembling right-hand a Tighten the bolt so that the arm will
armrest (10) is shown below. move smoothly.
(Assemble left-hand armrest (11) simi- q Operating effort at armrest end:
larly.) 49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set right-hand armrest 4. Seat cushion
(10) in position. Slide in the seat cushion from the front of the
fitting position.
a If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly

and turn armrest (10) by 180°.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
14 GD655-3E0, GD675-3E0
5. Seatback 3) Connect 3 air hoses (5) to the rear left of

1) Insert the left side of seatback (4), and seatback (4).
then lower and set the right side.
6. Headrest
Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6)

(M8 bolt).
3 Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
GD655-3E0, GD675-3E0 15
Removal and installation of a If the window glass is broken finely, it may

operator's cab glass (stuck be removed with knife [4] and a screw-
driver.
glass) 1 a While widening the cut with a screwdriver,
cut the adhesive and double stick tape
Removal
with knife [4].
a Remove the window glass to be replaced
(The figure shows the operator's cab of a
according to the following procedure.
wheel loader.)
1. Using seal cutter [1], cut the adhesive between
broken window glass (1) and operator's cab
(metal sheet) (2).
wheel loader.)
2. Remove the window glass.
a If a seal cutter is not available, make holes

on the adhesive and double stick tape 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 some-
thing) and move the wire to the right and
left to cut the adhesive and double stick
tape. Since the wire may be broken by
the frictional heat, apply lubricant to it.
wheel loader.)
16 GD655-3E0, GD675-3E0
Installation
1. Stuck glass
2. Stuck glass
3. Stuck glass
GD655-3E0, GD675-3E0 17
1. Work process
Outline
a Carry out the following work on each stuck glass.
2. Execution procedure 2) Remove oil, dust, dirt, etc. from the stick-
*1. Preparation ing surfaces of cab (2) and window glass
1) Using a knife and scraper [5], remove the (3) with white gasoline.
remaining adhesive and double stick tape a If the sticking surfaces are not
from the metal sheets (sticking surfaces) cleaned well, the glass may not be
of the operator's cab. stuck perfectly.
a Remove the adhesive and double a Clean the all black part on the back
stick tape to a degree that they will side of the window glass.
not affect adhesion of the new adhe- a After cleaning the sticking surfaces,
sive. Take care not to scratch the leave them for at least 5 minutes to
painted surfaces. (If the painted sur- dry.
faces are scratched, adhesion will be
lowered.)
(The figure shows the operator's cab
of a wheel loader.)
18 GD655-3E0, GD675-3E0
3) When the adhesive was removed with the *3. Position the replacement glass.
scraper, if any paint was flaked off, coat 1) Using tool X1, set the window glass to the
the bare part with paint. sticking position. Check the clearance
a If the glass is installed without repair- between the window glass and the opera-
ing the bare part, that part will be tor's cab on the right and left sides, and
rusted. upper and lower sides, and then adjust it
a Do not apply paint to a part which will evenly.
be coated with primer. a Position front window glass (1) from
inside of operator's cab (2). Adjust it
so that the difference between black
coated part (black ceramic) and the
metal sheet of operator's cab (2) will
be even on the right and left sides,
and upper and lower sides.
2) After positioning the glasses, stick tapes
[6] between front window glass (1) and
operator's cab (2), and then draw position-
ing line (e) on the tape.
3) Cut the tapes between window glass (1)
and operator's cab (2) with a knife and
then remove the window glass.
a Do not remove the tapes left on the
*2. Stick double stick tape (4) to the cab. window glasses and operator's cab
(The sticking positions and dimensions before installing the window glasses.
are indicated by shading in the figure (The figure shows the operator's cab
on the previous page.) of a bulldozer.)
a When sticking, make a clearance of 5
mm at the bottom (to drain water).
Stick double stick tape (4) along the inside
edge of the glass sticking section.
q Size of double stick tape: 7 x 4.8 mm
a When sticking the double stick tape,
do not touch the cleaned surface as
long as possible.
a Do not remove the release tape of the
double stick tape on the glass sticking
side before sticking the glass.
GD655-3E0, GD675-3E0 19
*4. Apply primer (5) to cab (2). q After applying the primer, start the
(All round the range of (d) = approx. 30% next step after 5 minutes and within
shown in the figure below) 24 hours.
2 Primer on cab side:
SUNSTAR 435-95
a The using limit of the primer is 4
months after the date of manufacture.
Do not use the primer after this limit.
a Use the primer within 2 hours after
unpacking it.
a Even if the primer is packed again
just after it is unpacked, use it within
24 hours after it is unpacked for the
first time. (Discard the primer 24
hours after it is unpacked.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a *6. Apply the adhesive to the metal sheet of
refrigerator, leave it at the room tem- the cab.
perature for at least half a day before (For the adhesive application area, see
stirring it. (If the primer is unpacked the figure below.)
just after taken out of the refrigerator, a When the ambient temperature is low,
water will be condensed. Accord- you may warm the adhesive cartridge
ingly, leave the primer at the room for the ease of work.
temperature for a sufficient time.) 2 Adhesive:
SUNSTAR PETASEAL 551
1) Set adhesive cartridge (7) to caulking gun
[7].
a An electric caulking gun is more effi-
cient.
*5. Apply the primer to glass (3).

