Komatsu GD655-3E0, GD675-3E0 Motor Grader Service Manual
1,066 pages · Publication SEN01775-06
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What's inside
From the manual's own table of contents: 190 sections, 389 entries. See sample pages (PDF, 1268 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification and technical data
General assembly drawing
Specifications
Weight table
Fuel, coolant, and lubricant selection
Engine and cooling system
Cooling line
Fan drive
Power train
Power train diagram
Transmission hydraulic piping
Transmission control
Torque converter
Torque converter control valve
Show all 190 sections
Transmission
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Final drive
Steering system
Steering hydraulic piping drawing
Steering valve (Q/Amp manual Orbit-roll type)
Priority valve
Accumulator pressure governor valve
Front axle
Brake system
Blake hydraulic piping
Brake valve
Wheel brake
Slack adjuster
Accumulator43 topics
- Parking brake
- Parking brake and bank control valve
- Undercarriage and frame
- Tandem drive
- Main frame
- Hydraulic system
- Work equipment hydraulic piping drawing
- Hydraulic pump
- Main control valve
- CLSS
- Work equipment
- Work equipment control
- Hydraulic tank
- Swivel joint
- Pilot check valve
- Blade accumulator, float valve
- Blade float device
- Circle rotation motor
- Hydraulic cylinder
- Circle, drawbar
- Blade
- Circle rotation gear
- Scarifier
- Ripper
- Cab and its attachments
- Air conditioner (If equipped)
- Electrical system
- Engine starting circuit
- Engine stop circuit
- Preheat circuit
- Automatic shift control system
- Transmission controller
- Monitor
- Sensors
- Communication controller
- KOMTRAX terminal system (if equipped)
- Standard service value table
- Standard value table for engine
- Standard value table for chassis
- Testing and adjusting, Part 1
- Tools for testing, adjusting and troubleshooting
- Measuring exhaust color
- Measuring exhaust temperature
Measuring intake air pressure (boost pressure)
Measuring blowby pressure
Measuring engine oil pressure
Measuring engine speed
Testing fan belt tension
Testing air conditioner compressor belt tension
Measuring torque converter stall speed
Checking clutch oil pressure
Checking torque converter oil pressure
Adjusting speed sensor
Flushing torque converter and transmission circuit
Testing brake disc
Testing and adjusting parking brake
Method for emergency release of parking brake
Testing and adjusting parking brake pad clearance
Testing accumulator charge pressure
Testing and adjusting work equipment oil pressure
Testing and adjusting LS differential pressure
Adjusting PC valve
Bleeding air from hydraulic circuit
Measuring internal cylinder leakage
Testing and adjusting differential lock oil pressure [Differential lock specification]
Measuring steering and brake oil pressure
Bleeding air from brake piping
Charging nitrogen gas for brake, work equipment accumulator
Testing and adjusting circle guide clearance
Testing and adjusting slip clutch type rotary device
Memorizing idle and full position procedure
Initial learning method for transmission controller
Inspection procedure of diode
Testing and adjusting, Part 2
Special functions of machine monitor (EMMS)
Self-diagnosis display of gear shift lever
Handling of high-voltage circuit of engine controller
Preparatory work for troubleshooting for electrical equipment system
Moving machine when transmission valve fails
Adjusting cab stopper bolt
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Pm-clinic
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Connection table for connector pin numbers
T- branch box and T- branch adapter table56 topics
- Troubleshooting by failure code, Part 1
- Failure code [(DF1000)] Neutral safety
- Failure code [2G42ZG] Decrease of accumulator oil pressure (Front)
- Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear)
- Failure code [AB00L6] Signal of alternator disagrees with operating state of engine
- Failure code [AB00MA] Malfunction of alternator
- Failure code [B@BAZG] Engine oil pressure too low
- Failure code [B@BCNS] Engine overheat
- Failure code [B@CENS] Torque converter oil temperature too high
- Failure code [B@CKNS] Differential oil overheat
- Failure code [CA111] Abnormality in controller
- Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors
- Failure code [CA122] Charge pressure sensor too high
- Failure code [CA123] Charge pressure sensor too low
- Failure code [CA131] Throttle sensor too high
- Failure code [CA132] Throttle sensor too low
- Failure code [CA144] Coolant temperature sensor too high
- Failure code [CA145] Coolant temperature sensor too low
- Failure code [CA153] Charge temperature sensor too high
- Failure code [CA154] Charge temperature sensor too low
- Failure code [CA155] Charge temperature too high and engine speed derated
- Failure code [CA187] Sensor power source 2 too low
- Failure code [CA221] Atmospheric pressure sensor too high
- Failure code [CA222] Atmospheric pressure sensor too low
- Failure code [CA227] Sensor power source 2 too high
- Failure code [CA234] Engine over speed
- Failure code [CA238] Abnormal power source for Ne speed sensor
- Failure code [CA271] Short circuit in fuel pump actuator
- Failure code [CA272] Disconnection in fuel pump actuator
- Failure code [CA281] Abnormal supply pump pressure balance
- Failure code [CA322] Disconnection or short circuit in injector No.1
- Failure code [CA323] Disconnection or short circuit in injector No.5
- Failure code [CA324] Disconnection or short circuit in injector No.3
- Failure code [CA325] Disconnection or short circuit in injector No.6
- Failure code [CA331] Disconnection or short circuit in injector No.2
- Failure code [CA332] Disconnection or short circuit in injector No.4
- Troubleshooting by failure code, Part 2
- Failure code [CA342] Abnormality in engine controller data consistency
- Failure code [CA351] Abnormality in injector drive circuit
- Failure code [CA352] Sensor power source 1 too low
- Failure code [CA386] Sensor power source 1 too high
- Failure code [CA428] Water detection sensor too high
- Failure code [CA429] Water detection sensor too low
- Failure code [CA435] Abnormality in engine oil pressure switch
- Failure code [CA441] Power supply voltage too low
- Failure code [CA442] Power supply voltage too high
- Failure code [CA449] Common rail pressure too high (2)
- Failure code [CA451] Common rail pressure sensor too high
- Failure code [CA452] Common rail pressure sensor too low
- Failure code [CA488] Charge temperature too high and torque derated
- Failure code [CA553] Common rail pressure too high (1)
- Failure code [CA559] Supply pump no pressure (1)
- Failure code [CA689] Abnormality in engine Ne speed sensor
- Failure code [CA731] Abnormality in engine Bkup speed sensor phase
- Failure code [CA757] Loss of all engine controller data
- Failure code [CA778] Abnormality in engine Bkup speed sensor
Failure code [CA1633] Abnormality in KOMNET
Failure code [CA2185] Accelerator pedal sensor power source too high
Failure code [CA2186] Accelerator pedal sensor power source too low
Failure code [CA2249] Supply pump no pressure (2)
Failure code [CA2265] Disconnection in electric lift pump
Failure code [CA2266] Short circuit in electric lift pump
Failure code [CA2311] Abnormal resistance in IMV solenoid
Failure code [CA2555] Disconnection in air intake heater relay
Failure code [CA2556] Short circuit in air intake heater relay
Troubleshooting by failure code, Part 3
Failure code [D19CKZ] Disconnection or short circuit in differential control relay
Failure code [D19KKZ] Differential lock-up relay : Disconnection
Failure code [DAQ0KK] Power source voltage of transmission controller too low
Failure code [DAQSKR] Communication controller cannot recognize S-NET
Failure code [DB2RKR] Communication lost engine controller
Failure code [DBF0KK] Power source voltage of communication controller too low
Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low
Failure code [DBFRKR] Communication lost communication controller
Failure code [DD1PKB] Power supply line short in RPM set switch
Failure code [DD1QKB] Short circuit in RPM set mode switch
Failure code [DDTGKA] Disconnection in lock-up clutch fill switch1 topic
- (lock-up clutch fill switch)
Failure code [DDTHKA] Disconnection in FH clutch fill switch1 topic
- (FH clutch fill switch)
Failure code [DDTJKA] Disconnection in FL clutch fill switch1 topic
- (FL clutch fill switch)
Failure code [DDTKKA] Disconnection in 1st clutch fill switch1 topic
- (1st clutch fill switch)
Failure code [DDTLKA] Disconnection in 2nd clutch fill switch1 topic
- (2nd clutch fill switch)
Failure code [DDTMKA] Disconnection in 3rd clutch fill switch1 topic
- (3rd clutch fill switch)
Failure code [DDTNKA] Disconnection in R clutch fill switch1 topic
- (R clutch fill switch)
Failure code [DDTPKA] Disconnection in 4th clutch fill switch1 topic
- (4th clutch fill switch)
Failure code [DF10KA] Disconnection in transmission shift lever switch
Failure code [DF10KB] Short circuit in transmission shift lever switch
Failure code [DGF1KX] Transmission oil temperature out of range
Failure code [DGT1KX] Torque converter oil temperature out of range
Failure code [DJF1KA] Disconnection in fuel level sensor
Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range
Failure code [DK70KX] Input of inching pedal potentiometer out of normal range
Failure code [DKD0KA] Disconnection in articulate sensor
Failure code [DLE2KA] Disconnection in engine speed sensor
Failure code [DLF1KA] Disconnection in transmission input speed sensor
Failure code [DLT3KA] Disconnection in transmission output speed sensor
Failure code [DV00KB] Short circuit in caution buzzer
Failure code [DW4BKA] Disconnection in parking brake relay51 topics
- Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid
- Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid
- Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid
- Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid
- Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid
- Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid
- Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid
- Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid
- Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid
- Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid
- Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid
- Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid
- Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid
- Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid
- Troubleshooting of electrical system (E-mode)
- Contents of troubleshooting table
- Engine does not start at all or does not start easily
- Transmission mode does not change
- Differential lock function does not work or is not reset [Differential lock specification]
- Wheel brake does not work normally
- Parking brake does not work or is not reset
- Lift arm lock pin is not locked or reset [Lift arm specification]
- [Blade accumulator and float specification]
- When starting switch is turned ON, machine monitor does not operate normally