(All round the range of (d) = approx. 30%
shown in the figure below)
2 Primer on glass side:
SUNSTAR 435-40
a When reusing primer brush (6), wash 2) Remove the release tape of the double
it in white gasoline. stick tape on the glass.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
q Before applying the primer, shake it
sufficiently to disperse the carbon.
q Take care not to leave an unpainted
part, apply the primer so thinly that
the undercoat paint color is seen, or
apply the primer roughly.
20 GD655-3E0, GD675-3E0
3) Apply adhesive (8) to the outside of dou- *8. After sticking the glass, keep fixing it for at
ble stick tape (4) of operator's cab (2). least 10 hours without giving an impact or
a Check again that the primer has been a tensile stress.
applied to the surface to be coated 1) Using styrene foam blocks [9] and rubber
with the adhesive. bands [10], fix the window glass and dou-
a Apply adhesive (8) to dimensions (s) ble stick tape to fit them completely.
and (t) of double stick tape (4) of (The figure shows the operator's cab of
operator's cab (2). PC200-7.)
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (8) higher than dou-
ble stick tape (4).
a Apply the adhesive evenly.
2) After installing the window glass, remove

the excessive primer and adhesive from
the operator's cab and window glass.
a Using white gasoline, wipe off the
adhesive before it is dried up.
a When cleaning the window glass, do
not give an impact to it.
3) Protect the stuck window glass.
1] Keep the stopper rubbers, styrene
f o am b l o c k s , a n d r u bb e r b a n ds
installed for 10 hours.
(Temperature: 20°C/Humidity: 60%)
2] Before operating the machine actu-
ally, wait at least 14 hours after
removing the stopper rubbers, sty-
rene foam blocks and rubber bands
and at least 24 hours after applying
the adhesive.
*7. Remove the protective tape from the dou- 3. Precautions

ble stick tape and stick the glass within 5 Observe the precautions for handling the
minutes after applying the adhesive. adhesive, primer, double stick tape, etc. and
( Si n ce the wi nd ow g la s s c a nn ot b e take extreme care in handling and keeping
removed and stuck again, check its posi- them to prevent entry and sticking of foreign
tion and dimensions very carefully before matter, deterioration, scratching, etc.
sticking.)
Press the glass until it is stuck to the dou-
ble stick tape and hold it under that condi-
tion for at least 10 hours.
GD655-3E0, GD675-3E0 21
Removal and installation of air 2. Remove operator's seat (2).

conditioner unit assembly 1 4 Operator's seat assembly: 35 kg
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Vacuum pump
799-703-1100 (100 V) t 1
Vacuum pump
X 799-703-1111 (220 V) t 1
Vacuum pump
799-703-1121 (240 V) t 1
799-703-1401 Gas leak detector t 1

3. Remove magazine box (3).
Removal
chocks.
(R134a).
tive goggles.
1. Set lock pin (1) to the frame. 4. Remove covers (4) and (5).
22 GD655-3E0, GD675-3E0
5. Disconnect 3 air conditioner connectors (6). 13. Disconnect connector (16).
6. Remove covers (7), (8) and (9). 14. Remove 3 air conditioner unit rear mounting
bolts (17).
7. Remove the fuse box from the rear side of
cover (7). 15. Remove air conditioner unit assembly (18).
8. Remove covers (10) and (11).

Installation
removal.

9. Disconnect connector (12).
10. Disconnect air conditioner piping (13).
11. Disconnect 2 heater hoses (14).
12. Remove 3 air conditioner unit front mounting

bolts (15).
GD655-3E0, GD675-3E0 23
SEN01921-00

© 2006 KOMATSU
All Rights Reserved
24
SEN01922-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Removal and installation of machine monitor assembly ...................................................................... 2
Removal and installation of engine controller assembly ...................................................................... 3
Removal and installation of transmission controller assembly ............................................................. 4
Removal and installation of KOMTRAX controller assembly ............................................................... 5
Removal and installation of COMMUNICATION controller assembly .................................................. 6
GD655-3E0, GD675-3E0 1
Electrical system 1
Removal and installation of Installation
machine monitor assembly 1 Carry out installation in the reverse order to
removal.
Removal
chocks.
2. Remove cover (2).
3. Disconnect connectors FP1 (3), FP2 (4) and

FP3 (5).
2 GD655-3E0, GD675-3E0
Removal and installation of 4. Remove 2 mounting bolts (6).

engine controller assembly 1
5. Remove 2 mounting nuts (7).
Removal
k Stop the machine on a level ground, apply 6. Remove engine controller (8).
chocks.
Installation
removal.
3. Disconnect connectors EC2 (3), EC3 (4) and

EC1 (5) from the engine controller.
GD655-3E0, GD675-3E0 3

transmission controller
assembly 1
Removal
chocks.
2. Disconnect connector CN-TCR (2).

Installation
3. Remove the 4 mounting bolts and COMMUNI- Carry out installation in the reverse order to
CATION controller assembly (3). removal.
4. Remove the 6 mounting bolts and cover (4).
5. Disconnect connectors (5) (CN-T1, CN-T2,

CN-T3-1, CN-T3-2, CN-T4, CN-T5).
6. Remove the 4 mounting bolts and transmission

controller assembly (6).
4 GD655-3E0, GD675-3E0
Removal and installation of 4. Disconnect connector CN-G01 (4).

KOMTRAX controller assembly 1
5. Remove the 4 mounting bolts and KOMTRAX
Removal controller assembly (5).
chocks.
Installation
removal.
2. Remove seat (2).
3. Remove the 4 mounting bolts and cover (3).
GD655-3E0, GD675-3E0 5

COMMUNICATION controller
assembly 1
Removal
chocks.
2. Disconnect connector CN-TCR (2).
3. Remove the 4 mounting bolts and COMMUNI-

CATION controller assembly (3).
Installation
removal.
6 GD655-3E0, GD675-3E0
SEN01922-00

© 2006 KOMATSU
All Rights Reserved
8
SEN01796-00
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 2
Power train hydraulic circuit diagram ................................................................................................... 2
Brake hydraulic circuit .......................................................................................................................... 4
Hydraulic circuit diagram (1/2) ............................................................................................................. 5
Hydraulic circuit diagram (2/2) ............................................................................................................. 7
GD655-3E0, GD675-3E0 1
SEN01796-00 90 Diagrams and drawings
Hydraulic diagrams and drawings 1

Power train hydraulic circuit diagram 1
2 GD655-3E0, GD675-3E0
90 Diagrams and drawings SEN01796-00
(With differential lock)
2. Oil filter
3. Solenoid valve
Solenoid ON: Lock
Solenoid OFF: Unlock
4. Breather
5. Final drive assembly
6. Magnet assembly
7. Piston
8. Differential assembly
GD655-3E0, GD675-3E0 3
SEN01796-00 90 Diagrams and drawings
Brake hydraulic circuit 1
4 GD655-3E0, GD675-3E0
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (1/2) GD655-3E0, GD675-3E0 1
SEN01796-00
GD655-3E0, GD675-3E0 5
Hydraulic circuit diagram (2/2)
Hydraulic circuit diagram (2/2) GD655-3E0, GD675-3E0 1
SEN01796-00
GD655-3E0, GD675-3E0 7
SEN01796-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01797-01
GD655-3E0,
GD675-3E0