- When starting switch is turned ON, machine monitor is not reset to ordinary display
- When starting switch is turned ON, caution item lights up
- While engine is running, emergency stop item lights up
- Indication of speedometer and engine tachometer is abnormal
- Indication of engine coolant temperature gauge is abnormal
- Indication of articulate gauge is abnormal
- Indication of torque converter oil temperature gauge is abnormal
- Indication of fuel level gauge is abnormal
- Display of character display is abnormal
- Centralized warning lamp does not light up or go off
- Alarm buzzer does not sound or stop
- Machine monitor mode selector switch does not function
- Headlamp, clearance lamp and tail lamp do not light up or go off
- Working lamp does not light up or go off
- Turn signal lamp and hazard lamp do not blink or go off
- Brake lamp does not light up or go off
- Backup lamp does not light up or go off
- Backup buzzer does not sound or stop
- Air conditioner does not work or stop
- KOMTRAX system does not operate normally
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Excessive drop in engine speed, or engine stalls
- Machine does not move in either forward or reverse direction
- Transmission does not shift up or shift down
- Machine is slow or lacks power when traveling
- Torque converter lockup function cannot be actuated or canceled
- Excessive time lag when starting or shifting gear
Torque converter oil temperature is high
Differential lock function is not operated or reset [Differential lock specification]
Machine is slow or lacks power when steering
Wheel brake does not work normally
Parking brake is not applied or released
All work equipment is slow or lacks power
No work equipment moves
Abnormal noise generated around pump
Blade is slow or lacks power in lifting
Excessive blade drift
Drawbar side shift operation is slow or lacks power
Blade side shift operation is slow or lacks power
Power tilt operation is slow or lacks power
Articulate operation is slow or lacks power
Leaning operation is slow or lacks power
Excessive drift of leaning
Blade does not rotate
Lift arm lock pin is not locked or reset [Lift arm specification]1 topic
- [Blade accumulator and float specification]
Troubleshooting of engine (S-mode)
Method of using troubleshooting charts
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back, or coolant level goes down)
Oil pressure drops
Oil level rises (water, fuel in oil)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine assembly
Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly40 topics
- Removal and installation of air conditioner condenser
- Removal and installation of oil cooler assembly
- Removal and installation of aftercooler assembly
- Removal and installation of radiator assembly
- Removal and installation of engine hood
- Power train, Part 1
- Removal and installation of engine and transmission assembly
- Removal and installation of transmission assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of transmission assembly
- Power train, Part 2
- Removal and installation of final drive assembly
- Disassembly and assembly of final drive assembly
- Disassembly and assembly of final brake case assembly
- Disassembly and assembly of side case assembly (For standard final drive)
- Disassembly and assembly of bevel gear assembly
- Disassembly and assembly of bevel gear shaft
- Disassembly and assembly of bevel pinion assembly
- Removal and installation of steering valve (Orbit-roll)
- Disassembly and assembly of steering valve
- Disassembly and assembly of work equipment control valve assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Removal and installation of blade assembly
- Removal and installation of circle drawbar assembly
- Removal and installation of blade circle gear assembly
- Removal and installation of blade circle rotation gear assembly (with shear pin)
- Disassembly and assembly of blade circle rotation gear assembly (with shear pin)
- Disassembly and assembly of circle rotation gear assembly (with slip clutch)
- Removal and installation of operator's cab assembly
- Removal and installation of floor frame assembly
- Disassembly and assembly of operator’s seat assembly
- Removal and installation of operator's cab glass (stuck glass)
- Removal and installation of air conditioner unit assembly
- Removal and installation of machine monitor assembly
- Removal and installation of engine controller assembly
- Removal and installation of transmission controller assembly
- Removal and installation of KOMTRAX controller assembly
- Removal and installation of COMMUNICATION controller assembly
- Hydraulic diagrams and drawings
- Power train hydraulic circuit diagram
Brake hydraulic circuit
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (2/2)
Electrical diagrams and drawings
Electrical circuit diagram (1/6)
Electrical circuit diagram (2/6)
Electrical circuit diagram (3/6)
Electrical circuit diagram (4/6)
Electrical circuit diagram (5/6)
Electrical circuit diagram (6/6)
Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,066 pages). Open the sample pages (PDF, 1267 KB)
- Specifications, page 61: 01 Specification
- Diagram, page 653: Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid 1
- Troubleshooting, page 749: E-28 Air conditioner does not work or stop
- Foldout diagram, page 1,064: Connector arrangement diagram
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This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,066 pages
Quantity one is the manual described above.
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