GD655-3E0 51501 and up
GD675-3E0 51301 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram (1/6) .............................................................................................................. 3
Electrical circuit diagram (5/6) .............................................................................................................11
Electrical circuit diagram (6/6) ............................................................................................................ 13
Connector arrangement diagram ....................................................................................................... 15
GD655-3E0, GD675-3E0 1
Electrical circuit diagram (1/6)
Electrical circuit diagram (1/6) GD655-3E0, GD675-3E0 1
SEN01797-01
GD655-3E0, GD675-3E0 3
SEN01797-01
GD655-3E0, GD675-3E0 5
SEN01797-01
GD655-3E0, GD675-3E0 7
SEN01797-01
GD655-3E0, GD675-3E0 9
SEN01797-01
GD655-3E0, GD675-3E0 11
SEN01797-01
GD655-3E0, GD675-3E0 13
Connector arrangement diagram
GD655-3E0, GD675-3E0
Connector arrangement diagram
Connector Number Address of Connector Number Address of Connector Number Address of

Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram
011 TERMINAL 1 GND L-9 ET41B TERMINAL 1 BATTERY ISOLATOR M-3 RT2 TERMINAL 1 BACK UP ALARM M-9
AC1 SWP 12 AIR CONDITIONER AB-6 ET42 TERMINAL 1 BATTERY JOINT N-6 RT3 TERMINAL 1 BACK UP ALARM M-9
AC3 SWP 14 AIR CONDITIONER C-4 ET43 TERMINAL 1 BATTERY JOINT I-9 SH1 DT2 6 RPM SET MODE SW R-9
AC4 SWP 6 AIR CONDITIONER C-4 ET44 TERMINAL 1 BATTERY + J-9 SH2 (VC2) 8 RPM SET SET/RESUME SW R-9
AC5 — 22 A/C CONTROL UNIT B-9 ET45 TERMINAL 1 BATTERY RELAY IN L-2 SP1 DT2 (B) 12 INTERMEDIATE CONNECTOR AB-3
AC6 — 14 A/C CONTROL UNIT B-9 ET46 TERMINAL 1 BATTERY RELAY L-2 SP10 Relay 6 FRONT WORK LAMP (OP) AB-7
B10 DT2 6 INTERMEDIATE CONNECTOR Q-2, AD-5 ET47 TERMINAL 1 SLOW BLOW FUSE K-2 SP11 Relay 6 REAR WORK LAMP (OP) AB-7
B11 L 2 INTERMEDIATE CONNECTOR S-1, AD-5 ET48 TERMINAL 1 SLOW BLOW FUSE K-2 SP12 Relay 5 STOP LAMP AA-8
B12 DTHD8 1 INTERMEDIATE CONNECTOR S-1, AD-5 ET49 TERMINAL 1 BATTERY RELAY OUT L-2 SP13 Relay 5 NEUTRAL SAFETY Y-9
B13 DT2 2 BRAKE LAMP SW U-2 ET50 TERMINAL 1 STARTER B K-9 SP14 Relay 5 START AID P-8
B15 KES 2 WINDOW WASHER Y-1 ET53 TERMINAL 1 SLOW BLOW FUSE K-2 SP18 DT2 3 ACCUMULATOR / FLOAT SW (OP) Q-9
B16 KES 2 WINDOW WASHER Z-1 ET54 TERMINAL 1 HEATER RELAY AE-4 SP19 (VCH) 8 HEAD LAMP SW X-9
B17 KES 2 WINDOW WASHER AA-1 ET58 TERMINAL 1 BATTERY RELAY OUT L-2 SP2 DT2 (Br) 12 INTERMEDIATE CONNECTOR AB-4
B28 DT2 (B) 12 JUMPER SOCKET / INTERMIT (OP) S-6 ET59 TERMINAL 1 SLOW BLOW FUSE K-2 SP20 (VCH) 8 HAZARD LAMP SW Q-9
B4 DT2 6 INTERMEDIATE CONNECTOR Q-2 ET60 TERMINAL 1 SLOW BLOW FUSE K-2 SP22 KES 4 FLASHER RELAY AA-8
B5 X 4 TM TOOL PORT S-7 ET64 TERMINAL 1 STARTER B K-9 SP23 DT2 3 WORK LAMP SW (OP) W-9
B8 DT2 (Br) 12 INTERMEDIATE CONNECTOR Q-3, AD-6 ET65 TERMINAL 1 ALTERNATOR B AD-7 SP24 KES 4 FRONT WIPER SW W-9
B9 DT2 (B) 12 INTERMEDIATE CONNECTOR Q-2, AD-6 ET66 TERMINAL 1 ALTERNATOR R AD-7 SP26 M 2 CAUTION BUZZER O-5
BR11 Relay 5 PARKING BRAKE RELAY O-8 ET67 TERMINAL 1 ALTERNATOR E AD-7 SP27 TERMINAL 3 HORN RELAY Y-9
BR6 Relay 5 BACK UP LAMP RELAY O-7 ET75 TERMINAL 1 BATTERY RELAY + L-1 SP29 DT2 2 TM MODE SW Q-9
BR7 Relay 5 DIFF LOCK RELAY (OP) O-8 ET76 TERMINAL 1 BATTERY RELAY – L-1 SP3 DT2 (Gr) 12 INTERMEDIATE CONNECTOR AB-2
C1 DT2 (Gre) 8 CAB E-5, AB-4 ET77 TERMINAL 1 R FRAME GND AD-6 SP30 DT2 2 LIFTER LOCK SW O-7
C10 KES 2 ROOM LAMP B-8 ET82 TERMINAL 1 HEATER RELAY AE-4 SP32 DT2 2 JUMPER SOCKET S-5
C10 DT2 4 INJECTOR #3&4 AK-7 ET88 DT2 2 FREON COMPRESSOR CLUTCH AE-8 SP33 DT2 2 JUMPER SOCKET Q-4
C11 M 2 F FAN SW (OP) E-7 ET89 TERMINAL 1 R FRAME GND AD-6 SP34 DT 2 DIODE (START AID RELAY) P-9
C11 DT2 4 INJECTOR #5&6 AN-8 ET94 TERMINAL 1 R FRAME GND AD-8 SP4 DT2 (Gre) 12 INTERMEDIATE CONNECTOR AB-3
C12 M 2 R FAN SW (OP) E-7 FL10 DT 2 ACCUMULATOR SOL L (OP) G-2 SP7 Relay 5 FLOAT LH (OP) AB-6
C13 M 2 DEFROSTER FAN FRONT (OP) A-6 FL11 DT 2 FLOAT SOLENOID RH (OP) G-6 SP8 Relay 5 FLOAT RH (OP) AB-6
C13 FRAMATOME 3 CAM POSITION SENSOR AJ-1 FL12 DT 2 FLOAT SOLENOID RB (OP) F-6 ST5 2PINS 2 CIGAR LIGHTER P-9
C14 M 2 DEFROSTER FAN REAR (OP) E-9 FL13 DT 2 FLOAT SOLENOID LH (OP) I-4 ST6 TERMINAL 1 STARTER SW (B) X-9
C15 KES 4 F WIPER MOTOR A-7 FL14 DT 2 FLOAT SOLENOID LB (OP) I-4 ST7 TERMINAL 1 STARTER SW (BR) X-9
C15 FRAMATOME 3 CRANK SPEED SENSOR AN-4 FL15 DT 2 DIODE (ACCUMULATOR SOL R) F-5 ST8 TERMINAL 1 STARTER SW (C) X-9
C16 KES 4 R WIPER MOTOR D-9 FL16 DT 2 DIODE (ACCUMULATOR SOL L) H-2 ST9 TERMINAL 1 STARTER SW (ACC) X-9
C17 KES 4 F WIPER MOTOR L (OP) B-4 FL17 DT 2 DIODE (FLOAT SOL RH) F-5 T1 MIC 13 TM CONTROLLER O-4
C17 DT2 2 FUEL PUMP ACTUATOR AN-5 FL18 DT 2 DIODE (FLOAT SOL RB) F-6 T10 DT2 (Gre) 12 INTERMEDIATE CONNECTOR Q-2
C18 KES 4 F WIPER MOTOR R (OP) B-5 FL19 DT 2 DIODE (FLOAT SOL LH) I-4 T11 DT2 (B) 12 INTERMEDIATE CONNECTOR Q-2
C18 DT2 2 LIFT PUMP AM-2 FL20 DT 2 DIODE (FLOAT SOL LB) G-2 s13 DRC26 24 TM SHIFTER S-9
C19 Relay 5 F LOWER WIPER RELAY (OP) A-7 FL21 DT2 4 INTERMEDIATE CONNECTOR G-6 T16 DT2 (B) 12 INTERMEDIATE CONNECTOR S-2, AC-5
C2 DT2 (Gr) 8 CAB D-4, AB-5 FL26 M 2 F WORK LAMP (R) G-8 T17 DT2 (Br) 12 INTERMEDIATE CONNECTOR S-2, AC-6
C2 FRAMATOME 2 ENGINE OIL PRESSURE SWITCH AN-2 FL27 M 2 F WORK LAMP (L) J-2 T18 DT2 (Gr) 12 INTERMEDIATE CONNECTOR S-3, AC-6
C20 M 2 BEACON SW (OP) E-7 FL3 DT2 (B) 12 INTERMEDIATE CONNECTOR D-3 T19 DT2 6 INTERMEDIATE CONNECTOR AG-9
C22 KES 3 WORK LAMP (OP) E-8 FL4 DT2 (B) 12 INTERMEDIATE CONNECTOR H-9, T-2 T2 MIC 21 TM CONTROLLER S-4
C25 M 2 WORK LAMP (OP) A-6 FL5 DT2 6 INTERMEDIATE CONNECTOR G-8, T-2 T20 DT2 (B) 12 INTERMEDIATE CONNECTOR AH-9
C26 M 2 WORK LAMP (OP) A-7 FL6 DT2 2 ARTICULATE SENSOR L-3 T21 DT2 4 INTERMEDIATE CONNECTOR AH-9
C27 M 3 HEAD LAMP RH A-8 FL7 DT2 2 LIFTER LOCK SOLENOID K-2 T22 DT2 (Gr) 12 INTERMEDIATE CONNECTOR AH-9
C28 M 3 HAED LAMP LH A-6 FL8 DT2 2 PARKING VALVE SOLENOID K-3 T24 DT2 2 FL CLUTCH SOL AF-3
C28 DT2 2 WATER IN FUEL AL-1 FL9 DT 2 ACCUMULATOR SOL R (OP) F-5 T25 DT2 2 FH CLUTCH SOL AF-3
C29 FRAMATOME 3 BAROMETRIC PRESSURE SENSOR AN-6 FP1 AMP 070 20 MONITOR MODULE U-8 T26 DT2 2 R CLUTCH SOL AF-3
C3 DT2 6 CAB D-4, AB-5 FP11 DT2 3 TURN SIGNAL SW T-7 T27 DT2 2 1 CLUTCH SOL. AF-2
C3 DELPHI 2 COOLANT TEMPERATURE SENSOR AI-6 FP12 DT2 3 DIMMER SW T-6 T28 DT2 2 2 CLUTCH SOL AF-2
C31 M 2 DEFROSTER FAN FRONT (OP) A-5 FP13 DT2 2 DIFF LOCK SW T-7 T29 DT2 2 3 CLUTCH SOL AF-2
C32 M 2 DEFROSTER FAN REAR (OP) E-9 FP14 DT2 6 MONITOR MODE SW2 V-8 T30 DT2 2 4 CLUTCH SOL AF-1
C33 M 3 RH COMB. LAMP A-8 FP15 DT2 6 MONITOR MODE SW1 T-5 T31 DT2 2 L/U CLUTCH SOL. AF-9
C34 M 3 LH COMB. LAMP A-5 FP19 DT2 2 START AID SW T-7 T32 DT2 2 T/M INPUT REV. SENSOR AH-8
C35 DT 2 BEACON LAMP (OP) A-8 FP2 AMP 070 12 MONITOR MODULE U-8 T33 DT2 2 T/M OUTPUT REV. SENSOR AH-5
C4 SUMITOMO 4 BOOST PRESSURE SENSOR AM-8 FP3 DT2 (B) 12 WARNING MODULE U-8 T34 DT2 2 T/C HYD. TEMP SENSOR AH-8
C45 Relay 5 BEACON RERLAY (OP) A-6 FP6 DT2 (B) 12 INTERMEDIATE CONNECTOR O-2 T35 DT2 2 T/M HYD. TEMP SENSOR AF-1
C46 DT 2 BEACON LAMP (OP) D-9 FP7 DT2 (Gr) 12 INTERMEDIATE CONNECTOR O-2 T36 DT2 2 FL CLUTCH HYD.P. SW AF-3
C47 KES 3 R HEAT GLASS SW E-8 FP8 DT2 4 INTERMEDIATE CONNECTOR O-1 T37 DT2 2 FH CLUTCH HYD.P. SW AF-3
C48 TERMINAL 1 REAR HEAT GLASS POWER C-9 FT01 TERMINAL 1 GND R-4 T38 DT2 2 R CLUTCH HYD.P. SW AF-3
C49 TERMINAL 1 REAR HEAT GLASS GND E-7 FT10 TERMINAL 1 GND X-1 T39 DT2 2 1 CLUTCH HYD.P. SW AF-2
C5 (YAZAKI) 9 RADIO (OP) C-9 FT11 TERMINAL 1 GND X-1 T3A AMP 040 20 TM CONTROLLER P-4
C51 Relay 5 R HEAT GLASS RELAY E-8 FT12 TERMINAL 1 F FRAME GND AC-6 T3B AMP 040 16 TM CONTROLLER P-4
C6 KES 2 SPEAKER R (OP) D-9 FT13 TERMINAL 1 R FRAME GND AD-6 T4 AMP 040 12 TM CONTROLLER Q-4
C7 KES 2 SPEAKER L (OP) E-8 FT16 TERMINAL 1 ARTICURATE SENSOR (–) M-3 T40 DT2 2 2 CLUTCH HYD.P. SW AF-2
C8 KES 6 R WIPER SW (OP) E-6 FT17 TERMINAL 1 ARTICURATE SENSOR (G) M-4 T41 DT2 2 3 CLUTCH HYD.P. SW AF-1
C8 BOSCH 3 COMMON RAIL SENSOR AN-5 FT37 DT2 2 HORN SW U-8 T42 DT2 2 4 CLUTCH HYD.P. SW AF-1
C9 KES 6 F LOWER WIPER SW (OP) E-6 FT6 2PINS 2 HORN (L) J-2 T43 DT2 2 L/U CLUTCH HYD.P. SW AF-9
C9 DT2 4 INJECTOR #1&2 AJ-6 FT7 2PINS 2 HORN (R) G-8 T46 DT2 2 ENG REV. SENSOR AH-8
CAN DT2 (Gr) 12 KOMNET TOOL PORT S-8 H1 X 1 CAR HEATER (24V) V-9 T5 MIC 17 TM CONTROLLER R-4
CAN1 DT04 3 CAN RESISTOR AF-4 L2 DT 2 DIODE (START AID SOLENOID) Y-2 T7 DT 4 DIFF TYPE SELECT CONNECTOR S-6
CT41 TERMINAL 1 GND E-5 L3 DT2 2 START AID VALVE SOLENOID Y-1 T8 DT2 3 INCHING PEDAL Y-1
CT50 TERMINAL 1 GND E-5 L4 DT2 3 FLOAT CANCEL SW R T-3 T9A DT2 6 ACCEL PEDAL A T-3
E07 TERMINAL 1 HEATER RELAY AE-4 L5 DT2 3 FLOAT CANCEL SW L W-1 T9B DT2 2 ACCEL PEDAL B T-4
E07A TERMINAL 1 GRID HEATER AF-9 OP1 X 1 OP (24V) V-9 TCR DRC26 40 COMMUNICATION CONTROLLER W-9
E16 DT2 4 INTERMEDIATE CONNECTOR AD-6 R15 DT2 3 BRAKE ACCU. PRESSURE SW F AD-5 TG4 DT 4 SPEED SIG OUTLET S-7
EC1 DRC26 60 ENG CONTROLLER AN-4 R16 DT2 3 BRAKE ACCU. PRESSURE SW R AD-5 TT1 TERMINAL 1 POTENTIO SET SW LOW Z-8
EC2 DRC26 50 ENG CONTOROLLER AH-5 R18 DT 2 DIODE M-1 TT2 TERMINAL 1 POTENTIO SET SW COMON AA-8
EC3 DTP06 4 ENG CONTOROLLER POWER AG-5 R19 DT 2 DIODE M-1 TT3 TERMINAL 1 POTENTIO SET SW HI AA-8
ER1 DT2 (B) 12 INTERMEDIATE CONNECTOR AG-5 R28 DT 2 DIODE STARTER C AG-4 TT4 TERMINAL 1 INITIALIZATION SW Z-8
ER2 DTP06 2 INTERMEDIATE CONNECTOR AG-5 R29 DT 2 DIODE STARTER C AE-9 TT5 TERMINAL 1 COMON Z-8
ER4 DT2 6 JOINT CONNECTOR AE-9 R30 DT 2 STARTER AF-4 TT6 TERMINAL 1 MEMORY RESET Z-8
ER5 DT2 6 JOINT CONNECTOR AE-9 R31 DT 2 DIODE HEATER RELAY AD-8 TT7 TERMINAL 1 RESET SW Z-9
ET100 TERMINAL 1 CIRCUIT BREAKER OUT N-1 R43 DT2 2 DIFF THERMO SW N-5 TT8 TERMINAL 1 RESET SW Z-9
ET102 TERMINAL 1 SLOW BLOW FUSE K-2 R44 DT2 2 DIFF LOCK SOLENOID N-4 TT-9 TERMINAL 1 GND P-4
ET103 TERMINAL 1 CIRCUIT BREAKER IN N-1 RL1 DT2 (Br) 12 INTERMEDIATE CONNECTOR AG-9 TWL DT2 3 J1939 ENG DATA LINK AL-1
ET103 TERMINAL 1 ENG CONTOROLLER GND N-7 RL2 M 6 COMBINATION LAMP (R) M-9
ET39 DT2 2 FUEL SENSOR K-9 RL3 M 6 COMBINATION LAMP (L) N-9
ET40A TERMINAL 1 BATTERY ISOLATOR M-3 RL4 M 2 REAR WORK LAMP (OP) M-9
ET40B TERMINAL 1 GND M-2 RL5 M 2 REAR WORK LAMP (OP) N-8
ET41A TERMINAL 1 BATTERY – N-6 RT1 X 1 LICENSE LAMP (OP) N-8
SEN01797-01
GD655-3E0, GD675-3E0
15
SEN01797-01

© 2006 KOMATSU
All Rights Reserved
18

GD675 3eo

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SEN01775-04

MOTOR GRADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01775-04

00 Index and foreword SEN01776-04

10 Structure, function and maintenance standard SEN01781-00

20 Standard value table SEN01791-00

30 Testing and adjusting SEN01792-01

50 Disassembly and assembly SEN01794-02

90 Diagrams and drawings SEN01795-01

10 Structure, function and maintenance standard

Parking brake .......................................................................................................................... 12

20 Standard value table

30 Testing and adjusting

Measuring intake air pressure (boost pressure) ...................................................................... 9

Troubleshooting by failure code, Part 1 SEN01839-00

Failure code [CA1633] Abnormality in KOMNET..................................................................... 40

Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid.......................................... 74

H-7 Torque converter oil temperature is high........................................................................... 11

50 Disassembly and assembly

Removal and installation of air conditioner condenser ............................................................ 40

90 Diagrams and drawings

Brake hydraulic circuit.............................................................................................................. 4

GD655-3E0, GD675-3E0 Motor grader

MOTOR GRADER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips