SEN01775-02D

SEN01775-02 Shop Manual GD655-3E0 GD675-3E0 MOTOR GRADER SERIAL NUMBERS GD655-3E0 GD675-3E0 51501 and up 51301 and up This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. Copyright 2006 Komatsu Printed in U.S.A. Komatsu America Corp. November 2006 SEN01775-02 Shop Manual GD655-3E0 GD675-3E0 MOTOR GRADER SERIAL NUMBERS GD655-3E0 GD675-3E0 51501 and up 51301 and up  www.KomatsuAmerica.com SEN01777-02 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 SEN01775-02 00 Index and foreword Index Foreword and general information SEN01776-02 SEN01777-02 q SEN01778-01 q 01 Specification Specification and technical data SEN01779-00 SEN01780-00 10 Structure, function and maintenance standard Engine and cooling system Power train Steering system Brake system Undercarriage and frame Hydraulic system Work equipment Cab and its attachments Electrical system SEN01781-00 SEN01782-00 SEN01783-00 SEN01784-00 SEN01785-00 SEN01786-00 SEN01787-00 SEN01788-00 SEN01789-00 SEN01790-00 20 Standard value table Standard service value table SEN01791-00 SEN01834-00 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 SEN01792-00 SEN01835-00 SEN01836-00 40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode) SEN01793-00 SEN01837-00 SEN01838-00 SEN01839-00 SEN01840-00 SEN01965-00 SEN01841-00 SEN01842-00 SEN01843-00 2 GD655-3E0, GD675-3E0 00 Index and foreword SEN01777-02 50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train, Part 1 Power train, Part 2 Steering system Hydraulic system Work equipment Cab and its attachments Electrical system SEN01794-00 SEN01914-00 SEN01915-00 SEN01916-00 SEN01917-00 SEN01918-00 SEN01919-00 SEN01920-00 SEN01921-00 SEN01922-00 90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings SEN01795-01 SEN01796-00 SEN01797-01 GD655-3E0, GD675-3E0 Q Q Q Q Q Q Q Q Q 3 SEN01777-02 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 00 Index and foreword 1 Index Composition of shop manual................................................................................................................ 2 Table of contents .................................................................................................................................. 4 GD655-3E0, GD675-3E0 1 SEN01777-02 00 Index and foreword Table of contents 1 00 Index and foreword Index SEN01777-02 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 SEN01782-00 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 SEN01784-00 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 00 Index and foreword SEN01777-02 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 SEN01787-00 Hydraulic system......................................................................................................................... 2 Work equipment hydraulic piping drawing ............................................................................... 2 Hydraulic pump........................................................................................................................ 10 Main control valve.................................................................................................................... 33 CLSS ....................................................................................................................................... 44 Work equipment SEN01788-00 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 SEN01789-00 Cab and its attachments.............................................................................................................. 2 Air conditioner (If equipped) .................................................................................................... 2 Electrical system SEN01790-00 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 SEN01835-00 Testing and adjusting, Part 1....................................................................................................... 3 Tools for testing, adjusting and troubleshooting ...................................................................... 3 Measuring exhaust color ......................................................................................................... 5 Measuring exhaust temperature.............................................................................................. 6 GD655-3E0, GD675-3E0 5 SEN01777-02 00 Index and foreword Measuring intake air pressure (boost pressure) ...................................................................... 8 Measuring blowby pressure..................................................................................................... 10 Measuring engine oil pressure................................................................................................. 11 Measuring engine speed ......................................................................................................... 12 Testing fan belt tension ............................................................................................................ 12 Testing air conditioner compressor belt tension....................................................................... 13 Measuring torque converter stall speed................................................................................... 14 Checking clutch oil pressure.................................................................................................... 15 Checking torque converter oil pressure ................................................................................... 16 Adjusting speed sensor ........................................................................................................... 17 Flushing torque converter and transmission circuit ................................................................. 19 Testing brake disc .................................................................................................................... 20 Testing and adjusting parking brake ........................................................................................ 21 Method for emergency release of parking brake ..................................................................... 23 Testing and adjusting parking brake pad clearance................................................................. 24 Testing accumulator charge pressure...................................................................................... 25 Testing and adjusting work equipment oil pressure ................................................................. 26 Testing and adjusting LS differential pressure ......................................................................... 27 Adjusting PC valve................................................................................................................... 29 Bleeding air from hydraulic circuit............................................................................................ 30 Measuring internal cylinder leakage ........................................................................................ 31 Testing and adjusting differential lock oil pressure [Differential lock specification] .................. 33 Measuring steering and brake oil pressure.............................................................................. 35 Bleeding air from brake piping ................................................................................................. 36 Charging nitrogen gas for brake, work equipment accumulator .............................................. 37 Testing and adjusting circle guide clearance ........................................................................... 39 Testing and adjusting slip clutch type rotary device................................................................. 41 Memorizing idle and full position procedure ............................................................................ 43 Initial learning method for transmission controller ................................................................... 44 Inspection procedure of diode ................................................................................................. 46 Testing and adjusting, Part 2 SEN01836-00 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 SEN01837-00 Failure code table and fuse locations.......................................................................................... 2 Failure code table .................................................................................................................... 2 Fuse locations.......................................................................................................................... 6 General information on troubleshooting SEN01838-00 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 6 GD655-3E0, GD675-3E0 00 Index and foreword SEN01777-02 Troubleshooting by failure code, Part 1 SEN01839-00 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 [CA323] Disconnection or short circuit in injector No.5....................................... 52 Failure code [CA324] Disconnection or short circuit in injector No.3....................................... 54 Failure code [CA325] Disconnection or short circuit in injector No.6....................................... 56 Failure code [CA331] Disconnection or short circuit in injector No.2....................................... 58 Failure code [CA332] Disconnection or short circuit in injector No.4....................................... 60 Troubleshooting by failure code, Part 2 SEN01840-00 Troubleshooting by failure code, Part 2....................................................................................... 3 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 SEN01777-02 00 Index and foreword 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 Troubleshooting by failure code, Part 3 SEN01965-00 Troubleshooting by failure code, Part 3....................................................................................... 4 Failure code [D19CKZ] Disconnection or short circuit in differential control relay ................... 4 Failure code [D5ZHL6] Terminal C signal does not match state of engine.............................. 6 Failure code [DAQ0KK] Power source voltage of transmission controller too low .................. 8 Failure code [DAQSKR] Communication controller cannot recognize S-NET......................... 9 Failure code [DB2RKR] Communication lost engine controller ............................................... 10 Failure code [DBF0KK] Power source voltage of communication controller too low ............... 12 Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low ..................... 14 Failure code [DBFRKR] Communication lost communication controller.................................. 16 Failure code [DD1PKB] Power supply line short in RPM set switch........................................ 18 Failure code [DD1QKB] Short circuit in RPM set mode switch................................................ 20 Failure code [DDTGKA] Disconnection in lock-up clutch fill switch ......................................... 22 Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch).................................................................................... 23 Failure code [DDTHKA] Disconnection in FH clutch fill switch ................................................ 24 Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch)........................................................................................... 25 Failure code [DDTJKA] Disconnection in FL clutch fill switch.................................................. 26 Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch) ........................................................................................... 27 Failure code [DDTKKA] Disconnection in 1st clutch fill switch ................................................ 28 Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)........................................................................................... 30 Failure code [DDTLKA] Disconnection in 2nd clutch fill switch................................................ 32 Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch) ......................................................................................... 34 Failure code [DDTMKA] Disconnection in 3rd clutch fill switch ............................................... 36 Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch) .......................................................................................... 38 Failure code [DDTNKA] Disconnection in R clutch fill switch .................................................. 40 Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch) ............................................................................................. 41 Failure code [DDTPKA] Disconnection in 4th clutch fill switch ................................................ 42 Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch) .......................................................................................... 44 Failure code [DF10KA] Disconnection in transmission shift lever switch ................................ 46 Failure code [DF10KB] Short circuit in transmission shift lever switch .................................... 50 Failure code [DGF1KX] Transmission oil temperature out of range ........................................ 54 Failure code [DGT1KX] Torque converter oil temperature out of range................................... 56 Failure code [DJF1KA] Disconnection in fuel level sensor ...................................................... 58 Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range ........... 60 Failure code [DK70KX] Input of inching pedal potentiometer out of normal range.................. 62 Failure code [DKD0KA] Disconnection in articulate sensor..................................................... 64 Failure code [DLE2KA] Disconnection in engine speed sensor .............................................. 66 Failure code [DLF1KA] Disconnection in transmission input speed sensor ............................ 67 Failure code [DLT3KA] Disconnection in transmission output speed sensor .......................... 68 Failure code [DV00KB] Short circuit in caution buzzer ............................................................ 69 Failure code [DW4BKA] Disconnection in parking brake relay ................................................ 70 8 GD655-3E0, GD675-3E0 00 Index and foreword SEN01777-02 Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid.......................................... 72 Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid ........................... 73 Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid ...................................... 74 Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid ....................... 76 Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid....................................... 78 Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid ........................ 80 Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid ...................................... 82 Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid ................ 83 Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid ..................................... 84 Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid ............... 85 Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid...................................... 86 Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid ........................................ 87 Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid.......................... 88 Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid ..................................... 90 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 SEN01777-02 00 Index and foreword 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 SEN01914-00 General information on disassembly and assembly.................................................................... 2 How to read this manual .......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tool list ......................................................................................................................... 7 Sketches of special tools ......................................................................................................... 11 Engine and cooling system SEN01915-00 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........................................................................... 25 Removal and installation of engine assembly.......................................................................... 30 Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly............. 33 10 GD655-3E0, GD675-3E0 00 Index and foreword SEN01777-02 Removal and installation of air conditioner condenser ............................................................ 37 Removal and installation of oil cooler assembly ...................................................................... 39 Removal and installation of aftercooler assembly ................................................................... 41 Removal and installation of radiator assembly ........................................................................ 44 Removal and installation of engine hood................................................................................. 47 Power train, Part 1 SEN01916-00 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 SEN01917-00 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 SEN01918-00 Steering system........................................................................................................................... 2 Removal and installation of steering valve (Orbit-roll) ............................................................. 2 Disassembly and assembly of steering valve.......................................................................... 4 Hydraulic system SEN01919-00 Hydraulic system......................................................................................................................... 2 Disassembly and assembly of work equipment control valve assembly ................................. 2 Disassembly and assembly of hydraulic cylinder assembly .................................................... 5 Work equipment SEN01920-00 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 SEN01921-00 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 SEN01922-00 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 SEN01777-02 00 Index and foreword 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 Electrical circuit diagram (2/6) ................................................................................................. 5 Electrical circuit diagram (3/6) ................................................................................................. 7 Electrical circuit diagram (4/6) ................................................................................................. 9 Electrical circuit diagram (5/6) ................................................................................................. 11 Electrical circuit diagram (6/6) ................................................................................................. 13 Connector arrangement diagram............................................................................................. 15 12 GD655-3E0, GD675-3E0 00 Index and foreword GD655-3E0, GD675-3E0 SEN01777-02 13 SEN01777-02 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01777-02 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 14 SEN01778-01 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 SEN01778-01 Safety notice 00 Index and foreword 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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. 2 General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) 8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 2. Precautions against work which you are not used to or you are used to too much Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. GD655-3E0, GD675-3E0 00 Index and foreword 3) 4) 3. When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the 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 machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 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 wiring. Damaged wiring may cause electrical fires. GD655-3E0, GD675-3E0 SEN01778-01 8) 9) 10) 11) 12) 13) 14) 15) 16) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check 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 installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul 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 installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well. 3 SEN01778-01 4. 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. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding 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 forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}. 00 Index and foreword 8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion. 11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. GD655-3E0, GD675-3E0 00 Index and foreword If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. SEN01778-01 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. q 5. 6. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting 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 immediately in an emergency. GD655-3E0, GD675-3E0 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4 a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6). 5 SEN01778-01 8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k k 2) Collect the air conditioner refrigerant gas (R134a). 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. Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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 00 Index and foreword GD655-3E0, GD675-3E0 00 Index and foreword How to read the shop manual q q q 1. SEN01778-01 1 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. Materials and specifications are subject to change without notice. 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. 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 disassembly 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 SEN01778-01 3. 4. 00 Index and foreword 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. Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol Item k Safety a Caution Special technical precautions or other precautions for preserving standards are necessary when performing work. 4 Weight Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. 3 Tightening torque 2 Coat 5 Oil, coolant 6 Drain Remarks Special safety precautions are necessary when performing work. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. 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, conventionally used Gravitational System of units is indicated in parentheses { }. 8 GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 Explanation of terms for maintenance standard 1 The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance 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 temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q Example: Standard size Tolerance –0.022 –0.126 120 a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) q Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them q Example: Standard size 60 Tolerance Shaft Hole –0.030 +0.046 –0.076 +0 GD655-3E0, GD675-3E0 9 SEN01778-01 2. Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value. 00 Index and foreword 5. q 3. 4. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance 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. Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q 6. Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q Repair limit and allowable value 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 product 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 various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q 10 GD655-3E0, GD675-3E0 00 Index and foreword Handling electric equipment and hydraulic component SEN01778-01 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, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive 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 SEN01778-01 12 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 soldering may be damaged, or the wiring may be broken. 4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface 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 compressed 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 compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air. 00 Index and foreword GD655-3E0, GD675-3E0 00 Index and foreword 3. SEN01778-01 Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q When removing from clips 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 stoppers. a If the connector is twisted up and down or to the left or right, the housing may break. 3] Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. GD655-3E0, GD675-3E0 13 SEN01778-01 2) 14 00 Index and foreword 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 damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the 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 breakage, 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 stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. GD655-3E0, GD675-3E0 00 Index and foreword 3) Heavy duty wire connector (DT 8-pole, 12pole) 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) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks GD655-3E0, GD675-3E0 SEN01778-01 q Disconnection q Connection (Example of incomplete setting of (a)) 15 SEN01778-01 4) 16 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with 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 connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble. GD655-3E0, GD675-3E0 00 Index and foreword 4. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point. 5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting 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 connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit. GD655-3E0, GD675-3E0 SEN01778-01 17 SEN01778-01 00 Index and foreword 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 performance should be checked with special test equipment. 3. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal. 4. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. 18 GD655-3E0, GD675-3E0 00 Index and foreword 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 equipment, 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 circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device. GD655-3E0, GD675-3E0 SEN01778-01 19 SEN01778-01 00 Index and foreword Connectors newly used for Tier 3 engines 1. Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines) 2. Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward. q Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you. 20 GD655-3E0, GD675-3E0 00 Index and foreword 3. SEN01778-01 Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q 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. 107 engine a 2) If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. GD655-3E0, GD675-3E0 21 SEN01778-01 q 4) 125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3) 00 Index and foreword 4. Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. q 1) Disconnect connector (6) according to the 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 harness side. 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) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2) Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. 22 GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 How to read electric wire code a 1 The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.) 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) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV AVS Heat-resistant low-voltAEX age wire for automobile Material Conductor Insulator Conductor Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Insulator Soft polyvinyl chloride Conductor Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Insulator GD655-3E0, GD675-3E0 Using temperature range (°C) Example of use General wiring (Nominal No. 5 and above) –30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place 23 SEN01778-01 2. 00 Index and foreword 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 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6 Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard 8 15 20 30 40 50 60 85 100 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1 3.7 – 5.5 5.3 4.8 – 7.0 7.0 6.0 – 8.2 8.2 8.0 – 10.8 10.8 8.6 – 11.4 11.4 9.8 – 13.0 13.0 10.4 – 13.6 13.6 12.0 – 16.0 16.0 13.6 – 17.6 17.6 108/0.80 127/0.80 169/0.80 217/0.80 “f” of nominal No. denotes flexible”. 24 GD655-3E0, GD675-3E0 00 Index and foreword 3. SEN01778-01 Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR Color of wire Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red 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 Charge Ground Start Light Instrument Signal Type of circuit Others GD655-3E0, GD675-3E0 AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch AEX – R B R D Y G L – – WG – – – – – – – – – – – – – – – – RB YR GW LW BrW LgR RY YB GR LR BrR LgY RG YG GY LY BrY LgB RL YL GB LB BrB LgW – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – YW GL – – Gr Br – – 25 SEN01778-01 00 Index and foreword 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. q q q q q q q q q q a Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. 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 number 02 03 04 05 06 10 12 2) 26 Sleeve nut (elbow end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234 Split flange type hoses and tubes Nominal number 04 05 3) Plug (nut end) Flange (hose end) Sleeve head (tube end) Split flange 07379-00400 07379-00500 07378-10400 07378-10500 07371-30400 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Nominal number Part Number 06 08 10 12 14 16 18 20 22 24 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 07049-02734 27 22.5 34 GD655-3E0, GD675-3E0 00 Index and foreword 2. q q q q q q q q q q q q q a a 3. SEN01778-01 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. 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. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 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. When using the machine for the first time after repair or long storage, follow the same procedure. 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 specified 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. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it. GD655-3E0, GD675-3E0 27 SEN01778-01 4) 5) 28 00 Index and foreword 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. 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”. GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 Method of disassembling and connecting push-pull type coupler k k 1 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. 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 SEN01778-01 00 Index and foreword Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8) 2. Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9) 30 GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12) 2. Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13) GD655-3E0, GD675-3E0 31 SEN01778-01 00 Index and foreword Standard tightening torque table 1. Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a a Fig. A Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33.0 – 41.0 455 – 565 46.5 – 58.0 610 – 765 62.5 – 78.0 785 – 980 80.0 – 100.0 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370 The following table corresponds to the bolts in Fig. B. Thread diameter of bolt mm 6 8 10 12 32 1 Width across flats mm 10 13 14 27 Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2 kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2 a Fig. B GD655-3E0, GD675-3E0 00 Index and foreword 2. Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt mm 10 12 16 3. Width across flats mm 14 17 22 Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5 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. Nominal No. 02 03,04 05,06 10,12 14 4. SEN01778-01 Thread diameter mm 14 20 24 33 42 Width across flats mm Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0} 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 No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 GD655-3E0, GD675-3E0 Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – – Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0} 33 SEN01778-01 5. 00 Index and foreword 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} Nominal No. of hose Width across flats 02 19 03 04 05 06 (10) (12) (14) 6. 22 24 27 32 36 41 46 55 Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0} Target 44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} mm 6 8 10 12 14 – 14 – 18 22 24 30 33 36 42 Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 — kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 — 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 mm 6 8 10 12 14 34 Thread size (mm) Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – – 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. Thread size 7. Taper seal Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5 kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 GD655-3E0, GD675-3E0 00 Index and foreword 8. SEN01778-01 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 inch 1/16 1/8 1/4 3/8 1/2 3/4 1 GD655-3E0, GD675-3E0 Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9 kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92 35 SEN01778-01 00 Index and foreword 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 horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from 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 (A) 36 (B) 0 10 20 30 40 0 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 50 60 70 80 90 1.969 2.362 2.756 3.150 3.543 2.008 2.402 2.795 3.189 3.583 2.047 2.441 2.835 3.228 3.622 2.087 2.480 2.874 3.268 3.661 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850 2.205 2.598 2.992 3.386 3.780 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898 GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 Millimeters to inches 0 10 20 30 40 0 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 50 60 70 80 90 1.969 2.362 2.756 3.150 3.543 2.008 2.402 2.795 3.189 3.583 2.047 2.441 2.835 3.228 3.622 2.087 2.480 2.874 3.268 3.661 2.126 2.520 2.913 3.307 3.701 2.165 2.559 2.953 3.346 3.740 2.205 2.598 2.992 3.386 3.780 2.244 2.638 3.032 3.425 3.819 1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898 Kilogram to pound 0 10 20 30 40 0 0 22.05 44.09 66.14 88.18 1 2.20 24.25 46.30 68.34 90.39 2 4.41 26.46 48.50 70.55 92.59 3 6.61 28.66 50.71 72.75 94.80 4 8.82 30.86 51.91 74.96 97.00 5 11.02 33.07 55.12 77.16 99.21 50 60 70 80 90 110.23 132.28 154.32 176.37 198.42 112.44 134.48 156.53 178.57 200.62 114.64 136.69 158.73 180.78 202.83 116.85 138.89 160.94 182.98 205.03 119.05 141.10 163.14 185.19 207.24 121.25 143.30 165.35 187.39 209.44 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26 Liters to U.S. Gallons 0 10 20 30 40 0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095 3 0.793 3.434 6.076 8.718 11.359 4 1.057 3.698 6.340 8.982 11.624 1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944 50 60 70 80 90 13.209 15.850 18.492 21.134 23.775 14.001 16.643 19.285 21.926 24.568 14.265 16.907 19.549 22.190 24.832 14.529 17.171 19.813 22.455 25.096 13.473 16.115 18.756 21.398 24.040 GD655-3E0, GD675-3E0 13.737 16.379 19.020 21.662 24.304 14.795 17.435 20.077 22.719 25.361 15.058 17.700 20.341 22.983 25.625 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153 37 SEN01778-01 00 Index and foreword Liters to U.K. Gallons 0 10 20 30 40 0 0 2.200 4.399 6.599 8.799 1 0.220 2.420 4.619 6.819 9.019 2 0.440 2.640 4.839 7.039 9.239 3 0.660 2.860 5.059 7.259 9.459 4 0.880 3.080 5.279 7.479 9.679 5 1.100 3.300 5.499 7.699 9.899 50 60 70 80 90 10.998 13.198 15.398 17.598 19.797 11.281 13.418 15.618 17.818 20.017 11.438 13.638 15.838 18.037 20.237 11.658 13.858 16.058 18.257 20.457 11.878 14.078 16.278 18.477 20.677 12.098 14.298 16.498 18.697 20.897 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777 kgm to ft.lb 0 10 20 30 40 0 0 72.3 144.7 217.0 289.3 1 7.2 79.6 151.9 224.2 296.6 2 14.5 86.8 159.1 231.5 303.8 3 21.7 94.0 166.4 238.7 311.0 4 28.9 101.3 173.6 245.9 318.3 5 36.2 108.5 180.8 253.2 325.5 6 43.4 115.7 188.1 260.4 332.7 1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4 50 60 70 80 90 361.7 434.0 506.3 578.6 651.0 368.9 441.2 513.5 585.9 658.2 376.1 448.5 520.8 593.1 665.4 383.4 455.7 528.0 600.3 672.7 390.6 462.9 535.2 607.6 679.9 397.8 470.2 542.5 614.8 687.1 405.1 477.4 549.7 622.0 694.4 412.3 484.6 556.9 629.3 701.6 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1 100 110 120 130 140 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 150 160 170 180 190 1084.9 1157.3 1129.6 1301.9 1374.3 38 1092.2 1164.5 1236.8 1309.2 1381.5 1099.4 1171.7 1244.1 1316.4 1388.7 1106.6 1179.0 1251.3 1323.6 1396.0 1113.9 1186.2 1258.5 1330.9 1403.2 1121.1 1193.4 1265.8 1338.1 1410.4 1128.3 1200.7 1273.0 1345.3 1417.7 1135.6 1207.9 1280.1 1352.6 1424.9 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4 GD655-3E0, GD675-3E0 00 Index and foreword SEN01778-01 kg/cm2 to lb/in2 0 10 20 30 40 0 0 142.2 284.5 426.7 568.9 1 14.2 156.5 298.7 440.9 583.2 2 28.4 170.7 312.9 455.1 597.4 3 42.7 184.9 327.1 469.4 611.6 4 56.9 199.1 341.4 483.6 625.8 5 71.1 213.4 355.6 497.8 640.1 6 85.3 227.6 369.8 512.0 654.3 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 50 60 70 80 90 711.2 853.4 995.6 1,138 1,280 725.4 867.6 1,010 1,152 1,294 739.6 881.8 1,024 1,166 1,309 753.8 896.1 1,038 1,181 1,323 768.1 910.3 1,053 1,195 1,337 782.3 924.5 1,067 1,209 1,351 796.5 938.7 1,081 1,223 1,365 810.7 953.0 1,095 1,237 1,380 825.0 967.2 1,109 1,252 1,394 839.2 981.4 1,124 1,266 1,408 100 110 120 130 140 1,422 1,565 1,707 1,849 1,991 1,437 1,579 1,721 1,863 2,005 1,451 1,593 1,735 1,877 2,020 1,465 1,607 1,749 1,892 2,034 1,479 1,621 1,764 1,906 2,048 1,493 1,636 1,778 1,920 2,062 1,508 1,650 1,792 1,934 2,077 1,522 1,664 1,806 1,949 2,091 1,536 1,678 1,821 1,963 2,105 1,550 1,693 1,835 1,977 2,119 150 160 170 180 190 2,134 2,276 2,418 2,560 2,702 2,148 2,290 2,432 2,574 2,717 2,162 2,304 2,446 2,589 2,731 2,176 2,318 2,460 2,603 2,745 2,190 2,333 2,475 2,617 2,759 2,205 2,347 2,489 2,631 2,773 2,219 2,361 2,503 2,646 2,788 2,233 2,375 2,518 2,660 2,802 2,247 2,389 2,532 2,674 2,816 2,262 2,404 2,546 2,688 2,830 200 210 220 230 240 2,845 2,987 3,129 3,271 3,414 2,859 3,001 3,143 3,286 3,428 2,873 3,015 3,158 3,300 3,442 2,887 3,030 3,172 3,314 3,456 2,901 3,044 3,186 3,328 3,470 2,916 3,058 3,200 3,343 3,485 2,930 3,072 3,214 3,357 3,499 2,944 3,086 3,229 3,371 3,513 2,958 3,101 3,243 3,385 3,527 2,973 3,115 3,257 3,399 3,542 GD655-3E0, GD675-3E0 39 SEN01778-01 00 Index and foreword Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C °F °C °F °C °F °C 1°C = 33.8°F °F –40.4 –37.2 –34.4 –31.7 –28.9 –40 –35 –30 –25 –20 –40.0 –31.0 –22.0 –13.0 –4.0 –11.7 –11.1 –10.6 –10.0 –9.4 11 12 13 14 15 51.8 53.6 55.4 57.2 59.0 7.8 8.3 8.9 9.4 10.0 46 47 48 49 50 114.8 116.6 118.4 120.2 122.0 27.2 27.8 28.3 28.9 29.4 81 82 83 84 85 177.8 179.6 181.4 183.2 185.0 –28.3 –27.8 –27.2 –26.7 –26.1 –19 –18 –17 –16 –15 –2.2 –0.4 1.4 3.2 5.0 –8.9 –8.3 –7.8 –7.2 –6.7 16 17 18 19 20 60.8 62.6 64.4 66.2 68.0 10.6 11.1 11.7 12.2 12.8 51 52 53 54 55 123.8 125.6 127.4 129.2 131.0 30.0 30.6 31.1 31.7 32.2 86 87 88 89 90 186.8 188.6 190.4 192.2 194.0 –25.6 –25.0 –24.4 –23.9 –23.3 –14 –13 –12 –11 –10 6.8 8.6 10.4 12.2 14.0 –6.1 –5.6 –5.0 –4.4 –3.9 21 22 23 24 25 69.8 71.6 73.4 75.2 77.0 13.3 13.9 14.4 15.0 15.6 56 57 58 59 60 132.8 134.6 136.4 138.2 140.0 32.8 33.3 33.9 34.4 35.0 91 92 93 94 95 195.8 197.6 199.4 201.2 203.0 –22.8 –22.2 –21.7 –21.1 –20.6 –9 –8 –7 –6 –5 15.8 17.6 19.4 21.2 23.0 –3.3 –2.8 –2.2 –1.7 –1.1 26 27 28 29 30 78.8 80.6 82.4 84.2 86.0 16.1 16.7 17.2 17.8 18.3 61 62 63 64 65 141.8 143.6 145.4 147.2 149.0 35.6 36.1 36.7 37.2 37.8 96 97 98 99 100 204.8 206.6 208.4 210.2 212.0 –20.0 –19.4 –18.9 –18.3 –17.8 –4 –3 –2 –1 0 24.8 26.6 28.4 30.2 32.0 –0.6 0 0.6 1.1 1.7 31 32 33 34 35 87.8 89.6 91.4 93.2 95.0 18.9 19.4 20.0 20.6 21.1 66 67 68 69 70 150.8 152.6 154.4 156.2 158.0 40.6 43.3 46.1 48.9 51.7 105 110 115 120 125 221.0 230.0 239.0 248.0 257.0 –17.2 –16.7 –16.1 –15.6 –15.0 1 2 3 4 5 33.8 35.6 37.4 39.2 41.0 2.2 2.8 3.3 3.9 4.4 36 37 38 39 40 96.8 98.6 100.4 102.2 104.0 21.7 22.2 22.8 23.3 23.9 71 72 73 74 75 159.8 161.6 163.4 165.2 167.0 54.4 57.2 60.0 62.7 65.6 130 135 140 145 150 266.0 275.0 284.0 293.0 302.0 –14.4 –13.9 –13.3 –12.8 –12.2 6 7 8 9 10 42.8 44.6 46.4 48.2 50.0 5.0 5.6 6.1 6.7 7.2 41 42 43 44 45 105.8 107.6 109.4 111.2 113.0 24.4 25.0 25.6 26.1 26.7 76 77 78 79 80 168.8 170.6 172.4 174.2 176.0 68.3 71.1 73.9 76.7 79.4 155 160 165 170 175 311.0 320.0 329.0 338.0 347.0 40 GD655-3E0, GD675-3E0 00 Index and foreword GD655-3E0, GD675-3E0 SEN01778-01 41 SEN01778-01 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01778-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 42 SEN01780-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 A B C 2 GD655-3E0 GD675-3E0 Overall length 8,715 8,715 Overall height (with full height cab) 3,350 3,345 Overall height (with low height cab) 3,120 3,115 Overall width 2,550 2,550 GD655-3E0, GD675-3E0 01 Specification SEN01780-00 Specifications 1 GD655-3E0 Machine model GD655-3E0 Serial number 51501 and up Machine weight 15,400 On front axle kg Dimensions On rear axle 11,300 Overall length 8,715 Overall width 2,550 Overall height (top of muffler) 3,000 Overall height (with ROPS cab) 3,120 mm Wheel base 6,070 Distance between centers of tandem wheels 1,535 Tread (Front) 2,130 Tread (Rear) 2,130 Ground clearance 370 Forward Performance 4,100 Travel speed Reverse 1st 3.3 2nd 4.7 3rd 6.7 4th 5th km/h 6th 21.2 7th 29.1 8th 42.2 1st 4.3 2nd 3rd km/h 4th Maximum drawbar pull Gradeability Min. turning radius Static stability GD655-3E0, GD675-3E0 9.7 14.6 8.8 19.3 38.3 kN {kg} 88.7 {9,040} deg. 24 m 6.9 deg. 35 3 SEN01780-00 01 Specification Machine model GD655-3E0 Serial number 51501 and up Engine model SAA6D114E-3 4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler Type Cylinder number – bore x stroke mm 6 – 114 x 135 l {cc} 8.27 {8,270} Flywheel horsepower kW/rpm {HP/rpm} 134.2 – 149.2/1,900 {180 – 200/1,900} Maximum torque Nm/rpm {kgm/rpm} 830.6 – 975.8/1,450 {84.7 – 99.5/1,450} Max. speed at no load rpm 2,225 Min. speed at no load rpm 825 Fuel consumption ratio g/kWh {g/HPh} 218.3 {162.9} Performance Engine Piston displacement 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 Automatic shifting, wet-type clutch Power train Torque converter Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds Transmission Reduction gear Spiral bevel gear, single-stage reduction Rear axle Fully floating tandem type 4 Front axle Type Steering system Steering Tandem Type Double-row chain drive Reverse Elliott, angle type Max. leaning angle 16 Fully hydraulic type Steering angle deg. 49 Articulate angle deg. 23 GD655-3E0, GD675-3E0 01 Specification SEN01780-00 Machine model GD655-3E0 Tires Steering related cylinders Control valve Hydraulic pump Brakes Hydraulic system Steering, operating system Serial number 51501 and up Tires (front) 14.00-24-10PR Tires (rear) 14.00-24-10PR Inflation pressure (front) kPa {kg/cm2} 216 {2.2} Inflation pressure (rear) kPa {kg/cm2} 216 {2.2} Main brake Rear 4-wheel braking, multiple-disc wet type Parking brake Dry disc type Type x No. Discharge at rated rpm Set pressure Komatsu LPV90 Variable swash plate type x 1 l/min. 194 MPa {kg/cm2} 20.6 {210} Type x No. 4-spool type x 2 (CLSS) Control method Hydraulic type Steering Type Articulating Double-acting piston type Cylinder bore mm 50 80 90 Piston rod outside diameter mm 35 40 50 Piston stroke mm 330 160 325 Blade lift Type Work equipment cylinders Leaning Blade side shift Blade tilt Drawbar side shift Ripper 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 Double-acting piston type Cylinder bore mm Piston rod outside diameter mm 50 Piston stroke mm 300 GD655-3E0, GD675-3E0 90 5 SEN01780-00 01 Specification Machine model GD655-3E0 Serial number 51501 and up Blade dimension (Length x Height x Thickness) Cutting edge dimension (Length x Width x Thickness – Number) Max. lift above ground 3,658 x 660 x 22 1,829 x 153 x 16 – 2 mm Max. cutting depth 815 Blade Blade base Blade load Turning angle (with scarifier) Max. shoulder reach outside rear tires (Frame straight) (left) Max. shoulder reach outside rear tires (Frame straight) (right) 2,600 kN {kg} 70.3 {7,170} deg. 360 (130) 2,000 mm 2,000 Cutting angle [Standard] [Adjustable] 6 505 — deg. 37 32 – 81 GD655-3E0, GD675-3E0 01 Specification SEN01780-00 GD675-E0 Machine model GD675-3E0 Serial number 51301 and up Machine weight 15,810 Dimensions On front axle kg 11,510 Overall length 8,715 Overall width 2,550 Overall height (top of muffler) 3,000 Overall height (with ROPS cab) 3,115 mm Wheel base Distance between centers of tandem wheels 6,070 1,535 Tread (Front) 2,130 Tread (Rear) 2,130 Ground clearance 370 1st Forward Performance 4,300 On rear axle Travel speed Reverse 3.3 2nd 4.7 3rd 6.7 4th 5th km/h Gradeability Min. turning radius Static stability GD655-3E0, GD675-3E0 14.6 6th 21.2 7th 29.1 8th 42.2 1st 4.3 2nd 3rd km/h 4th Maximum drawbar pull 9.7 8.8 19.3 38.3 kN {kg} 90.3 {9,210} deg. 24 m 6.9 deg. 35 7 SEN01780-00 01 Specification Machine Model GD675-3E0 Serial Number 51301 and up Engine model SAA6D114E-3 4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler Type Cylinder number – bore x stroke mm 6 – 114 x 135 l {cc} 8.27 {8,270} Flywheel horsepower kW/rpm {HP/rpm} 134.2 – 149.2/1,900 {180 – 200/1,900} Maximum torque Nm/rpm {kgm/rpm} 830.6 – 975.8/1,450 {84.7 – 99.5/1,450} Max. speed at no load rpm 2,225 Min. speed at no load rpm 825 Fuel consumption ratio g/kWh {g/HPh} 218.3 {162.9} Performance Engine Piston displacement Starting motor 24V, 7.5kW Alternator 24V, 60A Battery 12V, 112Ah x 2 Radiator type Aluminum looper 4-line 3-element, single-stage Automatic shifting, wet-type clutch Power train Torque converter Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds Transmission Reduction gear Spiral bevel gear, single-stage reduction Rear axle Fully floating tandem type 8 Steering system Front axle Steering Tandem Double-row chain drive Type Reverse Elliott, angle type Max. leaning angle 16 Type Fully hydraulic type Steering angle deg. 49 Articulate angle deg. 23 GD655-3E0, GD675-3E0 01 Specification SEN01780-00 Machine model GD675-3E0 Tires Steering related cylinders Control valve Hydraulic pump Brakes Hydraulic system Steering, operating system Serial number 51301 and up Tires (front) 14.00-24-12PR Tires (rear) 14.00-24-12PR Inflation pressure (front) kPa {kg/cm2} 245 {2.5} Inflation pressure (rear) kPa {kg/cm2} 245 {2.5} Main brake Rear 4-wheel braking, multiple-disc wet type Parking brake Dry disc type Type x No. Discharge at rated rpm Set pressure Komatsu LPV90 Variable swash plate type x 1 l/min. 194 MPa {kg/cm2} 20.6 {210} Type x No. 4-spool type x 2 (CLSS) Control method Hydraulic type Steering Type Articulating Double-acting piston type Cylinder bore mm 50 80 90 Piston rod outside diameter mm 35 40 50 Piston stroke mm 330 160 325 Blade lift Type Work equipment cylinders Leaning Blade side shift Blade tilt Drawbar side shift Ripper 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 Double-acting piston type Cylinder bore mm Piston rod outside diameter mm 50 Piston stroke mm 300 GD655-3E0, GD675-3E0 90 9 SEN01780-00 01 Specification Machine model GD675-3E0 Serial number 51301 and up Blade dimension (Length x Height x Thickness) Cutting edge dimension (Length x Width x Thickness – Number) Max. lift above ground 3,658 x 660 x 25 1,829 x 153 x 16 – 2 mm Max. cutting depth 815 Blade Blade base Blade load Turning angle (with scarifier) Max. shoulder reach outside rear tires (Frame straight) (left) Max. shoulder reach outside rear tires (Frame straight) (right) 2,600 kN {kg} 73.7 {7,520} deg. 360 (130) 2,000 mm 2,000 Cutting angle [Standard] [Adjustable] 10 505 — deg. 37 32 – 81 GD655-3E0, GD675-3E0 01 Specification SEN01780-00 Weight table k 1 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 SEN01780-00 01 Specification 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 Reservoir Fluid type -22 -30 -4 -20 14 -10 32 0 50 10 (Note.1) (Note.1) Engine oil pan Engine oil 68 20 86 30 104 40 122ºF 50ºC Recommended Komatsu fluids Komatsu EOS0W30 Komatsu EOS5W40 Komatsu EO10W30-DH Komatsu EO15W40-DH Komatsu EO30-DH Transmission case Power train oil (Note.2) TO10 Hydraulic system Power train oil TO10 Final drive case Tandem drive sase Power train oil TO30 GO90 Circle reverse gear case Gear oil GO80 GO75 Hyper grease (Note.3) Grease fitting Work equipment Lithium EP grease Lubricants with molybdenum disulfide Cooling system Fuel tank q 12 Supercoolant AF-NAC (Note.4) Diesel fuel G2-T, G2-TE G2-LI LM-G, LM-P AF-NAC ASTM Grade No.1-D S15 ASTM Grade No.1-D S500 ASTM Grade No.2-D S15 ASTM Grade No.2-D S500 ASTM: American Society of Testing and Material GD655-3E0, GD675-3E0 01 Specification SEN01780-00 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%. q q q q Fuel sulphur content Change interval of oil in engine oil pan 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval 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. Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change interval in half. 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. 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 SEN01782-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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. 2. 3. 4. Torque converter oil cooler Aftercooler Radiator Reservoir tank A. B. C. D. E. F. Torque convertor oil cooler input port Torque convertor oil cooler output port Aftercooler input port (from turbocharger) Aftercooler output port (for intake manifold) Radiator coolant inlet Radiator coolant outlet 2 Specification q Radiator Core type: Aluminum looper 4-line Total heat dissipation area: 47.261 m2 q Oil cooler Core type: CF40-1, 3.5/2P Total heat dissipation area: 9.32 m2 q Aftercooler Core type: 4.0/2P Total heat dissipation area: 21.69 m2 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Fan drive 1. 2. 3. 4. SEN01782-00 1 Fan drive pulley Drive pulley V-belt Tension pulley GD655-3E0, GD675-3E0 3 SEN01783-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01783-00 10 Structure, function and maintenance standard Power train Power train diagram q q q 2 1 1 The power produced by diesel engine (5) goes to transmission (4) through torque converter with lock-up clutch (3). Transmission (4), with a multiple shaft mechanism and a hydraulic control unit combined, allows an easy selection of eight forward speeds and four reverse speeds. Through drive shaft (6), the power is transmitted from the transmission to the final drive (7). Here, final drive (7) directs the power to the right and left, and the power is transmitted to the left and right tandem drives (8) through shaft (11). Tandem drive (8) transmits the power to the wheel by a chain and the machine travels. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cooling fan Hydraulic pump Torque converter Transmission Engine assembly Drive shaft Final drive Tandem drive Tire Wheel brake Shaft GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Transmission hydraulic piping 1. 2. 3. 4. 5. 6. 7. SEN01783-00 1 Transmission oil filter Transmission oil filter inlet hose Transmission oil filter outlet hose Transmission pump Transmission pump tube Transmission assembly Transmission oil filler/oil level check hole GD655-3E0, GD675-3E0 3 SEN01783-00 Transmission control 1. 2. 3. 4 Gear shift lever Transmission controller Communication controller 10 Structure, function and maintenance standard 1 Gear shift lever positions 1. Reverse 2. Forward 3. Parking 4. Neutral 5. 1 range (forward, reverse) 6. 2 range (forward, reverse) 7. 3 range (forward, reverse) 8. 4 range (forward, reverse) 9. 5 range (forward) 10. 6 range (forward) 11. 7 range (forward) 12. 8 range (forward) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Torque converter 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. PTO drive gear (Number of teeth: 70) Pump Race Drive case Stator Turbine Lockup clutch piston Lockup clutch housing (Number of teeth: 72) Pilot Boss Lockup clutch disc Free wheel Guide Stator shaft Transmission input shaft GD655-3E0, GD675-3E0 SEN01783-00 1 Specifications Type: 3-element, 1-stage, 2-phase with modulation with lockup clutch Lockup clutch: wet type single-disc clutch hydraulic control (with modulation valve) Stall torque ratio: 2.17 5 SEN01783-00 6 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Unit: mm No. Check item Criteria Remedy Standard size Tolerance Repair limit 71.954 –0.010 –0.040 71.9 1 Outside diameter of pilot 2 Inside diameter of pilot seal ring contact surface 35 +0.025 +0.025 35.5 Inside diameter of clutch piston seal ring contact surface 260 +0.081 +0.081 260.1 Width 5 –0.01 –0.04 4.5 Thickness 6 ±0.15 5.85 3 Wear of clutch housing seal ring 4 Inside diameter of clutch housing seal ring contact surface 340 +0.089 +0.089 340.5 5 Inside diameter of PTO drive gear seal ring contact surface 125 +0.040 +0.040 125.5 6 Inside diameter of stator shaft seal ring contact surface 55 +0.030 +0.030 55.5 7 Inside diameter of race free wheel transmission surface 88.882 +0.005 –0.008 88.912 8 Outside diameter of stator shaft free wheel transmission surface 72.217 +0.008 –0.005 72.187 9 Inside diameter of sliding portion of bushing 72.32 +0.015 +0.015 72.4 Thickness of sliding portion of bush10 ing 5 –0.1 –0.1 4.5 11 Thickness of clutch disc 5 ±0.1 4.5 12 Backlash between PTO drive gear and PTO idler gear GD655-3E0, GD675-3E0 Repair by hard chromium-plating or replace Replace Repair by hard chromium-plating or replace Replace 0.160 – 0.407 7 SEN01783-00 10 Structure, function and maintenance standard Power transmission route When lockup clutch is "disengaged" When lockup clutch is "engaged" Drive case (3) is disconnected from boss (9) and turbine (8) and lockup torque converter works as an ordinary torque converter. Drive case (3) is connected to boss (9) and turbine (8) and lockup torque converter is locked up. The power from engine O Flywheel (1) O Clutch housing (2) O Drive case (3), pump (5) and PTO drive gear (6) rotate together O Oil is used as medium O Turbine (8) and boss (9) O Transmission input shaft (10) The power from engine O Flywheel (1) O Clutch housing (2) O Drive case (3), pump (5) and PTO drive gear (6) rotate together O Lockup clutch (4) O Boss (9) O Transmission input shaft (10) q 8 The power transmitted to PTO drive gear (6) is also used as power for driving the pump after being transmitted through PTO idler gear (7). q The power transmitted to PTO drive gear (6) is also used as power for driving the pump after being transmitted through PTO idler gear (7). GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Oil flow q q q The oil flows through the main relief valve and its pressure is reduced to below the set pressure by the torque converter relief valve, and then it flows through inlet port (A) and oil passage of stator shaft (1) and guide (2) to pump (3). The oil is given centrifugal force by pump (3) and flows into turbine (4) to transmit its energy to turbine (4). 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 SEN01783-00 Torque converter control valve A: P: T: Dr: P1: 10 To clutch From pump Drain Drain Clutch oil pressure pick-up port 10 Structure, function and maintenance standard 1 1. 2. 3. 4. 5. 6. 7. 8. Proportional solenoid connector Lockup clutch ECMV Seat Fill switch connector Fill switch Pressure detection valve Pressure control valve Proportional solenoid GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Transmission 1 A: B: From power train pump To oil cooler 1. 2. Work equipment pump installation port Power train, differential lock pump installation port Transmission control valve Transmission oil temperature sensor Oil filler tube mounting port 3. 4. 5. GD655-3E0, GD675-3E0 SEN01783-00 6. 7. 8. 9. 10. Transmission case (front) Transmission case (rear) Transmission output shaft speed sensor Torque converter control valve Main relief valve and torque converter relief valve 11 SEN01783-00 1. 2. 3. 4. 5. 6. 7. 8. 9. 12 Torque converter Input shaft FL clutch Upper shaft FH clutch Lower shaft 3rd clutch Coupling 4th clutch 10 Structure, function and maintenance standard 10. 11. 12. 13. 14. 15. 16. 17. 18. Output shaft 2nd clutch 1st clutch R clutch Fun pulley drive shaft Fun pulley coupling PTO idler gear A (Number of teeth: 53) PTO gear A shaft PTO gear A (Number of teeth: 62) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01783-00 13 SEN01783-00 14 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Unit: mm No. 1 Check item Clearance between input shaft bearing and front case Criteria Tolerance Standard size Remedy Standard clearance Clearance limit +0.030 +0.030 0 – 0.048 — Shaft Hole 150 –0.018 –0.018 2 Clearance between input shaft bearing and rear case 100 –0.018 –0.015 +0.022 –0.013 –0.013 – 0.037 — 3 Clearance between upper shaft bearing and front case 100 –0.018 –0.015 +0.030 +0.030 0 – 0.045 — Clearance between upper shaft bearing and rear case 110 –0.018 –0.015 +0.022 –0.013 –0.013 – 0.037 — Clearance between upper shaft bearing and upper shaft 60 +0.034 +0.021 –0.018 –0.015 –0.049 – –0.021 — 5 Clearance between lower shaft bearing and front case 140 –0.018 –0.018 +0.026 –0.014 –0.014 – 0.044 — 6 Clearance between lower shaft bearing and rear case 130 –0.018 –0.018 +0.026 –0.014 –0.014 – 0.044 — 7 Clearance between output shaft bearing and front case 140 –0.018 –0.018 +0.026 –0.014 –0.014 – 0.044 — 8 Clearance between output shaft bearing and rear case 160 –0.018 –0.025 +0.004 +0.030 0 – 0.065 — Clearance between PTO idler gear A bearing and front case 90 –0.018 –0.015 +0.004 –0.018 –0.018 – 0.019 — Clearance between PTO idler gear A bearing and PTO idler gear A 50 +0.018 +0.002 –0.018 –0.012 –0.030 – –0.002 — Clearance between fan drive shaft bearing and rear case 80 –0.018 –0.013 +0.030 +0.030 0 – 0.043 — Clearance between fan drive shaft bearing and fan drive shaft 35 +0.025 +0.009 –0.018 –0.012 –0.037 – –0.009 — Clearance between PTO gear A shaft bearing and front case (front) 90 –0.018 –0.015 +0.030 +0.030 0 – 0.045 — Clearance between PTO gear A shaft bearing and PTO gear A shaft (front) 50 +0.020 +0.009 –0.018 –0.012 –0.032 – –0.009 — Clearance between PTO gear A shaft bearing and front case (rear) 110 –0.018 –0.015 +0.030 +0.030 0 – 0.045 — 70 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — 4 9 10 11 12 Clearance between PTO gear A shaft bearing and PTO gear A shaft (rear) Standard size Tolerance Repair limit 2.5 +0.18 +0.10 2.7 Width of input shaft seal ring groove (center) 3.2 +0.076 +0.076 3.5 Inside diameter of seal ring contact surface of case and retainer 50 +0.05 +0.06 50.1 Width of each shaft seal ring groove 3.2 +0.076 +0.076 3.5 16 Outside diameter of oil seal contact surface of output coupling 80 –0.074 –0.074 79.8 17 Outside diameter of oil seal contact surface of fan pulley coupling 65 –0.074 –0.074 64.8 13 Width of input shaft seal ring groove (front) 14 15 GD655-3E0, GD675-3E0 Replace 15 SEN01783-00 10 Structure, function and maintenance standard Unit: mm No. 1 2 3 4 16 Check item Criteria Tolerance Remedy Shaft Hole Standard clearance Clearance limit 90 –0.018 –0.015 +0.004 –0.018 –0.018 – 0.019 — Clearance between PTO idler gear B bearing and PTO idler gear B 50 +0.018 +0.002 –0.018 –0.012 –0.030 – –0.002 — Clearance between PTO gear B shaft bearing and front case (front) 90 –0.018 –0.015 +0.030 +0.030 0 – 0.045 — Clearance between PTO gear B shaft bearing and PTO gear B shaft (front) 50 +0.020 +0.009 –0.018 –0.012 –0.032 – –0.009 — Clearance between PTO gear B shaft bearing and front case (rear) 100 –0.018 –0.015 +0.030 +0.030 0 – 0.045 — Clearance between PTO gear B shaft bearing and PTO gear B shaft (rear) 70 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — Clearance between R idler gear bearing and R idler gear 100 –0.018 –0.015 –0.049 –0.073 –0.073 – –0.034 — Clearance between R idler gear bearing and rear case 70 +0.032 +0.002 –0.018 –0.015 –0.047 – –0.002 — Clearance between PTO idler gear B bearing and front case Standard size Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 5. 6. 7. 8. 9. 10. PTO gear B (Number of teeth: 62) PTO gear B shaft PTO idler gear B (Number of teeth: 53) R idler gear (Number of teeth: 37) Strainer Drain plug SEN01783-00 Outline q q q The transmission adopted is a "forward 8-gear speed and reverse 4-gear speed" transmission which consists of the counter-shaft type, constant mesh spur gear mechanisms and the disc clutches. 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 pressure by ECMV operation. The transmission transfers the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st – 8th or reverse 1st – 4th) by any combination of the FL, FH, R clutches and 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 GD655-3E0, GD675-3E0 Gear speed Operated clutches Reduction ratio 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 17 SEN01783-00 10 Structure, function and maintenance standard FL, R clutch A: B: C: D: 1. 2. 3. 4. 5. 6. 7. R clutch oil port FL clutch oil port Lubricating oil port Lockup clutch oil port R clutch gear (Number of teeth: 25) R clutch FL and R cylinders FL clutch FL clutch gear (Number of teeth: 28) Input gear (Number of teeth: 36) Input shaft Unit: mm No. 8 9 Check item Clearance between input shaft bearing and input shaft (front) Clearance between input shaft bearing and input shaft (rear) 10 Clutch plate 11 Criteria Clutch disc Tolerance Standard size Remedy Shaft Hole Standard clearance Clearance limit 60 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — 55 +0.034 +0.021 –0.018 –0.015 –0.049 – –0.021 — Standard size Tolerance Repair limit Thickness 1.7 ±0.05 1.5 Strain — 0.1 0.15 Thickness 2.2 ±0.08 1.8 — 0.1 0.25 Load of wave spring 12 (Testing height: 2.2 mm) Strain 1,010 N {103 kg} ±101 N {±10.3 kg} 859 N {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 Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 FH, 1st clutch A: B: C: 1. 2. 3. 4. 5. 6. 7. FH clutch oil port 1st clutch oil port Lubricating oil port Upper gear (Number of teeth: 42) 1st clutch gear (Number of teeth: 26) 1st clutch FH and 1st cylinders (Number of teeth: 62) FH clutch FH clutch gear (Number of teeth: 55) Upper shaft Unit: mm No. 8 Check item Criteria Clearance between upper shaft bearing and upper shaft (front) 55 9 Clutch plate 10 Clutch disc 11 Thickness Tolerance Standard size Shaft Hole Standard clearance Clearance limit +0.034 +0.021 –0.018 –0.015 –0.049 – –0.021 — Standard size Tolerance Repair limit 1.7 ±0.05 1.5 Strain — 0.1 0.15 Thickness 2.2 ±0.08 1.8 Strain Load of wave spring (Testing height: 2.2 mm) 12 Thrust washer thickness — 0.1 0.25 1,010 N {103 kg} ±101 N {±10.3 kg} 859 N {87.6 kg} 3 ±0.1 2.7 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 Remedy Replace 19 SEN01783-00 10 Structure, function and maintenance standard 2nd, 3rd clutch A: B: C: 1. 2. 3. 4. 5. 6. 7. 2nd clutch oil port 3rd clutch oil port Lubricating oil port Lower gear (Number of teeth: 29) 2nd clutch gear (Number of teeth: 61) 2nd clutch 2nd and 3rd cylinders (Number of teeth: 77) 3rd clutch 3rd clutch gear (Number of teeth: 55 and 41) Lower shaft Unit: mm No. 8 9 Check item Clearance between lower shaft bearing and lower shaft (front) Clearance between lower shaft bearing and lower shaft (rear) 10 Clutch plate 11 Criteria Clutch disc Tolerance Standard size Remedy Shaft Hole Standard clearance Clearance limit 65 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — 60 +0.054 +0.044 –0.018 –0.015 –0.069 – –0.044 — Standard size Tolerance Repair limit Thickness 1.7 ±0.05 1.5 Strain — 0.1 0.15 Thickness 2.2 ±0.08 1.8 — 0.1 0.25 Load of wave spring 12 (Testing height: 2.2 mm) Strain 1,010 N {103 kg} ±101 N {±10.3 kg} 859 N {87.6 kg} 13 Thrust washer thickness 3 ±0.1 2.7 14 End play of 2nd clutch gear 0.35 – 0.85 15 End play of 3rd clutch gear 0.38 – 0.82 20 Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 4th clutch A: B: C: 1. 2. 3. 4. 4th clutch oil port Lubricating oil port Lubricating oil port Output gear (Number of teeth: 44) 4th clutch 4th cylinders (Number of teeth: 42) Output shaft Unit: mm No. 5 Check item Criteria Clearance between output shaft bearing and output shaft (front) 6 Clearance between output shaft bearing and output shaft (rear) 7 Clutch plate 8 Clutch disc 9 Load of wave spring (Testing height: 2.2 mm) Thickness Shaft Hole Standard clearance Clearance limit 65 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — 75 +0.030 +0.011 –0.018 –0.015 –0.045 – –0.011 — Standard size Tolerance Repair limit 1.7 ±0.05 1.5 Strain — 0.1 0.15 Thickness 2.2 ±0.08 1.8 Strain — 0.1 0.25 1,010 N {103 kg} ±101 N {±10.3 kg} 859 N {87.6 kg} 3 ±0.1 2.7 Inside diameter of seal ring contact surface of cylinder 70 +0.030 +0.030 70.1 Width of output shaft seal ring groove 3.2 +0.076 +0.030 3.5 10 Thrust washer thickness 11 Tolerance Standard size Remedy 12 End play of 4th clutch gear GD655-3E0, GD675-3E0 Replace 0.30 – 0.70 21 SEN01783-00 10 Structure, function and maintenance standard Operation of the disc clutch When clutch is "engaged" (fixed) q q q q 22 The oil sent from the ECMV flows through the oil passage of shaft (1), is pressure-fed to the back side of piston (2), and pushes piston (2) to the right. Piston (2) compresses plates (3) and discs (4) and the rotation of discs (4) is stopped by the frictional force. As the internal teeth of disc (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transfer the power as a unit. The oil is drained from oil drain hole (6), but the drain amount is less than the amount of oil supplied, so there is no influence on the actuation of the clutch. When clutch is "disengaged" (released) q q q q a When the oil sent from the ECMV is shut off, pressure of the oil acting on the back face of piston (2) goes down. Piston (2) is pushed back to the left by repulsive force of wave spring (7). The friction force between plates (3) and discs (4) is eliminated and shaft (1) and clutch gear (5) are released. When the clutch is released, the oil in the backside of piston is drained by the centrifugal force through oil drain hole (6) to prevent the clutch from being partially applied. Oil drain hole (6) is made of only with the 2nd, 3rd, and 4th clutches. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Power transmitting route Forward 1st gear speed FL clutch (3) and 1st clutch (11) are fixed hydraulically. o (from left bottom) The power from the torque O converter 1st clutch (11) O O Input shaft (1) 1st clutch gear (14) O O FL and R cylinders (2) 2nd and 3rd cylinders (20) O O FL clutch (3) Lower shaft (21) O O FL clutch gear (5) Lower gear (22) O O FH and 1st cylinders (12) (To right top) o O (To center top) o GD655-3E0, GD675-3E0 o (from center bottom) O Output gear (25) O Output shaft (26) 23 SEN01783-00 10 Structure, function and maintenance standard Forward 2nd gear speed FH clutch (10) and 1st clutch (11) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (7) O FH clutch gear (9) O FH clutch (10) O FH and 1st cylinders (12) O (To center top) o 24 o (from left bottom) O 1st clutch (11) O 1st clutch gear (14) O 2nd and 3rd cylinders (20) O Lower shaft (21) O Lower gear (22) O Output gear (25) O (To right top) o o (from center bottom) O Output shaft (26) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Forward 3rd gear speed FL clutch (3) and 2nd clutch (18) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (3) O FL clutch gear (5) O FH and 1st cylinders (12) O (To center top) o GD655-3E0, GD675-3E0 o (from left bottom) O Upper shaft (13) O Upper gear (15) O 2nd clutch gear (16) O 2nd clutch (18) O 2nd and 3rd cylinders (20) O Lower shaft (21) O (To right top) o o (from center bottom) O Lower gear (22) O Output gear (25) O Output shaft (26) 25 SEN01783-00 10 Structure, function and maintenance standard Forward 4th gear speed FH clutch (10) and 2nd clutch (18) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (7) O FH clutch gear (9) O FH clutch (10) O FH and 1st cylinders (12) O (To center top) o 26 o (from left bottom) O Upper shaft (13) O Upper gear (15) O 2nd clutch gear (16) O 2nd clutch (18) O 2nd and 3rd cylinders (20) O Lower shaft (21) O (To right top) o o (from center bottom) O Lower gear (22) O Output gear (25) O Output shaft (26) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Forward 5th gear speed FL clutch (3) and 3rd clutch (19) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (3) O FL clutch gear (5) O FH and 1st cylinders (12) O (To right top) o GD655-3E0, GD675-3E0 o (from left bottom) O 3rd clutch gear (17) O 3rd clutch (19) O 2nd and 3rd cylinders (20) O Lower shaft (21) O Lower gear (22) O Output gear (25) O Output shaft (26) 27 SEN01783-00 10 Structure, function and maintenance standard Forward 6th gear speed FH clutch (10) and 3rd clutch (19) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (7) O FH clutch gear (9) O FH clutch (10) O FH and 1st cylinders (12) O (To center top) o 28 o (from left bottom) O 3rd clutch gear (17) O 3rd clutch (19) O 2nd and 3rd cylinders (20) O Lower shaft (21) O Lower gear (22) O Output gear (25) O (To right top) o o (from center bottom) O Output shaft (26) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Forward 7th gear speed FL clutch (3) and 4th clutch (24) are fixed hydraulically. The power from the torque converter O Input shaft (1) O FL and R cylinders (2) O FL clutch (3) O FL clutch gear (5) O FH and 1st cylinders (12) O (To right top) o GD655-3E0, GD675-3E0 o (from left bottom) O 3rd clutch gear (17) O 4th clutch gear (23) O 4th clutch (24) O Output shaft (26) 29 SEN01783-00 10 Structure, function and maintenance standard Forward 8th gear speed FH clutch (10) and 4th clutch (24) are fixed hydraulically. The power from the torque converter O Input shaft (1) O Input gear (7) O FH clutch gear (9) O FH clutch (10) O FH and 1st cylinders (12) O (To right top) o 30 o (from left bottom) O 3rd clutch gear (17) O 4th clutch gear (23) O 4th clutch (24) O Output shaft (26) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Reverse 1st gear speed R clutch (4) and 1st clutch (11) are fixed hydraulically. o (from left bottom) The power from the torque O converter R idler gear (8) O (Output rotation is reversed Input shaft (1) through R idler gear (8).) O O FL and R cylinders (2) Upper gear (15) O O R clutch (4) Upper shaft (13) O O R clutch gear (6) FH and 1st cylinders (12) O O (To center top) o 1st clutch (11) O (To right top) o GD655-3E0, GD675-3E0 o (from center bottom) O 1st clutch gear (14) O 2nd and 3rd cylinders (20) O Lower shaft (21) O Lower gear (22) O Output gear (25) O Output shaft (26) 31 SEN01783-00 Transmission control valve 32 10 Structure, function and maintenance standard 1 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard A: B: C: D: E: F: G: H: J: From power train pump To torque converter control valve FL clutch oil pressure pickup port R clutch oil pressure pickup port FH clutch oil pressure pickup port 1st clutch oil pressure pickup port 2nd clutch oil pressure pickup port 3rd clutch oil pressure pickup port 4th clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7. 8. 9. FL clutch ECMV R clutch ECMV FH clutch ECMV 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 4th clutch ECMV Seat Last chance filter SEN01783-00 Operation table of ECMV ECMV Gear speed F1 FL F8 2nd 3rd 4th Q Q Q Q Q Q Q Q F6 F7 1st Q Q F4 F5 R Q F2 F3 FH Q Q Q Q Q R1 Q R2 Q R3 Q R4 Q Q Q Q Q N q q q GD655-3E0, GD675-3E0 The oil from the pump flows through the oil filter to the transmission front case. The oil is then diverged to the main relief circuit and clutch actuation circuit. 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. 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. 33 SEN01783-00 ECMV 10 Structure, function and maintenance standard 1 a a ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed. A: P: T: Dr: P1: To clutch From pump Drain Drain Clutch oil pressure pickup port 1. 2. 3. 4. 5. 6. 7. Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1) *1: 34 Clutch used Printing on nameplate Lockup, FL, FH, R, 1st, 2nd, 3rd, 4th A******* GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard ECMV for lockup clutch Outline q This valve acts to set the lockup clutch oil pressure 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 prevents 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. SEN01783-00 Operation When traveling in torque converter range Torque converter travel o direct travel When shifting gear (direct travel) q GD655-3E0, GD675-3E0 When traveling in torque converter range, current 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). 35 SEN01783-00 When traveling in direct range (Torque converter travel o direct travel) During filling q 36 When traveling in direct (lockup) range, current is supplied to proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. If the clutch is filled with oil, oil pressure detection valve (4) is operated, and fill switch (5) is turned "ON". 10 Structure, function and maintenance standard Pressure adjustment q As current is conducted to proportional solenoid (1), the solenoid generates thrust in proportion to the current. The pressure is settled as the sum of this thrust of the solenoid, thrust generated by the oil pressure in clutch port and the repulsive force of pressure control valve spring (2) is balanced. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard ECMV for gear speed clutch Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch. SEN01783-00 ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current – propulsion force characteristics of proportional solenoid Propulsion force – Hydraulic pressure characteristics of proportional solenoid Range A: Before shifting gear (When draining) Range B: During filling Range C: Pressure regulation Range D: During filling (During triggering) Point E: Start of filling Point F: Finish of filling a ECMV and fill switch q For each ECMV, 1 fill switch is installed. If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal. 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 SEN01783-00 Operation of ECMV q ECMV is controlled with the command current 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. 10 Structure, function and maintenance standard Before shifting gear [when draining] (Range A in chart) q Range A: Range B: Range C: Range D: Point E: Point F: a 38 Before shifting gear (When draining) During filling Pressure regulation During filling (During triggering) Start of filling Finish of filling 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 detection valve (4). 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 10 Structure, function and maintenance standard During filling (Range B in chart) q If current is applied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. This opens pump port (P) and clutch port (A) to feed oil in the clutch. When the clutch is filled with oil, pressure detection valve (4) actuates to turn "ON" fill switch (5). GD655-3E0, GD675-3E0 SEN01783-00 Pressure adjustment (Range C in chart) q As current is conducted to proportional solenoid (1), the solenoid generates thrust in proportion to the current. The pressure is settled as the sum of this thrust of the solenoid, thrust generated by the oil pressure in clutch port and the repulsive force of pressure control valve spring (2) is balanced. 39 SEN01783-00 10 Structure, function and maintenance standard Main relief valve and torque converter relief valve 1 Unit: mm No. 1 2 Check item Clearance between main relief valve and valve body Clearance between torque converter relief valve and valve body Criteria Standard size Tolerance Shaft Hole Standard clearance Clearance limit 28 –0.035 –0.045 +0.013 +0.013 0.035 – 0.058 0.078 22 –0.035 –0.045 +0.013 +0.013 0.035 – 0.058 0.078 Standard size 3 Main relief valve spring (outside) Remedy Repair limit Replace Free length Installed length 108 82.5 245 N {25.0 kg} 104.8 233 N {23.8 kg} Installed load Free length Installed load 4 Main relief valve spring (inside) 108 82.5 290 N {29.6 kg} 104.8 276 N {28.1 kg} 5 Torque converter relief valve spring 50 42 153 N {15.6 kg} 48.5 145 N {14.8 kg} 6. 7. 8. 9. 10. 11. Body Piston Torque converter relief valve Piston Main relief valve Seat 40 A: B: C: D: E: P1: P2: Drain (Torque converter relief) Drain From pump Drain To torque converter Main relief oil pressure pickup port Torque converter relief oil pressure pickup port GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Outline 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 pressure. 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} (At rated engine speed) SEN01783-00 Operation of main relief valve q The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1). q As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2) and the resulting resisting force pushes spool (1) leftward, opening ports (C) and (E). Above operation conducts the oil from port (E) to the torque converter. Operation Operation of torque converter relief valve q q The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3). As the oil pressure to the torque converter goes beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting resisting force pushes torque converter 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 SEN01783-00 Final drive 10 Structure, function and maintenance standard 1 Standard final drive (non-spin differential) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 42 Cage Non-spin differential Coupling Bevel pinion (Number of teeth: 12) Bevel gear (Number of teeth: 43) Shaft Sprocket (Number of teeth: 12) Breather Drain plug Oil filler tube GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Unit: mm No. Check item 11 Preload of bevel pinion bearing 12 Preload of bevel gear bearing 13 Backlash between bevel pinion and bevel gear GD655-3E0, GD675-3E0 Criteria Remedy Starting rotation torque: 8.7 – 11.7 Nm {0.89 – 1.19 kgm} Starting rotation torque: (Item 11) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} (after setting, measure at pinion bearing) Adjust Standard size 0.25 – 0.33 43 SEN01783-00 10 Structure, function and maintenance standard Planetary final drive (with differential lock) 1. 2. 3. 4. 5. 6. 7. 8. 9. 44 Shaft (Number of teeth: 24) Coupling Bevel pinion (Number of teeth: 12) Bevel gear (Number of teeth: 43) Shaft Sprocket (Number of teeth: 20) Plate Disc Piston 10. 11. 12. 13. 14. 15. 16. 17. 18. Gear (Number of teeth: 10) Gear (Number of teeth: 20) Gear (Number of teeth: 66) Gear (Number of teeth: 20) Breather Drain plug Solenoid valve for differential lock-up Oil supply pipe Grease fitting GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 Unit: mm No. Check item 19 Preload of bevel pinion bearing 20 Preload of bevel gear bearing Backlash between bevel pinion and 21 bevel gear GD655-3E0, GD675-3E0 Criteria Remedy Starting rotation torque: 8.7 – 11.7 Nm {0.89 – 1.19 kgm} Starting rotation torque: (Item 19) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} Adjust Standard size 0.25 – 0.33 45 SEN01783-00 10 Structure, function and maintenance standard Solenoid valve for differential lock-up Unit: mm No. Check item Criteria Differential oil pressure Standard (Differential oil temperature 50 ± 5°C, 16 between engine low idle (800 ± 50 2.84 – 3.1 MPa {29.0 – 31.6 kg/cm2} rpm) and high idle (2,225 ± 50 rpm)) 46 Remedy Limit Max. 2.84 MPa {29.0 kg/cm2} Adjust GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01783-00 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 differential. 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 differential can be installed. q The optional final drive has a differential lockup mechanism, which can be controlled with the switch from the operator’s seat. Operation (with differential lock-up) 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 (F6F8), the controller acts to automatically cancel the differential lock. q GD655-3E0, GD675-3E0 47 SEN01784-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01784-00 Steering system 10 Structure, function and maintenance standard 1 Steering hydraulic piping drawing1 1. 2. 3. 4. 5. 6. 7. 2 Steering valve Steering wheel Priority valve Accumulator charge valve Hydraulic tank Hydraulic pump Steering cylinder GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Steering valve (Q/Amp manual Orbit-roll type) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. SEN01784-00 1 Gland Valve body Check valve Gerotor Spacer Cover Spacer Drive shaft Sleeve Spool Center pin Center spring GD655-3E0, GD675-3E0 3 SEN01784-00 Outline The Q/Amp manual Orbit-roll used on this machine has a flow amplification function. This function is provided by the structure of the Orbit-roll valve and orifice. With this, the steering pump speed range varies to change the steering discharge amount; in particular, at high speed it has the characteristic of providing an amplified flow above the metering amount of the Gerotor (Variable ratio steering function). The Gerotor used for this function has the following features. q Fine compensation of the steering is possible at high speed to ensure stable steering. q Quick turns are possible when the machine is traveling at low speed or when it is stationary. q Emergency steering is possible with the Orbitroll control used independently. 4 10 Structure, function and maintenance standard 1. Variable ratio steering function The amount of oil pushed out of the steering pump, in other words, the steering discharge amount, varies according to the steering wheel speed. When the steering wheel is turned at low speed, the steering discharge is small; and when the steering wheel is turned at high speed, the steering discharge is large. For this reason, when the machine is traveling at high speed, if the steering wheel is turned at low speed, the steering discharge is small. This makes fine compensation of the steering possible, and enables superior travel at high speed. When the machine is stationary or traveling at low speed, if the steering wheel is turned at high speed, a large steering discharge is easily ensured, so quick turns are possible. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 2. SEN01784-00 Flow amplification function 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 cylinder. In this way, even with a small Orbitroll, a large amount of oil can be sent to the steering cylinder when traveling at high speed. q 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 characteristics 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 SEN01784-00 Structure q The shaft connected to the steering wheel meshes with the spline at the top of the spool and the spool (10) is fitted inside the sleeve (9). In addition, the spool and sleeve are connected by the center pin (7) (not touching the spool when the steering wheel is not being used). 6 10 Structure, function and maintenance standard q q The top of drive shaft (3) is engaged with center pin (7) and made one with sleeve (9). The bottom of drive shaft (3) is engaged with the spline of rotor (1) of the Gerotor set (combination of rotor (1) and stator (11)). Four ports in the valve body connect to the pump circuit, tank circuit, and circuits to the head and bottom ends of the steering cylinders. Also, a check valve inside the body connects 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. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01784-00 Connection between hand pump and sleeve q q q q q q The diagrams above show the connections with the sleeve ports connecting the suction and discharge ports of the Gerotor. 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. Simultaneously, ports (b), (d), (f), (h), (j), and (i) connect to the head end of the steering cylinder in the same way. 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. 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). 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. If the pump or engine fails, the suction and discharge 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 SEN01784-00 q 10 Structure, function and maintenance standard 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 proportional 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 8 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 delivered to the cylinder. This action is performed at each port. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01784-00 Role of centering spring q The centering spring (4) consists of 4 Xshaped 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 generated 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 pressure 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 NEUTRAL position. GD655-3E0, GD675-3E0 9 SEN01784-00 Priority valve 1. 2. 3. 4. 5. 6. 7. 10 10 Structure, function and maintenance standard 1 Relief valve Orifice Spring Spool Orifice Orifice Fitting face of accumulator pressure governor valve P : From pump EF : To accumulator pressure governor valve (To work equipment circuit) CF1 : To accumulator pressure governor valve (To brake circuit) CF2 : To steering valve LS1 : To accumulator pressure governor valve (To pilot circuit) LS2 : To accumulator pressure governor valve (To pilot circuit) T : To accumulator pressure governor valve (To hydraulic tank) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01784-00 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 circuit 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 neutral, 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 abnormal pressure. GD655-3E0, GD675-3E0 11 SEN01784-00 10 Structure, function and maintenance standard Valve circuit diagram 12 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Operation 1. When engine is stopped Spool (1) is pushed to the right by spring (2). In this condition, port (CF) is opened to the maximum and port (EF) is closed. 2. SEN01784-00 When this flow from port (CF) passes through orifices (e) and (b), a difference in pressure of approx. 0.98 MPa {10 kg/cm 2 } is formed on both sides of the orifices. The pressure in 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 orifice (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 chamber (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)) 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 pressure 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 accumulator 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 accumulator 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 SEN01784-00 3. 10 Structure, function and maintenance standard 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 necessary 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 pressure on both sides of the variable throttle inside the steering valve becomes smaller, and the pressure in the LS circuit rises. (The pressure 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 steering 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 10 Structure, function and maintenance standard 4. Steering cylinder at end of stroke When the steering cylinder reaches the end of its stroke, and the operator continues to turn the steering wheel, the flow of oil to the cylinder is stopped regardless of the opening of the steering valve. There is no flow of oil, so the CF and LS pressure rise together with the pressure at pump port (P), and at the same time, pressure chamber (B) and chamber (C) also rise, and spool (1) is moved to the right. If pressure chamber (C) goes above 15.21 MPa {155 kg/cm2}, steering relief valve opens and drains the oil in chamber (C). Because of this flow of oil, a difference in pressure on both sides of orifices (b) and (e) is created, and pressure chamber (C) becomes lower than pressure chamber (B). As a result, spool (1) moves to the left to a position where the oil flow inside the spool is 1 l/ min. Spool (1) stabilizes at a position where portion (d) of the spool is throttled, and this prevents 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 chamber (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 maximum of 15.21 MPa {155 kg/cm2}. GD655-3E0, GD675-3E0 SEN01784-00 5. Steering valve at neutral, work equipment control lever operated If the work equipment control lever is operated, pressure (PA) changes to 1.96 – 24.5 MPa {20 – 250 kg/cm2}. However, the steering valve is at neutral, so the condition is the same as in Section 2. "When engine is started (steering and main control valves at neutral)", and the force acting on spool (1) is constant regardless of pressure (PA). If pressure (PA) rises, the pressure at port (CF) also rises momentarily, and the amount of oil flowing through orifice (b) increases. A large difference in pressure is created, so spool (1) is pushed to the left, and the area of the opening of portion (d) becomes smaller. The oil flow is automatically adjusted so that only 1 l/min. flows. 15 SEN01784-00 6. Steering, work equipment operated simultaneously 1) When the load on steering circuit is higher than the load on the work equipment circuit, the actuation condition is the same as in Section 3, "Steering operated (main control valve at neutral)". Port (CF) is at the same pressure as chamber (A), and port (EF) is throttled by portion (I) until it balances at the same pressure as the pressure needed for the work equipment. In other words, the oil pressure in the main circuit for the pump is sent to the steering circuit. 16 10 Structure, function and maintenance standard 2) When the load on the steering circuit is less than the load on the work equipment circuit, circuit (CF) satisfies the demand for the amount of oil and oil pressure for the steering, but compared with port (CF), when the pressure at port (EF) is higher, the flow of oil passing through portion (d) increases and the pressure in chamber (B) rises. As a result, spool (1) moves to the left, and the area of the opening at portion (d) becomes smaller. It balances so that the pressure and oil flow matches the needs 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. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 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 completed. 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 circuit 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) SEN01784-00 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 steering valve discharges an amount of oil to match the operating angle of the steering, so when an oil flow matching the operating 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 SEN01784-00 10 Structure, function and maintenance standard Accumulator pressure governor valve 1. 2. 3. 4. 18 Pressure governor valve Solenoid (For releasing LS pressure) Accumulator shuttle valve Fitting face of priority valve 1 EF1 EF2 A1 A2 LSS LSP1 LSP2 T : : : : : : : : To left main control valve To right main control valve To brake control To brake control From steering valve From parking and bank control valve From LS pressure reducing valve To hydraulic tank EF CF1 LS1 LS2 T : : : : : From priority valve From priority valve From priority valve From priority valve From priority valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01784-00 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 pressure in the brake accumulator. The accumulator 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 (particularly 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 SEN01784-00 Front axle 1. 2. 3. 4. 5. 6. 7. 20 Tie rod Steering cylinder Support axle Leaning rod Leaning cylinder Bracket Hub shaft 10 Structure, function and maintenance standard 1 Specifications Toe-in: –5 mm Camber: 0° GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01784-00 Unit: mm No. Check item Criteria Standard size 8 Clearance between center pin and bushing 55 Tolerance Remedy Standard clearance Clearance limit Shaft Hole –0.030 –0.076 +0.197 +0.137 0.167 – 0.273 3.0 9 Clearance between king pin and bushing 45 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 2.0 10 Clearance between axle end pin and bushing 45 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 2.0 11 Clearance between ball joint and bushing 55 –0.060 –0.090 +0.020 +0.020 0.060 – 0.110 1.0 12 Preload of hub bearing GD655-3E0, GD675-3E0 Start to rotate: 157 – 196 Nm {16 – 20 kgm} Replace bushing Adjust 21 SEN01784-00 Function of front axle 1. Lessening blade angling and up-and-down movement q The front axle is fixed in the center with a center pin to the frame so that it can oscillate 16°. This, like the tandem system, restricts the up-and-down movement of the blade to a minimum when one front wheel rides over an object or falls into a hole. When the front wheel rides over an object (height-H), the center point of the front axle rises H/2, as shown in drawing. Because of possible rocking of front axle blade movement rises only H/4 while holding its horizontal posture. Unless the whole oscillating range (left, right 16°) of the front axle is used, the blade moves upand-down holding its horizontal posture. 22 10 Structure, function and maintenance standard 2. Prevention of side slipping of front wheels (leaning system) q The front wheels can be tilted to the left or right. This is called the leaning system, and is to prevent the front wheel from slipping sidewards and to reduce the turning radius. Operations with blade at propulsion angle are frequent among grader operations. In proportion to the propulsion angle a side slipping force acts on the blade to cause side slipping. q Also, the distribution of weight on the front and rear wheels is about 3:7, and when the blade cuts into the ground, the load on the front wheels decreases and it is easier 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. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 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 distance 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 operation by turning a steering wheel in the same direction. Leaning angle is 16° GD655-3E0, GD675-3E0 SEN01784-00 23 SEN01785-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01785-00 10 Structure, function and maintenance standard Brake system Blake hydraulic piping 1. 2. 3. 4. 2 Wheel brake (front) Wheel brake (rear) Accumulator (front) Accumulator (rear) 1 1 5. 6. 7. 8. Stop lamp switch Brake valve Accumulator pressure governor valve Priority valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01785-00 9. Slack adjuster (front) 10. Slack adjuster (rear) GD655-3E0, GD675-3E0 3 SEN01785-00 Brake valve 1. 2. 3. Piston Spool Spool A B PA PB T : : : : : 4 10 Structure, function and maintenance standard 1 To rear slack adjuster To front slack adjuster To accumulator To accumulator To hydraulic tank GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01785-00 Unit: mm No. Check item 4 Clearance between pedal mounting hole and bracket 5 Clearance between roller and pin 6 Outside diameter of roller Criteria Standard size Tolerance Remedy Shaft Hole Standard clearance Clearance limit — –0.025 –0.075 +0.013 +0.013 0.175 – 0.025 0.25 — –0.025 –0.075 +0.013 +0.013 0.175 – 0.025 0.25 Size Tolerance Repair limit 30 0 –0.5 29.2 Standard size 7 8 9 Control spring Control spring Return spring 10 Spring 11 Return spring GD655-3E0, GD675-3E0 Repair limit Free length Installed height Installed load Free length Permissible load 54.5 49.7 80 N {8.1 kg} 33.4 — 29.1 — — 28.7 — 86.2 58 60.8 N {6.2 kg} 78 — 17 16.5 17.7 N {1.8 kg} 16.2 — 31.5 19.5 16.7 N {1.7 kg} 28 — Replace 5 SEN01785-00 Operation 1. Depressing the brake pedal Depressing the brake pedal causes the piston (1) and spring (2) to make the spools (3, 4) move down. The port a (port b) close and oil now flows from port PA to port A and port PB and port B. Oil then flows from port A (port B) to the rear (front) slack adjuster and actuate the brakes. When this happens, the slack adjuster makes the flow of oil to the left and right brakes the same to ensure the same braking effect on both the left and right sides. 6 10 Structure, function and maintenance standard 2. When the operation is in balance at the rear (front) brake When the brake cylinder-fills with oil and the pressure between port PA (port PB) and port A (port B) increase, the oil entering port e (port f) from orifice c (orifice d) of spool (3) (spool 4) up against the spring (2), and port PA (port PB) and port A (port B) are shut off. When this situation happens, drain port a remains closed. Thus, the oil entering the rear (front) slack adjuster is held and the brake remains actuated. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 3. SEN01785-00 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 SEN01785-00 10 Structure, function and maintenance standard Wheel brake 1. 2. 1 Guide pin Brake piston Unit: mm No. Criteria Remedy Size Repair limit 3.8 ± 0.1 3.3 ± 0.1 3 Disc thickness 4 Plate thickness 2.3 ± 0.08 — 5 Total thickness of disc and plate 26.7 ± 0.8 24.7 ± 0.8 Standard size Repair limit 6 8 Check item Return spring Free length Installed height Installed load Installed load 76.5 60.5 75.0 654 N {66.7 kg} Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Slack adjuster 1. 2. 3. Bleeder Check valve Piston A: B: Inlet port Outlet port SEN01785-00 1 Function q The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. The slack adjuster provides a fixed time lag when applying the brakes. Specifications Piston actuation pressure: 0.01 ± 0.01 MPa {0.1 ± 0.1 kg/cm2} Check valve cracking pressure: 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 No. 4 Check item Clearance between body and piston Criteria Standard size — Tolerance Remedy Shaft Hole Standard clearance Clearance limit –0.030 –0.076 +0.074 +0.074 0.030 – 0.150 0.25 Standard size 5 6 Slack adjuster spring Spring GD655-3E0, GD675-3E0 Repair limit Free length Installed height Installed load Free length Permissible load 198 38 43.2 N {4.4 kg} — — 38.8 33 66.7 N {6.8 kg} — — Replace 9 SEN01785-00 10 Structure, function and maintenance standard Operation 1. Brake pedal depressed q Before depressing the brake pedal, the piston is returned by the distance of stroke S (full stroke). Depressing the brake pedal discharges the oil from the brake valve and flows from port P of the slack adjuster. 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. q 2. Depressing the brake pedal further and the oil pressure discharged from the brake valve goes above the set pressure, the check valve (3) opens and the pressure applied to port C acts as the braking force. Thus, when the brake is applied, the time lag is a fixed value. Brake pedal released Releasing the brake pedal causes the piston (4) to return by action of the brake return spring (8) by an amount equivalent to the oil for stroke S. Thus, the brake releases. In other words, the return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant, regardless of disc brake wear. q q 10 Depressing the brake pedal moves the brake piston (7) a distance of stroke S. In this condition, the closer the clearance between the brake piston and the disc is to zero (0), the greater the braking force becomes. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Accumulator 1. 2. 3. 4. SEN01785-00 1 Valve assembly Top cover Cylinder Piston Function The accumulator is installed between the pressure governor valve and brake valve. Cylinder (3) is charged with nitrogen gas. Even after the engine stops, braking force is kept by the pressure of the nitrogen gas compressed by free piston (4). The compressibility of the nitrogen gas absorbs the pulsating pressure from the hydraulic pump. GD655-3E0, GD675-3E0 Specifications Gas used: Nitrogen Amount of gas: 3000 cc Gas charging pressure (at 20 ± 5°C): 3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2} 11 SEN01785-00 10 Structure, function and maintenance standard Parking brake 1. 2. 3. 4. 1 Outline q The parking brake is a disc type, and is installed to the final drive. q The parking brake is applied mechanically by the force of the spring inside the caliper, and is 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. Piston Adjustment bolt Caliper Disc Unit: mm No. 5 6 12 Check item Disc thickness Pad thickness Criteria Remedy Standard size Repair limit 10.4 9.4 12.5 9.5 (Remaining thickness when pad groove has disappeared) Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Parking brake and bank control valve 1. 2. Solenoid valve for bank control Solenoid valve for parking brake AP : B1 : B2 : QC : ST : BR : T1 : T2 : T3 : T4 : From accumulator To bank control cylinder To bank control cylinder To parking brake (Plugged) (Plugged) (Plugged) To hydraulic tank To accumulator pressure governor valve (Plugged) GD655-3E0, GD675-3E0 SEN01785-00 1 Outline The parking brake control valve has the solenoid valves for parking brake and bank control. If the solenoid for the parking brake is turned on, hydraulic oil is supplied to the parking brake to release the parking brake. If the solenoid for the bank control is turned on, hydraulic oil is supplied to the bank control cylinder to move the lock pin in the pulling out direction. 13 SEN01786-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 Undercarriage and frame Undercarriage and frame ................................................................................................................................ 2 Tandem drive........................................................................................................................................ 2 Main frame ........................................................................................................................................... 5 GD655-3E0, GD675-3E0 1 SEN01786-00 10 Structure, function and maintenance standard Undercarriage and frame 1 Tandem drive 1 For standard final drive 1. 2. 3. 4. 5. 6. 7. Breather Hub shaft Sprocket (45 teeth) Disc Plate Oil level plug Drain plug Unit: mm No. 8 9 2 Check Item Hub bearing preload Extension of chain (10 links) Criteria Remedy Turning torque: 11 – 16 Nm {1.15 – 1.65 kgm} Size Repair limit 317.5 322.26 Adjust Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01786-00 For planetary final drive 1. 2. 3. 4. 5. 6. 7. Breather Hub shaft Sprocket (20 teeth) Disc Plate Oil level plug Drain plug Unit: mm No. Check Item 8 Hub bearing preload 9 Extension of chain (10 links) GD655-3E0, GD675-3E0 Criteria Remedy Turning torque: 11 – 16 Nm {1.15 – 1.65 kgm} Adjust Size Repair limit 508.0 515.62 Replace 3 SEN01786-00 10 Structure, function and maintenance standard 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 upand-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. 4 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. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Main frame 1. 2. 3. 4. 5. SEN01786-00 1 Articulate cylinder Front frame Rear frame Upper center pin Lower center pin GD655-3E0, GD675-3E0 5 SEN01787-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01787-00 10 Structure, function and maintenance standard Hydraulic system 1 Work equipment hydraulic piping drawing 1 Main piping (1/2) 1. 2. 3. 4. 2 Main control valve (left) Main control valve (right) Hydraulic tank Hydraulic pump 5. 6. 7. LS pressure reducing valve Priority valve Accumulator pressure governor valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Main piping (2/2) GD655-3E0, GD675-3E0 3 SEN01787-00 10 Structure, function and maintenance standard High pressure piping (1/3) Left side 4 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard High pressure piping (2/3) Right side GD655-3E0, GD675-3E0 SEN01787-00 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Pilot check valve – drawbar shift Pilot check valve – leaning Pilot check valve – articulate Pilot check valve – right blade lift Main control valve – right Articulate cylinder Main control valve Pilot check valve – left blade lift Pilot check valve – blade tip Blade lift cylinder 5 SEN01787-00 10 Structure, function and maintenance standard High pressure piping (3/3) 1. 2. 3. 6 Swivel joint Drawbar side-shift cylinder Blade tilt cylinder GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Lifter lock piping 1. 2. 3. Parking and bank control valve Bank pin Lifter bracket GD655-3E0, GD675-3E0 Function The lifter bracket (3) is fixed by the bank pin (2). 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. 7 SEN01787-00 10 Structure, function and maintenance standard Bank pin 1. 2. 3. 4. 5. 6. 8 Pin Piston Cover Shaft Case Bushing GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01787-00 9 SEN01787-00 Hydraulic pump PA PA1 PA2 PA3 PDA PD1 PD2 PEN PLS PS 10 : : : : : : : : : : Pump discharge Pump pressure detection port LS pump pressure port Drain port Pump air bleed Pump drain Pump drain Control pressure detection port LS pressure input Pump suction 10 Structure, function and maintenance standard 1 a The main pump consists of one unit formed by the pump, servo piston, PC valve, and LS valve. The explanation in Structure, function and maintenance standard is divided into two parts: the pump and the PC valve + LS valve. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SEN01787-00 Shaft Cradle Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston GD655-3E0, GD675-3E0 11 SEN01787-00 10 Structure, function and maintenance standard 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 Cylinder block (7) is supported to shaft (1) by spline a, and shaft (1) is supported by the front and rear bearings. q The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface A, and shoe (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). q 12 q q Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8). GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 (The diagram shows chamber F at the end of the suction process and chamber E at the end of the discharge process.) Operation 1. Operation of pump 1) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface 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) 2) Center line X of rocker cam (4) maintains swash plate angle (α) in relation to the axial direction of cylinder block (7), and 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 4) 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.) In other words, there is a proportional relationship between swash plate angle (α) and the pump discharge amount. 13 SEN01787-00 2. q q q q q 14 10 Structure, function and maintenance standard Control of discharge amount 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). Servo piston (1) moves in reciprocating directions 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. Servo piston (1) has different pressure receiving areas on its top and bottom. Main pump discharge pressure (self pressure) PA is constantly led in the pressure chamber on the small-diameter piston side (upper side). LS valve output pressure PEN is led in the pressure chamber on the large-diameter piston side (lower side). 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 smalldiameter piston to that of the large-diameter piston. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01787-00 15 SEN01787-00 10 Structure, function and maintenance standard PC valve, LS valve, servo piston PA PA2 PA3 PLS : : : : Pump discharge pressure LS pump pressure inlet Drain LS pressure inlet Servo piston 1. Servo piston 2. Lever 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 10 Structure, function and maintenance standard SEN01787-00 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 control valve and control valve outlet pressure PLS and controls main pump discharge amount Q. (PA2 is called the LS pump pressure, PLS is called the LS pressure, and dPLS is called the LS differential pressure.) q In other words, the pressure loss (= LS differential 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 differential pressure dPLS and pump discharge amount Q changes as shown in the figure below. GD655-3E0, GD675-3E0 17 SEN01787-00 10 Structure, function and maintenance standard Operation 1. When control valve is at HOLD position 18 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q q q SEN01787-00 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. 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. Before the engine is started, servo piston (1) is pushed down (toward the maximum swash plate angle side) by spring (3). 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 connected 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}. 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). Pump pressure PA is constantly led in chamber Y on the small diameter side of servo piston (1). Since the force applied to the large diameter side is larger because of the area difference 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 SEN01787-00 2. 20 10 Structure, function and maintenance standard When opening area of control valve is maximum (lever operated fully) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q q SEN01787-00 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 pressure PLS is reduced. 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. 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. 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). 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 SEN01787-00 3. 22 10 Structure, function and maintenance standard When opening area of control valve is small (small movement of lever) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q SEN01787-00 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 pressure dPLS between LS pump pressure PA2 and LS pressure PLS is increased. 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). In other words, on the basis of the LS set differential 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 control 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 differential pressure dPLS lowers below 2.35 MPa {24 kg/cm 2 }, the swash plate angle increases. GD655-3E0, GD675-3E0 23 SEN01787-00 4. 24 10 Structure, function and maintenance standard When pump flow is amount demanded by control valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q q q q Let the pressure receiving area on the large diameter side of servo piston (1) be A1, the pressure receiving area on the small diameter side be A2, the pressure applied on the large diameter side be PEN, and the pressure applied on the small diameter side be PA. When the oil flow from the pump reaches the flow rate demanded by the control valve, LS pump pressure PA2 applied to port b of the LS valve is balanced with the resultant of "LS pressure PLS and the force of spring (13)" applied to spring chamber a and spool (14) is stopped at an almost intermediate point. As a result, ports c, d, and e are opened almost equally. Then, some of the pump oil from port c flows in port d and the other is drained through port e into the tank case. Accordingly, the pressure of this oil is reduced to about 1/2 and applied to chamber X on the large diameter side of servo piston (1). At this time, since the relationship of the pressure 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 control valve is balanced with the pump discharge. 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). In other words, when the open area of the control 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}. 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 temporarily. Accordingly, the LS valve operates to increase the pump discharge. After the swash plate angle increases to 3/4, however, LS differential pressure dPLS rises to 2.35 MPa {24 kg/cm2} and the spool is balanced at this point. GD655-3E0, GD675-3E0 SEN01787-00 PC valve Function q When discharge pressure PA rises and the open area of the control valve is wide, the LS valve increases pump discharge amount Q. At this time, the PC valve controls discharge amount Q so that it will not exceed a certain level according to discharge pressure PA. That is, the PC valve performs approximate equal horsepower control so that the pump absorption horsepower will not exceed the engine horsepower. q In other words, when the load increases and pump discharge pressure PA rises during work, pump discharge amount Q is reduced. When pump discharge pressure PA lowers, pump discharge amount is increased. q The relationship between pump discharge pressure PA and pump discharge amount Q is shown below. 25 SEN01787-00 10 Structure, function and maintenance standard Operation 1. When actuator load is large (pump discharge pressure PA is high) 26 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q q q q q SEN01787-00 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). 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. 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. 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 chamber X on the large diameter side of servo piston (1) to stop servo piston (1). 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). If servo piston (1) moves up, piston (4) is moved through lever (2) to the right. Accordingly, springs (5) and (7) are compressed and they push back spool (8) to the right. If spool (8) is pushed back to the right and ports f and g are disconnected, servo piston (1) stops moving up. 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 SEN01787-00 2. 28 10 Structure, function and maintenance standard When actuator load becomes smaller (pump discharge pressure PA drops) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q SEN01787-00 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). As a result, ports g and f are disconnected and port f is connected to the drain circuit. 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. 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 SEN01787-00 3. 30 10 Structure, function and maintenance standard Action of spring GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q q q SEN01787-00 The forces of springs (5) and (7) of the PC valve vary with the swash plate angle of the pump. 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). 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. The pump absorption torque curve showing the relationship between pump discharge pressure PA and discharge amount Q is broken as shown in the following figure, since the spring constants of springs (5) and (7) are different. 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 SEN01787-00 32 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Main control valve SEN01787-00 1 Left 4-spool valve (1/3) P PP LS T TS A1 B1 : Pump port (from main pump) : PP port (to main pump) : LS port (to main pump) : Tank port (to tank) : Seal drain port (to tank) : To left blade lift cylinder bottom : To left blade lift cylinder head GD655-3E0, GD675-3E0 A2 B2 A3 B3 A4 B4 : To blade shift cylinder bottom : To blade shift cylinder head : To circle motor : To circle motor : To blade tilt cylinder bottom : To blade tilt cylinder head 33 SEN01787-00 10 Structure, function and maintenance standard Left 4-spool valve (2/3) 34 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Left 4-spool valve (3/3) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (Left blade lift) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle) Pressure compensation valve F (blade tilt) Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) LS bypass plug Unload valve Safety-suction valve Unit: mm No. Check item Criteria Remedy Standard size 16 Spool return spring 17 Spool return spring (circle) Repair limit Free length x OD Installed length 56.27 x 20.1 25.4 34.8 N {3.55 kg} — 27.9 N {2.84 kg} 87.7 x 19.7 25.4 34.8 N {3.55 kg} — 27.9 N {2.84 kg} Installed load Free length Installed load 18 Pressure compensation valve spring (R) 23 x 8.4 15 6.9 N {0.7 kg} — 5.52 N {0.56 kg} 19 Pressure compensation valve spring (F) 15.4 x 6 8 7.45 N {0.76 kg} — 5.98 N {0.61 kg} 35.25 x 19 20.5 137 N {14 kg} — 110 N {11.2 kg} 20 Unload valve spring GD655-3E0, GD675-3E0 Replace spring if damaged or deformed 35 SEN01787-00 36 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Right 4-spool valve (1/3) P PP LS T TS A1 B1 A2 B2 A3 B3 A4 B4 : Pump port (from main pump) : PP port (to main pump) : LS port (to main pump) : Tank port (to tank) : Seal drain port (to tank) : To right blade lift cylinder bottom : To left blade lift cylinder head : To leaning cylinder head : To leaning cylinder bottom : To articulating cylinder head : To articulating cylinder bottom : To drawbar shift cylinder head : To drawbar shift cylinder bottom GD655-3E0, GD675-3E0 37 SEN01787-00 10 Structure, function and maintenance standard Right 4-spool valve (2/3) 38 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Right 4-spool valve (3/3) 1. 2. 3. 4. 5. 6. 7. Spool (right blade lift) Spool (leaning) Spool (articulating) Spool (drawbar shift) Pressure compensation valve F (right blade lift) Pressure compensation valve F (leaning) Pressure compensation valve F (articulating) 8. 9. 10. 11. 12. Pressure compensation valve F (drawbar shift) Pressure compensation valve R (drawbar shift) Pressure compensation valve R (articulating) Pressure compensation valve R (leaning) Pressure compensation valve R (right blade lift) 13. LS relief valve 14. Main relief valve Unit: mm No. Check item Criteria Remedy Standard size 15 Spool return spring Repair limit Free length x OD Installed length 56.27 x 20.1 25.4 34.8 N {3.55 kg} — 27.8 N {2.84 kg} Installed load Free length Installed load 16 Pressure compensation valve spring (R) 23 x 8.4 15 6.9 N {0.7 kg} — 5.52 N {0.56 kg} 17 Pressure compensation valve spring (F) 15.4 x 6 8 7.45 N {0.76 kg} — 5.98 N {0.61 kg} GD655-3E0, GD675-3E0 Replace spring if damaged or deformed 39 SEN01787-00 40 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Left 5-spool valve (1/3) P PP LS T TS A1 B1 A2 : : : : : : : : Pump port (from main pump) PP port (to main pump) LS port (to main pump) Tank port (to tank) Seal drain port (to tank) To ripper cylinder bottom To ripper cylinder head To left blade lift cylinder bottom GD655-3E0, GD675-3E0 B2 A3 B3 A4 B4 A5 B5 : : : : : : : To left blade lift cylinder head To blade shift cylinder bottom To blade shift cylinder head To circle motor To circle motor To blade tilt cylinder bottom To blade tilt cylinder head 41 SEN01787-00 10 Structure, function and maintenance standard Left 5-spool valve (2/3) 42 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Left 5-spool valve (3/3) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (left blade lift) Spool (ripper) Pressure compensation valve F (ripper) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle) Pressure compensation valve F (blade tilt) Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) Pressure compensation valve (ripper) LS bypass plug Unload valve Safety-suction valve Safety-suction valve Unit: mm No. Check item Criteria Remedy Standard size 20 Spool return spring 21 Spool return spring Repair limit Free length x OD Installed length 56.27 x 20.1 25.4 34.8 N {3.55 kg} — 27.9 N {2.84 kg} 87.7 x 19.7 25.4 34.8 N {3.55 kg} — 27.9 N {2.84 kg} — 5.52 N {0.56 kg} Installed load Free length Installed load Pressure compensation 22 valve spring (R) 23 x 8.4 15 6.9 N {0.7 kg} Pressure compensation valve spring (F) 15.4 x 6 8 7.45 N {0.76 kg} — 5.98 N {0.61 kg} 35.25 x 19 20.5 137 N {14 kg} — 110 N {11.2 kg} 18.9 x 8.4 15 15.68 N {1.6 kg} — 12.54 N {1.28 kg} 23 24 Unload valve spring 25 Pressure compensation valve spring (R) GD655-3E0, GD675-3E0 Replace spring if damaged or deformed 43 SEN01787-00 CLSS 10 Structure, function and maintenance standard 1 1. Outline of CLSS Features CLSS stands for Closed center Load Sensing System, 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 single 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 10 Structure, function and maintenance standard SEN01787-00 2. Basic principle 1) Control of pump swash plate angle q The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure (dPLS) (the difference between pump pressure (PP) and control valve outlet port LS pressure (PLS)) (load pressure of actuator) is constant. 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 SEN01787-00 2) 46 10 Structure, function and maintenance standard 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). Accordingly, the oil flow from the pump is distributed (compensated) in proportion to the open areas (S1) and (S2) of the operated valves. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 3. Functions and operation of each valve Hydraulic circuits and names of valves 1. 2. 3. Unload valve LS relief valve Main relief valve GD655-3E0, GD675-3E0 4. 5. 6. Pressure compensation valve Safety-suction valve LS pressure reducing valve 47 SEN01787-00 10 Structure, function and maintenance standard Unload valve 1) When control valve is at HOLD Function q When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. 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 is acting on area S1, and at the right end of spool (1), pump pressure PP is acting on area S2, and LS pressure PLS is acting on area S3. q When the control valve is at HOLD, LS pressure PLS is not generated, so only pump discharge 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 circuit T through the drill hole. q In this way, pump discharge pressure PP is set to 2.9 MPa {30 kg/cm2}. 48 PP PLS T A B : : : : : Pump circuit LS circuit Tank circuit To valves To pump LS valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 2) During fine control of control valve operation 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 pressure 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 valve, LS pressure PLS is generated and acts on area S3 at the right end of spool (1). When this happens, the area of the opening of the control valve spool is small, so there is a big 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 PP PLS T A B : Pump circuit : LS circuit : Tank circuit : To valves : To pump LS valve 49 SEN01787-00 10 Structure, function and maintenance standard 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 minimum 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 circuit. Operation When the control valve is operated to a larger stroke, LS pressure PLS is generated and acts on area S3 at the right end of spool (1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure PLS and pump discharge 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. q 50 PP PLS T A B : Pump circuit : LS circuit : Tank circuit : To valves : To pump LS valve GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 Introduction of LS pressure Function q The LS pressure is the actuator load pressure at the outlet port end of the control valve. Operation q When spool (1) is operated, pump pressure PP flows from flow control valve (2) and notch a in a spool (1) through bridge passage b to actuator circuit A. q At the same time, reducing valve (3) also moves to the right, so pump pressure PP has its pressure reduced by the pressure loss at notch C. It is introduced to LS circuit PLS, and then goes to spring chamber PLS1. 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 q It actually reduces pump pressure PP at reducing valve (3) of the pressure compensation valve to the same pressure as actuation circuit pressure A, and sends it to the LS circuit PLS. q Actuator circuit pressure PA (=A) acts on the left end of reducing valve (3); the reduced pump pressure PP acts on the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pressure of spring chamber PLS1 are the same. Pump pressure PP reduced at notch C becomes actuator circuit pressure A and is taken to LS circuit pressure PLS. q 51 SEN01787-00 10 Structure, function and maintenance standard Pressure compensation valve Function q During compound operations, if the load pressure 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 side) becomes higher during compound operations, the oil flow in actuator circuit A on this side (left side) tries to increase. q If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, 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 pressure loss between PP and PPA on both sides of flow control valve (2) are the same. 52 q In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools used during compound operations is the same, so the pump flow is divided in proportions to the area of opening of notch a of each spool. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 LS bypass plug Function q It releases the residual pressure of LS pressure 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 pressure 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 from clearance filter a (formed by the clearance between LS bypass plug (1) and the valve body) through orifice b and flows to the bank circuit T. GD655-3E0, GD675-3E0 PP PLS T A B : Pump circuit : LS circuit : Tank circuit : To valves : To pump LS valve 53 SEN01787-00 10 Structure, function and maintenance standard LS relief valve A: B: L.H. control valve (unload section) R.H. control valve (LS relief section) Function q Even if the LS orifice functions, if another actuator is relieved in compound operation, the actuator speed is lower than in single operation. q When another actuator is relieved, if the speed lowers remarkably, the working performance is lowered. To prevent this, the LS relief valve is employed. q A small pilot relief valve installed to the LS circuit controls the maximum pressure. q The unload valve works as a relief 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 Operation q If the LS circuit pressure PLS goes up and reaches the set pressure of LS relief valve (1), PLS is kept constant. q When this happens, the pump circuit PP is set to PLS + the spring force of unload valve (2). q The relief amount of pump circuit PP flows from unload valve (2) to circuit T. (Pump minimum swash plate flow). q Relief valve (3) is a backup for the LS relief valve and has the function of a surge absorption valve. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01787-00 LS reducing valve A: B: C: D: E: To main control valve To pump LS port From steering valve LS port From steering valve P port To pump PP port Function q The LS differential pressure (dPLS) of the main control valve and the steering valve are set to different values; the value for the main control valve is higher. q If the steering is operated with this circuit, the pump discharges the maximum flow. The excess oil is relieved by the unload valve of the main control valve, so there is a large energy loss. To prevent this, the steering LS pressure 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 Operation q Pump pressure PCF and LS pressure PLS (st) are brought in from the steering valve. q The PCF pressure is taken as the base pressure, and LS pressure PLS (v) reduced from PLS (st) by the load of spring (1) is taken to the main control valve. q Check valve (2) is installed to prevent the PP pressure when the work equipment is operated from entering the steering valve. 55 SEN01788-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01788-00 10 Structure, function and maintenance standard Scarifier .............................................................................................................................................. 32 Ripper................................................................................................................................................. 34 2 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01788-00 3 SEN01788-00 10 Structure, function and maintenance standard Work equipment Work equipment control 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Steering adjustment knob R.H. blade lift lever Leaning lever Articulation lever Drawbar shift lever Blade rotation lever Blade tilt lever Blade shift lever Ripper, scarifier lever (if equipped) L.H. blade lift lever Steering control tilt pedal 1 1 Outline Steering tilt mechanism: Rotate the steering adjustment knob (1) to release the lock. Set steering to a suitable position, and then tighten the lever. Console box tilt mechanism: Depress the steering control tilt pedal (11) and adjust the console box. The tilt angle can be adjusted steplessly to a maximum of 24°. 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 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01788-00 5 SEN01788-00 Hydraulic system 10 Structure, function and maintenance standard 1 Structure of system Outline of system 1. Hydraulic pump 1) The hydraulic oil inside the hydraulic tank passes through the hydraulic pump and is sent to the priority valve. 2) The hydraulic pump is the source of hydraulic power for the steering brake, work equipment, parking brake, and bank control lock pin. When there is a demand from the equipment, it generates an oil flow of the necessary amount and pressure to match the demands of the equipment. = LS pressure + control pressure 2.35 MPa {24 kg/cm2} At neutral, the steering LS pressure 0.8 to 1.1 MPa {8 to 11 kg/cm 2 } + 2.35 MPa {24 kg/cm2} + pressure loss in piping = 3.24 to 3.63 MPa (33 to 37 kg/cm2}. 6 3) 4) The pressure loss caused by flow resistance in the piping varies according to the temperature. At low temperature, the necessary control pressure may be lacking, and the necessary flow may not be provided. But to prevent this, pressure PP which is close to each piece of equipment is brought to the hydraulic pump, and the pressure generated by the hydraulic pump is controlled so that the differential pressure between PP and LS is 2.35 MPa {24 kg/cm2}. In addition, it checks the pressure and discharge amount of the hydraulic pump, and ensures the resilience of the engine when there is compound operation or when there is excessive load caused by PQ control when controlling at PQ = constant value. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 5) 2. When there are no demands for oil from the steering or work equipment (the system is at neutral), the swash plate in the hydraulic pump is held at a position where a fixed minimum flow is discharged so that the hydraulic pump can respond swiftly to any rapid operation of the steering wheel or work equipment. Steering circuit 1) The priority valve is provided to ensure the necessary oil flow and to give priority to the oil flow in the steering brake system, which is closely related to safety, rather than to the work equipment. 2) The steering valve is an energy saving closed center type which lets the hydraulic oil flow only when necessary. When the steering is not being operated, it stops the flow of oil. When the steering wheel is operated, the pressure (LS pressure) passes through the accumulator pressure governor valve o LS pressure regulator valve, and goes to the servo valve of the hydraulic pump to ensure the necessary flow. It also generates pressure so that Pb = LS pressure + 2.35 MPa {24 kg/cm2} + pressure loss in piping. At the same time, the LS pressure is transmitted to the priority valve through the accumulator pressure governor valve. Priority is given to the steering circuit by keeping the spool at a position where it can provide the necessary oil flow to the steering circuit, regardless of whether there is any demand for oil from the work equipment. 3) The steering valve is a Q-Amp type that provides good control at high speed and can also ensure the steering ability if the engine should stall or if any problem should occur in the variable pump. 4) The maximum pressure in the steering circuit is determined by the relief valve inside the priority valve. It is different from the hydraulic pressure for the work equipment. GD655-3E0, GD675-3E0 SEN01788-00 3. Brake circuit 1) The oil that is given priority and ensured for the circuit has its pressure raised to the necessary pressure by the priority valve and is charged in the brake accumulators inside the piping of the two systems. 2) If the brake is used and the pressure goes down to 9.36 MPa {95 kg/cm2 } the accumulator pressure governor valve is actuated and the brake accumulator is charged to the specified pressure of 13.4 MPa {137 kg/cm2}. 3) Even after the engine is stopped, braking is possible for a limited time using the pressure inside the brake accumulator. 4) When the brake accumulator pressure goes down, the force releasing the parking brake is reduced and the parking brake is automatically applied by the force of the spring. If the machine is stopped for a certain time, the parking brake is automatically applied, and it can only be released by starting the engine. 5) In postures such as the bank cut posture or shoulder reach posture, when changing the posture of the work equipment, the lifter lock pin is removed and installed. When doing this, the accumulator is also used as the source of hydraulic power. 6) The brakes are the most important devices for ensuring safety, so charging always starts immediately after the engine is started. But particularly when starting in 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 charged during the starting operation, there will be an excessive load on the hydraulic pump, and this will make it difficult to start the engine. To prevent this, an electromagnetic LS pressure release valve is installed in the accumulator pressure governor valve. This cancels the charging of the accumulator when the starting motor is cranking and makes it easier to start the engine. 7 SEN01788-00 4. LS pressure regulator valve 1) To improve the response when the steering is operated suddenly and to ensure a quick response for the work equipment, a specified minimum flow of oil is discharged from the hydraulic pump, so an unload valve is installed to the control valve. 2) When the steering is operated, the steering LS pressure rises and the pump discharge pressure is increased. For this reason, the steering Pb pressure also rises, but the function of the priority valve sends the excess oil used for the steering to the control valve. When this happens, if the control valve is open, this excess oil flow is relieved by the unload valve and returns to the tank. This causes an energy los s, s o when the steer ing brak e i s charged and the oil is not being used for the work equipment, a signal is sent to the unload valve. The control valve is set to on-load and shuts off the flow of oil back to the hydraulic tank to prevent loss of energy. 3) The internal shuttle valve transmits the higher of the steering brake charge LS pressure and the work equipment LS pressure to the pump to make it possible to carry out simultaneous operations. 4) The excess oil flow for the steering brake is sent to the control valve. 10 Structure, function and maintenance standard 5. Control valve 1) The control valve is closed center type, so at neutral when the work equipment is not being used, the hydraulic oil returns from the unload valve to the hydraulic tank. The unload pressure 3.1 MPa {32 kg/cm 2 } when the engine is at low idle and 3.5 MPa {35 kg/cm2} when it is at full throttle. 2) When the work equipment control valve lever is operated, the pressure at the valve inlet side is transmitted to the hydraulic pump as Pb. At the same time, the maximum pressure for the work equipment load passes through the LS line and is transmitted to the hydraulic pump, so the necessary oil flow is sent from the hydraulic pump. 3) At the hydraulic relief, the upper limit for the LS pressure is determined by the LS relief valve. The control valve is a closed center load sensing valve, and has a proportional flow and proportional dividing pressure compensation function. It also has a built-in unload valve, LS relief valve, a surge absorption valve. This gives it the following features. q The operating effort is light and the lever travel is short. q It is possible to adjust each work equipment to the optimum cylinder set speed. 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 features. 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 operations or when there is a large load. 8 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Hydraulic tank 1. 2. 3. 4. 5. SEN01788-00 1 Filter Filter by-pass Oil filler Oil filler strainer Strainer GD655-3E0, GD675-3E0 9 SEN01788-00 Swivel joint 1. 2. 3. 4. 5. 10 Plug Plate Cover Shaft Rotor 10 Structure, function and maintenance standard 1 a. b. c. d. Blade tilt cylinder head Blade tilt cylinder bottom Blade shift cylinder head Blade shift cylinder bottom GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Pilot check valve SEN01788-00 1 For blade lift (right), leaning, articulating, drawbar shift 1. 2. 3. 4. 5. Piston Check valve Body Piston Check valve A: B: C: D: From control valve From control valve To cylinder head To cylinder bottom Operation When the hydraulic cylinder is extended, the control 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 SEN01788-00 10 Structure, function and maintenance standard For blade lift (left) 1. 2. 3. 4. 5. Check valve Plug Body Piston Relief valve The check valve with safety valve prevents hydraulic 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 position and the drawbar is shifted to the side, the drawbar 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 equipment and relieves the shock. 12 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 For blade tilt, ripper 1. 2. 3. 4. 5. Check valve Piston Body Check valve Relief valve The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. 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 cylinder 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 chamber B1 to relieve the shock. GD655-3E0, GD675-3E0 13 SEN01788-00 10 Structure, function and maintenance standard For scarifier 1. 2. 3. 4. 5. Check valve Piston Body Check valve Relief valve A1: A2: B1: B2: From control valve From control valve To cylinder head To cylinder bottom The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. 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 chamber 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 pressure 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 equipment and relieves the shock. 14 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Blade accumulator, float valve 1 SEN01788-00 q The blade float can be used in clearing fresh snow. It allows only the weight of the work equipment to push against the snow, making it possible to carry out operations following the ups and downs on the road surface, allowing fresh snow to be cleared effectively at high speed, while increasing the safety of the operation. A: B: C: D: From main control valve From main control valve To cylinder head To cylinder bottom Outline q The blade accumulator prevents excessive load and pushing up by the blade in propulsion work on roads where there are many buried rocks. In this way, it improves the durability of the work equipment and blade, and reduces operator fatigue. The blade accumulator can also be used effectively in snow-clearing operations on compacted 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. 2. 3. 4. 5. Body Piston Check valve Check valve Piston GD655-3E0, GD675-3E0 15 SEN01788-00 10 Structure, function and maintenance standard For blade lift (right) 1. 2. 3. 4. 5. 16 Body Check valve Piston Piston Check valve A: B: C: D: From main control valve From main control valve To cylinder head To cylinder bottom GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 Accumulator For blade float 1. 2. 3. 4. Valve assembly Top cover Cylinder Cylinder Function When oil pressure is applied to the blade cylinder, the pressure oil flows to the accumulator through the solenoid valve and the oil flows into cylinder (4). Thereby, nitrogen gas is compressed and piston moves upper side. Consequently, the shock 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 cylinder 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 Specifications Gas used: Nitrogen gas Amount of gas: 1,000 cc Gas charging pressure: 2.0 ± 0.1 MPa {20 ± 1.0 kg/cm2} (at 20 ± 5°C) 17 SEN01788-00 Blade float device 18 10 Structure, function and maintenance standard 1 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 1. 2. 3. 4. 5. 6. SEN01788-00 Blade float and accumulator switch Blade accumulator, float valve Blade lift cylinder Proximity switch Blade lift control valve 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 connected 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 SEN01788-00 Circle rotation motor 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 20 10 Structure, function and maintenance standard 1 Output shaft Flange Shaft seal Taper roller bearing for heavy loads Main drive O-ring Giroller Valve drive Wear compensation mechanism valve PF1/2 rolling port Check valve Valve plate GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 Outline The circle rotation motor is a small, compact lowspeed 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 reduction 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 stable 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 positions 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 SEN01788-00 10 Structure, function and maintenance standard Hydraulic cylinder 1 Unit: mm No. Check item Criteria Standard size 1 Shaft Hole Standard clearance Clearance limit 35 –0.025 –0.087 +0.132 +0.006 0.031 – 0.219 0.519 Blade lift 50 –0.025 –0.087 +0.164 +0.007 0.032 – 0.251 0.551 Blade side shift 50 –0.025 –0.087 +0.164 +0.007 0.032 – 0.251 0.551 45 –0.025 –0.087 +0.152 +0.007 0.032 – 0.239 0.539 40 –0.025 –0.087 +0.132 +0.006 0.031 – 0.219 0.519 Articulate 50 –0.025 –0.087 +0.164 +0.007 0.032 – 0.251 0.551 Blade tilt 40 –0.025 –0.087 +0.132 +0.006 0.031 – 0.219 0.519 Scarifier 50 –0.025 –0.087 +0.164 +0.007 0.032 – 0.251 0.551 Ripper 55 –0.030 –0.104 +0.163 +0.006 0.036 – 0.267 0.567 Standard clearance Clearance limit Clearance between Drawbar shift piston rod and bushing Leaning Steering Clearance between piston rod support Blade lift and bushing Blade side shift Drawbar shift 22 Remedy Steering Standard size 2 Tolerance Tolerance Shaft Hole 55 –0.06 –0.09 +0.02 +0.02 0.06 – 0.11 1.0 80 –0.05 –0.15 +0.1 +0.1 0.05 – 0.25 1.0 40 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 80 –0.05 –0.15 +0.1 +0.1 0.05 – 0.25 1.0 Replace bushing GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 Unit: mm No. 2 3 4 Check item Remedy Leaning 50 –0.025 –0.064 +0.142 +0.080 0.104 – 0.206 1.0 Articulate 50 –0.025 –0.064 +0.142 +0.080 0.104 – 0.206 1.0 Clearance between piston rod support Blade tilt and bushing 40 –0.025 –0.064 –0.012 –0.012 0.013 – 0.064 1.0 Scarifier 50 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 Ripper 60 –0.030 –0.076 +0.174 +0.100 0.13 – 0.25 1.0 Steering 35 –0.025 –0.064 –0.012 –0.012 0.013 – 0.064 1.0 Blade lift 45 –0.080 –0.142 +0.062 +0.062 0.080 – 0.204 1.0 Blade side shift 40 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 80 –0.05 –0.15 +0.10 +0.10 0.05 – 0.25 1.0 45 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 50 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 Blade tilt 40 –0.025 –0.064 –0.012 –0.012 0.013 – 0.064 1.0 Scarifier 50 –0.025 –0.064 +0.142 +0.080 0.105 – 0.206 1.0 Ripper 60 –0.100 –0.174 +0.174 +0.100 0.200 – 0.348 1.0 Clearance between Drawbar shift cylinder bottom (yoke, support ball Leaning joint, support) and bushing Articulate Piston nut tightening torque 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 shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41) Drawbar shift 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41) Leaning 618 ± 61.8 Nm {63 ± 6.3 kgm} (width across flats: 41) Replace bushing 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 Ripper 5 Criteria 785 ± 78.5 Nm {80 ± 8 kgm} (width across flats: 46) 1770 ± 77 Nm {180 ± 18 kgm} (width across flats: 60) Steering 392 ± 39.2 Nm {40 ± 4 kgm} Blade lift 588 ± 58.8 Nm {60 ± 6 kgm} Blade side shift 588 ± 58.8 Nm {60 ± 6 kgm} Cylinder head tight- Drawbar shift ening torque Leaning 588 ± 58.8 Nm {60 ± 6 kgm} 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 Retighten 23 SEN01788-00 Circle, drawbar 24 10 Structure, function and maintenance standard 1 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. SEN01788-00 Outline q The drawbar is an important piece of equipment which supports the circle and blade. If ball joint (6) is worn, use shim (5) to adjust the clearance at the joint so that there is no excessive play. q When adjusting the clearance at the contact portions of guides (15), (18), and (20), adjust with shims (14), (17), and (19), and adjustment bolt (13). q There are two cylinders installed in the lifter for moving the blade device. Brackets (7) and (9) are installed by the guide, which is welded to the main frame. They can be revolved by revolving the guide by extracting a pin (11) controlled from the operator's seat. There are four insertion holes altogether for the pin stopping revolution. Holes b, c and d, e are used for the blade to make a bank cut to left or right. 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 clearance between the bracket and the guide welded to the frame can be adjusted with shims (8). Circle Drawbar Blade lift cylinder Drawbar side shift cylinder Shim Ball joint Lifter bracket (Upper) Shim Lifter bracket (Lower) Yoke Pin Bushing Adjustment bolt Shim Guide Bolt Shim Guide Shim Guide Unit: mm No. Check item 21 Wear of drawbar ball joint end 22 Clearance between yoke and bushing 23 Axial clearance of yoke 24 Clearance between circle and drawbar GD655-3E0, GD675-3E0 Criteria Standard size Tolerance Remedy Shaft Hole Standard clearance Clearance limit 150 –0.050 –0.100 +0.100 +0.100 0.050 – 0.200 — 75 –0.030 –0.076 +0.220 +0.160 0.190 – 0.296 0.6 Adjust or replace Replace bushing Standard clearance Clearance limit 0.8 to 1.3 2.0 Replace yoke or bushing 0 to 3.0 1.0 to 2.0 Adjust or replace 25 SEN01788-00 Blade 1. 2. 26 Adjuster Blade tilt cylinder 10 Structure, function and maintenance standard 1 3. 4. Drawbar side-shift cylinder Blade side-shift cylinder GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 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 cutting angle of the blade. Adjustment can be made freely between 32° and 81° using a single 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 No. Check item 5 Wear of cutting edge 6 Wear of side edge 7a 7b 8a Wear of blade rail Wear of blade rail 8b guide Criteria Remedy Standard size Repair limit From blade holder: 32 From blade holder: 10 From blade holder: 48 From blade holder: 25 Height 368 364 Thickness 25 21 Height 8 5 Width of groove 25 33 GD655-3E0, GD675-3E0 Replace 27 SEN01788-00 Circle rotation gear 1. 2. 3. 4. 5. 6. 28 10 Structure, function and maintenance standard 1 Drain plug Worm wheel Oil filler plug Joint Shear pin Worm gear GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01788-00 Unit: mm No. 7 Check item Clearance between worm wheel shaft and bushing 8 Clearance between worm wheel shaft and bushing 9 Backlash between worm and worm wheel 10 Clearance between pinion gear and wear plate 11 Pinion gear wear 12 Wormshaft bearing preload GD655-3E0, GD675-3E0 Criteria Tolerance Standard size Remedy Standard clearance Clearance limit +0.057 +0.010 0.281 – 0.02 0.4 +0.057 +0.010 0.052 – 0.025 0.4 Shaft Hole 75 +0.291 +0.077 75 +0.035 +0.005 Standard clearance Clearance limit 0.3 – 0.4 2.0 0.1 – 0.5 0.6 Standard size Repair limit 25 20 Starting torque: 2.9 – 7.8 Nm {0.3 – 0.8 kgm} when worm wheel is not meshed Replace bushing Replace Adjust Replace Adjust 29 SEN01788-00 10 Structure, function and maintenance standard With slip clutch 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 30 Floating seal Shaft Case Worm wheel Plate Disc Spring Cover Shim Pinion gear Drain plug Worm gear shaft Oil motor Outline q The circle rotation gear is driven by an oil motor connected to worm gear shaft (12). q Pinion gear shaft (2) has a clutch mechanism, and if an abnormal rotating force is transmitted from the blade, disc (6) slips to prevent breakage of the blade. q The clutch pressure of this clutch mechanism is adjusted by the thickness of shim (9). GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01788-00 31 SEN01788-00 Scarifier 32 10 Structure, function and maintenance standard 1 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 1. 2. 3. 4. SEN01788-00 Lift arm Scarifier cylinder Scarifier body Wedge Unit: mm No. Check item 5 Tooth wear 6 Point tooth wear GD655-3E0, GD675-3E0 Criteria Remedy Standard size Repair limit 450 330 450 407 Replace tooth Replace point 33 SEN01788-00 10 Structure, function and maintenance standard Ripper 1. 2. 3. 4. 1 Outline Ripper lifting height and digging depth can be controlled with ripper cylinder (4). Since the point tips cut into the ground under the load of the ripper’s heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier. Bracket Rod Shank Ripper cylinder q Unit: mm No. 5 Check item Clearance between pin and bushing Criteria Tolerance Remedy Shaft Hole Standard clearance Clearance limit 50 –0.025 –0.050 +0.142 +0.080 0.105 – 0.292 0.5 Standard size 6 Clearance between pin and bushing 60 –0.030 –0.076 +0.054 +0.054 0.03 – 0.13 0.5 7 Clearance between trunnion and bushing 60 –0.100 –0.174 +0.174 +0.100 0.200 – 0.348 0.5 8 Point wear 34 Standard size Repair limit 290 150 Replace GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01788-00 35 SEN01789-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 Cab and its attachments Cab and its attachments ................................................................................................................................. 2 Air conditioner (If equipped) ................................................................................................................. 2 GD655-3E0, GD675-3E0 1 SEN01789-00 10 Structure, function and maintenance standard Cab and its attachments Air conditioner (If equipped) 1. 2. 3. 2 1 1 Condenser Air conditioner compressor Receiver-dryer GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard 4. SEN01789-00 Air conditioner unit 4a. Hot water heater 4b. Evaporator 4c. Blower unit GD655-3E0, GD675-3E0 3 SEN01790-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 10 Structure, function and maintenance standard 1 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 SEN01790-00 10 Structure, function and maintenance standard Electrical system Engine starting circuit 1 1 Function q The neutral safety circuit is employed to secure safety when the engine is started. This circuit allows the engine to start only when the gear shift lever is in the P (Parking) position. q When the engine is started, storing pressure in the accumulator of the brake circuit is canceled temporarily to reduce the load of the hydraulic pump on the engine for the ease of starting of the engine. In addition, the engine start auxiliary switch is installed to reduce the load on the engine and stabilize the engine rotation when the engine is started at low temperature. Operation If the starting switch is turned from the OFF position to the START position, a current flows from starting switch terminal BR to the battery relay to "close" the contacts of the battery relay. q The current flows in the holding coil of the solenoid 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 q 2 q q q current also flows in the pull-in coil of the fuel shut-off solenoid to supply the fuel at the maximum rate so that the engine will be started easily. If the gear shift lever is in the P (Parking) position, a current flows from gear shift lever terminal 6 to the neutral relay coil to connect contacts 1 and 2 of the neutral relay. While the gear shift lever is not in the P (Parking) position, the current does not flow from gear shift lever terminal 6. Accordingly, any current does not flow in the neutral relay coil and the starting circuit is not formed. A current flows from starting switch terminal C through neutral relay terminals 1 and 2 to the starting motor to start the engine. At this time, another current flows from starting switch terminal C to the engine startup solenoid to temporarily cancel storing pressure in the brake accumulator so that the load on the engine will be reduced and the engine will be started easily. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard q q q SEN01790-00 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 solenoid is turned OFF, the solenoid is returned to the normal state, and the hydraulic pump starts storing pressure in the accumulator. A current keeps flowing from starting switch terminal ACC to the engine controller. If the engine start auxiliary switch is held even after the engine is started in when the temperature 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 SEN01790-00 Engine stop circuit 10 Structure, function and maintenance standard 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 immediately to stop the engine. 4 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Preheat circuit SEN01790-00 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 position while the preheater is in operation, the engine controller turns the heater relay OFF to stop preheating. GD655-3E0, GD675-3E0 5 SEN01790-00 Automatic shift control system 10 Structure, function and maintenance standard 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 transmission 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 10 Structure, function and maintenance standard GD655-3E0, GD675-3E0 SEN01790-00 7 SEN01790-00 Transmission controller 10 Structure, function and maintenance standard 1 Outline q This transmission controller controls the system using a built-in computer, which has the following functions: q Upshifts and downshifts in relation to the accelerator pedal angle. q Drives and controls the torque converter lockup solenoid. q Installed separately from the gear shift lever. 8 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 Connector signals CN1 CN3 Pin No. Signal name Input/ Output Pin No. CN4 Signal name Input/ Output Pin No. Signal name Input/ Output 1 NC Output 1 Transmission temperature sensor Input 1 Transmission output revolution sensor Input 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) 10 NC Output 10 Differential select switch Input 10 RS232C GND – Output Torque converter temperature 11 sensor Input 11 NC – Input 12 NC Input 12 NC – Input 13 Inching potentio meter (if equipped) Input 14 NC Input CN5 15 NC Input Pin No. Output 1 GND (puls) Input Differential control relay 11 (if equipped) 12 GND 13 Power supply (+24V) CN2 Pin No. Signal name Input/ Output 16 GND (sensor) Signal name Output Input/ Output Output Input 17 GND (sensor) Output 2 Transmission input revolution sensor 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 9 Differential switch (if equipped) Input 1 Power supply for A-solenoid 2 Input/ Output 8 FH solenoid (+) Output 24 SNET 9 R solenoid (+) Output 25 FL clutch oil pressure switch Input 10 GND (puls) Output 26 R clutch oil pressure switch Input 11 Tier 3 select switch Input 10 Lock up solenoid (+) Output 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 14 1st, 3rd solenoid (–) Input Differential oil temperature 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/ Output 17 Lock-up switch Input 16 2nd, 4th solenoid (–) Input 32 SNET 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 switch Input 21 PGND Input GD655-3E0, GD675-3E0 9 SEN01790-00 ECMV Speed range F1 10 Structure, function and maintenance standard Clutches used Low F8 10 2nd 3rd 4th Q Q Q Q Q Q Q Q F6 F7 1st Q Q F4 F5 R Q F2 F3 High Q Q Q Q Q R1 Q R2 Q R3 Q R4 Q Q Q Q Q GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 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 converter 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 Speed Range Lever position N N A F1 F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 B F2 B F3 B F4 B F5 B F6 B F7 B F8 B R1 B R2 B R3 A R4 A Auto Speed Range Lever position N N A F1 F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 A F2 F3 A A F4 A F5 A C F6 A C C F7 A C C C F8 A C C C R1 R2 R3 R4 C A A A A A = Does not lockup B = Locks up C = Locks up automatically GD655-3E0, GD675-3E0 11 SEN01790-00 10 Structure, function and maintenance standard 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 10 Structure, function and maintenance standard Automatic gear shift wiring diagram q Transmission mode switch: Auto q Lever position: F5 – F8 SEN01790-00 Overrun prevention function q When shifting gears suddenly, the transmission may enter a speed range that does not match the position of the lever. This action prevents 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 When the gear shift lever is at F1, the transmission 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. q 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 diagram below, by turning the lock-up switch ON/ OFF. Transmission mode switch Auto F1 F2 Standard output Manual Standard output F3 F4 F5 F6 High output High output F7 F8 GD655-3E0, GD675-3E0 13 SEN01790-00 Monitor 10 Structure, function and maintenance standard 1 Monitor panel 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Engine coolant temperature gauge Torque converter oil temperature gauge Turn signal pilot lamp Engine tachometer Head lamp high beam pilot lamp Articulation gauge Working pilot lamp Speedometer Shift indicator Fuel gauge Parking brake pilot lamp Brake oil pressure caution lamp Engine coolant temperature caution lamp Engine oil pressure caution lamp Engine preheating pilot lamp PRM SET pilot lamp Differential oil temperature caution lamp (if equipped) 18. Torque converter oil temperature caution lamp 19. Battery charge circuit caution lamp 14 20. 21. 22. 23. 24. 25. 26. 27. Differential lock pilot lamp (if equipped) Maintenance caution lamp Water separator monitor Lift arm lock pin pilot lamp (if equipped) Blade accumulator pilot lamp (if equipped) Blade float pilot lamp (if equipped) Central caution lamp Character display Right side panel 28. Starting switch 29. Hazard lamp switch 30. Working lamp switch (if equipped) 31. Blade accumulator/float switch (if equipped) 32. Cigarette lighter 33. Lift arm lock switch 34. Front wiper switch (top) GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 Monitor items display Category Symbol Caution Pilot GD655-3E0, GD675-3E0 Item indicated Indicated range Description Differential oil temperature More than 120° C Torque converter oil temperature More than 110° C Brake oil pressure Less than 4.2 MPa {42.5 kg/cm2} Battery charge When charge is defective Engine oil pressure Less than 49 kPa {0.5 kg/cm2} Turn signal indicator When operated Parking brake When operated Head lamp beam When operated Blade float When operated Lights up when blade accumulator/float switch is at FLOAT Engine preheating When electricity flows in the preheating circuit While starting, lights up When auto preheating is activated Off when normal, lights up when problem detected Lights up when operated 15 SEN01790-00 Category 10 Structure, function and maintenance standard Symbol Item indicated Indicated range Description Blade accumulator When operated Lights up when blade accumulator/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 — Engine coolant temperature Displays while starting switch is ON Indicator shows engine coolant temperature — Articulate Displays while starting switch is ON Indicator shows angle — Fuel Displays while starting switch is ON Torque converter oil temperature Displays while starting switch is ON Indicator shows torque converter oil temperature Gauges — Speedometer — Speedometer Displays while starting switch is ON Indicator shows vehicle speed Message center — Message center Digital display: displays speed range, error code, travel speed 16 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Sensors SEN01790-00 1 Accelerator pedal 1. 2. Pedal Sensor GD655-3E0, GD675-3E0 17 SEN01790-00 10 Structure, function and maintenance standard Engine coolant temperature sensor Torque converter oil temperature sensor (for machine monitor) 1. 2. 3. Connector Plug 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 installed to the engine cylinder block. As the engine temperature changes, so does the sensor’s resistance. The gauge on the monitor panel moves to indicate the engine temperature. q The torque converter oil temperature sensor is installed to the torque converter outlet port on the transmission. If it senses the torque converter outlet oil temperature, its resistance changes. The resistance is converted into temperature and displayed on the monitor panel. Brake oil pressure switch 1. 2. 3. 18 Pressure sensor Cable Connector Function This electronic switch uses a semiconductor. 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. q GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 Transmission speed sensor 1. 2. 3. 4. Sensor Locknut Wiring harness Connector Function q Two transmission speed sensors are screwed into the transmission case: one sensor detects 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 transmission. Differential oil temperature sensor 1. 2. 3. Sensor Wiring harness Connector GD655-3E0, GD675-3E0 Function q The differential oil temperature sensor is a 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 signal is sent to the transmission controller and is also used to control the transmission. 19 SEN01790-00 10 Structure, function and maintenance standard Hydraulic oil temperature sensor Transmission oil temperature sensor Torque converter oil temperature sensor (for transmission controller) 1. 2. 3. 4. Thermistor Plug Wiring harness Connector Function q The hydraulic oil sensor, transmission oil temperature sensor, and torque converter oil temperature 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. 20 Lever Function q The articulation sensor is installed to the center 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. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 Fuel level gauge sensor 1. 2. 3. 4. Float Arm Variable resistor Connector GD655-3E0, GD675-3E0 Function q The fuel level gauge sensor is installed to the rear side of the fuel tank and its float moves up 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. 21 SEN01790-00 10 Structure, function and maintenance standard Inching pedal potentiometer 1. 2. 3. 4. 5. 6. 7. 22 Connector Case Shaft Element Bearing Contact Mold Function q This sensor is installed to the inching pedal. The sensor detects the pedal angle when depressing the pedal. q Inside the potentiometer, the pedal angle is converted into a voltage signal. A variable resistor adjusts the 5 volt source signal as the pedal angle changes. The adjusted voltage signal is now sent to the transmission controller. GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard Communication controller SEN01790-00 1 Connector signal Deutsch-40P [CR 310] Pin No. Signal name Input/Output Pin No. Signal name Input/Output 1 PWR_IN_batt Input 21 GND_PWR 2 PWR_CTR_key Input 22 PWR_OUT_5V 3 PWR_CTR_ext Input 23 NC 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 7 NC Output 27 NC 8 Output accel Output 28 COMM_CAN_H_0 9 NC Output 29 NC 10 NC Output 30 PWR_IN_bry — Output Input Input Output Input/Output Output 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 Input 37 NC Input/Output 38 COMM_CAN_L_0 Input/Output 17 NC 18 S_NET Input/Output 19 NC Input 39 CAN0_SH Input/Output 20 NC Input 40 GND_ACT — GD655-3E0, GD675-3E0 23 SEN01790-00 10 Structure, function and maintenance standard KOMTRAX terminal system (if equipped) q 1 The KOMTRAX terminal transmits various kinds of machine information wirelessly. Persons 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 terminal system includes the following. 1) Travel history 2) Service meter and others. 24 GD655-3E0, GD675-3E0 10 Structure, function and maintenance standard SEN01790-00 KOMTRAX communication mode TC300 1. 2. 3. 4. DRC connector (40 poles) connecting part (Not connected) GPS antenna connector connecting part Orbcomm Outline q The KOMTRAX terminal can obtain various kinds of machine information from network signals or input signals in the machine, and transmit 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 No. Signal name Input/Output Pin No. Signal name Input/Output 1 (If equipped) Input 21 Inspection mode 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) — 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) 10 (If equipped) 26 (If equipped) Input — — Input — 29 (If equipped) — Input/Output 30 (If equipped) Output 11 (If equipped) — 31 (If equipped) (5V max) 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 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 will occur GD655-3E0, GD675-3E0 Input Input — — *: Never connect to NC or malfunctions or failure will occur 25 SEN01834-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 Category Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Check item Rotation speed Measurement condition • Engine coolant temperature: Within operating range High idle Low idle Engine • All speed range • Ambient temperature: 20°C Exhaust gas color • Engine coolant temperature: Within operating range 2,225 ± 50 2,225 ± 50 825 ± 50 825 ± 50 1,900 1,900 At sudden acceleration At high idle Intake valve Max. 650 Bosch index Max. 2.5 Max. 2.5 Max. 1.0 Max. 2.0 • Engine coolant temperature: Within operating kPa range {mmH2O} • At rated output Exhaust valve At rating At low idle 107 {800} Max. 650 Blow-by pressure • All speed range (In oil pan) Service limit value °C • At cold Oil temperature Standard value for new machine kPa 133 – 173 {mmHg} {1,000 – 1,300} Valve clearance • SAE15W-40 oil Engine oil pressure • Engine coolant temperature: Within operating range 2 rpm Rated speed Intake air pressure • At rated output (Boost pressure) • On aftercooler outlet side Exhaust temperature Unit mm MPa {kg/cm2} °C 0.305 0.152 – 0.559 0.559 0.381 – 0.813 Max. 1.6 {Max. 160} Max. 2.55 {Max. 260} 0.34 – 0.59 {3.5 – 6.0} Min. 0.21 {Min. 2.1} Min. 0.15 {Min. 1.5} Min. 0.08 {Min. 0.8} 80 – 110 Max. 120 GD655-3E0, GD675-3E0 20 Standard value table SEN01834-00 Standard value table for chassis 1 Strokes of lever, pedal and steering wheel Category Check item Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Unit Standard value for new machine Service limit value mm 56 ± 10 — 87 ± 10 — 0 — 178 ± 5 — Height (Pressed) 91 ± 5 — PoN 35 ± 5 — N o F1 30 ± 5 — F1 o F2 30 ± 5 — F2 o F3 30 ± 5 — F3 o F4 30 ± 5 — 30 ± 5 — 30 ± 5 — 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 — Rotation 6–7 — mm 0 – 10 — 58 ± 4 58 ± 10 Max. 5 — Measurement condition Accelerator pedal • Amount of up-down movement of tip of pedal Inching pedal • Engine stopped • Tip of pedal • Stroke: Between released position – pressed position • Play: At released position • Height: Released position and pressed position above floor level Gear shift lever Steering wheel Brake pedal • Engine stopped • Tip of lever Stroke Play Height (Released) F4 o F5 F5 o F6 • Engine at low idle Number of • Float front wheels rotations • Number of rotations: Between steering stroke ends • Play: Between rotation start point of steering wheel and point Play where wheels start turning • Engine stopped • Tip of pedal • Stroke: Between released position – braking position • Play: At released position mm mm Stroke mm Play Left blade lift cylinder lever N o Forward N o Reverse 22 ± 2.2 — Scarifier lever N o Forward N o Reverse 22 ± 2.2 — 22 ± 2.2 — Blade rotation lever • Engine stopped • At center of lever knob N o Forward N o Reverse mm Articulation lever N o Forward N o Reverse 22 ± 2.2 — Drawbar side shift lever N o Forward N o Reverse 22 ± 2.2 — GD655-3E0, GD675-3E0 3 SEN01834-00 Operating efforts of lever, pedal and steering wheel Strokes of lever, pedal and steering wheel Category 4 Check item 20 Standard value table Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Measurement condition N o Forward N o Reverse Power tilt lever Leaning lever Blade side shift lever Unit • Engine stopped • At center of lever knob N o Forward N o Reverse N o Forward N o Reverse Service limit value 22 ± 2.2 — 22 ± 2.2 — 22 ± 2.2 — 22 ± 2.2 — mm N o Forward N o Reverse Right blade lift cylinder lever Standard value for new machine Accelerator pedal • Engine stopped • At 150 mm from center of pedal rotation • Max. value in travel between low and high N {kg} Max. 69 {Max. 7} — Inching pedal • Engine stopped • At 150 mm from center of pedal rotation • Max. value in stroke N {kg} Max. 93 {Max. 9.5} — PoN Max. 39 {Max. 4.0} — N o F1 Max. 39 {Max. 4.0} — F1 o F2 Max. 39 {Max. 4.0} — F2 o F3 Max. 39 {Max. 4.0} — F3 o F4 Max. 39 {Max. 4.0} — F4 o F5 Max. 39 {Max. 4.0} — Max. 39 {Max. 4.0} — Max. 39 {Max. 4.0} — F7 o F8 Max. 39 {Max. 4.0} — N o R1 Max. 39 {Max. 4.0} — R1 o R2 Max. 39 {Max. 4.0} — R2 o R3 Max. 39 {Max. 4.0} — R3 o R4 Max. 39 {Max. 4.0} — Gear shift lever • Engine stopped • At center of lever knob F5 o F6 • Max. value in travel to just before finish of gearshifting F6 o F7 N {kg} Steering wheel • Engine at low idle • During travel in F1 N {kg} Max. 29 {Max. 3.0} — Brake pedal • Engine at high idle • At 150 mm from center of pedal rotation • Max. value in travel to stop machine completely N {kg} 276 ± 27.5 {28.1 ± 2.8} — GD655-3E0, GD675-3E0 20 Standard value table Power train oil pressure and pump performance Rotation speed Operating efforts of lever, pedal and steering wheel Category Check item SEN01834-00 Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Measurement condition Unit Standard value for new machine Service limit value Left blade lift cylinder lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Scarifier lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Blade rotation lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Articulation lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Max. 26 {Max. 2.7} — Drawbar side shift lever • Engine stopped • At center of lever knob • Max. value in stroke N o Forward N o Reverse N {kg} Power tilt lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Leaning lever N o Forward N o Reverse Max. 25 {Max. 2.5} — Blade side shift lever N o Forward N o Reverse Max. 26 {Max. 2.7} — Right blade lift cylinder lever N o Forward N o Reverse Max. 26 {Max. 2.7} — 1,689 ± 100 — Low idle 2.4 ± 0.1 {24.5 ± 1.0} 2.4 ± 0.1 {24.5 ± 1.0} High idle 2.46 ± 0.2 {25.1 ± 2.0} 2.46 ± 0.2 {25.1 ± 2.0} High idle 0.88 ± 0.05 {9.0 ± 0.5} 0.88 ± 0.05 {9.0 ± 0.5} 0.59 ± 0.05 {6.0 ± 0.5} 0.59 ± 0.05 {6.0 ± 0.5} High idle 2.01 ± 0.15 {20.5 ± 1.5} 2.01 ± 0.15 {20.5 ± 1.5} Transmission FL clutch pressure High idle 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} Transmission R clutch pressure High idle 2.06 – 2.45 {21 – 25} 2.06 – 2.45 {21 – 25} Torque converter stall speed • • • • Engine coolant temperature: Operating range Torque converter oil temperature: 60 – 80°C Engine at high idle Engine stall speed when wheel brake pedal is pressed and inching pedal is released with engine at full throttle and gear in R4 Power train main relief pressure Torque converter inlet pressure Torque converter outlet pressure Torque converter lockup clutch pressure GD655-3E0, GD675-3E0 • Torque converter oil temperature: 60 – 80°C • Engine at low idle or high idle • During no-load travel with gear shift lever in P position or each gear speed High idle rpm MPa {kg/cm2} 5 SEN01834-00 Steering Differential Power train performance Power train oil pressure and pump performance Category Check item Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Power train pump delivery Travel speed Standard value for new machine Service limit value High idle 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} High idle 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} High idle 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} High idle 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 135 — F1 3.3 ± 0.17 — F2 4.7 ± 0.24 — F3 6.7 ± 0.34 — Measurement condition • Torque converter oil temperature: 60 – 80°C • Engine at low idle or high idle • During no-load travel with gearshift lever in P position or each gear speed Transmission 4th clutch pressure High idle • Torque converter oil temperature: 60 – 80°C • Engine at high idle • Torque converter oil temperature: 60 – 80°C • During travel at rated engine speed (1,900 rpm) Unit MPa {kg/cm2} l/min F4 9.7 ± 0.49 — F5 14.6 ± 0.37 — 21.2 ± 1.06 — 29.1 ± 1.46 — 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 — 2.84 – 3.10 {29.0 – 31.6} Max. 2.84 {Max. 29.0} +0.7 +0 +7 {185 +0 } — cc/min 0 — F6 F7 km/h Differential lock pressure [Differential lock specification] • Final drive oil temperature: 45 – 55°C • Engine at high idle • When differential lock is ON MPa {kg/cm2} Steering oil pressure • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • When steering cylinder is relieved MPa {kg/cm2} • Hydraulic oil temperature: 45 – 55°C Oil leakage through • Engine at high idle steering cylinder • When steering cylinder is relieved Camber Leaning angle Tire runout Tire Machine model Transmission FH clutch pressure Toe-in 6 20 Standard value table Tire inflation pressure 18.1 • On flat paved road • Camber: Leaning angle of king pin • Toe-in: Difference between distance between tire front centers and that between tire rear centers • Leaning angle: Leaning angle of front tire rad {°} 0 {0} — mm –5 ± 5 — rad {°} 0.279 ± 0.017 {16 ± 1} — • Measure side of tire with dial gauge (both front and rear wheels) mm Max. 7 — kPa {kg/cm2} 220 {2.2} — 250 {2.5} — • GD655-3E0: 14.00-24-10PR • GD675-3E0: 14.00-24-12PR GD655-3E0, GD675-3E0 20 Standard value table Category Check item Brake accumulator charge pressure Work equipment oil pressure and pump performance Stroke and operating effort of control valve Brake Wheel brake oil pressure SEN01834-00 Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Measurement condition • Hydraulic oil temperature: 45 – 55°C • Engine at high idle Unit MPa {kg/cm2} • Hydraulic oil temperature: 45 – 55°C • Engine stopped (after accumulator pressure is increased) • When brake pedal is pressed • Hydraulic oil temperature: 45 – 55°C • Engine stopped (after accumulator pressure is Wheel brake oil increased) pressure reduction • Pressure reduction in 5 minutes while brake pedal is pressed kPa {kg/cm2} 12.26 {125 +0.98 +0 +10 +0 } +0.10 –0.31 +1 {40 –3 } 3.9 9.36 – 13.24 {95.5 – 135} 9.36 – 13.24 {95.5 – 135} Max. 17.7 Max. 18.4 (ISO3450 = 18.4 m) 5 — 6 — Max. 109.8 {Max. 11.2} — Max. 73.5 {Max. 7.5} — Unload pressure 2.8 ± 0.98 {29 ± 10} — Work equipment relief pressure 20.6 ± 1.0 {210 ± 10} — 2.35 ± 0.1 {24 ± 1} — 76 — m Blade rotation only Other than blade rotation Blade rotation only Other than blade rotation • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • During blade rotation operation (Pa = 14.7 MPa {150 kg/cm2}) • LS differential pressure = Pump pressure – LS pressure Steering, brake and • Hydraulic oil temperature: 45 – 55°C work equipment • Engine at low idle pump delivery • Rotate blade (Measure during operation) GD655-3E0, GD675-3E0 {125 +0.98 +0 +10 +0 } 98 {1.0} • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • When brake is applied at speed of 38.2 km/h (as per ISO3450) LS differential pressure 12.26 9.36 98 {1.0} Stopping distance with wheel brake • Hydraulic oil temperature: 45 – 55°C • Engine at high idle Work equipment oil • Unload pressure: When all work pressure equipment is in neutral • Work equipment relief pressure: When blade lift cylinder is raised +0.2 +0 +2 {95.5 +0 } +0.10 –0.31 +1 {40 –3 } Parking brake oil pressure Operating effort of • Engine stopped control valve spool • Max. value in stroke +0.2 +0 +2 {95.5 +0 } 3.9 • Hydraulic oil temperature: 45 – 55°C • Engine stopped (after accumulator pressure is MPa increased) {kg/cm2} • Turn starting switch ON and set gear shift lever in N position. Control valve spool • Engine stopped stroke Service limit value 9.36 Cut-in pressure Cut-out pressure Standard value for new machine mm N {kg} MPa {kg/cm2} l/min 7 SEN01834-00 Category 20 Standard value table Check item Machine model GD655-3E0 GD675-3E0 Engine SAA6D114E-3 Blade lifting speed Work equipment speed Blade side shift speed Drawbar side shift speed Blade rotation speed Power tilt speed Articulation speed Leaning speed • Hydraulic oil temperature: 35 – 45°C • Engine at high idle • Blade lift: Lift in cylinder travel of 350 mm. Measure right and left sides separately. • Blade side shift: Shift in cylinder stroke • Drawbar side shift: Shift in cylinder stroke when blade bottom height is 100 mm • Blade rotation: Rotation of 90° • Power tilt: In cylinder stroke • Articulation: In cylinder stroke (during travel) • Leaning: In cylinder stroke • Scarifier lifting: In cylinder travel of 180 mm Work equipment hydraulic drift and oil leakage Scarifier lifting speed Service limit value Raise 2.7 ± 0.4 4.0 Lower 2.7 ± 0.4 4.0 Left side shift 9.1 ± 1.1 11.0 Right side shift 9.1 ± 1.1 11.0 Left side shift 7.3 ± 1.1 10.0 Right side shift 7.5 ± 1.1 10.0 Left rotation 8.8 ± 1.3 12.0 8.8 ± 1.3 12.0 Wide digging angle 4.05 ± 0.7 7.0 Narrow digging angle 4.58 ± 0.8 7.0 Right rotation 7.17 ± 1.0 14.0 7.17 ± 1.0 14.0 Left leaning 2.37 ± 0.4 6.0 Right leaning 2.46 ± 0.4 6.0 Raise 2.0 ± 0.3 3.0 Lower 2.0 ± 0.3 3.0 10 20 20 35 0 0 10 20 20 35 • Hydraulic oil temperature: 45 – 55°C Work equipment • Engine at high idle cylinder oil leakage • When cylinder is relieved • • • • sec Right turn • Right and left blade lift cylinders: Lower stroke end (Push-up of machine) Blade hydraulic drift • Hydraulic oil temperature: 40 ± 5°C (Raising of • Engine stopped machine) • Cylinder retraction in 10 minutes after finish of setting Scarifier hydraulic drift (No load on cylinder) Unit Left turn • Right and left blade lift cylinders: Raise stroke end Blade hydraulic drift • Hydraulic oil temperature: 40 ± 5°C (No load on • Engine stopped cylinder) • Cylinder extraction in 10 minutes after finish of setting Scarifier hydraulic drift (Raising of machine) 8 Standard value for new machine Measurement condition mm cc/min Scarifier cylinder: Raise stroke end Hydraulic oil temperature: 40 ± 5°C Engine stopped Cylinder extraction in 10 minutes after finish of setting • Scarifier cylinder: Lower stroke end (Push-up of machine) • Hydraulic oil temperature: 40 ± 5°C • Engine stopped • Cylinder retraction in 10 minutes after finish of setting mm GD655-3E0, GD675-3E0 20 Standard value table SEN01834-00 GD655-3E0, GD675-3E0 9 SEN01834-00 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01834-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 08-06 (01) 10 SEN01835-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 ...................................................................................................................... 5 Measuring exhaust temperature .......................................................................................................... 6 Measuring intake air pressure (boost pressure)................................................................................... 8 Measuring blowby pressure ............................................................................................................... 10 Measuring engine oil pressure ............................................................................................................11 Measuring engine speed.................................................................................................................... 12 Testing fan belt tension ...................................................................................................................... 12 Testing air conditioner compressor belt tension ................................................................................. 13 Measuring torque converter stall speed ............................................................................................. 14 Checking clutch oil pressure .............................................................................................................. 15 Checking torque converter oil pressure ............................................................................................. 16 Adjusting speed sensor...................................................................................................................... 17 Flushing torque converter and transmission circuit............................................................................ 19 Testing brake disc .............................................................................................................................. 20 GD655-3E0, GD675-3E0 1 SEN01835-00 30 Testing and adjusting Testing and adjusting parking brake................................................................................................... 21 Method for emergency release of parking brake................................................................................ 23 Testing and adjusting parking brake pad clearance ........................................................................... 24 Testing accumulator charge pressure ................................................................................................ 25 Testing and adjusting work equipment oil pressure............................................................................ 26 Testing and adjusting LS differential pressure.................................................................................... 27 Adjusting PC valve ............................................................................................................................. 29 Bleeding air from hydraulic circuit ...................................................................................................... 30 Measuring internal cylinder leakage................................................................................................... 31 Testing and adjusting differential lock oil pressure [Differential lock specification]............................. 33 Measuring steering and brake oil pressure ........................................................................................ 35 Bleeding air from brake piping............................................................................................................ 36 Charging nitrogen gas for brake, work equipment accumulator......................................................... 37 Testing and adjusting circle guide clearance...................................................................................... 39 Testing and adjusting slip clutch type rotary device ........................................................................... 41 Memorizing idle and full position procedure ....................................................................................... 43 Initial learning method for transmission controller .............................................................................. 44 Inspection procedure of diode ............................................................................................................ 46 2 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Testing and adjusting, Part 1 1 Tools for testing, adjusting and troubleshooting 1 Check or measurement item Measuring exhaust color Symbol A Coolant temperature, oil temperature and exhaust temperature Air boost pressure (boost pressure) Measuring torque converter stall speed Smoke meter C 799-201-2202 Boost gauge kit –101 – 200 kPa (–760 – 1500 mmHg) 1 799-201-1504 Blowby checker 0 – 4,900 Pa {0 – 500 mm H2O} 2 799-201-1511 Nozzle Orifice diameter: 7.67 mm Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester Pressure gauge 58.8 MPa {600 kg/cm2} 2 799-401-2320 Hydraulic gauge 0.98 MPa {10 kg/cm2} 1 799-203-8001 Multi-tachometer 2 795-790-2500 Adapter Digital display L: 60 – 2,000 rpm H: 60 – 19,999 rpm 1 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5002 Hydraulic tester 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5160 799-101-5220 Nipple 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester G H 1 J 2 1 Testing and adjusting LS differential pressure GD655-3E0, GD675-3E0 Bosch index 0 – 9 (with standard color) Digital temperature gauge –99.9 – 1299°C F Testing accumulator charge pressure Testing and adjusting work equipment oil pressure Handy smoke checker Remarks 799-101-1502 E Checking clutch oil pressure 1 799-201-9001 Commercially 2 available Part name B Measuring blowby pressure D Measuring engine oil pressure Part No. K 2 799-101-5160 799-101-5220 Nipple Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge 58.8 MPa {600 kg/cm2} Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge 58.8 MPa {600 kg/cm2} RC 1/8 M10 x 1.25 Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge 58.8 MPa {600 kg/cm2} RC 1/8 M10 x 1.25 3 799-401-2701 Differential pressure gauge DC 12V 4 799-261-1231 Elbow M10 x 1.25 (RC 1/8) 3 SEN01835-00 Check or measurement item Measuring steering, brake oil pressure 30 Testing and adjusting Symbol N Remarks 799-101-5002 Hydraulic tester Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} 790-261-1204 Digital hydraulic tester Pressure gauge 58.8 MPa {600 kg/cm2} 799-101-5160 799-101-5220 Nipple RC 1/8 M10 x 1.25 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 07002-11023 Nipple O-ring 799-401-3100 799-401-3200 Adapter (size 02) Adapter (size 03) 799-401-3300 79A-264-0021 Adapter (size 04) 1 M 2 Oil pressure Part name 1 L 2 Testing and adjusting differential lock oil pressure (Differential lock specification) Part No. M10 x 1.25 — — — 0 – 294 N {0 – 30 kg} Operating effort P Stroke Q Troubleshooting of wiring harnesses and sensors R 799-601-2500 799-601-9200 T-adapter assembly Measuring voltage and resistance values S Commercially available Tester — T 792-610-1700 Charging tool — U 794-423-1190 Plug — Charging accumulator Procedure for moving machine when transmission valve fails 4 79A-261-0091 Commercially available Push-pull scale Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge 58.8 MPa {600 kg/cm2} 0 – 490 N {0 – 50 kg} Scale — — For DT series GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Measuring exhaust color a Part No. 1 799-201-9001 A Commercially 2 available a 2. Connect the air hose of the probe hose accelerator switch to the tool A2. a Keep the air pressure supply below 1.47 MPa {15 kg/cm2}. 3. Connect the power cord to the AC 100V socket. a When connecting the cord, check that the power switch of tool A2 is OFF. 4. Loosen the cap nut of the suction pump and fit the filter paper. 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 simultaneously 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. Exhaust gas color measurement tools Symbol q 1 Part name Handy smoke checker Smoke meter When measuring in the field where is no air or electric power supply, use tool A1; when recording formal data, use tool A2. Increase the coolant temperature to the operating 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 simultaneously operating the handle of tool A1. 4. Remove the filter paper and compare it with the scale supplied to judge the condition. 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. GD655-3E0, GD675-3E0 5 SEN01835-00 30 Testing and adjusting Measuring exhaust temperature 1 a Measuring instruments for exhaust temperature Symbol B k k a Part No. 799-101-1502 Part name Digital thermometer Stop the machine on a level ground, set the gear shift lever in the P position, and set chocks under the wheels. Install and remove the measuring instruments after the exhaust manifold is cooled. Measure the exhaust temperature under the following conditions. q Engine coolant temperature: Within operating range q Torque converter oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55°C 1. Open the engine right side cover and remove exhaust temperature pickup plug (1) of the exhaust manifold. 2. Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement. 3. Procedure for measuring exhaust temperature periodically for Pm clinic a To prevent the torque converter from overheating, stabilize the exhaust temperature first by performing the full stall operation (stalling the torque converter and relieving the hydraulic system) and then stall only the torque converter and measure the exhaust temperature. 1) Start the engine, set the gear shift lever in the P position, and set the fuel control lever in the low idle position. 2) Move the right and left blade lift cylinders to the raise stroke end with the right and left blade lift control levers. 3) Change the machine monitor screen to "Torque converter stall function" and prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor (EMMS)". a The engine speed is displayed on the upper line and the torque converter oil temperature is displayed on the lower line. 4) 5) 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. 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 30 Testing and adjusting 6) 7) SEN01835-00 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 converter is stalled. 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 thermometer (Set the thermometer in the PEAK mode, and the maximum temperature 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 measuring instrument and return the removed parts. GD655-3E0, GD675-3E0 7 SEN01835-00 30 Testing and adjusting Measuring intake air pressure (boost pressure) a k k a 4. Start the engine, set the gear shift lever in the P position, and hold the fuel control lever in the low idle position. 5. Change the machine monitor screen to "Torque converter stall function" and prepare for stalling the torque converter. a For the operating method, see "Special functions of machine monitor (EMMS)". a The engine speed is displayed on the upper line and the torque converter oil temperature is displayed on the lower line. 1 Part No. 799-201-2202 Part name Boost gauge kit Stop the machine on a level ground, set the gear shift lever in the P position, and set chocks under the wheels. Be careful not to touch a hot part of the engine when removing or installing the measuring instrument. Measure the intake air pressure (boost pressure) under the following conditions. q Engine coolant temperature: Within operating range q Torque converter oil temperature: Within operating range q Hydraulic oil temperature: 45 – 55°C 1. Open the engine left side cover and remove intake air pressure pickup plug (1) of the intake air connector. 2. Install nipple [1] of boost gauge kit C and connect it to gauge [2]. 8 Run the engine at a medium or higher speed and drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the selfseal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you may drain the oil by using the oil draining coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. Measuring instrument for intake air pressure (boost pressure) Symbol C 3. GD655-3E0, GD675-3E0 30 Testing and adjusting 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 measuring instrument and return the removed parts. GD655-3E0, GD675-3E0 SEN01835-00 9 SEN01835-00 30 Testing and adjusting Measuring blowby pressure a Part No. 1 799-201-1504 2 799-201-1511 Part name Blowby checker Nozzle Before measuring the blowby pressure, heighten the coolant temperature to the operating range. 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 measure the blowby pressure. k a q 10 q Measuring tools for blow-by pressure Symbol D 1 a If it is impossible to run the engine at the rated output or perform a stall operation, measure while the engine is running at high idle. The value obtained in this case is about 80 percent of the blowby pressure at the rated output. The blowby pressure may vary largely with the engine condition. If the measured value is judged abnormal, check for oil consumption increase, bad exhaust gas color, oil deterioration, high speed of oil deterioration, etc., which are related to the abnormal blowby pressure. Take care not to touch the hot or rotating parts during measurement. The regular blowby pressure is measured while the engine is running at the rated output. In the field, perform a stall operation for an approximate value. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Measuring engine oil pressure a Engine oil pressure measurement tools Symbol E 1 Part No. 799-101-5002 790-261-1204 2 799-401-2320 1. 1 Part name Hydraulic tester Digital hydraulic tester Hydraulic gauge Open the cover of engine left side, and remove the oil pressure measurement plug (1) of the cylinder block. 5. 2. Install nipple [1] of hydraulic tester E1 and connect 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. GD655-3E0, GD675-3E0 Detach the measurement tool after the measurement, and make sure that the machine is back to normal condition. 11 SEN01835-00 Measuring engine speed 30 Testing and adjusting 1 Measure the engine speed under the following condition. q Coolant temperature: Within operating range q Power train oil temperature: 60 – 80°C q Hydraulic oil temperature: 40 – 55°C 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 measure the engine speed. 3. Measuring high idle speed 1) Start the engine and press the accelerator pedal fully. 2) Set the gear shift lever in the "P" range, set the work equipment control lever in neutral, release the brake pedal and measure the engine speed. 4. 12 Measuring torque converter stall speed 1) Set the transmission mode switch to "TC AUTO". 2) Start the engine. 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 converter oil temperature gauge enters the 3rd level of the green range. a Immediately after finishing the measurement, return the gear shift lever to the "P" range and run the engine at high idle to lower the torque converter oil temperature. Testing fan 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 2. Deflection (A) New belt 11.8 – 12.8 After adjusting tension 14.0 – 15.6 Adjusting the belt tension 1) Loosen the nut (1). 2) Loosen the locknut (2), then turn the adjustment nut (3) to adjust the belt tension. 3) After adjusting the belt tension, tighten the nut (1) and then the locknut (2). GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 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 2. Deflection (a) New belt 15 – 16 After adjusting 17 – 19 Adjusting the belt tension 1) Loosen the locknut (1), then turn the adjustment nut (2) and move the compressor (4) with the shaft (3) at the center to adjust the belt tension. 2) After adjusting the belt tension, tighten the locknut (1). GD655-3E0, GD675-3E0 13 SEN01835-00 30 Testing and adjusting Measuring torque converter stall speed 1 a Measuring tools for torque converter stall speed Symbol F k a q q q 1. 14 Part No. 1 799-203-8001 2 795-790-2500 Part name Multi-tachometer Adapter 2. Start the engine and run at low idle. 3. Depress the brake pedal. Stop the engine and move the gear shift lever to TOP reverse speed (R4). 4. Measure the speed when the accelerator pedal is set to the full throttle position. a Measure when the engine speed is stable. Do not touch the hot parts when measuring. And ensure that no one is near the machine during the procedure. Measure the torque converter stall speed under the following conditions: Coolant temperature: within operating range Power train oil temperature: 60 – 80°C Hydraulic oil temperature: 45 – 55°C Remove the cap from the engine speed pickup port, install the adapter assembly F2 and multi-tachometer sensor [1], then connect to the main body F1. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Checking clutch oil pressure a Checking tools for clutch oil pressure Symbol G k k k k k a 1. 1 Part No. Part name 799-101-5002 790-261-1204 Hydraulic tester Digital hydraulic tester Set the front frame and rear frame facing straight to the front, then secure in position with the lock pin. Raise the tandem drive with a hydraulic jack and raise the 4 rear wheels off the ground. Set the blade at right angles to the chassis and lower the blade completely to the ground. The oil is hot, so be careful not to burn yourself. Stop the engine before removing or installing the plug or pressure gauge. Oil temperature when measuring: 60 – 80°C 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. All gauges: 5.88 MPa {60 kg/cm2} 4) ECMV Plug No. Oil pressure circuit Plug No. Oil pressure circuit 1 FL clutch 5 R clutch 2 FH clutch 6 3rd clutch 3 1st clutch 7 4th clutch F2 4 2nd clutch — — F3 Plug size: Rc1/8 or 1/4 3) ECMV clutch actuation table Run the engine at low idle and shift the gear shift lever to the speed range (oil pressure circuit) to be measured. Run the engine at full throttle and measure the clutch pressure of that circuit. Speed Range F1 FL F8 1st 2nd 3rd 4th Q Q Q Q Q Q Q Q Q Q F6 F7 R Q F4 F5 FH Q Q Q Q Q R1 Q R2 Q R3 Q R4 Q Q Q Q Q N GD655-3E0, GD675-3E0 15 SEN01835-00 Checking torque converter oil pressure k k k k k a 30 Testing and adjusting Torque converter outlet port pressure 1) Measurement port: 3 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle. 4. Torque converter lock-up port pressure 1) Measurement port: 4 (Rc 1/4) 2) Start the engine and measure the pressure at high and low idle. 1 Set the front frame and rear frame facing straight to the front, then secure in position with the lock pin. Raise the tandem drive with a hydraulic jack and raise the 4 rear wheels off the ground. Set the blade at right angles to the chassis and lower the blade completely to the ground. The oil is at high temperature, so be careful not to burn yourself. Stop the engine before removing or installing the plug or pressure gauge. Oil temperature: 60 – 80°C 1. Main relief pressure 1) Measurement port: 1 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle. 2. Torque converter inlet port pressure 1) Measurement port: 2 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle. 16 3. GD655-3E0, GD675-3E0 30 Testing and adjusting Adjusting speed sensor 1. SEN01835-00 1 Engine speed sensor 1) Screw the sensor (1) 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 the sensor in contact. Never use a wrench or any other tool when tightening. 2) 3) 2. Transmission input shaft speed sensor 1) Screw the sensor (4) 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 it is in contact. Never use a wrench or any other tool to tighten the sensor. 2) When the sensor (4) tip contacts the gear (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 prevent 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. When the sensor (1) tip contacts the gear (2), screw the sensor out 1/2 to 1 turn. Standard clearance (a): 0.68 – 1.13 mm Tighten the locknut (3). 3 Locknut: 49.0 – 68.6 Nm {5 – 7 kgm} a Tighten the sensor carefully to prevent 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. GD655-3E0, GD675-3E0 17 SEN01835-00 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) 3) 18 30 Testing and adjusting When the sensor (5) contacts the gear (2), turn the sensor out 1/2 to 1 turn. Standard clearance (a): 0.68 – 1.13 mm Tighten the locknut (3). 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. a Be careful not to scratch the sensor tip or let any iron filings or powder stick to the tip. GD655-3E0, GD675-3E0 30 Testing and adjusting Flushing torque converter and transmission circuit SEN01835-00 Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the torque converter and transmission life, and will cause internal damage. To prevent this situation, flush the system to remove the dirt in the hydraulic circuit. 1. Flush the circuit, if the following conditions apply. 1) If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are circulating in the hydraulic circuit. 2) When the torque converter and transmission have been overhauled or repaired. 2. Cleaning the filter 1) After removing the filter, remove the drain plug (1) and drain the system. 3. Remove the transmission oil filter, clean the inside, then reinstall the element for a second flushing. Fill the transmission case with oil. 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 Perform the flushing as follows. 1) After starting the engine, run the engine for approx. 20 minutes at low idle, without operating the gear shift lever. a From time to time, increase the engine speed to approx. 1,500 rpm. a If the ambient temperature is low and the en gin e c ool ant tempe ra tur e gauge does not enter the green range, continue the warming-up operation longer. 2) Travel or perform the actual operations for at least 20 minutes. a Use all the speed ranges (FORWARD, REVERSE, and 1st – 8th). 3) Repeat the procedure in Step 4.1) and run the engine at low idle for approx. 20 minutes. 5. Replace the flushing element. 1) Using the procedure in Step 2.1), replace the flushing element with the standard element (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 circumference of the case (5). a Coat the outside circumference of the O-ring with a small amount of grease. 4) Install the case (5). 3 Case bolts: 34.3 – 44.1 Nm {3.5 – 4.5 kgm} 5) Install the filter assembly (2). 1 a 2) 4. Transmission case: 45 l GD655-3E0, GD675-3E0 19 SEN01835-00 Testing brake disc k 30 Testing and adjusting 1 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. 20 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Testing and adjusting parking brake k 1. 2. 1 4) Stop the machine on a flat ground, set the gear shift lever in the P position and set chocks to the tires. Measuring pad thickness 1) Start the engine, increase the accumulator pressure and then stop the engine. 2) Turn the starting switch ON and set the gear shift lever in the N position. 3) Measure thicknesses (a) and (b) of the front and rear pads. q Thicknesses (a) and (b) are 3 mm or larger: Pads can be used as they are. q Thicknesses (a) and (b) are less than 3 mm: Pads cannot be used. Replace them. Measuring pad clearance 1) Start the engine, increase the accumulator pressure and then stop the engine. 2) Turn the starting switch ON and set the gear shift lever in the N position. 3) Measure clearances (c) and (d) between each of front and rear pads (1) and disc (2). GD655-3E0, GD675-3E0 3. Calculate the total clearance. a If the total clearance (c + d) is 2.5 mm or larger, it must be adjusted. q Total clearance (c + d) when pads are new: 0.5 – 0.8 mm Adjusting pad clearance 1) Start the engine, increase the accumulator pressure and then stop the engine. 2) Turn the starting switch ON and set the gear shift lever in the N position. 3) Remove plug (3) and loosen locknut (4). 4) Set the brake calipers free according to the following procedure. 1] Loosen double nut (5) and then loosen bolt (6) about 5 turns. 2] Loosen locknut (7) and then loosen bolt (8) about 3 turns. a Move the locknut toward the mount bracket. 5) Tighten adjustment bolt (9) until front and rear pads (1) touch disc (2). 6) Tighten bolt (8) until it touches polyurethane spring (10) and then tighten it 1/2 turn more. 21 SEN01835-00 7) 8) 9) 10) 11) 12) 13) a 22 30 Testing and adjusting Tighten locknut (7) toward the mount bracket. 3 Locknut: 242 – 302 Nm {24.7 – 30.8 kgm} (Target: 272 Nm {27.7kgm}) 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 While touching bracket (11) with the tip of bolt (6), adjust double nut (5) so that clearances (a) and (b) between each of front and rear pads (1) and disc (2) will 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}) 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}) Check clearances (a) and (b) between each of front and rear pads (1) and disc (2) again. Install plug (3). 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). 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 30 Testing and adjusting Method for emergency release of parking brake 1 a k k If any problem occurs in the electrical system or hydraulic system of the parking brake and the parking brake is not released, it is possible to release the parking brake temporarily as follows. If any problem occurs in the hydraulic system, there is a strong possibility that the brake will not work properly, so after releasing the parking brake, always tow the machine at low speed to a safe place. When carrying out the operation to release the parking brake, stop the machine on level ground and check that the surrounding area is safe before starting the operation. If the parking brake must be released o n a slo p e i n a n eme rg e n cy o r o t h e r 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. GD655-3E0, GD675-3E0 SEN01835-00 3. Drive or tow the machine to a safe place. a After moving the machine, set chocks securely to the tires. 4. After repairing the parking brake, adjust the pad clearance, referring to "Testing and adjusting parking brake". 23 SEN01835-00 Testing and adjusting parking brake pad clearance k 1. 2. 30 Testing and adjusting 7) 1 Stop the machine on flat ground and put blocks under the front wheels. Checking the parking brake pad clearance 1) Start the engine, charge the accumulator with hydraulic oil, then stop the engine. 2) Turn the engine starting switch to the ON position and set the gear shift lever to the N position. 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 Adjusting the parking brake pad clearance 1) Start the engine, charge the accumulator with hydraulic oil, then stop the engine. 2) Turn the engine starting switch ON and set the gear shift lever to the N position. 3) Measure parking brake pad (1) thickness. q If thickness is 3 mm or more: Use again q If thickness is less than 3 mm: Replace 4) Remove the plug (3); loosen the locknut (4). 5) Loosen the double nut (5), then loosen the bolt (6) five turns. 6) After loosening the nut (7), loosen the bolt (8) three turns. Tighten the bolt (9) so that the front and rear pads (1) contact disc (2). 8) Tighten the bolt (8) until it contacts the urethane spring (10), then tighten the bolt an additional 1/2 turn. 9) Tighten nut (7). 3 Nut: 242 – 302 Nm {24.7 – 30.8 kgm} (Target: 272 Nm {27.7 kgm}) 10) Loosen the adjustment bolt (9) to adjust so that the total clearance (a + b) between the disc and pads is 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}) 12) Secure the adjustment bolt (9) with the locknut (4). 3 Locknut: 102.8 – 128.2 Nm {10.5 – 13.1 kgm} (Target: 115.5 Nm {11.8 kgm}) 13) Check the clearance between the disc (2) and pads (1) again. 14) Install the plug (3). 15) Set the gear shift lever to the P position and check that the clearance between the pads (1) and disc (2) is removed. k If the adjustment procedure for steps 3) thru 15) takes longer than 15 minutes, perform the adjustment procedure continuously after completing the procedure in steps 1) and 2). 16) Turn the engine starting switch OFF. 24 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Testing accumulator charge pressure a 1 Testing tool for accumulator charge pressure Symbol H 5. Part No. 799-101-5002 Part name Hydraulic tester a Hydraulic oil temperature: 45 – 55°C Stop the engine and depress the brake pedal slowly at least 30 times to release the pressure inside the accumulator circuit. 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 pressure. 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 pressure. 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 pressure. 4. After stopping the engine, press and release the brake pedal slowly at least 20 times repeatedly, 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}. k GD655-3E0, GD675-3E0 Charge fully (to the cut-out pressure) with the engine at full throttle, then stop the engine. Turn the starting switch to the ON position and press and release the brake pedal repeatedly. At this time, if the low brake oil pressure caution buzzer sounds before the brake pedal is pressed 10 times, check the accumulator gas pressure. q For the method of checking the accumulator gas pressure, see "Charging nitrogen gas for brake, work equipment accumulator". 25 SEN01835-00 30 Testing and adjusting Testing and adjusting work equipment oil pressure a Testing and adjusting tools for work equipment oil pressure Symbol a 1. 2. 26 Part No. Part name 1 799-101-5002 790-261-1204 Hydraulic tester Digital hydraulic tester 2 799-101-5160 799-101-5220 Nipple J k 1 Adjusting 1. Adjusting the LS relief valve a If the work equipment oil pressure is not normal, adjust the LS relief valve (2) as follows. 1) Loosen the locknut (3) and turn the adjustment screw (4) as follows. q To INCREASE the pressure, turn CLOCKWISE. q To DECREASE the pressure, turn COUNTER-CLOCKWISE. Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Oil temperature when measuring: 45 – 55°C Measuring unload oil pressure 1) Remove the pressure measurement plug (1) (M10 × 1.25). 2) Fit the nipple J2, then install the oil pressure gauge J1 (5.9 MPa {60 kg/cm2}). 3) Run the engine at full throttle and measure the oil pressure with all levers at HOLD. Measuring work equipment pressure (relief pressure) 1) Remove the pressure measurement plug (1) (M10 × 1.25). 2) Fit the nipple J2, then install the oil pressure gauge J1 (39.2 MPa {400 kg/cm2}). 3) Run the engine at full throttle and measure the relief pressure; operate the blade lift lever to the RAISE position. a 2) a One turn of the adjustment screw equals 15.1 MPa {154 kg/cm2} After adjusting, tighten the locknut (3). 3 Locknut: 68.6 – 78.5 Nm {7 – 8 kgm} After completing the adjustment, use the measurement procedure above to check the oil pressure again. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Testing and adjusting LS differential pressure a 1 Connect the differential pressure gauge K3. Testing and adjusting tools for LS differential pressure Symbol Part No. Part name 1 799-101-5002 790-261-1204 Hydraulic tester Digital hydraulic tester K 2 799-101-5160 799-101-5220 Nipple 3 799-401-2701 4 799-261-1231 1. 3) Differential pressure gauge Elbow Measuring LS differential pressure with the main relief differential pressure gauge 1) Remove the high-pressure (1) and lowpressure (2) measurement plugs. a 4) Connect the LS pump pressure (1) to the high-pressure side of the differential pressure gauge and LS pressure (2) to the low-pressure side. Set to the conditions in Table 1, and measure the LS differential pressure. Table 1 2) Accelerator Operation Differential pressure (MPa {kg/cm2}) Full Levers at neutral 2.84 – 3.9 {29 – 40} Full Blade lever (operate fully to raise) 2.35 ± 0.1 {24 ± 1} Fit the elbow K4 and nipple K2. GD655-3E0, GD675-3E0 27 SEN01835-00 2. Measuring with an oil pressure gauge a Measure with the same gauge. 1) Remove the high-pressure (1) and lowpressure (2) oil measurement plugs. 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}. Set to the conditions in Table 1, and measure the LS pump pressure. a Read the gauge indicator while standing directly in front of it. Set to the conditions in Table 1, and measure the LS pressure. a Read the gauge indicator while standing directly in front of it. LS differential pressure = (LS pump pressure) – (LS pressure) 4) 5) 28 30 Testing and adjusting Adjusting the LS valve When measuring the differential pressure under the above conditions and the pressure is not within the 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. GD655-3E0, GD675-3E0 30 Testing and adjusting Adjusting PC valve SEN01835-00 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 differential 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 COUNTERCLOCKWISE. 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} GD655-3E0, GD675-3E0 29 SEN01835-00 Bleeding air from hydraulic circuit1 1. Bleeding air from the pump 1) Loosen the air bleed plug (1), and bleed the air from the pump. a When air no longer is discharged with the oil, the air bleeding operation is completed. 2) Tighten the plug (1). 3 Plug: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} a Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low 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 completed. 2) Tighten the plugs (1) and (2). 30 30 Testing and adjusting 3. Bleeding air from the hydraulic cylinder 1) Start the engine and run at idle for approx. 5 minutes. 2) Run the engine at low idle, and raise and lower the boom 4 to 5 times in succession. a Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from all the cylinders. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Measuring internal cylinder leakage a a Blade shift cylinder 1 If the hydraulic drift of the work equipment is not within the standard value, measure the amount of leakage inside the cylinder as follows 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 standard 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. Oil temperature when measuring: 45 – 55°C. 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 equipment 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. Be careful not to disconnect the piping at the bottom end. k 3. Start the engine, then run the engine at high idle and apply the relief pressure to the bottom 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. GD655-3E0, GD675-3E0 Power tilt cylinder Drawbar shift cylinder R.H. 31 SEN01835-00 30 Testing and adjusting Leaning cylinder Articulation cylinder R.H. L.H. Ripper cylinder 32 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Testing and adjusting differential lock oil pressure [Differential lock specification] 1 a 1 M 2 a q Start the engine and turn differential lock switch [1] ON. 4) Run the engine at high idle and measure the differential lock pump outlet pressure. 5) After finishing measurement, remove the measuring instruments and return the removed parts. Testing and adjusting tools for differential lock oil pressure Symbol k 3) Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023 Part name Hydraulic tester Digital hydraulic tester Nipple O-ring Stop the machine on a level ground, set the gear shift lever in the P position, and lock the tires with chocks. Test and adjust the differential lock pressure under the following conditions. Final drive case oil temperature: 45 – 55°C Testing 1. Testing differential lock pump outlet pressure 1) Remove oil pressure pickup plug (1) from the differential lock valve inlet piping. 2. 2) Measuring differential lock valve outlet pressure 1) Remove oil pressure pickup plug (2) from the differential lock valve outlet piping. Install nipple M2 and connect the oil pressure gauge of hydraulic tester M1. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. GD655-3E0, GD675-3E0 33 SEN01835-00 2) 3) 4) 5) 34 Install nipple M2 and connect the oil pressure gauge of hydraulic tester M1. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. Start the engine and turn differential lock switch [1] ON. Run the engine at high idle and measure the differential lock pump outlet pressure. 30 Testing and adjusting Adjusting Adjusting differential lock relief valve a If both of the differential lock pump outlet pressure and differential lock valve outlet pressure are below 2.8MPa {29 kg/cm2}, adjust differential lock relief valve (3) according to the following procedure. 1. While fixing adjustment screw (4), loosen locknut (5). 2. Turn adjustment screw (4) to adjust the pressure. a If the adjustment screw is q turned to the right, the pressure is heightened. q turned to the left, the pressure is lowered. a Quantity of adjustment per turn of adjustment screw: 0.989 MPa {10.1 kg/cm2} 3. While fixing adjustment screw (4), tighten locknut (5). 3 Locknut: 8 Nm {0.81 kgm} 4. After finishing adjustment, check again that the oil pressure is normal according to the above procedure. After finishing measurement, remove the measuring instruments and return the removed parts. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Measuring steering and brake oil pressure 1 a Measuring tools for steering, brake oil pressure Symbol k 1. Measuring the brake circuit pressure a After charging the brake accumulator fully with oil pressure, stop the engine. 1) Remove the air bleed plug (2) (Rc 1/4). Part name 1 799-101-5002 790-261-1204 Hydraulic tester Digital hydraulic tester 2 799-101-5160 799-101-5220 Nipple L k Part No. 2. Stop the machine on flat ground, apply the parking brake, and lower the blade completely to the ground. Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Measuring the steering circuit pressure 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 pressure gauge L1 (39.2 MPa {400 kg/cm2}). 3) Run the engine at full throttle, and measure the oil pressure after relieving the left or right steering circuits (operate to end of the stroke). 2) Fit the nipple L2, then install the oil pressure gauge L1 (5.88 MPa {60 kg/cm2}). 3) Measure the oil pressure after depressing the brake pedal. After measuring the oil pressure, install the plug and bleed the air from the system. a GD655-3E0, GD675-3E0 35 SEN01835-00 Bleeding air from brake piping k a 1. 30 Testing and adjusting 1 Stop the machine on flat ground and put blocks under the front wheels. Start the engine and charge the accumulator. 2. Bleeding the air between the slack adjuster and the brake 1) Install the vinyl tube (4) to the tip of the air bleed valve (3). 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) 3) 2) 3) 4) 36 Depress the brake pedal and loosen the air bleed valve (1) 3/4 turns, then close the valve and release the pedal. Continue this procedure until no more bubbles exit with the oil discharged from the air bleed valve (1). Bleed the air from the slack adjuster air bleed valves at 2 places on the left and right. 4) Depress the brake pedal and loosen the air bleed valve (3) 3/4 turns, then close the valve and release the pedal. Continue this procedure until no more bubbles exit with the oil discharged from the air bleed valve (3). Bleed the air from the brake air bleed valves at four places on the left and right. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Charging nitrogen gas for brake, work equipment accumulator 1 7. Turn the handle [1] slowly clockwise to push the piston of the gas valve (1). 1. Before charging with gas, check that the oil pressure is completely released. a If the oil pressure is not released, it is impossible to charge with the nitrogen gas. 8. 2. Turn the charging assembly handle [1] counterclockwise and raise it to the point where it stops. Open the valve of the nitrogen cylinder slowly and charge the cylinder (bladder) with nitrogen gas. a While doing this step, close the nitrogen cylinder valve from time to time, wait for the charging assembly pressure gauge [4] to become stable, and check the displayed pressure. 3. Turn the bleed plug handle [2] counterclockwise to open it. 9. When the gas is charged to the specified pressure, close the valve of the nitrogen cylinder securely. a If the pressure in the cylinder is too high, turn the handle [2] counterclockwise gradually to release the excessive pressure. 1) q q q 4. Remove the cap from the gas valve (1), then assemble the charging assembly to the gas valve (1). 2) q q q 5. Connect the nitrogen cylinder and charging assembly with hose assembly [3]. 6. Open the nitrogen cylinder valve slightly, take care that the gas does not discharge quickly, and let the gas flow at a pressure from 0.20 to 0.29 MPa {2 to 3 kg/cm2}. When the gas starts to exit from the handle [2], turn the handle [2] clockwise to stop the gas from escaping. GD655-3E0, GD675-3E0 Accumulator (721-32-10240, capacity: 3 l): Specified pressure at 20 ± 5°C: 3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2} The relationship between the temperature and pressure of the charged gas at the time of charging is as follows. Px = 35 (kg/cm2) × {273 + t (°C)} / {273 +20(°C)} Px: Pressure of charged gas t: Gas temperature when charging (nearly ambient temperature) 35: Specified gas pressure Accumulator (721-32-10250, capacity: 1 l): Specified pressure at 20 ± 5°C: 2.0 ± 0.1 MPa {20 ±1.0 kg/cm2} The relationship between the temperature and pressure of the charged gas at the time of charging is as follows. 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 the gas valve piston to its original position. Then, turn the handle [2] counterclockwise to release the gas remaining inside the hose and charging assembly. 11. Remove the charging assembly from the accumulator. 37 SEN01835-00 30 Testing and adjusting 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 performed, the pressure will go down. Thus, add a slight charge to replace the pressure that is lost. 38 GD655-3E0, GD675-3E0 30 Testing and adjusting Testing and adjusting circle guide clearance 1 k q q If the following conditions occur during adjustment, replace the circle guide. When clearance (R) between the circle and circle guide is lost. When the clearance between the tip (or root) of the teeth of the circle gear and the root (or tip) of the teeth of the pinion gear of the circle rotation gear becomes zero (0). SEN01835-00 Adjusting 1. Adjusting clearance in top-to-bottom direction Raise the blade, remove the bolts (1), (5), and (9), and circle guides (2), (6), and (10). Adjust with shims. a Standard shim thickness: 5.5 mm (Shim thickness: 1 mm, 0.5 mm) Testing 1. Testing clearance in top-to-bottom direction Let the blade hang and measure clearance (P) between the top face of the circle and the bottom face of the drawbar as shown in the diagram. Standard clearance (P): 1.5 ± 0.5 mm 2. Checking clearance in front-to-rear direction Leave the blade hanging down, apply force to the rear, then measure clearance (Q) between the circle and circle guide as shown in the figure. Standard clearance QF (front): 0 mm QC (center): 0.7 mm QR (rear): 1.5 mm or QF = QR = 1 mm GD655-3E0, GD675-3E0 39 SEN01835-00 2. Adjusting clearance in front-to-rear direction 1) Bring the blade lightly into contact with the ground. Loosen the bolt (1) and locknut (4). Extend the bolt (3). Push the circle guide (2) open to make QF = 0. a Push open the left and right circle guides (2) uniformly. 2) Adjust clearance (D) between the end face of the flange at the bottom of the circle rotation gear and the sliding surface on the inside diameter of the circle. Standard clearance at (D): 15 – 17 mm (shear pin type) 20 – 22 mm (slip clutch type) 3) 40 When QF = 0, tighten locknut (4), then tighten bolt (1). 3 Bolt: 490.3 – 608 Nm {50 – 62 kgm} 30 Testing and adjusting 3. Adjusting clearance in left-to-right direction 1) Loosen the bolt (9) and locknut (12), extend bolt (11), and push the circle guide (10) open to make QR = 0. a Push open the left and right circle guides (10) uniformly. 2) Loosen the bolt (5) and locknut (8). Extend the bolt (7), and push the circle guide (6) open to make QC = 0. a Push open left and right circle guides (6) uniformly. 3) When QR = 0, turn the bolt (11) back 1/4 turn, and tighten the locknut (12). Turn back the circle guide (10) until it contacts 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° high bank position on the left and right. GD655-3E0, GD675-3E0 30 Testing and adjusting Testing and adjusting slip clutch type rotary device 1 Testing 1. Remove bolts (1) and cover (2). 2. 3. Check that you can see the internal teeth of worm wheel (3) through the hole at (P). 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. 2) Apply the parking brake. SEN01835-00 4. Run the engine at full throttle and operate the circle rotation lever slowly to see if the clutch slips. q Check by rotation of worm wheel (3). q If worm wheel (3) rotates and the blade does not rotate, the clutch is slipping. 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) 4) 5) GD655-3E0, GD675-3E0 Check the clutch for slipping according to the "Testing" procedure. Repeat steps 1) – 3) until the clutch slips and set the clutch to the critical slipping point. 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. 41 SEN01835-00 2. When clutch slips 1) Remove bolts (4) and holder (5), and then remove 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) 4) 5) Check the clutch for slipping according to the "Testing" procedure. Repeat steps 1) – 3) until the clutch does not slip and set the clutch to the critical slipping point. At the critical slipping point, remove 1 shim 0.2 mm thick (6). a After the shim is adjusted, the clutch must not slip. 30 Testing and adjusting 3. Installation of cover 1) Install cover (2) and tighten bolts (1). 3 Bolt (1): 65.7 ± 6.8 Nm {6.7 ± 0.7 kgm} Running in clutch q After the clutch disc is replaced with new one, run in the clutch according to the following procedure. a When installing the disc, apply oil GO #90 to its both sides. 2) Set the clutch to the critical slipping point according to adjusting steps 1 and 2. 3) Add 1 shim 0.2 mm thick so that the clutch will 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 intervals of 3 minutes. k k 6) 7) 8) 42 If the clutch housing temperature exceeds 50°C, stop the work until it lowers to the normal temperature. If the clutch stops slipping during the work, add 1 shim 0.2 mm thick. Wait until the clutch is cooled to the normal temperature. Set the clutch to the critical slipping point again (according to steps 1 and 2). Remove 1 shim 0.2 mm thick so that the clutch will not slip. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01835-00 Memorizing idle and full position procedure 1 Accelerator and inching potentiometer a If the accelerator pedal assembly and inching pedal assembly have been replaced, perform the operation to memorize the idle position and full position after installing. 1. Memorizing the idle position 1) Release the accelerator pedal and inching pedal, and leave the pedal free. 2) Turn the starting switch to the ON position. 3) Push the potentiometer set switch (1) down for at least 1 second. a If the buzzer sounds 2 times, 0.1 second each, the value for the accelerator and inching potentiometer idle position has been stored correctly. a If the buzzer sounds continuously for 1 second, the setting has not been stored in memory. 2. Memorizing the full position 1) Depress the accelerator pedal and inching pedal fully. 2) Turn the starting switch to the ON position. 3) Push the potentiometer set switch (1) up for at least 1 second. a If the buzzer sounds continuously for 2 seconds, the value for the accelerator and inching potentiometer full position has been stored correctly. a If the buzzer sounds three times in a cycle of 1 second ON, 1 second OFF, the setting has not been stored in memory. Measuring voltage Pedal Accelerator Inching Connector Potentiometer voltage T3-3 to T2-11 2.42 – 4.3 T8 C to B 3.2 – 4.0 Measuring voltage Pedal Accelerator Inching Connector Potentiometer voltage T3-3 to T2-11 1–2 T8 C to B 0.8 – 1.6 GD655-3E0, GD675-3E0 43 SEN01835-00 Initial learning method for transmission controller q q q 1. q 44 30 Testing and adjusting 2. Resetting learned data a Do as follows to return all the previously learned control data in the controller to the default values. 1) Check that the starting switch is at the OFF position. 2) Turn the starting switch ON. (Do not start the engine.) 3) Push memory set/learning function initializing switch (1) down for at least 1 second, then turn the starting switch OFF. 3. Method for learning correction for individual differences in valves When correcting the individual differences in the valves, do as follows. The correction operation is for three types of clutch: FL, FH, and R. 1) Start the engine and run it at low idle. (Depress the accelerator pedal, then let it back fully.) 2) Push memory set/learning function initializing switch (1) up, then within 0.8 seconds, push the reset switch (2). Hold it in this condition for at least 1 second, then release the switch. 1 The transmission controller is equipped with a self-compensating learning function that corrects to a fixed level the differences in operating feeling caused by the individual differences in the hydraulic valves and maintains a constant gear shifting feeling by compensating for the changes in the transmission clutches caused by wear. If the transmission is overhauled or replaced, or the hydraulic valves are replaced, the transmission controller still has the control command values learned to match the previous transmission. For this reason, transmission shock, abnormal noise, or defective operating feeling may occur. After operating the machine for a short time, the controller will learn the condition of the new transmission and will gradually return to the optimum condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to carry out resetting of the learned data, learning of correction of individual valve differences, and initial learning of stabilized transmission feeling as follows. Preparation of machine for learning of correction for individual differences in valves and initial learning of transmission feeling stabilization It is necessary to carry out the learning operation 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 temperature. During the stall operation, keep the gear shift lever at R4 and do not shift to any other speed range. (If the stall operation is carried out in any speed range other than R4, there is danger that the machine may pitch or the clutch may be damaged.) 2) Raise the machine and set it on a stand to keep the rear wheels off the ground 3) Operate the gear shift lever as follows to circulate the oil fully through the transmission valves and the whole of the case. P o N o F1 o F2 o F3 o F4 o N o R1 o R2 o R3 o R4 o N 4) Use the above operation to raise the oil temperature to 50 – 60°C. 5) Set to N, run the engine at idle for 3 minutes, check again that the oil is at the specified level, then turn the engine starting switch OFF. q 3) q The learning of the correction for individual differences in the valves will start. The transmission oil temperature is displayed on the controller LED during the correction of the individual differences in the valves. 4) The corrected values are saved in the controller memory and the correction learning function is automatically completed. 5) When the correction learning is completed, the controller LED returns to the normal display. 6) Turn the starting switch OFF. GD655-3E0, GD675-3E0 30 Testing and adjusting 4. q SEN01835-00 Initial learning method for stabilized transmission feeling 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. GD655-3E0, GD675-3E0 45 SEN01835-00 Inspection procedure of diode 30 Testing and adjusting 1 a The direction of continuity of diode is marked on the surface of the diode. 1. When using digital tester 1) Switch to diode range and check displayed value. a Voltage of internal battery is displayed by normal tester. 2) Set red (+) test lead to diode anode (P) 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) 46 2. When using analog tester 1) Switch to resistance range. 2) Check the deflection of needle while connecting 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 connection 1] but deflects with connection 2]: Normal (however deflection range (resistance value) varies depending on the type of tester and measuring range.) q Needle deflects with both connection 1] and 2]: Defective (internal short circuit) q Needle does not deflect with either connection 1] or 2]: Defective (internal disconnection) GD655-3E0, GD675-3E0 30 Testing and adjusting GD655-3E0, GD675-3E0 SEN01835-00 47 SEN01835-00 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01835-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 09-06 (01) 48 SEN01836-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 SEN01836-00 30 Testing and adjusting Testing and adjusting, Part 2 1 Special functions of machine monitor (EMMS) 1 Display section 1. Character display (16 characters, 2 lines) a Operation section 2. Machine monitor mode selector switch 1 U : Enter/Execute t : Cancel/Reset (Only ON/OFF screen) 3. Machine monitor mode selector switch 2 > : Right/Next/Go < : Left/Previous/Return a 2 Language in figures and that on machine monitor: Since English (default) is set on the machine monitor when the machine is delivered, it is also used in the figures. The language used on the machine monitor can be changed to the following 7 languages with the language selection function, however (only in the operator mode). 1) English, 2) Japanese, 3) Germany, 4) French, 5) Spanish, 6) Swedish, 7) Italian EMMS: Equipment Management Monitoring System GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 Each mode and flow of function (Function table) Operator mode 1 Service meter/Integrated odometer display function Service mode 10 Electrical equipment system fault history display function [ELECTRIC FAULT] [>] O I [<] [U] O I [t] 11 Mechanical equipment system fault history display function [MACHINE FAULT] [>] O I [<] 2 Reverse integrated odometer display function Real-time monitoring function 12 [REAL-TIME MONITOR] [>] O I [<] 3 Maintenance monitor function and filter/oil replacement time display function [>] O I [<] 13 Reduced cylinder mode [CYLINDER CUT-OUT] [>] O I [<] 4 Telephone No. input function [>] O I [<] 14 No-injection cranking function [NO INJECTION] [>] O I [<] 5 Language selection function [>] O I [<] 15 [>] O I [<] 6 Speedometer/gear shift indicator selection function [>] O I [<] Maintenance monitor function 16 [MAINTENANCE MONITOR] [>] O I [<] 7 Monitor brightness adjustment function Tuning function [TUNING] [>] O I [<] 17 Operation information display function [OPERATION INFO] [>] O I [<] O [Automatic] 18 Option selection function [OPTIONAL SELECTION] [>] O I [<] 8 Action code display function [>] O 9 Failure code display function 19 Low idle fixing function [ENG LOW IDLE] [>] O I [<] Initializing function (Special for factory) 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 displayed 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 SEN01836-00 30 Testing and adjusting Each mode and flow of function (Display on panel) 4 GD655-3E0, GD675-3E0 30 Testing and adjusting Functions in operator mode (Outline) a Only outline of the operator mode is described in this section. For details of the contents/ operation of each function/mode, see the Operation and Maintenance Manual. 1. Service meter/Integrated odometer display function If the starting switch is turned ON, the service meter is displayed on the upper line and the integrated odometer is displayed on the lower line after the self-check. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. 2. SEN01836-00 3. Maintenance monitor function and filter/oil replacement time display function 1) Filter/Oil replacement time display function (Automatic display) If a filter or an oil comes near the replacement time, the machine monitor displays the information on that filter or oil automatically to call the operator's attention to the maintenance. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. 2) Maintenance monitor function (Selection function) Reverse integrated odometer display function The machine monitor displays the reverse integrated odometer according to the switch operation. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. GD655-3E0, GD675-3E0 After maintenance of a filter or an oil, the replacement time of that filter or oil displayed on the machine monitor can be reset by switch operation. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. a The replacement interval can be set in the service mode. 5 SEN01836-00 4. Telephone No. input function 30 Testing and adjusting 6. The telephone No. to be set in the machine monitor can be input/change/reset by switch operation. a When action code "E03" is displayed, the telephone No. and "CALL" are also displayed. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. 5. The speedometer display section can be changed to the gear shift indicator display section. The gear shift indicator indicates the gear speed which the controller actually outputs to the transmission, not the gear shift lever position. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. Language selection function 7. The language used on the machine monitor can be selected by switch operation. a In the service mode, English is always used. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. 6 Speedometer/gear shift indicator selection function Monitor brightness adjustment function The brightness of LCD1 and LCD2 of the monitor panel can be adjusted. a For details of the display method, see the "Structure, function and maintenance standard" volume or Operation and Maintenance Manual. GD655-3E0, GD675-3E0 30 Testing and adjusting 8. SEN01836-00 Action code display function If an abnormality occurs in the machine, the machine monitor displays action code automatically to urge the operator to take a proper remedy, depending on the level of the abnormality. a In the above example, action code "E03" and "CALL + Telephone No." are displayed alternately. a If action codes "E01" and "E02" are displayed, "CALL + Telephone No." is not displayed. a Action codes and actions urged on operator Action CALL + code Telephone No. Action urged on operator (Contents of Operation and Maintenance Manual) E01 • 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. Not displayed • If "E01" and "MAINTENANCE" are displayed simultaneously, check the failure code and ask your Komatsu distributor for repair. E02 • 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 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. E03 Displayed • If this code is displayed, stop the machine immediately and then check the failure code and ask your Komatsu distributor for repair. GD655-3E0, GD675-3E0 7 SEN01836-00 9. Failure code display function While an action code is displayed on the machine monitor, if the [>] button is pressed once, the failure code(s) occurring currently are displayed. q [>] button: Display failure code a The failure codes detected in the past are classified into the electrical system and mechanical system and recorded as the fault histories (For details, see the service mode). a If multiple failure codes are occurring, the next one is displayed each time the [>] button is pressed. a After all the failure code occurring currently are displayed, if the [>] button is pressed further, the screen returns to the service meter/integrated odometer screen. If the [>] button is pressed again, the failure 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 30 Testing and adjusting a The failure code display function displays the following information. q Part A: Failure code (4-digit portion code + 2-digit phenomenon code) Part B: Controller code (MON: Machine monitor) (ENG: Engine controller) (TM: Transmission controller) Part C: Failed system For details of the displayed failure codes, see the failure code table in "Troubleshooting when failure code is displayed (Display of code)". The information displayed by the failure code display function is partly different from that displayed by the fault history display function (service mode). q q a a GD655-3E0, GD675-3E0 30 Testing and adjusting Functions in service mode SEN01836-00 3) Inputting/Entering ID Input an ID with the buttons. a ID: 6491 q [>] button: Increase number q [<] button: Decrease number q [U] button: Enter number at cursor and move cursor to the right q [t] button: Return to initial screen (See note) Note: If the cursor is at the left end, the screen returns to the ordinary screen (operator mode). If the cursor is not at the left end, it returns to the left end. a If no switch is operated for 60 seconds while the ID input screen is displayed, the screen changes to the ordinary screen automatically. 4) Display of menu initial screen Enter all of the 4 digits of the ID and display 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. Operation to select service mode a When using the service mode, change the screen by the following special operation. 1) Check of screen Check that the machine monitor is in the operator mode and displays the "Service/ Integrated odometer", "Action code", or "Failure code" screen. 2) Display of ID input initial screen Hold down the following 2 buttons similarly for 5 seconds to display the ID input initial screen. q [t] button and [<] button a If these buttons are held down for 5 seconds, no items are displayed on the screen. After checking this condition, release the buttons. GD655-3E0, GD675-3E0 9 SEN01836-00 5) 10 Selection of service mode menu On the menu screen, press the [>] button or [<] button, and the menus in the service mode are displayed endlessly in the following order. a The menu/information is displayed on the parts marked with *. q [>] button: Go to next menu q [<] button: Return to previous menu (1) ELECTRIC FAULT: Electrical equipment system fault history display function (2) MACHINE FAULT: Mechanical equipment system fault history display function (3) REAL-TIME MONITOR: Real-time monitoring function (4) CYLINDER CUT-OUT: Reduced cylinder mode (5) TUNING: Tuning function (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 30 Testing and adjusting 6) Finish of mode/function The current mode or function can be finished by either of the following methods, regardless of the currently used function and its hierarchy (level). (1) When continuing operation in another mode or function: Press the [t] button and return to the mode screen or menu screen to be used next. a The [t] button is used as the enter button on the "YES/NO". Take care. a If you have returned to the ordinary screen (operator mode) by mistake, carry out the operation from step 1) above (You do not need to input the ID at this time). (2) When finishing operations perfectly: Turn the starting switch OFF. GD655-3E0, GD675-3E0 30 Testing and adjusting 10. Electrical equipment system fault history display function [ELECTRIC FAULT] The machine monitor records the information of the past faults and currently occurring faults of the electrical system by failure code. This information can be displayed by the following operation. 1) Selection of menu On the service mode menu screen, select "ELECTRIC FAULT". a The total number of the currently recorded fault histories is displayed on the parts marked with "**". 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 SEN01836-00 3) Displayed fault history information The following information is displayed with the electrical equipment system fault history display function. q Part 1: Record No. q Part A: Failure code (4-digit portion code + 2-digit phenomenon code) q Part 2: Number of occurrence (Number of past occurrence of the same code) q Part 3: Elapsed time 1: (Elapsed time after first occurrence measured by service meter) q Part 4: Elapsed time 2: (Elapsed time after last occurrence measured 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 electrical equipment system fault history display function is partly different from that displayed by the failure code display function (Operator mode). a GD655-3E0, GD675-3E0 If no fault history is recorded, "–" is displayed on all the display parts. 11 SEN01836-00 12 4) Selection of fault history information While the fault history information is displayed, if [>] button or [<] button i s pressed, another recorded fault history information is displayed. q [>] button: Go to information of next record No. q [<] button: Return to information of previous record No. a If the fault history information screens are selected in order, the all clear menu screen is displayed. 5) Clearing of each fault history 1] While the fault history to be cleared is displayed, press the [U] button once t o d is pl ay the on e- by - on e c l ear screen. q [U] button: Display clear screen 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 occurring fault (which is blinking) cannot be cleared. 30 Testing and adjusting 6) Clearing of all fault histories 1] While the fault history information is displayed, press the [>] button or [<] button to display the all clear screen. a If the fault history information screens are selected in order, the all clear menu screen is displayed. 2] Press the [U] button once to display the all clear screen. q [U] button: Enter all clear menu 3] 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 occurring fault (which is blinking) cannot be cleared. GD655-3E0, GD675-3E0 30 Testing and adjusting 11. Mechanical equipment system fault history display function [MACHINE FAULT] The machine monitor records the information of the past faults and currently occurring faults of the mechanical system by failure code. This information can be displayed by the following operation. 1) Selection of menu On the service mode menu screen, select "MACHINE FAULT". a The total number of the currently recorded fault histories is displayed on the parts marked with "**". 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 SEN01836-00 3) Displayed fault history information The following information is displayed with the mechanical equipment system fault history display function. q Part 1: Record No. q Part A: Failure code (4-digit portion code + 2-digit phenomenon code) q Part 2: Number of occurrence (Number of past occurrence of the same code) q Part 3: Elapsed time 1: (Elapsed time after first occurrence measured by service meter) q Part 4: Elapsed time 2: (Elapsed time after last occurrence measured 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 different from that displayed by the failure code display function (Operator mode). a GD655-3E0, GD675-3E0 If no fault history is recorded, "–" is displayed on all the display parts. 13 SEN01836-00 4) Selection of fault history information While the fault history information is displayed, if [>] button or [<] button i s pressed, another recorded fault history information is displayed. q [>] button: Go to information of next record No. q [<] button: Return to information of previous record No. a If the fault history information screens are selected in order, the all clear menu screen is displayed. 5) Clearing of fault history information (No clearing) a The fault history information of the mechanical system cannot be cleared. 30 Testing and adjusting 12. Real-time monitoring function [REAL-TIME MONITOR] The machine monitor can monitor the machine condition in real time by the signals from various switches, sensors, and actuators installed to the machine. The following 2 types of display are available in the real-time monitoring function. q Display of only 1-item (for each controller) q Simultaneous display of 2 items (Input of code) 1) Selection of menu On the service mode menu screen, select "REAL-TIME MONITOR". 2) Display of sub menu While the menu is selected, press the [U] button to display the sub menu initial screen. [U] button: Enter menu q 3) 14 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 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 3] (1) MONITOR PANEL: Machine monitor system (2) TRANSMISSION1: Transmission controller system 1 (3) TRANSMISSION2: Transmission controller system 2 (4) ENGINE: Engine controller system (5) 2 ITEMS: Display of 2 items 4) 5) Information displayed in 1-item monitoring 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 displayed. a For details, see the monitoring code table. 6) Setting of 2-item monitoring 1] On the sub menu screen, select "2 ITEMS". Setting of 1-item monitoring 1] On the sub menu screen, select the "controller system to be monitored". 2] While the sub menu is selected, press the [U] button to display the monitoring information initial screen. q [U] button: Enter sub menu GD655-3E0, GD675-3E0 Press the [>] button or [<] button to select an item to be monitored. q [>] button: Go to next item q [<] button: Return to previous item a The monitoring items scroll in the order set internally. a If the button is held down, the items scroll fast. 15 SEN01836-00 2] 3] 4] 16 While the sub menu is selected, press the [U] button to display the monitoring code input screen. q [U] button: Enter sub menu Directly input the monitoring codes of the 2 items to be monitored with the buttons. q [>] button: Increase number at cursor q [<] button: Decrease number at cursor q [U] button: Enter number at cursor q [t] button: Return to code input screen a If the monitoring code on the left side is entered, the cursor moves to the monitoring code on the right side. If both monitoring codes are entered, the screen changes to the 2-item display screen. 30 Testing and adjusting 7) Information displayed in 2-item monitoring mode The following information is displayed in the 2-item monitoring mode. q Part 1: Monitoring code 1 q Part A: Monitoring data 1 (including unit) q Part 2: Monitoring code 2 q Part B: Monitoring data 2 (including unit) a When the monitoring data is q a number: The number + unit are displayed. q not a number: Letters are displayed. a For details, see the monitoring code table. 8) Holding and resetting of monitoring data While the machine monitor is monitoring, if the [U] button is pressed, the monitoring data is held and the [U] mark blinks. If the [U] button is pressed again, the monitoring data becomes active again. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 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 — SERIAL NUMBER 20402 8-digit — 10 Serial No. 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] No. Monitoring item Display of item Monitoring code Data display range Unit 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] No. Monitoring item Display of item Monitoring code Data display range Unit 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 SEN01836-00 30 Testing and adjusting MACHINE MONITOR [Machine monitor system] No. Monitoring item Display of item Monitoring code Data display range Unit 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 30 Testing and adjusting 13. Reduced cylinder mode [CYLINDER CUT-OUT] The machine monitor has the reduced cylinder mode to cut out a cylinder (injector) for troubleshooting of the engine. 1) Starting of engine a Since a failed cylinder is detected by the change of engine speed in the reduced cylinder mode, keep the engine running during the following operation. 2) Selection of menu 1] On the service mode menu screen, select "CYLINDER CUT-OUT". 2] While the menu is selected, press the [U] button to display the cylinder selection screen. q [U] button: Enter menu a The cylinder No. and engine speed are displayed simultaneously. GD655-3E0, GD675-3E0 SEN01836-00 3) Setting of cylinder to be cut out Select a cylinder to be cut out by switch operation. q [>] button: Selector cursor moves to right q [<] button: Selector cursor moves to left q [U] button: Enter cylinder q [t] button: Return to menu screen a If a cylinder to be cut out is entered 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 engine controller. The cylinder No. blinks during the communication. 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. 4) Resetting of cylinder cut out a Reset the cylinder cut out according to the setting procedure. 19 SEN01836-00 30 Testing and adjusting 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 tuning function mode. q Tuning of items related to articulate angle sensor 20 1) Selection of menu On the service mode sub menu screen, select "TUNING". 2) Display of sub menu While the menu is selected, press the [U] button to display the sub menu initial screen. q [U] button: Enter menu 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) GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 <Tuning procedure of actual machine> For the actual tuning procedure in each tuning menu, see the following. (1) Tuning procedure for articulate meter 0point This tuning is performed to have the communication controller recognize the 0-point of the articulate angle (straight travel posture). 1) Set the machine in the straight travel posture 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 SEN01836-00 15. Maintenance monitor function [MAINTENANCE MONITOR] The machine monitor can set the maintenance intervals of various filters and oils which are the basis of the filter/oil replacement time. The maintenance monitor function can be turned ON and OFF. 22 1) Selection of menu On the service mode menu screen, select "MAINTENANCE MONITOR". 2) Selection of filter/oil replacement interval setting item 1] While the menu is selected, press the [U] button to display the setting item initial screen. q [U] button: Enter menu 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 internally (See the filter/oil replacement 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). 30 Testing and adjusting 3) Displayed filter/oil replacement interval setting items If a maintenance item is selected, the following are displayed. q Part 1: Code (2 digits) q Part A: Filter/Oil replacement interval setting item q Part 2: Currently set interval q Part 3: Number replacement times up to now 4) Change of interval 1] While the setting item is selected, press the [U] button to display the interval change screen. q [U] button: Select change function GD655-3E0, GD675-3E0 30 Testing and adjusting 2] Press the [U] button again to display the interval input screen. q [U] button: Enter change function a The current interval is displayed on the lower line of the screen. 3] Input a new interval with the buttons. [>] button: Increase number at cursor q [<] button: Decrease number at cursor q [U] button: Enter number at cursor q [t] button: Return to item selection screen a Since the interval must be a 4digit value, input "0" to a position where no digit is required. After all the positions of the interval are entered, the change confirmation screen is displayed. Then, operate according to the displayed instruction. q [<] button: Select YES q [>] button: Select NO q [t] button: Enter SEN01836-00 5) Default setting function/operation a All the setting items can be changed to the initial values (default values) and the maintenance monitor function 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 function. q 4] GD655-3E0, GD675-3E0 2] Press the [U] button again, and the change confirmation screen is displayed. Then, operate according to the displayed instruction. q [<] button: Select YES q [>] button: Select NO q [t] button: Enter 23 SEN01836-00 6) 30 Testing and adjusting 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 function. 3] 2] Press the [U] button again, and the change confirmation screen is displayed. Then, change the setting screen with the [<] button and [>] button. q [<] button: Select YES q [>] button: Select NO q [t] button: Enter Press the [U] button again, and the change confirmation screen is displayed. Then, change the setting screen with the [<] button and [>] button. a If the setting screen is changed, the upper half of the following figure is displayed first. q [<] button: Select OFF screen q [>] button: Select ON screen Filter/Oil setting items and replacement intervals No. 24 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 — GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 16. Option selection function [OPTIONAL SELECTION] 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 SEN01836-00 17. Low idle fixing function [ENG LOW IDLE] The machine monitor has a function of fixing the engine speed to low idle forcibly. This function is used to prevent the engine from running at high speed to break the hydraulic system when it is started again after disassembled and assembled. 26 1) Selection of menu 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 accelerator 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 30 Testing and adjusting 18. Initializing function [INITIALIZE] a This function is special for the factory and not used for the service. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 Self-diagnosis display of gear shift lever q q q q q 1 The gear shift lever has error indicator (1) for self-diagnosis. 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. 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.) For errors other than above, see the troubleshooting volume. The self-diagnosis display of the gear shift lever is shown in the following table. Display of indicator Turned ON 1 time and OFF for 2 seconds repeatedly Condition Remedy Return gear shift lever to N position and then set it Gear shift lever is held between gear in desired gear speed. If error is not reset by this 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 Electric circuit has short circuit. for 2 seconds repeatedly Since the gear shift lever may have trouble, carry out related troubleshooting. Turned ON 4 times and OFF Gear shift lever system must be for 2 seconds repeatedly reset. Restart engine. If condition does not change, gear shift lever may have trouble. Carry out related troubleshooting. Kept ON Power supply is unstable. Since the ground wire or power supply circuit may have trouble, carry out related troubleshooting. OFF Gear shift lever is normal. — GD655-3E0, GD675-3E0 27 SEN01836-00 30 Testing and adjusting Handling of high-voltage circuit of engine controller 1 k a k The engine controller has a high-voltage circuit (110 – 130 V) to drive the fuel injector. This circuit is connected to the wiring harness an d con nectors between th e engine controller and fuel injector. 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. 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 highvoltage 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 30 Testing and adjusting Preparatory work for troubleshooting for electrical equipment system SEN01836-00 1 a When carrying out troubleshooting for an electric 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. 2) Transmission controller a The transmission controller is installed in the right side box. 1) Remove the 4 mounting bolts and cover (3). Insert or connect troubleshooting T-adapters in or to connectors FP1 and FP2 of the machine monitor. 2) 2. Insert or connect troubleshooting T-adapters 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} Engine controller a The engine controller is installed to the side of the engine on the left side of the machine. 1) Insert or connect troubleshooting T-adapters 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 SEN01836-00 Moving machine when transmission valve fails a k k k k k 1. 30 30 Testing and adjusting 2. Disconnect wiring connectors (2). (14 places) 3. Depending on the direction for moving the machine (forward or reverse), remove the following 2 ECMV solenoids (3) and install plug (K). q FORWARD: FL solenoid and 2nd solenoid q REVERSE: R solenoid and 2nd solenoid a If there is any mistake in the selection of the solenoid to remove, there is danger that the transmission may be damaged. a Install plug (K) with the protruding surface facing the ECMV. Check also that there is an O-ring installed to the mating surface. a Be careful not to let any dirt or mud get inside the removed solenoid or valve. 1 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). Plug (K) is only for emergency use when the machine cannot be moved by any other means because of a failure in the transmission control valve system. It is only used to move the machine from a dangerous working area to a safe place for repairs. When carrying out this operation, keep strictly to the procedure and pay careful a t t e n t i on t o s a f e t y w h e n mo vi n g t h e machine. To prevent the machine from moving, lower the work equipment completely to the ground, apply the parking brake, and put blocks under the tires. Carry out operation with the engine stopped. Be careful not to burn yourself if the oil is hot. Remove valve cover (1) at front of transmission. a Clean around the ECMV and remove all dirt and dust. GD655-3E0, GD675-3E0 30 Testing and adjusting 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. Remove the blocks under the tires. When the engine is started, the transmission 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. After moving the machine, stop the engine, apply the parking brake, and put blocks under the tires. k k k GD655-3E0, GD675-3E0 SEN01836-00 31 SEN01836-00 Adjusting cab stopper bolt 1. 30 Testing and adjusting 1 5. Check clearance (a) between door handle (5) and cab (surface of glass). q Clearance (a) = 8 mm 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 (standard) 8. If clearance (a) is less than 8 mm, move the mounting of door striker (3) out from the surface of door glass (6) by an amount equal to clearance (a) – 8 mm. Fit the door to the cab again and check that clearance (a) is 8 mm. 9. If the center of door striker (3) is not aligned, remove door link cover (2) and move door striker (3) up or down to set it in the center. Remove 4 stopper bolts (1). (Top, bottom, left, right) 2. Check that door striker (3) is properly set and is not angled to the left or right. 3. Fit door striker (3) to lock (4) on the cab. 4. Check that the centers of door striker (3) and lock (4) on cab are aligned. 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 30 Testing and adjusting SEN01836-00 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 SEN01836-00 How to start operation of KOMTRAX terminal 30 Testing and adjusting 3) 1 In the case where the KOMTRAX terminal has already been installed at the plant before shipment: a Implement the following procedure in the case where the KOMTRAX terminal has already been installed at the plant before shipment (as standard equipment). 1. Notification of model, model number and serial number Notify the model, model number and serial number of the machine to the KOMTRAX operations administrator. 2. Registration of machine The KOMTRAX operations administrator registers the machine using a KOMTRAX client personal computer. a Refer to "Manual for KOMTRAX operations administrator" for the procedure. a Now the terminal is ready for use. In the case where the KOMTRAX terminal is retrofitted 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 connector are installed in the right console box. a Complete procedures 4) – 7) in 30 seconds. 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. q Test connector 1: CHK0 q Test connector 2: CHK1 34 4) 5) 6) 7) 8) Disconnect test connector 1 and keep that condition for 5 seconds. Turn on the starting switch ON and keep that condition for 5 seconds. Disconnect test connector 2 and keep that condition for 5 seconds. Reconnect test connector 1 and keep that condition for 5 seconds. Reconnect test connector 2 and keep that condition for 5 seconds. Check that the 7-segment indicator lamp of the KOMTRAX terminal is indicating normally. a a Move on to the next step if you can check that the display is [Normal]. If the display is [Abnormal], start from procedure 1) again. GD655-3E0, GD675-3E0 30 Testing and adjusting 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 procedure 1) again. 10) Return the starting switch to the ON position 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 trouble] 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 indicated, check if there is any abnormality on the appearance of the communication antenna or cable. If there is any abnormality, repair it then repeat from procedure 1) again. a If [GPS position data detection trouble and communication trouble] is indicated, check if there is any abnormality on the GPS antenna/cable or communication antenna/cable. If there is any abnormality, repair it and start from procedure 1) again. a If [Fuel sensor trouble] is indicated, check the display of [LED-C4] referring to "Lamp display of KOMTRAX terminal". If the fuel sensor is not recognized, check the fuel sensor harness of the KOMTRAX terminal, and then if there is any abnormality, repair it and start from procedure 1) again. SEN01836-00 9) GD655-3E0, GD675-3E0 13) Turn the starting switch OFF. 14) Check that the 7-segment indicator lamp is indicating normally in 10 seconds. a If you can check that the display is [Normal], that is the end of sign-up test. a If the display shows [Abnormal], r ep eat fr om pr oc ed ur e 1) ag ai n because the sign-up test has not been completed successfully. 35 SEN01836-00 2. Application for the start of use a Application for the start of use should be made only after the sign-up test is finished. 1) Notify to the KOMTRAX operations administrator 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) 36 30 Testing and adjusting The KOMTRAX operations administrator registers the machine using KOMTRAX client personal computer. a Refer to "Manual for KOMTRAX operations administrator" for the procedure. a Now the terminal is ready for use. GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 Lamp display of KOMTRAX terminal Communication module LED 1. LED-A1 (Power indicator lamp) 2. LED-A2 (Within corresponding area lamp) 3. LED-A3 (During correspondence lamp) 4. LED-A4 (Internal transmitting lamp) 5. LED-A5 (Internal reception lamp) 1 7-segment and dot for CPU 12. 7-segment (number of unsent mails) 13. Dot (GPS positioning status) 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 SEN01836-00 30 Testing and adjusting 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 normally. 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 1 LED-A1 Power indicator lamp 2 LED-A2 Within corresponding area lamp 3 LED-A3 During correspondence lamp 4 LED-A4 Internal transmitting lamp 5 LED-A5 Internal reception lamp Display ON OFF ON OFF ON OFF ON OFF ON 38 OFF Contents of display The LED is ON when the electric power is normally supplied. The LED is ON when the machine is within the corresponding area of the KOMTRAX system. The LED is ON when the KOMTRAX terminal is connected to the KOMTRAX server. (The connection should be made only when it is necessary.) The LED is ON when the CPU transmits data to the communication module. (Transmitting should be made only when it is necessary.) The LED is ON when the CPU receives data from the communication module. (Reception should be made only when it is necessary.) GD655-3E0, GD675-3E0 30 Testing and adjusting 2. No. SEN01836-00 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. LED Name/Function Display ON 6 Starting switch ACC sig- Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON LED-C1 nal and alternator R sigSlow blinking Starting switch ACC signal: ON, alternator R signal: OFF nal OFF Starting switch ACC signal: OFF, alternator R signal: OFF Engine control signal status ON Engine control signal: ON OFF Engine control signal: OFF 7 LED-C2 8 ON S-NET connection staFast blinking LED-C3 tus and starting switch C Slow blinking signal status OFF ON 9 Contents of display Starting switch ACC signal: ON, alternator R signal: ON LED-C4 CAN status and fuel sensor status LED-C5 11 LED-C6 Download and wiring status Starting switch C signal: ON (Not used) S-NET: Unconnected, starting switch C signal: OFF CAN: active (fuel sensor: no communication) Fast blinking CAN: active (fuel sensor: in communication) Slow blinking CAN: Inactive (fuel sensor: in communication) OFF 10 S-NET: connected, starting switch C signal: OFF CAN: Inactive (fuel sensor: no communication) Either one Download and wiring status (special function for system is ON administrator) Both are OFF Normal operation method 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. No. 12 13 LED Name/Function 7-seg- Number of unsent ment mails Dot GPS positioning status Display 0–9 Contents of display Number of unsent mails ON GPS positioning has been completed. (Position has been recognized. Refer to *.) OFF GPS positioning has not been completed. (Position has 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 SEN01836-00 30 Testing and adjusting Pm-clinic 1 Model Serial No. Service meter GD655-3E0 GD675-3E0 h 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 Construction Construction, civil engineering Quarry, mine Coal Others ( Grading % Ditching Ripping % % Sand Sandy loam Bank cutting % Travel % Clay Snow removal Others ( Roads Gold Limestone Soft Others ( ) ) Type of work Type of soil Rock Medium Gravel Hard % % ) Existence of abnormalities Oil, coolant level check Engine coolant level Hydraulic oil level Engine oil level Transmission case Final drive Tandem case Engine coolant temperature max. range Circle reverse gear case Power train oil temperature max. range Ambient temperature Max. Min. Ambient temperature Height above sea level Height above sea level °C m Existence of abnormalities Operator's opinion Visual check results Failure code history h h Content: Content: h h Content: a 40 Engine coolant temperature max. range Content: a Power train oil temperature max. range GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 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 SEN01836-00 30 Testing and adjusting Pm-clinic measuring points (2/3) Reference items (pages) in “Testing and adjusting, Part 1” for measurement procedure *6. Power train oil pressure: Checking clutch oil pressure (Page 15) Checking torque converter oil pressure (Page 16) 42 GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 Pm-clinic measuring points (3/3) Reference items (pages) in “Testing and adjusting, Part 1” for measurement procedure *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 SEN01836-00 30 Testing and adjusting Pm-clinic check sheet (1/3) hour check Work order Engine speed Engine Engine serial No. SAA6D114E-3 # Service meter / h Measurement conditions • Engine coolant temperature: Within operating range • Torque converter oil temperature: 60 – 80°C Blow-by pressure • Torque converter stall Engine oil pressure SAE15W-40 oil Engine coolant temperature: Within operating range Boost pressure • Torque converter stall Exhaust temperature • Torque converter stall + Work equipment relief Check item Unit Low idle High idle Torque converter stall rpm kPa {mmH2O} Rated speed Low idle MPa {kg/cm2} kPa {mmHg} Ambient temperature Exhaust temperature Measurement conditions Unit High idle • Torque converter oil temperature: 60 – 80°C Torque converter inlet High idle • Set gear shift lever in P position or pressure each gear speed position and run Torque converter outHigh idle under no load. let pressure Torque converter lockup clutch presHigh idle sure FL MPa {kg/cm2} R FH Transmission control valve set pressure • Oil temperature: 60 – 80°C • Engine at full throttle 1ST 2ND 3RD 4TH Check item Brake accumulator charge pressure Wheel brake actuating pressure Measurement conditions • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • • • Braking distance with • wheel brake 44 Standard value Service limit for new machine value 800 – 850 800 – 850 2,175 – 2,275 2,175 – 2,275 1,590 – 1,790 — <Max. 1.6> {<Max. 160>} <Max. 2.55> {<Max. 260>} 0.34 – 0.59 {3.5 – 6.0} Min. 0.15 {Min. 1.5} 133 – 173 {1,000 – 1,300} Min. 0.21 {Min. 2.1} Min. 0.08 {Min. 0.8} Max. 107 {Max. 800} 2.0 2.0 Max. 650 Max. 650 Standard value for new machine 2.12 – 2.52 {21.7 – 25.7} 2.26 – 2.66 {23.1 – 27.1} 0.83 – 0.93 {8.5 – 9.5} 0.54 – 0.64 {5.5 – 6.5} Service limit value 2.12 – 2.52 {21.7 – 25.7} 2.26 – 2.66 {23.1 – 27.1} 0.83 – 0.93 {8.5 – 9.5} 0.54 – 0.64 {5.5 – 6.5} 1.86 – 2.16 {19 – 22} 1.86 – 2.16 {19 – 22} 1.96 – 2.45 {20 – 25} 2.06 – 2.45 {21 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 2.06 – 2.45 {21 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} 1.96 – 2.45 {20 – 25} < >: Reference value Measurement Pass Fail results °C Low idle Power train main relief pressure Brake Serviceman Check after starting engine! Torque converter oil temperature must not exceed 90°C when torque converter is stalled! Check item Power train oil pressure GD655-3E0 # GD675-3E0 # Date / a Machine serial No. Measurement Pass Fail results Standard value Service limit Measurement Pass Fail for new machine value results 9.36 – 9.56 9.36 – 9.56 {95.5 – 97.5} {95.5 – 97.5} MPa 12.26 – 13.24 12.26 – 13.24 {125 – 135} {125 – 135} {kg/cm2} 3.59 – 4.0 3.59 – 4.0 {37 – 41} {37 – 41} Max. 18.4 m Max. 17.7 (ISO 3450 = 18.4 m) Unit Cut-in pressure Cut-out pressure Hydraulic oil temperature: 45 – 55°C Engine at high idle Hydraulic oil temperature: 45 – 55°C Braking distance required when initial speed is 38.2 km/h (under conditions by ISO 3450) GD655-3E0, GD675-3E0 30 Testing and adjusting SEN01836-00 Pm-clinic check sheet (2/3) Steering Check item • • • • Play of steering wheel • Steering oil pressure Work equipment oil pressure and LS differential pressure Standard value for new machine Service limit value MPa {kg/cm2} 18.1 – 18.8 {185 – 192} — mm 0 – 10 — Unit Standard value for new machine Service limit value °C — — Unload pressure 1.82 – 3.78 {19 – 39} — Work equipMPa ment relief pressure {kg/cm2} 19.6 – 21.6 {200 – 220} — 2.25 – 2.45 {23 – 25} — Standard value for new machine 2.3 – 3.1 2.3 – 3.1 2.3 – 3.1 2.3 – 3.1 8.0 – 10.2 8.0 – 10.2 6.2 – 8.4 6.4 – 8.6 7.5 – 10.1 7.5 – 10.1 Service limit value 4.0 4.0 4.0 4.0 11.0 11.0 10.0 10.0 12.0 12.0 3.35 – 4.75 7.0 3.78 – 5.38 7.0 6.17 – 8.17 6.17 – 8.17 1.97 – 2.77 14.0 14.0 6.0 2.06 – 2.86 6.0 1.7 – 2.3 1.7 – 2.3 3.0 3.0 Standard value for new machine Service limit value 10 20 20 35 0 0 10 20 20 35 Hydraulic oil temperature: 45 – 55°C Engine at high idle Steering relief Engine at low idle Float front wheels. Check item Measurement conditions Hydraulic tank sur• face temperature • • Work equipment oil • pressure • LS differential pressure Unit Measurement conditions Engine stopped Hydraulic oil temperature: 45 – 55°C Engine at high idle Unload pressure: All work equipment in neutral Work equipment relief pressure: Blade lift cylinder raise relief • Hydraulic oil temperature: 45 – 55°C • Engine at high idle • During blade turning operation Check item Measurement conditions Raise Lower Raise Right blade lifting speed Lower Left shift Blade side shift speed Right shift • Hydraulic oil temperature: 35 – 45°C Left shift Drawbar side shift • Engine at high idle speed • Blade lift: In 350-mm stroke of cylinder. Right shift Operate right and left sides separately. Left turn Blade turning speed • Blade side shift: In cylinder stroke • Drawbar side shift: At 100 mm of blade Right turn Wide cutbottom height. In cylinder stroke. ting angle • Blade turn: From start of turn to 90° Power tilt turning • Power tilt: In cylinder stroke speed Narrow cut• Articulation: In cylinder stroke ting angle • Leaning: In cylinder stroke Left turn • Scarifier lifting: In 180 mm of stroke Articulation speed Right turn Left leaning Leaning speed Right leaning Raise Scarifier lifting speed Lower Unit Work equipment speed Left blade lifting speed a Measurement Pass Fail results Measurement Pass Fail results Set blade and stop engine! Check item Work equipment hydraulic drift and oil leakage sec. Measurement Pass Fail results Blade hydraulic drift (No load on cylinder) Blade hydraulic drift (Raising of machine) Measurement conditions • • • • • • • • • Work equipment cyl• inder oil leakage • • Scarifier hydraulic • drift (No load on cylin• der) • • Scarifier hydraulic drift (Raising of • machine) • • Right and left blade lift cylinders: Raise stroke end Hydraulic oil temperature: 35 – 45°C Engine stopped Cylinder extraction in 10 minutes after finish of setting Right and left blade lift cylinders: Lower stroke end (Push-up of machine) Hydraulic oil temperature: 35 – 45°C Engine stopped Cylinder retraction in 10 minutes after finish of setting Hydraulic oil temperature: 35 – 45°C Engine at high idle When cylinder is relieved Scarifier cylinder at raise stroke end Hydraulic oil temperature: 35 – 45°C Engine stopped Cylinder extraction in 10 minutes after finish of setting Scarifier cylinder at lower stroke end (Push-up of machine) Hydraulic oil temperature: 35 – 45°C Engine stopped Cylinder retraction in 10 minutes after finish of setting GD655-3E0, GD675-3E0 Unit Measurement Pass Fail results mm cc/min mm 45 SEN01836-00 30 Testing and adjusting Pm-clinic check sheet (3/3) a Replace with spare plug FD Check item Visual check of final drive drain plug Tire Check item Tire inflation pressure Measurement conditions • Engine stopped Unit — Measurement conditions Unit Standard value Service limit for new machine value There must not be abnormally much metal powder. Measurement Pass Fail results Standard value for new machine Measurement Pass Fail results Front left wheel Front right wheel 14.00-24-10PR: Rear left front wheel kPa 14.00-24-12PR: {kg/cm2} Rear left rear wheel 17.5R25: Rear right front wheel Rear right rear wheel Service limit value 350 {3.5} 450 {4.5} 375 {3.75} Memo: Write phenomena and information you noticed during today's check. 46 GD655-3E0, GD675-3E0 30 Testing and adjusting GD655-3E0, GD675-3E0 SEN01836-00 47 SEN01837-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 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 SEN01837-00 40 Troubleshooting Failure code table and fuse locations 1 Failure code table 1 Failure code Failure contents (DF1000) Neutral safety 2G42ZG Decrease of accumulator oil pressure (Front) Con- Action troller code History classification TM — — MON E03 Mechanical system 2G43ZG Decrease of accumulator oil pressure (Rear) MON E03 Mechanical system AB00L6 MON E03 Electrical system Signal of alternator disagrees with operating state of engine 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 Mechanical system B@CKNS Differential oil overheat 2 TM E02 CA111 Abnormality in engine controller ENG E03 Electrical system CA115 Abnormality in engine NE and Bkup speed sensor 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 CA153 Charge temperature sensor too high ENG E01 Electrical system CA154 Charge temperature sensor too low ENG E01 Electrical system 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 CA323 Disconnection or short circuit in injector No.5 ENG E03 Electrical system CA324 Disconnection or short circuit in injector No.3 ENG E03 Electrical system CA325 Disconnection or short circuit in injector No.6 ENG E03 Electrical system CA331 Disconnection or short circuit in injector No.2 ENG E03 Electrical system CA332 Disconnection or short circuit in injector No.4 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 CA435 Abnormality in engine oil pressure switch ENG E01 Electrical system CA441 Power supply voltage too low ENG E03 Electrical system 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 Reference document No. GD655-3E0, GD675-3E0 40 Troubleshooting Failure code CA553 SEN01837-00 Failure contents Common rail pressure too high (1) Con- Action troller code ENG E03 History classification 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 CA2185 Accelerator pedal sensor power source too high ENG E03 Electrical system CA2186 Accelerator pedal sensor power source too low ENG E03 Electrical system 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 D5ZHL6 Terminal C signal does not match state of engine DAQ0KK Power source voltage of Transmission controller too low DAQSKR Communication controller cannot recognize S-NET TM E01 Electrical system MON E01 Electrical system TM E03 Electrical system 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 The voltage of the 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 (lock-up clutch fill switch) TM E03 Electrical system DDTHKA Disconnection in FH clutch fill switch TM E03 Electrical system Fill signal is ON when command current is OFF DDTHKB (FH clutch fill switch) TM E03 Electrical system DDTJKA Disconnection in FL clutch fill switch TM E03 Electrical system Fill signal is ON when command current is OFF DDTJKB (FL clutch fill switch) TM E03 Electrical system DDTKKA Disconnection in 1st clutch fill switch TM E03 Electrical system Fill signal is ON when command current is OFF DDTKKB (1st clutch fill switch) TM E03 Electrical system DDTLKA Disconnection in 2nd clutch fill switch TM E03 Electrical system Fill signal is ON when command current is OFF DDTLKB (2nd clutch fill switch) TM E03 Electrical system DDTMKA Disconnection in 3rd clutch fill switch TM E03 Electrical system TM E03 Electrical system TM E03 Electrical system TM E03 Electrical system DDTPKA Disconnection in 4th clutch fill switch TM E03 Electrical system Fill signal is ON when command current is OFF DDTPKB (4th clutch fill switch) TM E03 Electrical system DDTMKB Fill signal is ON when command current is OFF (3rd clutch fill switch) DDTNKA Disconnection in R clutch fill switch DDTNKB Fill signal is ON when command current is OFF (R 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 DGT1KX Torque converter oil temperature out of range TM E01 Electrical system GD655-3E0, GD675-3E0 Reference document No. 3 SEN01837-00 Failure code 40 Troubleshooting Failure contents DJF1KA Disconnection in fuel level sensor Con- Action troller code MON History classification E01 Electrical system DK10KX Input of acceleration pedal potentiometer out of normal range TM E01 Electrical system DK70KX Input of inching pedal potentiometer out of normal range TM E03 Electrical system COM E01 Electrical system TM E03 Electrical system DKD0KA Disconnection in articulate sensor DLE2KA Disconnection in engine speed sensor DLF1KA Disconnection in transmission input speed sensor TM E03 Electrical system DLT3KA Disconnection in transmission output speed sensor TM E03 Electrical system MON E01 Electrical system DW4BKA Disconnection in parking brake relay DV00KB Short circuit in caution buzzer TM E03 Electrical system DXH1KA Disconnection in lock-up ECMV solenoid TM E03 Electrical system DXH1KY Power supply line short in lock-up ECMV solenoid TM E03 Electrical system DXH2KA Disconnection in FH clutch ECMV solenoid TM E03 Electrical system 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 a a a 4 Reference document No. 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. 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 Action code: Action code indicates what is displayed in the operator mode when a failure is detected. History classification: History classification indicates in which system, either electrical system or mechanical system in the failure history displayed function, a failure has been recorded. GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01837-00 5 SEN01837-00 40 Troubleshooting 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 circuit 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 Type of power supply Switched power supply starting switch ACC Switched power supply slow blow fuse (80A) Constant power supply slow blow fuse (30A) 6 Fuse No. Capacity of circuit breaker 1 5A Engine controller (B) circuit 2 3 10A 10A Horn circuit Back up alarm and lamp circuit 4 5 10A 20A Brake lamp circuit Illumination circuit 6 7 10A 20A Transmission controller circuit Front work lamp circuit 8 9 20A 10A Rear work lamp circuit Cigar lighter circuit 10 11 10A 20A Solenoid power Heater circuit 12 13 20A 10A 12V converter circuit (if equipped) Starting switch terminal B circuit 14 15 10A 10A Turn signal and hazard lamp circuit Monitor and communication controller Destination of power GD655-3E0, GD675-3E0 40 Troubleshooting SEN01837-00 Fuse box II Type of power supply Fuse No. 1 Switched power supply slow blow fuse (80A) Constant power supply slow blow fuse (30A) GD655-3E0, GD675-3E0 Capacity Destination of power of fuse 20A Wiper front upper circuit 2 3 20A 10A Wiper front lower circuit Beacon lamp, Defroster fan circuit (if equipped) 4 5 10A 5A Cab work lamp circuit (if equipped) Air conditioner controller 6 7 10A 10A Cab work lamp circuit (if equipped) Rear wiper circuit 8 9 5A 5A Air conditioner compressor Radio 10 11 — 20A Rear window defroster 12 13 — 5A Constant power for cab option 14 15 15A — Air conditioner blower fan circuit 7 SEN01837-00 40 Troubleshooting Slow blow fuse, Circuit breaker Slow blow fuse Type of power supply Constant power supply Switched power supply Slow blow Capacity fuse No. of fuse 1 30A 2 80A 3 120A Circuit breaker No. Capacity of fuse 4 20A Destination of power Starting switch terminal B circuit, Turn signal circuit, Hazard lamp 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, Illumination circuit, Transmission controller circuit, Front work lamp circuit, Rear work lamp circuit, Cigar lighter circuit, Solenoid power, Heater circuit, 12V converter circuit (if equipped), Wiper front upper 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 Heater relay circuit Circuit breaker Type of power supply Constant power supply 8 Destination of power Engine controller (A) circuit GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01837-00 9 SEN01838-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 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 SEN01838-00 40 Troubleshooting General information on troubleshooting 1 Points to remember when troubleshooting 1 k k k k k k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. 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 connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent 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 symptoms. 1. 2. 3. 4. 5. 6. 2 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 procedure. 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? 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. 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 investigation or measurement that may make the problem worse. 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. 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. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01838-00 Sequence of events in troubleshooting 1 GD655-3E0, GD675-3E0 3 SEN01838-00 40 Troubleshooting Testing before troubleshooting Check item 1 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 Check final drive oil level — Add oil Check tandem drive oil level — Add oil 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 Check for looseness and corrosion of battery cable terminals — Retighten or replace Check for looseness and corrosion of alternator harness terminals — Retighten or replace Check for looseness and corrosion of starting motor harness terminals — Retighten or replace Check operation of instruments — Repair or replace Check for abnormal noise and smell — Repair Check for oil leakage — Repair Carry out air bleeding — Bleed air 20 – 30 V Replace Lubricating 7. oil and cool8. ant 9. 1. 2. Electrical equipment 3. 4. Hydraulic 1. and 2. mechanical equipment 3. 1. Check battery voltage (engine stopped) 2. Check battery electrolyte level — Refill or replace 3. Check for discoloration, burn-out of wiring, and peeling of harness coating — Replace 4. Check for missing wiring clamps and a slack of wire — Repair Electrical 5. equipment Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals) — Disconnect connector and dry 6. Check of blown or corroded fuse — Replace 7. Check alternator voltage (engine running at half throttle or above) After running for several minutes: 27.5 – 29.5 V Replace 8. Check of operating noise of battery relay (when turning the starting switch ON or OFF) — Replace 4 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01838-00 Classification and procedures of troubleshooting 1 Classification of troubleshooting code Troubleshooting code Code display Contents 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 failure 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 troubleshooting 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 SEN01838-00 Connection table for connector pin numbers 40 Troubleshooting 1 a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. 6 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 7 SEN01838-00 8 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 9 SEN01838-00 10 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 11 SEN01838-00 12 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 13 SEN01838-00 14 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 15 SEN01838-00 16 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 17 SEN01838-00 18 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 19 SEN01838-00 20 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 21 SEN01838-00 22 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 23 SEN01838-00 24 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 25 SEN01838-00 26 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 27 SEN01838-00 28 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 29 SEN01838-00 30 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 31 SEN01838-00 32 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01838-00 33 SEN01838-00 34 40 Troubleshooting GD655-3E0, GD675-3E0 40 Troubleshooting SEN01838-00 T-adapter box and T-adapter table 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. 799-601-2600 T-box (for ECONO) 21 799-601-3100 T-box (for MS) 37 799-601-3200 T-box (for MS) 37 q q q q Out of kit 799-601-4200 799-601-4100 799-601-9300 799-601-9200 799-601-9100 799-601-9000 799-601-8000 799-601-7500 799-601-7400 799-601-7100 799-601-7000 799-601-2800 Identification symbol 799-601-2700 Part name T-adapter kit 799-601-2500 Part No. Number of pins a 1 q q 799-601-3380 • Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q 799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q 799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q 799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q 799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q q 799-601-3470 Case 799-601-2710 Adapter for MIC 5 MIC-5P q q 799-601-2720 Adapter for MIC 13 MIC-13P q q 799-601-2730 Adapter for MIC 17 MIC-17P q q q 799-601-2740 Adapter for MIC 21 MIC-21P q q q 799-601-2950 Adapter for MIC 9 MIC-9P 799-601-2750 Adapter for ECONO 2 ECONO2P q q 799-601-2760 Adapter for ECONO 3 ECONO3P q q 799-601-2770 Adapter for ECONO 4 ECONO4P q q 799-601-2780 Adapter for ECONO 8 ECONO8P q q 799-601-2790 Adapter for ECONO 12 ECONO12P q q 799-601-2810 Adapter for DLI 8 DLI-8P q q 799-601-2820 Adapter for DLI 12 DLI-12P q q 799-601-2830 Adapter for DLI 16 DLI-16P q q 799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q q q q q q q q q q q q q q 799-601-2850 Case 799-601-4210 Adapter for DRC 50 799-601-7010 Adapter for X (T-adapter) 1 799-601-7020 Adapter for X 2 799-601-7030 Adapter for X 799-601-7040 Adapter for X q DRC50 q q X2P q q q q 3 X3P q q q q 4 X4P q q q q 799-601-7050 Adapter for SWP 6 SW6P q q q 799-601-7060 Adapter for SWP 8 SW8P q q q 799-601-7310 Adapter for SWP 12 SW12P 799-601-7070 Adapter for SWP 14 SW14P 799-601-7320 Adapter for SWP 16 SW16P 799-601-7080 Adapter for M (T-adapter) 1 799-601-7090 Adapter for M 2 GD655-3E0, GD675-3E0 M2P q q q q q q q q q q 35 SEN01838-00 40 Troubleshooting S8P q q q q q Out of kit M8P 8 799-601-4200 8 799-601-7140 Adapter for S 799-601-4100 799-601-7340 Adapter for M 799-601-9300 q 799-601-9200 q q q 799-601-9100 M6P 799-601-9000 6 799-601-8000 q 799-601-7130 Adapter for M 799-601-7500 q q q q 799-601-7400 q q q M4P 799-601-7100 M3P 4 799-601-7000 3 799-601-2800 799-601-7110 Adapter for M 799-601-7120 Adapter for M Part name 799-601-2700 Identification symbol Part No. 799-601-2500 Number of pins T-adapter kit q 799-601-7150 Adapter for S (White) 10 S10P 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 799-601-7330 Adapter for S (White) 16 S16PW 799-601-7350 Adapter for S (White) 12 S12PW q q q q 799-601-7180 Adapter for AMP040 8 A8P 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 q q 799-601-7240 Case q 799-601-7270 Case 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 799-601-9030 Adapter for DT 3 DT3 q q 799-601-9040 Adapter for DT 4 DT4 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 12 DT12BR q q 799-601-9210 Adapter for HD30-18 8 D18-8 q q 799-601-9220 Adapter for HD30-18 14 D18-14 q q 799-601-9230 Adapter for HD30-18 20 D18-20 q q 799-601-9240 Adapter for HD30-18 21 D18-21 q q 799-601-9250 Adapter for HD30-24 9 D24-9 q q 799-601-9260 Adapter for HD30-24 16 D24-16 q q 799-601-9270 Adapter for HD30-24 21 D24-21 q q 799-601-9280 Adapter for HD30-24 23 D24-23 q q 36 GD655-3E0, GD675-3E0 40 Troubleshooting 799-601-9290 Adapter for HD30-24 799-601-9320 T-box (for DT/HD) 12 Out of kit 799-601-4200 799-601-4100 799-601-9300 799-601-9200 799-601-9100 799-601-9000 799-601-8000 799-601-7500 799-601-7400 799-601-7100 799-601-7000 D24-31 799-601-2800 31 799-601-9310 Plate for HD30 (24-pin) 799-601-2700 Identification symbol 799-601-2500 Part name T-adapter kit Number of pins Part No. SEN01838-00 q q q q q q q q q 799-601-9330 Case q 799-601-9340 Case 799-601-9350 Adapter for DRC 40 DRC-40 q 799-601-9360 Adapter for DRC 24 DRC-24 q 799-601-9410 Adapter for engine (CRI-T2) 2 G q 799-601-9420 Adapter for engine (CRI-T2) Adapter for engine (CRI-T3) PFUEL 3 A3 q q 799-601-9430 Adapter for engine (CRI-T2) Adapter for engine (CRI-T3) PCV 2 P q q 799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q 795-799-5520 Adapter for engine (HPI-T2) 2 S q Adapter for engine (HPI-T2) 795-799-5530 Adapter for engine (CRI-T3) Temperature sensor 2 C q q 2 A q q 795-799-5540 Adapter for engine (HPI-T2) Adapter for engine (CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 3 q 795-799-5470 Cable for engine (HPI-T2) 3 q 795-799-5480 Cable for engine (HPI-T2) 3 q 799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N 799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q 3 FCIG q q 799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 2 4160 q q 799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q Adapter for engine (CRI-T3) 799-601-4190 Commonrail pressure 3 1,2,3L q q 4 1,2,3,4C q q 799-601-4240 Adapter for engine (CRI-T3) PAMB 3 1,2,3A q q 799-601-4250 Adapter for engine (CRI-T3) PIM 3 1,2,3B q q 799-601-4330 Adapter for engine (CRI-T3) G 3 1,2,3,G q q Adapter for engine (CRI-T3) 799-601-4340 Pump actuator 2 2,PA q q 799-601-9020 Adapter for engine (CRI-T3) Injector 2 DT2 q q 799-601-4140 799-601-4230 Adapter for engine (CRI-T3) Atmosphere pressure Adapter for engine (CRI-T3) Air intake pressure/temperature q 799-601-9040 Adapter for engine (CRI-T3) SEGR, SBP 4 DT4 q q 799-601-4260 Adapter for controller (ENG) 4 DTP4 q q 799-601-4211 Adapter for controller (ENG) 50 DRC50 q 799-601-4220 Adapter for controller (ENG) 60 DRC60 q 799-601-4280 Box for controller (PUMP) 121 799-601-9720 Adapter for controller (HST) 16 HST16A q 799-601-9710 Adapter for controller (HST) 16 HST16B q 799-601-9370 Adapter for controller (HST) 26 HST26A q GD655-3E0, GD675-3E0 q 37 SEN01839-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 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 SEN01839-00 40 Troubleshooting 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 [CA323] Disconnection or short circuit in injector No.5 ................................................. 52 Failure code [CA324] Disconnection or short circuit in injector No.3 ................................................. 54 Failure code [CA325] Disconnection or short circuit in injector No.6 ................................................. 56 Failure code [CA331] Disconnection or short circuit in injector No.2 ................................................. 58 Failure code [CA332] Disconnection or short circuit in injector No.4 ................................................. 60 2 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Troubleshooting by failure code, Part 1 1 Failure code [(DF1000)] Neutral safety 1 Action code Failure code — (DF1000) Contents of trouble Action of controller Trouble Neutral safety (Transmission controller system) • Starting switch was turned ON while lever is not in "P" or "N". • Does not transmit trouble information. Problem that appears on machine — Related information — GD655-3E0, GD675-3E0 3 SEN01839-00 40 Troubleshooting Failure code [2G42ZG] Decrease of accumulator oil pressure (Front) Action code Failure code E03 2G42ZG Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state 4 Trouble 1 Decrease of accumulator oil pressure (Front) (Machine monitor system) • Front accumulator oil pressure switch detected front accumulator pressure reduction while engine was running. • Blinks warning lamp and sounds alarm buzzer. • If trouble is repaired, system resets itself. • Brake oil pressure caution lamp lights up while engine is running. • Method of reproducing failure code: Start engine. Cause Standard value when normal and remarks for troubleshooting Front accumulator pressure 1 reduction (When system is normal) A phenomenon seems to have caused front accumulator pressure reduction during operation of engine. Find and stop it and repair the damaged part. 2 Carry out troubleshooting for brake oil pressure caution lamp sysDefective brake oil pressure tem in "E-14 Emergency stop item lights up while engine is running" caution lamp system in E mode. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Failure code [2G43ZG] Decrease of accumulator oil pressure (Rear) Action code Failure code E03 2G43ZG Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Trouble 1 Decrease of accumulator oil pressure (Rear) (Machine monitor system) • Rear accumulator oil pressure switch detected rear accumulator pressure reduction while engine was running. • Blinks warning lamp and sounds alarm buzzer. • If trouble is repaired, system resets itself. • Brake oil pressure caution lamp lights up while engine is running. • Method of reproducing failure code: Start engine. Cause Standard value when normal and remarks for troubleshooting Rear accumulator pressure 1 reduction (When system is normal) A phenomenon seems to have caused rear accumulator pressure reduction during operation of engine. Find and stop it and repair the damaged part. 2 Carry out troubleshooting for brake oil pressure caution lamp sysDefective brake oil pressure tem in "E-14 Emergency stop item lights up while engine is running" caution lamp system in E mode. GD655-3E0, GD675-3E0 5 SEN01839-00 40 Troubleshooting Failure code [AB00L6] Signal of alternator disagrees with operating state of engine Action code Failure code E03 AB00L6 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Signal of alternator disagrees with operation and stop of engine (Machine monitor system) • When engine is stopped, alternator terminal R input voltage is above 12 V. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself. • The engine does not start. • After the starting switch is simply turned ON, the service meter advances. • The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302, ALTERNATOR R). • Method of reproducing failure code: Start engine. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective alternator 1 (Internal defect) Possible causes and standard value in normal state Alternator Between terminal R (E03) and chassis ground Engine Voltage 27.5 – 29.5 V Start (Temperature of regu(Throttle: Above 1/2) lator case: 25°C) Stopped Max. 1 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting 2 Hot short in wiring harness (Contact with 24 V circuit) Between chassis ground and wiring harness between alternator terminal R – FP2 (female) (9), – starter terminal R, – G01 (female) (28), – circuit branch end point Voltage Max. 1 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. FP2 3 Defective machine monitor Between (9) and chassis ground Engine 27.5 – 29.5 V Start (Temperature of regu(Throttle: Above 1/2) lator case: 25°C) Stopped 6 Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to alternator GD655-3E0, GD675-3E0 7 SEN01839-00 40 Troubleshooting Failure code [AB00MA] Malfunction of alternator Action code Failure code E03 AB00MA Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Malfunction of alternator (Machine monitor system) • While the engine is running, the alternator terminal R input voltage is below 5 V. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself. • Deteriorated battery • The engine does not start. • The service meter does not advance. • The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302, ALTERNATOR R). • Method of reproducing failure code: Start engine. Cause 1 Deteriorated battery Standard value when normal and remarks for troubleshooting The battery may be deteriorated. Check it directly. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective alternator 2 (Internal defect) Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection or defective contact of connector) Alternator Between terminal R (E03) and chassis ground Engine Voltage 27.5 – 29.5 V Start (Temperature of regu(Throttle: Above 1/2) lator case: 25°C) Stopped Max. 1 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between alternator terminal R – FP2 (female) (9) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring harBetween chassis ground and wiring harness 4 ness (Contact with ground circuit) between alternator terminal R – FP2 (female) (9), – starter terminal R, – G01 (female) (28) Resistance Min. 1 Mz a Prepare with starting switch OFF, then start engine and carry out troubleshooting. FP2 5 Defective machine monitor Between (9) and chassis ground Engine 27.5 – 29.5 V Start (Temperature of regu(Throttle: Above 1/2) lator case: 25°C) Stopped 8 Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to alternator GD655-3E0, GD675-3E0 9 SEN01839-00 40 Troubleshooting Failure code [B@BAZG] Engine oil pressure too low Action code Failure code E03 B@BAZG Contents of trouble Action of controller Problem that appears on machine Related information 10 Engine oil pressure too low (Engine controller system) • Signal circuit of engine oil low pressure switch was closed (connected to GND) while engine was running. • Blinks warning lamp and sounds alarm buzzer. • Continues operation under normal control. • Engine oil pressure caution lamp lights up while engine is running. • If machine is operated as it is, engine may be seized. • Method of reproducing failure code: Start engine. Cause Possible causes and standard value in normal state Trouble 1 Standard value when normal and remarks for troubleshooting 1 Engine oil pressure reduction A phenomenon seems to have caused engine oil pressure reduc(When system is normal) tion. Find and stop it and repair the damaged part. 2 Carry out troubleshooting for engine oil pressure caution lamp sysDefective engine oil pressure tem in "E-14 Emergency stop item lights up while engine is running" caution lamp system in E mode. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Failure code [B@BCNS] Engine overheat Action code Failure code E02 B@BCNS Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Trouble 1 Engine overheat (Engine controller system) • Engine coolant temperature is above operating range. • Blinks warning lamp and sounds alarm buzzer. • Limits fuel injection rate until coolant temperature lowers to operating range. • If machine is operated as it is, engine may be seized. • Engine output lowers. • State (Temperature) of engine coolant can be checked with monitoring function. (Code: 04104 COOLANT TEMP) • Method of reproducing failure code: Turn starting switch ON. Cause Standard value when normal and remarks for troubleshooting Overheat of engine coolant 1 (When system is normal) A phenomenon seems to have caused overheat of engine coolant. Find and stop it and repair the damaged part. 2 Defective engine coolant temperature gauge system GD655-3E0, GD675-3E0 Carry out troubleshooting for "E-16 Engine coolant temperature gauge does not display normally". 11 SEN01839-00 40 Troubleshooting Failure code [B@CENS] Torque converter oil temperature too high Action code Failure code E02 B@CENS Contents of trouble Action of controller Problem that appears on machine Related information Trouble 12 Torque converter oil temperature too high (Machine monitor system) • Torque converter oil temperature is above operating range. • Blinks warning lamp and sounds alarm buzzer. • Torque converter oil temperature caution lamp lights up while engine is running. • If machine is operated as it is, torque converter may be seized. • State (Temperature) of torque converter oil can be checked with monitoring function. (Code: 30100 TC OIL TEMP) • Method of reproducing failure code: Turn starting switch ON. Cause Possible causes and standard value in normal state 1 Overheat of torque con1 verter oil (When system is normal) Standard value when normal and remarks for troubleshooting A phenomenon seems to have caused overheat of torque converter oil. Find and stop it and repair the damaged part. Defective torque converter 2 oil temperature caution lamp Carry out troubleshooting for failure code [DGT1KX]. system GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Failure code [B@CKNS] Differential oil overheat Action code Failure code E02 B@CKNS Contents of trouble Action of controller Problem that appears on machine Related information Trouble Differential oil overheat (Transmission controller system) • Differential oil temperature caution occurred. • Blinks warning lamp and sounds alarm buzzer. • Differential oil temperature caution lamp lights up while engine is running. • If machine is operated as it is, differential may be seized. • Method of reproducing failure code: Turn starting switch ON. Cause Possible causes and standard value in normal state 1 1 Overheat of differential oil (When system is normal) Standard value when normal and remarks for troubleshooting A phenomenon seems to have caused overheat of differential oil. Find and stop it and repair the damaged part. Defective differential oil tem- Carry out troubleshooting for differential oil temperature caution 2 perature caution lamp syslamp system in "E-14 Emergency stop item lights up while engine is tem running" in E mode. GD655-3E0, GD675-3E0 13 SEN01839-00 40 Troubleshooting Failure code [CA111] Abnormality in controller Action code Failure code E03 CA111 Contents of trouble Action of controller Problem that appears on machine Trouble 14 Abnormality in controller (Engine controller system) • An abnormality occurs in internal memory or internal power supply circuit. • Takes no particular action. • Engine can not start. Related information Possible causes and standard value in normal state 1 — Cause Standard value when normal and remarks for troubleshooting 1 Defective engine controller Internal defect of engine controller is suspected. (It cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Failure code [CA115] Abnormality in engine Ne and Bkup speed sensors Action code Failure code E03 CA115 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Trouble 1 Abnormality in engine Ne and Bkup speed sensors (Engine controller system) • Abnormality occurred in both signals of engine Ne speed sensor and engine Bkup speed sensor. • Takes no particular action. • Engine stops. • Engine does not start. • Duplication of failure code: start the engine. Cause 1 Standard value when normal and remarks for troubleshooting Defective connection of sen- The defective (wrong) connections of engine Ne and Bkup speed sor connector sensor connectors are suspected. Visually check it. GD655-3E0, GD675-3E0 15 SEN01839-00 40 Troubleshooting Failure code [CA122] Charge pressure sensor too high Action code Failure code E03 CA122 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Charge pressure sensor too high (Engine controller system) • Excessively high voltage is detected at pressure signal circuit of boost pressure and temperature sensor. • Operates with a fixed charge pressure. • Engine output is reduced. • The signal voltage of boost pressure and temperature sensor on boost pressure side can be checked in monitoring function. (Code: 36501 Boost pressure sensor voltage) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 2 system Standard value when normal and remarks for troubleshooting If failure code [CA227] is displayed at the same time, carry out troubleshooting for that in advance. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. Defective boost pressure 2 and temperature sensor [pressure signal circuit] Possible causes and standard value in normal state Hot short of harness 3 (a contact with 5 V circuit or 24 V circuit) 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller C4 Between (2) – (4) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. Between ground and wiring harness between EC1 (female) (44) – C4 (female) (1) Voltage Max. 1 V a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (44) – C4 (female) (1) and wiring harness among EC1 (female) (37) – S10 – C4 (female) (2) Resistance Min. 100 kz The connections among boost pressure and temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC1 Between (37) – (47) 16 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to charge pressure and temperature sensor GD655-3E0, GD675-3E0 17 SEN01839-00 40 Troubleshooting Failure code [CA123] Charge pressure sensor too low Action code Failure code E03 CA123 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Charge pressure sensor too low (Engine controller system) • Excessively low voltage is detected at pressure signal circuit of boost pressure and temperature sensor. • Operates with a fixed charge pressure. • Engine output is reduced. • The signal voltage of boost pressure and temperature sensor on boost pressure side can be checked in monitoring function. (Code: 36502 CHG PRESS-A) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 2 system Standard value when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for that first. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. Defective boost pressure 2 and temperature sensor [pressure signal circuit] Possible causes and standard value in normal state C4 Between (2) – (4) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 3 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (44) – C4 (female) (1) tance 100 kz 4 5 6 Harness short (Harness internal short) Defective wiring harness connector Defective engine controller a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (44) – C4 (female) (1) and wiring harness among EC1 (female) (47) – S11 – C4 (female) (4) Resistance Min. 100 kz The connections among boost pressure and temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC1 Between (37) – (47) 18 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to charge pressure and temperature sensor GD655-3E0, GD675-3E0 19 SEN01839-00 40 Troubleshooting Failure code [CA131] Throttle sensor too high Action code Failure code E03 CA131 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Throttle sensor too high (Engine controller system) • Excessively high voltage is detected at signal circuit of throttle sensor. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in the same abnormal condition, the controller operates with 100% value. • Engine speed cannot be controlled by throttle sensor. • The signal voltage of throttle sensor can be checked in monitoring mode. (Code: 31707 THROTTLE POS) • Duplication of failure code: turn ON the starting switch. Cause 1 Defective throttle sensor power supply circuit Standard value when normal and remarks for troubleshooting If failure code [CA2185] is displayed at the same time, carry out troubleshooting for that first. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. T9A 2 Defective decelerator pedal Between (1) – (3) Voltage Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. Possible causes and standard value in normal state a Prepare with starting switch OFF, then start troubleshooting with Hot short of harness (a constarting switch ON. 3 tact with 5 V circuit or 24 V Between ground and wiring harness between circuit) Voltage Max. 1 V EC2 (female) (9) – T9A (female) (2) 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC2 (female) (9) – T9A (female) (2) and wiring harness between EC2 (female) (22) – T9A (female) (1) Min. 100 kz The connections among throttle sensor – body harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC2 Between (22) – (23) 20 Resistance Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to fuel control dial GD655-3E0, GD675-3E0 21 SEN01839-00 40 Troubleshooting Failure code [CA132] Throttle sensor too low Action code Failure code E03 CA132 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Throttle sensor too low (Engine controller system) • Excessively low voltage is detected at signal circuit of throttle sensor. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in the same abnormal condition, the controller operates with 100% value. • Engine speed cannot be controlled by throttle sensor. • The signal voltage of decelerator pedal can be checked in monitoring mode. (Code: 31707 THROTTLE POS) • Duplication of failure code: turn ON the starting switch. Cause 1 Defective throttle sensor power supply circuit Standard value when normal and remarks for troubleshooting If failure code [CA2186] is displayed at the same time, carry out troubleshooting for that first. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. T9A 2 Defective decelerator pedal Between (1) – (2) Voltage Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. Possible causes and standard value in normal state a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 3 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC2 (female) (9) – T9A (female) (2) tance 100 kz 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC2 (female) (9) – DCL (female) (B) and wiring harness between EC2 (female) (23) – T9A (female) (3) Min. 100 kz The connections among throttle sensor – body harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC2 Between (22) – (23) 22 Resistance Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to fuel control dial GD655-3E0, GD675-3E0 23 SEN01839-00 40 Troubleshooting Failure code [CA144] Coolant temperature sensor too high Action code Failure code E01 CA144 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Coolant temperature sensor too high (Engine controller system) • Excessively high voltage is detected at signal circuit of engine coolant temperature sensor. • Operates with a fixed engine coolant temperature. • Exhaust gas color becomes white. • Overheat prevention function does not work. • The signal voltage of engine coolant sensor can be checked in monitoring mode. (Code: 04105 COOLANT TEMP) • Duplication of failure code: turn ON the starting switch. Cause 1 Defective engine coolant temperature sensor Disconnection in wiring harness 2 (Disconnection or poor connector contact) Possible causes and standard value in normal state 1 3 4 Harness short (Harness internal short) Defective wiring harness connector Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. C3 (male) Resistance Between (A) – (B) 0.18 – 160 kz a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (15) – C3 (female) (2) Resistance Max. 10 z Wiring harness among EC1 (female) (38) – S13 – C3 (female) (1) Resistance Max. 10 z a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (15) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among engine coolant temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defect in other locations than 5 EC1 (female) Resistance engine controller Between (15) – (38) 6 Defective engine controller 24 0.18 – 160 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to coolant temperature sensor GD655-3E0, GD675-3E0 25 SEN01839-00 40 Troubleshooting Failure code [CA145] Coolant temperature sensor too low Action code Failure code E01 CA145 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Coolant temperature sensor too low (Engine controller system) • Excessively low voltage is detected at signal circuit of engine coolant temperature sensor. • Operates with a fixed engine coolant temperature. • Exhaust gas color becomes white. • Overheat prevention function does not work. • The signal voltage of engine coolant sensor can be checked in monitoring mode. (Code: 04105 COOLANT TEMP) • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. 1 Defective engine coolant temperature sensor C3 (male) Resistance Between (1) – (2) 0.18 – 160 kz Between (2) – chassis ground Min. 100 kz a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (15) – C3 (female) (2) tance 100 kz Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (15) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among engine coolant temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. 5 Defect in other locations than engine controller 6 Defective engine controller 26 EC1 (female) Resistance Between (15) – (38) 0.18 – 160 kz Between (15) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to coolant temperature sensor GD655-3E0, GD675-3E0 27 SEN01839-00 40 Troubleshooting Failure code [CA153] Charge temperature sensor too high Action code Failure code E01 CA153 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • Operates with a fixed charge temperature. • Exhaust gas color becomes white. • Engine protection function by boost temperature does not work. • The signal voltage of boost pressure and temperature sensor on boost temperature side can be checked in monitoring function. (Code: 18501 CHG TEMP) • Duplication of failure code: turn ON the starting switch. Defective boost pressure 1 and temperature sensor [temperature signal circuit] Disconnection in wiring harness 2 (Disconnection or poor connector contact) 3 4 Harness short (Harness internal short) Defective wiring harness connector Defect in other locations than 5 engine controller 6 Defective engine controller 28 Charge temperature sensor too high (Engine controller system) • Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature sensor. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. C4 (male) Resistance Between (3) – (4) 0.18 – 160 kz a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (23) – C4 (female) (3) Resistance Max. 10 z Wiring harness among EC1 (female) (47) – S11 – C4 (female) (4) Resistance Max. 10 z a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (23) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among boost pressure and temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. EC1 (female) Resistance Between (23) – (47) 0.18 – 160 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to charge pressure and temperature sensor GD655-3E0, GD675-3E0 29 SEN01839-00 40 Troubleshooting Failure code [CA154] Charge temperature sensor too low Action code Failure code E01 CA154 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Charge temperature sensor too low (Engine controller system) • Excessively low voltage is detected at temperature signal circuit of boost pressure and temperature sensor. • Operates with a fixed charge temperature. • Exhaust gas color becomes white. • Engine protection function by boost temperature does not work. • The signal voltage of boost pressure and temperature sensor on boost temperature side can be checked in monitoring function. (Code: 18501 CHG TEMP) • Duplication of failure code: turn ON the starting switch. Cause Defective boost pressure 1 and temperature sensor [temperature signal circuit] Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. C4 (male) Resistance Between (3) – (4) 0.18 – 160 kz Between (3) – chassis ground Min. 100 kz a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (23) – C4 (female) (3) tance 100 kz Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (23) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among boost pressure and temperature sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. 5 Defect in other locations than engine controller 6 Defective engine controller 30 EC1 (female) Resistance Between (23) – (47) 0.18 – 160 kz Between (23) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to charge pressure and temperature sensor GD655-3E0, GD675-3E0 31 SEN01839-00 40 Troubleshooting Failure code [CA155] Charge temperature too high and engine speed derated 1 Action code Failure code E03 CA155 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • The temperature signal of boost pressure and temperature sensor exceeds upper control limit temperature. • Operates with limited output. • Engine output is reduced. • Engine stops. • The boost temperature can be checked in monitoring function. (Code: 18500 CHG TEMP) • Duplication of failure code: Start the engine. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1 Degradation of cooling performance of aftercooler The degradation of aftercooler cooling performance is suspected. Directly check the following points: • Looseness and damage of fun belt • Insufficient cooling air amount • Clogging of aftercooler fin 2 Abnormal rise in turbocharger outlet temperature The abnormal rise in turbocharger outlet temperature is suspected. Directly check the related parts. 3 Defective engine controller 32 Charge air temperature too high and engine speed derated (Engine controller system) Engine controller is possibly defective if no problem is found in causes 1 – 2. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01839-00 33 SEN01839-00 40 Troubleshooting Failure code [CA187] Sensor power source 2 too low Action code Failure code E03 CA187 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Sensor power source 2 too low (Engine controller system) • Excessively low voltage has been detected at sensor power source 2 circuit. • Operates with a fixed boost pressure. • Operates with fixed charge temperature. • Runs by limiting output. • Engine output is reduced. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Disconnect connectors with starting switch OFF, then turn it ON for troubleshooting. Possible causes and standard value in normal state Boost pressure and Disconnect the temperature sensor devices on the right one at a time and try to Common rail pressure 1 Defective sensor or harness duplicate the problem. sensor If the failure code Bkup sensor changes from flashing to continuously illuminating, Engine harness that device or harness is defective. C4 C8 C13 EC1 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 • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation 3 Defective engine controller 34 Engine controller is possibly defective if no problem is found in causes 1 – 2. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to sensor power supply 2 GD655-3E0, GD675-3E0 35 SEN01839-00 40 Troubleshooting Failure code [CA221] Atmospheric pressure sensor too high Action code Failure code E01 CA221 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Atmospheric pressure sensor too high (Engine controller system) • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with a fixed atmospheric pressure. • Startability gets worse. • Engine output is reduced. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37402 AMBIENT PRESS) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 1 system Standard value when normal and remarks for troubleshooting If failure code [CA386] is displayed at the same time, carry out troubleshooting for that first. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. C29 2 Possible causes and standard value in normal state Defective atmospheric pressure sensor Between (1) – (2) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF, then start troubleshooting with Hot short of harness (a constarting switch ON. 3 tact with 5 V circuit or 24 V Between ground and wiring harness between circuit) Voltage Max. 1 V EC1 (female) (3) – C29 (female) (3) 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (3) – C29 (female) (3) and wiring harness between EC1 (female) (33) – C29 (female) (1) Resistance Min. 100 kz The connections among atmospheric pressure sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC1 Between (33) – (38) 36 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to atmospheric pressure sensor GD655-3E0, GD675-3E0 37 SEN01839-00 40 Troubleshooting Failure code [CA222] Atmospheric pressure sensor too low Action code Failure code E01 CA222 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Atmospheric pressure sensor too low (Engine controller system) • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor. • Operates with a fixed atmospheric pressure. • Startability gets worse. • Engine output is reduced. • The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37402 AMBIENT PRESS) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 1 system Standard value when normal and remarks for troubleshooting If failure code [CA352] is displayed at the same time, carry out troubleshooting for that first. a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. C29 2 Possible causes and standard value in normal state Defective atmospheric pressure sensor Between (1) – (2) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 3 (Contact with ground circuit) Between ground and wiring harness ResisMin. tance 100 kz between EC1 (female) (3) – C29 (female) (3) 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (3) – C29 (female) (3) and wiring harness between EC1 (female) (38) – S13 – C29 (female) (2) Resistance Min. 100 kz The connections among atmospheric pressure sensor – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. EC1 Between (33) – (38) 38 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to atmospheric pressure sensor GD655-3E0, GD675-3E0 39 SEN01839-00 40 Troubleshooting Failure code [CA227] Sensor power source 2 too high Action code Failure code E03 CA227 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • Operates with a fixed boost pressure. • Operates with fixed charge temperature. • Runs by limiting output. • Engine output is reduced. • Duplication of failure code: turn ON the starting switch. 1 Defective wiring harness connector 2 Defective engine controller 40 Sensor power source 2 too high (Engine controller system) • Excessively high voltage has been detected in sensor power source 2 circuit Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting The connections among each sensor – engine harness – engine controller are suspected to be defective. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation Engine controller is possibly defective if no problem is found in cause 1. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to sensor power supply 2 GD655-3E0, GD675-3E0 41 SEN01839-00 40 Troubleshooting Failure code [CA234] Engine over speed Action code Failure code E02 CA234 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 42 Engine over speed (Engine controller system) • The engine speed exceeds upper control limit speed. • Stops operation of injector until the engine speed drops to the normal speed. • Engine speed fluctuates. • The engine speed can be checked in monitoring function. (Code: 01002 ENG SPEED) • Duplication of failure code: Start engine and operate at high idle. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1 Improper fuel has been used. The use of improper fuel is suspected. Visually check it. 2 Improper usage The improper usage of equipped machine is suspected. Instruct the proper usage. 3 Defective engine controller Engine controller is possibly defective if no problem is found in causes 1 – 2. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Failure code [CA238] Abnormal power source for Ne speed sensor Action code Failure code E03 CA238 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormal power source for Ne speed sensor (Engine controller system) • Excessively low voltage is detected at power source circuit of engine Ne speed sensor. • Continues the control by engine Bkup speed sensor signal. • Engine is hard to start. • Engine is hunting. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn it ON for troubleshooting. Possible causes and standard value in normal state Defective sensor or wiring 1 harness 2 Defective wiring harness connector Disconnect the devices on the right one at a time and try to duplicate the problem. If the failure code changes from flashing to continuously illuminating, that device or harness is defective. Ne speed sensor C15 Engine harness EC1 The connections among each sensor – engine harness – engine controller are suspected to be defective. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation Circuit diagram related to engine Ne speed sensor GD655-3E0, GD675-3E0 43 SEN01839-00 40 Troubleshooting Failure code [CA271] Short circuit in fuel pump actuator Action code Failure code E03 CA271 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Short circuit in fuel pump actuator (Engine controller system) • Short circuit has been detected at drive circuit of supply pump actuator. • No particular action • Engine speed does not increase from low idle. • Engine output is reduced. • Fuel pressure of common rail increases above command value. • Duplication of failure code: turn ON the starting switch. Cause Defective supply pump actu1 ator Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. FUEL PUMP (male) Resistance Between (1) – chassis ground Min. 100 kz a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (2) – FUEL PUMP (female) (1) tance 100 kz Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (2) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among inlet metering valve – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Defect in other locations than 5 engine controller EC1 (female) Resistance Between (2) – chassis ground 6 Defective engine controller 44 Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to supply pump actuator (metering unit) GD655-3E0, GD675-3E0 45 SEN01839-00 40 Troubleshooting Failure code [CA272] Disconnection in fuel pump actuator Action code Failure code E03 CA272 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • No particular action • Engine runs, but it does not stabilize. • Fuel pressure of common rail increases above commanded value. • Duplication of failure code: turn ON the starting switch. Defective supply pump actu1 ator Disconnection in wiring harness 2 (Disconnection or poor connector contact) Hot short of harness 3 (a contact with 24 V circuit) 4 5 Harness short (Harness internal short) Defective wiring harness connector Defect in other locations than 6 engine controller 7 Defective engine controller 46 Disconnection in fuel pump actuator (Engine controller system) • Disconnection is detected at drive circuit of supply pump actuator. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. C17 (male) Resistance Between (1) – (2) Max. 5 z a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Wiring harness between EC1 (female) (2) – C17 (female) (1) Resistance Max. 10 z Wiring harness between EC1 (female) (32) – C17 (female) (2) Resistance Max. 10 z a Prepare with starting switch OFF, then start troubleshooting with starting switch ON. Between ground and wiring harness between EC1 (female) (2) – C17 (female) (1) Voltage Max. 3 V a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. Between EC1 (female) (2) – EC1 (female) all pins (With all connectors in the harness disconnected) Resistance Min. 100 kz The connections among inlet metering valve – engine harness – engine controller are suspected to be defective. Visually check it. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF, then start troubleshooting with starting switch OFF. EC1 (female) Resistance Between (2) – (32) Max. 5 z Engine controller is possibly defective if no problem is found in causes 1 – 6. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to supply pump actuator (metering unit) GD655-3E0, GD675-3E0 47 SEN01839-00 40 Troubleshooting Failure code [CA281] Abnormal supply pump pressure balance Action code Failure code E03 CA281 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Trouble Abnormal supply pump pressure balance (Engine controller system) • Due to the abnormality in supply pump mechanical system, response of fuel pressure feed is not appropriate. • No particular action • Engine does not start. Or it starts, but it does not stabilize. • The pressure of high-pressure fuel is different in front side and rear side of supply pump. • Duplication of failure code: start the engine. Cause Standard value when normal and remarks for troubleshooting 1 Residual air in the fuel circuit Refer to “Bleeding air from fuel circuit” in Testing and adjusting, and bleed air from the fuel circuit. Defective wiring harness connector Problem is possibly at the connections between common rail pressure sensor – engine harness – engine controller, so inspect them directly. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation 2 3 Defective engine controller 48 1 Engine controller is possibly defective if no problem is found in causes 1 – 2. (Internal failure which cannot be diagnosed) GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01839-00 49 SEN01839-00 40 Troubleshooting Failure code [CA322] Disconnection or short circuit in injector No.1 Action code Failure code E03 CA322 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Disconnection or short circuit in injector No.1 (Engine controller system) • A disconnection or short circuit has been detected in No. 1 injector drive circuit. • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause Standard value when normal and remarks for troubleshooting 1 Defective engine controller 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 Between (3) – (4) Max. 2 z Between (3) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between EC1 (female) (45) – 3 (Disconnection or defective C9 (3) – No. 1 injector (1) contact of connectors) Wiring harness between EC1 (female) (53) – C9 (4) – No. 1 injector (2) Possible causes and standard value in normal state Resistance Max. 2 z Resistance Max. 2 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (45) – C9 (3) – No. 1 injector (1) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) 6 50 Defective wiring harness connector Between EC1 (female) (45) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (53) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between No. 1 injector – engine harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Possible causes and standard value in normal state 7 Defect in other locations than engine controller 8 Defective engine controller EC1 (female) Resistance Between (45) – (53) Max. 2 z Between (45) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1-7. (Since this is an internal defect, it cannot be diagnosed.) Circuit diagram related to injector No. 1 GD655-3E0, GD675-3E0 51 SEN01839-00 40 Troubleshooting Failure code [CA323] Disconnection or short circuit in injector No.5 Action code Failure code E03 CA323 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Disconnection or short circuit in injector No.5 (Engine controller system) • A disconnection or short circuit has been detected in No. 5 injector drive circuit • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause Standard value when normal and remarks for troubleshooting 1 Defective engine controller If the following failure codes are displayed at the same time, engine controller is internally defective: ([CA323] [CA325] [CA332]) a Prepare with starting switch OFF and diagnose with starting switch still OFF. 2 Defective No. 5 injector Disconnection in wiring harness 3 (Disconnection or defective contact of connectors) Possible causes and standard value in normal state C11 (male) Resistance Between (3) – (4) Max. 2 z Between (3) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (46) – C11 (3) – No. 5 injector (1) Resistance Max. 2 z Wiring harness between EC1 (female) (60) – C11 (4) – No. 5 injector (2) Resistance Max. 2 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (46) – C11 (3) – No. 5 injector (1) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) 6 52 Defective wiring harness connector Between EC1 (female) (46) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (60) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between No. 5 injector – engine harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Possible causes and standard value in normal state 7 Defect in other locations than engine controller 8 Defective engine controller EC1 (female) Resistance Between (46) – (60) Max. 2 z Between (46) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 7. (Since this is an internal defect, it cannot be diagnosed.) Circuit diagram related to injector No. 5 GD655-3E0, GD675-3E0 53 SEN01839-00 40 Troubleshooting Failure code [CA324] Disconnection or short circuit in injector No.3 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA324 Trouble 1 Disconnection or short circuit in injector No.3 (Engine controller system) • A disconnection or short circuit has been detected in No. 3 injector drive circuit • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause 1 Defective engine controller Standard value when normal and remarks for troubleshooting 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. 3 injector Disconnection in wiring harness 3 (Disconnection or defective contact of connectors) C10 (male) Between (3) – (4) Resistance Max. 2 z Between (3) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (55) – ResisMax. 2 z C10 (3) – No. 3 injector (1) tance Wiring harness between EC1 (female) (52) – C10 (4) – No. 3 injector (2) Resistance Max. 2 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Possible causes and standard value in normal state Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (55) – C10 (3) – No. 3 injector (1) Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) 6 Defective wiring harness connector 7 Defect in other locations than engine controller 8 Defective engine controller 54 Resistance Between EC1 (female) (55) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (52) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since problem is possibly at the connections between No. 3 injector – engine harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. EC1 (female) Between (55) – (52) Resistance Max. 2 z Between (55) – ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 7. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to injector No. 3 GD655-3E0, GD675-3E0 55 SEN01839-00 40 Troubleshooting Failure code [CA325] Disconnection or short circuit in injector No.6 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA325 Trouble 1 Disconnection or short circuit in injector No.6 (Engine controller system) • A disconnection or short circuit has been detected in No. 6 injector drive circuit • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause 1 Defective engine controller Standard value when normal and remarks for troubleshooting If the following failure codes are displayed at the same time, engine controller is internally defective: ([CA323] [CA325] [CA332]) a Prepare with starting switch OFF and diagnose with starting switch still OFF. 2 Defective No. 6 injector Disconnection in wiring harness 3 (Disconnection or defective contact of connectors) C11 (male) Between (2) – (1) Resistance Max. 2 z Between (2) – ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (57) – ResisMax. 2 z C11 (2) – No. 6 injector (1) tance Wiring harness between EC1 (female) (59) – C11 (1) – No. 6 injector (2) Resistance Max. 2 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Possible causes and standard value in normal state Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (57) – C11 (2) – No. 6 injector (1) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) Between EC1 (female) (57) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (59) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between No. 6 injector – engine harness – engine controller, check for a defective connection. Defective wiring harness • Connector is loose, lock is broken, seal is broken 6 connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations than EC1 (female) Resistance 7 engine controller Between (57) – (59) Max. 2 z Between (57) – ground Min. 100 kz 8 Defective engine controller 56 Engine controller is possibly defective if no problem is found in causes 1 – 7. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to injector No. 6 GD655-3E0, GD675-3E0 57 SEN01839-00 40 Troubleshooting Failure code [CA331] Disconnection or short circuit in injector No.2 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA331 Trouble 1 Disconnection or short circuit in injector No.2 (Engine controller system) • A disconnection or short circuit has been detected in No. 2 injector drive circuit • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause 1 Defective engine controller Standard value when normal and remarks for troubleshooting 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. 2 injector C9 (male) Between (2) – (1) Resistance Max. 2 z Between (2) – ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between EC1 (female) (54) – ResisMax. 2 z 3 (Disconnection or defective C9 (2) – No. 2 injector (1) tance contact of connectors) Wiring harness between EC1 (female) (51) – ResisMax. 2 z C9 (1) – No. 2 injector (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Possible causes and standard value in normal state Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (54) – C9 (2) – No. 2 injector (1) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) Between EC1 (female) (54) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (51) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between No. 2 injector – engine harness – engine controller, check for a defective connection. Defective wiring harness 6 • 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 a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations than EC1 (female) Resistance 7 engine controller Between (54) – (51) Max. 2 z Between (54) – ground Min. 100 kz 8 Defective engine controller 58 Engine controller is possibly defective if no problem is found in causes 1 – 7. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to injector No. 2 GD655-3E0, GD675-3E0 59 SEN01839-00 40 Troubleshooting Failure code [CA332] Disconnection or short circuit in injector No.4 Action code E03 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA332 Trouble 1 Disconnection or short circuit in injector No.4 (Engine controller system) • A disconnection or short circuit has been detected in No. 4 injector drive circuit • No particular action • Poor combustions or hunting occurs. • Engine output is reduced. • Duplication of failure code: start the engine. Cause 1 Defective engine controller Standard value when normal and remarks for troubleshooting If the following failure codes are displayed at the same time, engine controller is internally defective: ([CA323] [CA325] [CA332]) a Prepare with starting switch OFF and diagnose with starting switch still OFF. 2 Defective No. 4 injector Disconnection in wiring harness 3 (Disconnection or defective contact of connectors) C10 (male) Between (2) – (1) Resistance Max. 2 z Between (2) – ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (56) – ResisMax. 2 z C10 (2) – No. 4 injector (1) tance Wiring harness between EC1 (female) (58) – C10 (1) – No. 4 injector (2) Resistance Max. 2 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 4 Possible causes and standard value in normal state Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (56) – C10 (2) – No. 4 injector (1) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 5 (Harness internal short) Between EC1 (female) (56) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Between EC1 (female) (58) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between No. 4 injector – engine harness – engine controller, check for a defective connection. Defective wiring harness • Connector is loose, lock is broken, seal is broken 6 connector • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations than EC1 (female) Resistance 7 engine controller Between (56) – (58) Max. 2 z Between (56) – ground Min. 100 kz 8 Defective engine controller 60 Engine controller is possibly defective if no problem is found in causes 1 – 7. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01839-00 Circuit diagram related to injector No. 4 GD655-3E0, GD675-3E0 61 SEN01840-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 2 .......................................................................................................... 3 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 SEN01840-00 40 Troubleshooting 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 40 Troubleshooting SEN01840-00 Troubleshooting by failure code, Part 2 1 Failure code [CA342] Abnormality in engine controller data consistency 1 Action code Failure code E03 CA342 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Trouble Abnormality in engine controller data consistency (Engine controller system) • Data matching error has been detected in engine controller. • No particular action • Normal operation is continued. • Engine stops or engine does not start. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting 1 Defective related circuits Check the failure codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. 2 Defective engine controller Internal defect of engine controller is suspected. (It cannot be diagnosed.) GD655-3E0, GD675-3E0 3 SEN01840-00 40 Troubleshooting Failure code [CA351] Abnormality in injector drive circuit Action code Failure code E03 CA351 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormality in injector drive circuit (Engine controller system) • Trouble occurred in injector drive circuit. • Limits engine output and continues operation (Limits common rail pressure). • Engine output drops. • Source voltage of engine controller can be checked with monitoring function. (Code: 03200 POWER SUPPLY) Cause Standard value when normal and remarks for troubleshooting 1 Defective related system If another failure code (failure code of trouble in injector system) is indicated, carry out troubleshooting for it. 2 Defective circuit breaker If circuit breaker is turned OFF, circuit probably has ground fault (See cause 4). a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC3 (female) (3), (4) – ET100 Disconnection in wiring harness (Disconnection in wiring 3 Wiring harness between ET103 – ET102 or defective contact in connector) Wiring harness between ET47 – battery relay ET46 Possible causes and standard value in normal state Wiring harness between EC3 (female) (1), (2) – engine ground (ET103) Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between EC3 (female) (3), (4) – ET100 Ground fault in wiring harWiring harness between ET103 – ET102 or 4 ness (Contact with GND circircuit branch end cuit) Wiring harness between ET47 – battery relay ET46 Wiring harness between EC3 (female) (1), (2) – engine ground (ET103) 5 DEfective engine controller 4 Resistance Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. EC3 Voltage Between (3), (4) – (1), (2) 20 – 30 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine controller power supply GD655-3E0, GD675-3E0 5 SEN01840-00 40 Troubleshooting Failure code [CA352] Sensor power source 1 too low Action code Failure code E03 CA352 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Sensor power source 1 too low (Engine controller system) • Excessively low voltage has been detected in sensor power source 1 circuit • Operates with a fixed atmospheric pressure. • Startability of engine deteriorates. • Engine output is reduced. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch ON. Defective sensor or wiring 1 harness Possible causes and standard value in normal state 2 Defective wiring harness connector 3 Defective engine controller 6 Disconnect the devices on the right one at a time and try to duplicate the problem. If the failure code changes from flashing to continuously illuminating, that device or harness is defective. Atmospheric pressure sensor C29 Engine harness EC1 Since the connections among atmospheric pressure sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation Engine controller is possibly defective if no problem is found in causes 1 – 2. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to sensor power supply 1 GD655-3E0, GD675-3E0 7 SEN01840-00 40 Troubleshooting Failure code [CA386] Sensor power source 1 too high Action code Failure code E03 CA386 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Sensor power source 1 too high (Engine controller system) • Excessively high voltage has been detected in sensor power source 1 circuit • Operates with a fixed atmospheric pressure. • Startability of engine deteriorates. • Engine output is reduced. • Duplication of failure code: turn ON the starting switch. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting Defective wiring harness connector Since the connections among atmospheric pressure sensor – engine harness – engine controller are suspected to be defective, check for a defective connection. • Connector is loose, lock is broken, seal is broken Pin is corroded, bent, broken, pushed in, expanded. Moisture in connector, entry of dirt or sand, etc., and insufficient insulation 2 Defective engine controller Engine controller is possibly defective if no problem is found in cause 1. (Since this is an internal defect, it cannot be diagnosed.) 1 Circuit diagram related to sensor power supply 1 8 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01840-00 9 SEN01840-00 40 Troubleshooting Failure code [CA428] Water detection sensor too high Action code Failure code E01 CA428 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Water detection sensor too high (Engine controller system) • Excessively high voltage has occurred in the fuel water detection sensor signal circuit • No particular action • Water separator monitor does not display normally. • The signal status of the fuel water detection sensor can be checked with the monitoring function. (Code: 18800 WATER IN FUEL) • Duplication of failure code: turn ON the starting switch. Cause 1 Defective fuel water detection sensor Disconnection in wiring harness 2 (Disconnection or defective contact of connectors) Possible causes and standard value in normal state 1 3 4 Harness short (Harness internal short) Defective wiring harness connector Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. WIF (female) Resistance Between (1) – (2) Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (14) – WIF (male) (1) Resistance Max. 10 z Wiring harness between EC1 (female) (47) – S11 – WIF (male) (2) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC1 (female) (14) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Problem is possibly at the connections between fuel water detection sensor – engine harness – engine controller, so inspect them directly. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations than 5 engine controller EC1 (female) Resistance Between (14) – (47) 6 Defective engine controller 10 Max. 10 z Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to fuel water sensor GD655-3E0, GD675-3E0 11 SEN01840-00 40 Troubleshooting Failure code [CA429] Water detection sensor too low Action code Failure code E01 CA429 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Water detection sensor too low (Engine controller system) • Excessively low voltage has occurred in the fuel water detection sensor signal circuit • No particular action • Water separator monitor does not display normally. • The signal status of the fuel water detection sensor can be checked with the monitoring function. (Code: 18800 WATER IN FUEL) • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. 1 Defective fuel water detection sensor WIF (female) Resistance Between (1) – (2) Max. 10 z Between (1) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness ResisMin. between EC1 (female) (14) – WIF (male) (1) tance 100 kz Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC1 (female) (14) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Problem is possibly at the connections between fuel water detection sensor – engine harness – engine controller, so inspect them directly. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. 5 Defect in other locations than engine controller 6 Defective engine controller 12 EC1 (female) Resistance Between (14) – (47) Max. 10 z Between (14) – ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to fuel water sensor GD655-3E0, GD675-3E0 13 SEN01840-00 40 Troubleshooting Failure code [CA435] Abnormality in engine oil pressure switch Action code Failure code E01 CA435 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • No particular action • Protection function by engine oil pressure does not operate. • Engine oil pressure monitor does not display normally. • Duplication of failure code: turn ON the starting switch or start the engine. 1 Defective engine oil switch Disconnection in wiring harness 2 (Disconnection or defective contact of connectors) 3 4 Harness short (Harness internal short) Defective wiring harness connector Defect in other locations than 5 engine controller 6 Defective engine controller 14 Abnormality in engine oil pressure switch (Engine controller system) • A problem has occurred in the engine oil pressure switch signal circuit Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. C2 (male) Resistance Between (1) – body Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (17) – C2 (female) (1) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC1 (female) (17) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz Since the problem is possibly at the connections between engine oil pressure switch – engine harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. EC1 (female) Resistance Between (17) – ground Max. 10 z Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine oil pressure switch GD655-3E0, GD675-3E0 15 SEN01840-00 40 Troubleshooting Failure code [CA441] Power supply voltage too low Action code Failure code E03 CA441 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Power supply voltage too low (Engine controller system) • Excessively low voltage has occurred in the controller power source voltage circuit • No particular action • Engine stops. • Engine is hard to start. • Duplication of failure code: turn ON the starting switch. 1 Cause Standard value when normal and remarks for troubleshooting Loose or corroded battery terminal Battery terminal is possibly loose or corroded, so inspect it directly. a Prepare with starting switch OFF and diagnose with starting switch OFF and START. 2 Defective battery voltage 3 Defective fuse No. 9 Disconnection in wiring harness 4 (Disconnection or defective contact of connectors) Possible causes and standard value in normal state Battery (1 unit) Starting switch Voltage Between (+) – (–) terminals OFF Min. 12 V START Min. 6.2 V If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred in the circuit (refer to cause 5). a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ET102 – EC3 (female) (3), (4) Resistance Max. 10 z Wiring harness between EC3 (female) (1), (2) – engine ground (M10) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 5 (Contact with ground circuit) Between ground and wiring harness ResisMin. between ET102 – EC3 (female) (3), (4) tance 100 kz 6 7 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between pins EC3 (female) (3), (4) – EC3 (female) (1), (2) (Battery terminals disconnected) Resistance Min. 100 kz • Since the problem is possibly at the connections between FS2 (9) – body harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON and START. 8 Defect in other locations than engine controller EC3 (female) Between (3), (4) – (1), (2) 9 Defective engine controller 16 Starting switch Voltage ON Min. 24 V START Min. 12 V Engine controller is possibly defective if no problem is found in causes 1 – 8. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine controller power supply GD655-3E0, GD675-3E0 17 SEN01840-00 40 Troubleshooting Failure code [CA442] Power supply voltage too high Action code Failure code E03 CA442 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • No particular action • Engine may stop. • Duplication of failure code: turn ON the starting switch. 1 Defective battery voltage Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Battery Voltage Between (+) – (–) terminals Max. 32 V a Prepare with starting switch OFF and start the engine to diagnose. 2 Defective alternator 3 Defective engine controller 18 Power supply voltage too high (Engine controller system) • Excessively high voltage (36 V or more) has occurred in the controller power source voltage circuit Cause Possible causes and standard value in normal state 1 E22 (male) Engine speed Voltage Between (4) – ground Medium speed or higher 27.5 – 29.5 V a Prepare with starting switch OFF and diagnose with starting switch ON. EC3 (female) Voltage Between (3), (4) – (1), (2) Max. 32 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine controller power supply GD655-3E0, GD675-3E0 19 SEN01840-00 40 Troubleshooting Failure code [CA449] Common rail pressure too high (2) Action code Failure code E03 CA449 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Common rail pressure too high (2) (Engine controller system) • Excessively high pressure trouble (2) has occurred in the common rail circuit. • Operates with limited output. • Engine noise becomes louder at no or light load. • Engine output is reduced. • Common rail pressure can be checked with the monitoring function. (Code: 36400 RAIL PRESS) • Duplication of failure code: Start the engine. Cause 1 Defective related circuits Standard value when normal and remarks for troubleshooting Check the failure codes that are displayed at the same time. If any 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 circuit, 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 and standard value in normal state Fuel low pressure circuit pressure At high idle (When engine can be started) Min. 0.48 MPa {Min. 4.9 kg/cm2} • 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 3 Defective fuel low pressure circuit devices Fuel low pressure circuit pressure drop At high idle Max. 0.14 MPa {Max. 1.4 kg/cm2} a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel suction pressure inspection. • Measurement on the gear pump fuel inlet side of the supply pump Fuel suction circuit pressure (Gear pump side) At high idle Max. 33.9 kPa {Max. 254 mmHg} • Measurement on the fuel connector side Fuel suction circuit pressure (Fuel connector side) 4 Defective fuel cooler 20 At high idle Max. 27.1 kPa {Max. 203 mmHg} a Inspect directly if fuel is leaking from the fuel tube for fuel cooler, if O-ring or seal washer is damaged, or if check valve is clogged or damaged. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch ON and diagnose with starting switch ON. 5 Defective common rail pressure sensor Monitoring code (Monitor panel) 36400 Common rail pressure 6 Defective O-ring for supply pump actuator Monitoring information When engine is stopped 0 ± 0.39 MPa {0 ± 4 kg/cm2} a Inspect directly if supply pump actuator O-ring is not damaged. a Prepare with starting switch OFF and diagnose with starting switch ON. Monitoring code (Monitor panel) Possible causes and standard value in normal state 36400 Common rail pressure 7 Monitoring information When engine is stopped Defective supply pump actua Prepare with starting switch OFF, then start the engine to diagator nose. • Measure after idling for at least 1 minute. Monitoring code (Monitor panel) 36400 Common rail pressure 8 9 0 ± 0.39 MPa {0 ± 4 kg/cm2} Defective wiring harness connector Defective engine controller ground harness 10 Defective supply pump GD655-3E0, GD675-3E0 Monitoring information At low idle 1.96 MPa {20 kg/cm2} Problem is possibly in the common rail fuel pressure sensor connector or supply pump actuator, so inspect them directly. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. EC3 Resistance Between (1), (2) – chassis ground Max. 10 z Supply pump is possibly defective if no problem is found in causes 1 – 9. 21 SEN01840-00 40 Troubleshooting Circuit diagram related to common rail pressure sensor 22 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01840-00 23 SEN01840-00 40 Troubleshooting Failure code [CA451] Common rail pressure sensor too high Action code Failure code E03 CA451 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Common rail pressure sensor too high (Engine controller system) • Excessively high voltage has occurred in the common rail pressure sensor signal circuit • Operates with limited output. • Engine does not start. • Engine speed or output is reduced. • The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36402 RAIL PRESS) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 2 circuit Standard value when normal and remarks for troubleshooting If failure code [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. C8 2 Possible causes and standard value in normal state Defective common rail pressure sensor Between (3) – (1) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF and diagnose with starting Hot short of harness (a conswitch ON. 3 tact with 5 V circuit or 24 V Between ground and wiring harness between circuit) Voltage Max. 1 V EC1 (female) (25) – C8 (female) (2) 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (25) – C8 (female) (2) and wiring harness between EC1 (female) (37) – S10 – C8 (female) (3) Resistance Min. 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 is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON. EC1 Between (37) – (47) 24 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to common rail pressure sensor GD655-3E0, GD675-3E0 25 SEN01840-00 40 Troubleshooting Failure code [CA452] Common rail pressure sensor too low Action code Failure code E03 CA452 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Common rail pressure sensor too low (Engine controller system) • Excessively low voltage is detected in the common rail pressure sensor signal circuit • Operates with limited output. • Engine does not start. • Engine speed or output is reduced. • The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36402 RAIL PRESS) • Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source 2 circuit Standard value when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. C8 2 Possible causes and standard value in normal state Defective common rail pressure sensor Between (3) – (1) Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 3 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (25) – C8 (female) (2) tance 100 kz 4 5 Harness short (Harness internal short) Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harnesses between EC1 (female) (25) – C8 (female) (2) and among EC1 (female) (47) – S11 – C8 (female) (1) Resistance Min. 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 is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON. EC1 Between (37) – (47) 26 Voltage Voltage Power source 4.75 – 5.25 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to common rail pressure sensor GD655-3E0, GD675-3E0 27 SEN01840-00 40 Troubleshooting Failure code [CA488] Charge temperature too high and torque derated 1 Action code Failure code E03 CA488 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • The temperature signal of charge pressure and temperature sensor exceeds upper control limit temperature. • Operates with limited output. • Engine output decreases. • The charge temperature can be checked in monitoring function. (Code: 18500 CHG TEMP) • Duplication of failure code: Start the engine. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1 Degradation of cooling performance of aftercooler The degradation of aftercooler cooling performance is suspected. Directly check the following points: • Looseness and damage of fan belt • Insufficient cooling air amount • Clogging of aftercooler fin 2 Abnormal rise in turbocharger outlet temperature The abnormal rise in turbocharger outlet temperature is suspected. Directly check the related parts. 3 Defective engine controller 28 Charge air temperature too high and torque derated (Engine controller system) Engine controller is possibly defective if no problem is found in causes 1 – 2. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Failure code [CA553] Common rail pressure too high (1) Action code Failure code E03 CA553 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Common rail pressure high trouble (1) (Engine controller system) • Excessively high pressure trouble (1) has occurred in the common rail circuit. • No particular action • Engine noise becomes louder at no or light load. • Engine output is reduced. • Common rail pressure can be checked with the monitoring function. (Code: 36400 RAIL PRESS) • Duplication of failure code: Start the engine. Cause 1 Defective related circuits Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting Check the failure codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. 2 Defective connection of the ground terminal Defective connection of the ground terminal is suspected. Check the following terminals directly: • Ground terminal of the machine body (negative terminal of the battery) • Ground terminal of the engine • Ground terminal of the engine controller • Ground terminal of the starting motor 3 Damaged O-ring of supply pump actuator Since a damage of O ring of supply pump actuator is suspected, visually check the O-ring. GD655-3E0, GD675-3E0 29 SEN01840-00 40 Troubleshooting Failure code [CA559] Supply pump no pressure (1) Action code Failure code E03 CA559 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Supply pump no pressure (1) (Engine controller system) • Loss of pressure feed (1) occurred in the common rail circuit. • No particular action • Engine does not start or engine is hard to start. • Exhaust gas color becomes black. • Engine output is reduced. • Common rail pressure can be checked with the monitoring function. (Code: 36400 RAIL PRESS) • Duplication of failure code: Start the engine. Cause Standard value when normal and remarks for troubleshooting 1 Fuel leakage to the outside Since the fuel leakage to the outside is suspected, check for a leakage. (Visually check at low idle of the engine) a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel low pressure circuit pressure inspection. • Measurement on the inlet side of the fuel filter • Cranking speed: Min. 150 rpm Fuel low pressure circuit pressure Min. 0.14 MPa {1.4 kg/cm2} When cranking • Measurement on the outlet side of the fuel filter Fuel low pressure circuit pressure 2 Possible causes and standard value in normal state Defective low pressure circuit device At high idle Min. 0.48 MPa {4.9 kg/cm2} • 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 circuit pressure drop At high idle Min. 0.14 MPa {1.4 kg/cm2} a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel suction pressure inspection. • Measurement on the gear pump fuel inlet side of the supply pump Fuel suction circuit pressure (Gear pump side) At high idle Max. 33.9 kPa {Max. 254 mmHg} • Measurement on the fuel connector side Fuel suction circuit pressure (Fuel connector side) At high idle Max. 27.1 kPa {Max. 203 mmHg} a As for testing return amount of injector, see testing and adjusting “Testing fuel return and leak amount”. Defective injector 3 (Including high-pressure pipes within the head) 30 Injector return amount When cranking (When engine cannot start) Max. 100 cc/30 sec. At low idle (When engine can be started) Max. 300 cc/45 sec. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Cause Standard value when normal and remarks for troubleshooting a As for testing return amount of supply pump, see testing and adjusting “Testing fuel return and leak amount”. 4 Defective supply pump Possible causes and standard value in normal state 5 Defective pressure limiter 6 Defective plunger of supply pump Amount of supply pump return When cranking (When engine cannot start) Max. 200 cc/30 sec. At low idle (When engine can be started) Max. 300 cc/30 sec. a As for testing an amount of pressure limiter leak, see testing and adjusting “Testing fuel return and leak amount”. Pressure limiter leak amount At low idle Max. 30 drops/min. a Remove supply pump head and visually inspect the plunger for 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 minutes. When air bleeding is complete, engine revolutions become stable and the error display disappears. GD655-3E0, GD675-3E0 31 SEN01840-00 40 Troubleshooting Failure code [CA689] Abnormality in engine Ne speed sensor Action code Failure code E03 CA689 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormality in engine Ne speed sensor (Engine controller system) • Abnormal signal of the engine Ne speed sensor has been detected. • Continues the control by engine Bkup speed sensor signal. • Engine is hunting. • Engine is hard to start. • Engine output is reduced. • Duplication of failure code: start the engine. Cause 1 Defective Ne speed sensor power source circuit Standard value when normal and remarks for troubleshooting If failure code [CA238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. C15 Defective engine Ne speed 2 sensor Possible causes and standard value in normal state Between (1) – (2) Voltage Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. 3 Damaged engine Ne speed sensor or improper gap Since a damage or improper mounting gap of engine Ne speed sensor is suspected, inspect it visually. 4 Damaged speed detection wheel Since a damage of speed detection wheel is suspected, visually check it. Disconnection in wiring harness 5 (Disconnection or defective contact of connectors) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (27) – C15 (female) (3) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 6 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (27) – C15 (female) (3) tance 100 kz a Prepare with starting switch OFF and diagnose with starting switch ON. Hot short in wiring harness (a 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 40 Troubleshooting SEN01840-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 8 (Harness internal short) Possible causes and standard value in normal state 9 Defective wiring harness connector 10 Defective engine controller Wiring harnesses between EC1 (female) (27) – C15 (female) (3) and between EC1 (female) (16) – C15 (female) (1) Resistance Min. 100 kz Wiring harnesses between EC1 (female) (27) – C15 (female) (3) and between EC1 (female) (48) – C15 (female) (2) Resistance Min. 100 kz Since the connections among engine Ne speed sensor – engine harness – engine controller are suspected to be defective, check a the defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON. EC1 Between (16) – (48) Voltage Power source 4.75 – 5.25 V Circuit diagram related to engine Ne speed sensor GD655-3E0, GD675-3E0 33 SEN01840-00 40 Troubleshooting Failure code [CA731] Abnormality in engine Bkup speed sensor phase1 Action code Failure code E03 CA731 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • Abnormal phase is detected from the signals of engine Ne speed sensor and engine Bkup speed sensor. • Continues the control using engine Ne speed sensor signal. • Engine can not start or engine is hard to start. • Idle speed is not stable. • Exhaust gas color becomes black. • Duplication of failure code: start the engine. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1 Damaged engine Ne speed sensor Since a damage of engine Ne speed sensor is suspected, visually check it. 2 Damaged engine Bkup speed sensor Since a damage of engine Bkup speed sensor is suspected, visually check it. Defective mounting or dam3 age of speed detection ring on the crankshaft side Since a defective mounting or a damage of speed detection ring on the crankshaft side is suspected, carry out the inspection according to the following procedure. 1) Set the No.1 cylinder to the compression top dead center (align 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. Since a defective mounting or a damage of speed detection gear on the camshaft side is suspected, carry out the inspection according to the following procedure. Defective mounting or dam1) 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. 5 6 34 Abnormality in engine Bkup speed sensor phase (Engine controller system) Defective timing adjustment of crankshaft and camshaft Since a defective timing adjustment of crankshaft and camshaft is suspected, inspect directly. Defective connection of the ground terminal Defective connection of the ground terminal is suspected. Check the following terminals directly: • Ground terminal of the machine body (negative terminal of the battery) • Ground terminal of the engine • Ground terminal of the engine controller • Ground terminal of the starting motor GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01840-00 35 SEN01840-00 40 Troubleshooting Failure code [CA757] Loss of all engine controller data Action code Failure code E03 CA757 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Loss of all engine controller data (Engine controller system) • Loss of all data in engine controller has been detected. • No particular action • Engine may stop and can not restart. • Monitoring function of monitor panel (engine controller system) may not operate normally. • Duplication of failure code: turn ON the starting switch. Cause 1 Defective related circuits 2 Loose or corroded battery terminal Standard value when normal and remarks for troubleshooting Check the failure codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Battery terminal is possibly loose or corroded, so inspect it directly. a Prepare with starting switch OFF and diagnose with starting switch OFF and START. 3 Defective battery voltage 4 Defective fuse No. 9 Possible causes and standard value in normal state Battery (1 unit) Starting switch Voltage Between (+) – (–) terminals OFF Min. 12 V START Min. 6.2 V If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred in the circuit. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness Wiring harness between ET102 – EC3 5 (Disconnection or defective (female) (3), (4) contact of connectors) Wiring harness between EC3 (female) (1), (2) – engine ground (ET103) 6 Defective wiring harness connector Resistance Max. 10 z Resistance Max. 10 z Since the problem is possibly at the connections between ET102 – body harness – engine controller, check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON and START. 7 Defective engine controller 36 EC3 (female) Starting switch Voltage Between (3), (4) – (1), (2) ON Min. 24 V START Min. 12 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine controller power supply GD655-3E0, GD675-3E0 37 SEN01840-00 40 Troubleshooting Failure code [CA778] Abnormality in engine Bkup speed sensor Action code Failure code E03 CA778 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormality in engine Bkup speed sensor (Engine controller system) • Abnormal engine Bkup speed sensor signal has been detected. • Continue the control using engine Ne speed sensor signal. • Engine is hard to start. • Output decreases. • Duplication of failure code: start the engine. 1 Cause Standard value when normal and remarks for troubleshooting Defective sensor power source 2 circuit If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. C13 Defective engine Bkup 2 speed sensor Possible causes and standard value in normal state Damaged engine Bkup 3 speed sensor or improper gap 4 Damaged speed detection gear Disconnection in wiring harness 5 (Disconnection or defective contact of connectors) Between (1) – (2) Voltage Power source 4.75 – 5.25 V Since voltage is measured with the harness connected, further diagnose 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. Since a damage of engine Bkup speed sensor or improper gap is suspected, visually check it. Since a damage of speed detection gear is suspected, visually check it. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (26) – C13 (female) (3) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. 6 Defective harness grounding (Contact with ground circuit) Between ground and wiring harness between EC1 (female) (26) – C13 (female) (3) Resistance Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch ON. Hot short in wiring harness (a 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 40 Troubleshooting SEN01840-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 8 (Harness internal short) Possible causes and standard value in normal state 9 Defective wiring harness connector 10 Defective engine controller Wiring harnesses between EC1 (female) (26) – C13 (female) (3) and among EC1 (female) (37) – S10 – C13 (female) (1) Resistance Min. 100 kz Wiring harnesses between EC1 (female) (26) – C13 (female) (3) and among EC1 (female) (47) – S11 – C13 (female) (2) Resistance Min. 100 kz Since the connections among engine Bkup speed sensor – engine harness – engine controller are suspected to be defective, check a the defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch ON. EC1 Between (37) – (47) Voltage Power source 4.75 – 5.25 V Circuit diagram related to engine Bkup speed sensor GD655-3E0, GD675-3E0 39 SEN01840-00 40 Troubleshooting Failure code [CA1633] Abnormality in KOMNET Action code Failure code E03 CA1633 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormality in KOMNET (Engine controller system) • Engine controller detected an abnormal communication in the KOMNET communication circuit between pump controller and monitor panel. • Operate in a default mode. • When the cause of the failure has been eliminated, it returns to normal. • Machine may not operate normally because the informations which are exchanged through KOMNET communication are not trasmitted properly. (A symptom of failure depends on the location where it occurrs.) • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness 1 (Disconnection or defective contact of connectors) Wiring harnesses between FP2 (female) (1), (6) – EC2 (female) (46), TCR (female) (28), CAN (male) (3), and CAN1 (female) (A) Resistance Max. 1 z Wiring harnesses between FP2 (female) (3) – EC2 (female) (47), TCR (female) (38), CAN (male) (10), and CAN1 (female) (B) Resistance Max. 1 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harnesses between FP2 (female) (1), (6) – EC2 Defective harness grounding (female) (46), TCR (female) (28), CAN 2 (Contact with ground circuit) (male) (3), and CAN1 (female) (A) Between ground and wiring harnesses between FP2 (female) (3) – EC2 (female) (47), TCR (female) (38), CAN (male) (10), and CAN1 (female) (B) Possible causes and standard value in normal state Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch ON. Hot short of wiring harness 3 (a contact with 24 V circuit) Between ground and wiring harnesses between FP2 (female) (1), (6) – EC2 (female) (46), TCR (female) (28), CAN (male) (3), and CAN1 (female) (A) Voltage Max. 5.5 V Between ground and wiring harnesses between FP2 (female) (3) – EC2 (female) (47), TCR (female) (38), CAN (male) (10), and CAN1 (female) (B) Voltage Max. 5.5 V a Prepare with starting switch OFF and diagnose with starting Defective terminal resisswitch still OFF. tance in CAN 4 CAN1 (male) Resistance (Internal short circuit and disconnection) Between (A) – (B) 120 ± 12 z 5 Defective pump controller 40 Engine controller is possibly defective if no problem is found in causes 1 – 4. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related CAN communication GD655-3E0, GD675-3E0 41 SEN01840-00 40 Troubleshooting Failure code [CA2185] Accelerator pedal sensor power source too high 1 Action code Failure code E03 CA2185 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Accelerator pedal sensor power source too high (Engine controller system) • Excessively high voltage (Min. 5.25 V) is detected in the circuit of accelerator pedal sensor power source. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in the same abnormal condition, the controller operates with 100% value. • Engine speed cannot be controlled by accelerator pedal. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 1 (Harness internal short) Possible causes and standard value in normal state 2 Defective wiring harness connector 3 Defective engine controller 42 Between EC2 (female) (22) – all pins of EC2 (female) (with T9A disconnected) Resistance Min. 100 kz Wiring harness between EC2 (female) (9) – T9A (female) (2) and wiring harness between EC2 (female) (22) – T9A (female) (1) Resistance Min. 100 kz Since the connections among accelerator pedal – body harness – engine controller are suspected to be defective, visually check them. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation Engine controller is possibly defective if no problem is found in causes 1 – 2. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to accelerator pedal GD655-3E0, GD675-3E0 43 SEN01840-00 40 Troubleshooting Failure code [CA2186] Accelerator pedal sensor power source too low 1 Action code Failure code E03 CA2186 Contents of trouble Action of controller Problem that appears on machine Related information Trouble Accelerator pedal sensor power source too low (Engine controller system) • Excessively low voltage is detected at accelerator pedal sensor power source circuit. • Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the starting switch in the ON position. • If the starting switch is turned to the ON position in the same abnormal condition, the controller operates with 100% value. • Engine speed cannot be controlled by accelerator pedal. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 1 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC2 (female) (22) – T9A (female) (1) tance 100 kz Possible causes and standard value in normal state 2 3 Harness short (Harness internal short) Defective wiring harness connector 4 Defective engine controller 44 a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC2 (female) (9) – all pins of EC2 (female) (with T9A also disconnected) Resistance Min. 100 kz Since the connections among decelerator pedal – body harness – engine controller are suspected to be defective, visually check them. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation Engine controller is possibly defective if no problem is found in causes 1 – 3. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to accelerator pedal GD655-3E0, GD675-3E0 45 SEN01840-00 40 Troubleshooting Failure code [CA2249] Supply pump no pressure (2) Action code Failure code E03 CA2249 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state 46 Trouble 1 Supply pump no pressure (2) (Engine controller system) • Loss of pressure feed (2) occurred in the common rail circuit. • Operates with limited output. • Engine is hard to start. • Exhaust gas color becomes black. • Output decreases. • Common rail pressure can be checked with the monitoring function. (Code: 36400 RAIL PRESS) • Duplication of failure code: Start the engine. Cause 1 Standard value when normal and remarks for troubleshooting Carry out troubleshooting of [CA559]. GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01840-00 47 SEN01840-00 40 Troubleshooting Failure code [CA2265] Disconnection in electric lift pump Action code Failure code E01 CA2265 Contents of trouble Action of controller Problem that appears on machine Related information Trouble • Takes no paticular action. • Engine is hard to start. • Duplication of failure code: turn ON the starting switch. Defective electric lift pump 1 (Internal disconnection and short circuit) Disconnection in wiring harness 2 (Disconnection or defective contact of connectors) Hot short of wiring harness 3 (a contact with 12 V circuit) 4 5 Harness short (Harness internal short) Defective wiring harness connector Defect in other locations than 6 engine controller 7 Defective engine controller 48 Disconnection in electric lift pump • Disconnection is detected in the drive circuit of electric lift pump actuator. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. C18 (male) Resistance Between (1) – (2) Max. 20 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (1) – C18 (female) (1) Resistance Max. 10 z Wiring harness between EC1 (female) (11) – C18 (female) (2) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch ON. Between ground and wiring harness between EC1 (female) (1) – C18 (female) (1) Voltage Max. 6 V a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC1 (female) (1) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz The connections among lift pump valve – engine harness – engine controller are suspected to be defective. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. EC1 (female) Resistance Between (1) – (11) Max. 20 z Engine controller is possibly defective if no problem is found in causes 1 – 6. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to electric lift pump actuator GD655-3E0, GD675-3E0 49 SEN01840-00 40 Troubleshooting Failure code [CA2266] Short circuit in electric lift pump Action code Failure code E01 CA2266 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Short circuit in electric lift pump • Short circuit is detected in the drive circuit of electric lift pump actuator. • Takes no particular action. • Engine is hard to start. • Duplication of failure code: turn ON the starting switch. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. 1 Defective electric lift pump (internal short circuit) C18 (female) Resistance Between (1) – (2) Max. 20 z Between (1) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness ResisMax. between EC1 (female) (1) – C18 (female) (1) tance 100 kz 3 Possible causes and standard value in normal state 4 5 Hot short of wiring harness (a contact with 24 V circuit) Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF and diagnose with starting switch ON. Between ground and wiring harness between EC1 (female) (1) – C18 (female) (1) Voltage Max. 6 V a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC1 (female) (1) – EC1 (female) all pins (All connectors in the harness disconnected) Resistance Min. 100 kz The connections among lift pump valve – engine harness – engine controller are suspected to be defective. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. 6 Defect in other locations than engine controller 7 Defective engine controller 50 EC1 (female) Resistance Between (1) – (11) Max. 20 z Between (1) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 6. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to electric lift pump actuator GD655-3E0, GD675-3E0 51 SEN01840-00 40 Troubleshooting Failure code [CA2311] Abnormal resistance in IMV solenoid Action code Failure code E03 CA2311 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Abnormal resistance in IMV solenoid (Engine controller system) • Resistance value of supply pump actuator circuit is abnormally high or low. • No particular action • Engine output decreases. • Duplication of failure code: start the engine. Cause 1 Defective related circuits Standard value when normal and remarks for troubleshooting Check the failure codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. a Prepare with starting switch OFF and diagnose with starting switch still OFF. 2 Defective supply pump actuator Disconnection in wiring harness 3 (Disconnection or defective contact of connectors) Possible causes and standard value in normal state C17 (male) Resistance Between (1) – (2) Max. 5 z Between (1) – chassis ground Min. 100 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC1 (female) (2) – C17 (female) (1) Resistance Max. 5 z Wiring harness between EC1 (female) (32) – C17 (female) (2) Resistance Max. 5 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 4 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC1 (female) (2) – C17 (female) (1) tance 100 kz 5 Defective wiring harness connector Since the connections among inlet metering valve – engine harness – engine controller are suspected to be defective, visually check for a defective connection. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. 6 Defect in other locations than engine controller 7 Defective engine controller 52 EC1 (female) Resistance Between (2) – (32) Max. 5 z Between (2) – chassis ground Min. 100 kz Engine controller is possibly defective if no problem is found in causes 1 – 6. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to inlet metering GD655-3E0, GD675-3E0 53 SEN01840-00 40 Troubleshooting Failure code [CA2555] Disconnection in air intake heater relay Action code Failure code E01 CA2555 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Disconnection in air intake heater relay (Engine controller system) • Disconnection is detected in the drive circuit of air intake heater relay. • No particular action • Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is exhausted.) • Duplication of failure code: Turn the starting switch ON with coolant temperature below -4°C. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF (diagnose by itself). 1 Defective preheat relay (internal disconnection) Heater relay Resistance Between ET82 – Relay bracket 300 – 600 z a Prepare with starting switch OFF and diagnose with starting 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. Disconnection in wiring harness 2 (Disconnection or defective contact of connectors) Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between EC2 (female) (40) – ET82 Resistance Max. 10 z Wiring harness between ET54 – ET53 (Slow blow fuse) Resistance Max. 10 z a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC2 (female) (40) – all pins of EC2 (female) (with heater relay also disconnected) Resistance Min. 100 kz The connections among preheat relay – body harness – engine controller are suspected to be defective. Visually check them. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations than 5 engine controller EC2 (female) Resistance Between (40) – Engine GND 6 Defective engine controller 54 300 – 600 z Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine preheat GD655-3E0, GD675-3E0 55 SEN01840-00 40 Troubleshooting Failure code [CA2556] Short circuit in air intake heater relay Action code Failure code E01 CA2556 Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Short circuit in air intake heater relay (Engine controller system) • Short circuit is detected in the drive circuit of air intake heater relay. • No particular action • Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is exhausted.) • Duplication of failure code: Turn the starting switch ON with coolant temperature below –4°C. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF (diagnose by itself). 1 Defective preheat relay (internal disconnection) Heater relay Resistance Between ET82 – Relay bracket 300 – 600 z a Prepare with starting switch OFF and diagnose with starting 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding 2 (Contact with ground circuit) Between ground and wiring harness between ResisMin. EC2 (female) (40) – ET82 tance 100 kz Possible causes and standard value in normal state 3 4 Harness short (Harness internal short) Defective wiring harness connector Defect in other locations than 5 engine controller 6 Defective engine controller 56 a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between EC2 (female) (40) – all pins of EC2 (female) (with heater relay also disconnected) Resistance Min. 100 kz The connections among preheat relay – body harness – engine controller are suspected to be defective. Visually check them. • Connector is loose, lock is broken, seal is broken • Pin is corroded, bent, broken, pushed in, expanded. • Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. EC2 (female) Resistance Between (40) – Engine ground 300 – 600 z Engine controller is possibly defective if no problem is found in causes 1 – 5. (Since this is an internal defect, it cannot be diagnosed.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01840-00 Circuit diagram related to engine preheat GD655-3E0, GD675-3E0 57 SEN01965-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 3 .......................................................................................................... 4 Failure code [D19CKZ] Disconnection or short circuit in differential control relay................................ 4 Failure code [D5ZHL6] Terminal C signal does not match state of engine .......................................... 6 Failure code [DAQ0KK] Power source voltage of transmission controller too low ............................... 8 Failure code [DAQSKR] Communication controller cannot recognize S-NET ..................................... 9 Failure code [DB2RKR] Communication lost engine controller.......................................................... 10 Failure code [DBF0KK] Power source voltage of communication controller too low.......................... 12 Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low................................ 14 Failure code [DBFRKR] Communication lost communication controller ............................................ 16 Failure code [DD1PKB] Power supply line short in RPM set switch .................................................. 18 Failure code [DD1QKB] Short circuit in RPM set mode switch .......................................................... 20 Failure code [DDTGKA] Disconnection in lock-up clutch fill switch.................................................... 22 Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch) 23 Failure code [DDTHKA] Disconnection in FH clutch fill switch........................................................... 24 Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch) ....... 25 Failure code [DDTJKA] Disconnection in FL clutch fill switch ............................................................ 26 GD655-3E0, GD675-3E0 1 SEN01965-00 40 Troubleshooting Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch) ......... 27 Failure code [DDTKKA] Disconnection in 1st clutch fill switch ........................................................... 28 Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch)........ 30 Failure code [DDTLKA] Disconnection in 2nd clutch fill switch .......................................................... 32 Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch)....... 34 Failure code [DDTMKA] Disconnection in 3rd clutch fill switch .......................................................... 36 Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch)....... 38 Failure code [DDTNKA] Disconnection in R clutch fill switch ............................................................. 40 Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch).......... 41 Failure code [DDTPKA] Disconnection in 4th clutch fill switch........................................................... 42 Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch) ....... 44 Failure code [DF10KA] Disconnection in transmission shift lever switch ........................................... 46 Failure code [DF10KB] Short circuit in transmission shift lever switch............................................... 50 Failure code [DGF1KX] Transmission oil temperature out of range................................................... 54 Failure code [DGT1KX] Torque converter oil temperature out of range ............................................. 56 Failure code [DJF1KA] Disconnection in fuel level sensor................................................................. 58 Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range ...................... 60 Failure code [DK70KX] Input of inching pedal potentiometer out of normal range ............................ 62 Failure code [DKD0KA] Disconnection in articulate sensor ............................................................... 64 Failure code [DLE2KA] Disconnection in engine speed sensor ......................................................... 66 Failure code [DLF1KA] Disconnection in transmission input speed sensor ....................................... 67 Failure code [DLT3KA] Disconnection in transmission output speed sensor ..................................... 68 Failure code [DV00KB] Short circuit in caution buzzer....................................................................... 69 Failure code [DW4BKA] Disconnection in parking brake relay .......................................................... 70 Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid .................................................... 72 Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid...................................... 73 Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid................................................. 74 Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid .................................. 76 Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid ................................................. 78 Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid................................... 80 Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid................................................. 82 Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid ........................... 83 Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid................................................ 84 Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid .......................... 85 Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid ................................................ 86 Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid ................................................... 87 Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid .................................... 88 Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid ................................................ 90 2 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 3 SEN01965-00 40 Troubleshooting Troubleshooting by failure code, Part 3 1 Failure code [D19CKZ] Disconnection or short circuit in differential control relay 1 Action code Failure code E01 D19CKZ Contents of trouble Action of controller Trouble Disconnection or short circuit in differential control relay (Transmission controller system) • There is disconnection or short circuit in differential lock relay circuit. • Differential control relay output OFF. Problem that appears on machine • If there is short circuit, differential operates constantly. If there is disconnection, differential is locked constantly Related information — Cause Defective differential control 1 relay 2 Hot short in wiring harness Standard value when normal and remarks for troubleshooting 1) Replace BR7 with a known good one. If the condition become normal, parking brake relay has a defect. 1) Turn starting switch OFF. 2) Disconnect T1 and BR7. Between T1(female)(11) and BR7(female)(1) Possible causes and standard value in normal state 3 Defective contact or open circuit in wiring harness. 4 Hot short in wiring harness 4 Defective transmission controller Max. 1 z Resistance Max. 1 z Voltage Max. 1 V 1) Turn starting switch ON. 2) Disconnect BR7. Between BR7(female)(1) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T1 and BR7. 3) Turn starting switch ON. Between T1(female)(11) and chassis ground 5 Resistance If no problem is found in causes 1 to 3, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to differential control relay GD655-3E0, GD675-3E0 5 SEN01965-00 40 Troubleshooting Failure code [D5ZHL6] Terminal C signal does not match state of engine1 Action code Failure code E01 Contents of trouble Action of controller Problem that appears on machine Related information D5ZHL6 Trouble Terminal C signal does not match state of engine (Machine monitor system) • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500 rpm and no starting switch terminal C signal has been input.) • None in particular. • If cause of failure disappears, system resets itself. • The engine does not start. • The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function (Code: 40921, D-IN-0) (Machine monitor system). • Method of reproducing failure code: Set the starting switch to START position Cause 1 Defective fuse No.1 of fuse box A Standard value when normal and remarks for troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 2.) a Prepare with starting switch OFF, then turn starting switch ON, OFF or START and carry out troubleshooting 2 Defective starting switch (Internal disconnection) Starting switch Between B and C Starting switch Resistance START Max. 1 z OFF, ON Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection or defective contact of connector) Wiring harness between terminal C – SP13 (female) (3) Resistance Max. 1 z Wiring harness between SP13 (female) (5) – B28 (female) (7) Resistance Max. 1 z Wiring harness between B28 (female) (7) – B28 (female) (8) Resistance Max. 1 z Wiring harness between B28 (male) (8) – SP1 (male) (11) Resistance Max. 1 z Wiring harness between SP1 (female) (11) – B4 (male) (1) Resistance Max. 1 z Wiring harness between B4 (female) (1) – TCR (female) (37) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring har4 ness Between ground and wiring harness Resis(Contact with ground circuit) between terminal C – TCR (female) (37) – 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 6 C02 Starting switch Voltage Between (2) and chassis ground START 20 – 30 V OFF, ON Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to engine starting system GD655-3E0, GD675-3E0 7 SEN01965-00 40 Troubleshooting Failure code [DAQ0KK] Power source voltage of transmission controller too low Action code Failure code E03 DAQ0KK Contents of trouble Action of controller Problem that appears on machine Trouble Power source voltage of transmission controller too low (Transmission controller system) • Transmission controller source voltage is below 18 V. • Flashes warning lamp and turns on alarm buzzer • All solenoids output OFF (set to Neutral) • Stays in N Related information — Cause Defective lock-up clutch 1 ECMV solenoid (Internal defect) Possible causes and standard value in normal state 1 2 3 4 Defective contact or open circuit in wiring harness. Defective contact or open circuit in wiring harness. Defective contact or open circuit in wiring harness. Standard value when normal and remarks for troubleshooting 1) Disconnect T1,T2 and connect T-branch adapter. 2) Turn starting switch ON. If voltage is normal, it is suspected that transmission controller is defective. Between T1 (female) (7), (13) and (6), (12) Between T2 (female) (1), (12) and (11), (21) Voltage 20 – 30 V Voltage 20 – 30 V Resistance Max. 1 z 1) Turn starting switch ON. Between T11(female)(1) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T1,T2. Between T1 (female) (6), (12), T2 (female) (11), (21) and chassis ground If no problem is found in causes 1 to 3, it is suspected that there is defective contact or open circuit in wiring harness. Circuit diagram related to transmission controller power supply 8 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DAQSKR] Communication controller cannot recognize S-NET 1 Action code Failure code E03 DAQSKR Contents of trouble Action of controller Problem that appears on machine Related information Trouble Communication controller cannot recognize S-NET (Communication controller system) • Communication controller cannot recognize S-NET. • Takes no particular action. • Transmission controller does not give signal to KOMNET, and machine does not allow normal operation of system. • Method of reproducing error code: Turn starting switch ON. Cause Standard value when normal and remarks for troubleshooting Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 1 or defective contact in con- Wiring harness between TCR (female) (18) – ResisMax. 1 z nector) T3 (female) (24), – T3 (female) (32) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Short circuit with chassis 2 ground in wiring harness Between chassis ground and wiring harness (Contact with ground circuit) between TCR (female) (18) – T3 (female) (24), – T3 (female) (32) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short circuit in wiring har3 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 4 controller a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TCR Voltage Between (18) – chassis ground 6–9V Circuit diagram related to S-NET communication GD655-3E0, GD675-3E0 9 SEN01965-00 40 Troubleshooting Failure code [DB2RKR] Communication lost engine controller Action code Failure code E03 DB2RKR Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Communication lost engine controller (Machine monitor system) • Communication controller cannot recognize engine controller with CAN communication circuit. • Flashes caution lamp and turns on caution buzzer. • System may not operate normally. • Method of reproducing error code: Turn starting switch ON. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector) Wiring harness between FP2 (female) (1), (6) – EC2 (female) (46) – TCR (female) (28) – CAN1 (female) (A) – CAN (female) (3) Resistance Max. 1 z Wiring harness between FP2 (female) (3) – EC2 (female) (47) – TCR (female) (38) – CAN1 (female) (B) – CAN (female) (10) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis 2 ground in wiring harness (Contact with ground circuit) Possible causes and standard value in normal state Short circuit of wiring harness between FP2 (female) (1), (6) – EC2 (female) (46) – TCR (female) (28) – CAN1 (female) (A) – CAN (female) (3) and chassis ground Resistance Min. 1 Mz Short circuit of wiring harness between FP2 (female) (3) – EC2 (female) (47) – TCR (female) (38) – CAN1 (female) (B) – CAN (female) (10) and chassis ground Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between FP2 (female) (1), (6) – EC2 (female) (46) – TCR Hot short circuit in wiring har(female) (28) – CAN1 (female) (A) – CAN 3 ness (female) (3) and chassis ground (Contact with 24V circuit) Short circuit of wiring harness between FP2 (female) (3) – EC2 (female) (47) – TCR (female) (38) – CAN1 (female) (B) – CAN (female) (10) and chassis ground Defective CAN terminal 4 resistance Defective engine controller, defective transmission con5 troller, or defective steering controller 10 Voltage Max. 1V Voltage Max. 1V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between CAN (male) (3) and (10) Between CAN1 (male) (A) and (B) Resistance 40 – 80 z If no problem is found in causes 1 to 4, it is suspected that engine controller, transmission controller, or steering controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to CAN communication GD655-3E0, GD675-3E0 11 SEN01965-00 40 Troubleshooting Failure code [DBF0KK] Power source voltage of communication controller too low Action code Failure code E03 DBF0KK Contents of trouble Action of controller Problem that appears on machine Trouble Power source voltage of communication controller too low (Communication controller system) • C-terminal signal is OFF and battery direct voltage is below 16 V. • • • • Flashes warning lamp and turns on alarm buzzer. Fixes accelerator position output sent to value for transmission controller to 0%. Sets RPM set function in OFF mode. Fixes VHPC control to standard side. • gear shift points in auto-shift mode are limited. • RPM set function cannot be used. • VHPC is not set to high output side. Related information — Cause 1 Possible causes and standard value in normal state 2 3 Defective contact or open circuit in wiring harness. Grounding fault in wiring harness Defective communication controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B12. 3) Connect T-adapter. Between T11 (female) (3) and B12 (male) Resistance Max. 1 z Between T11 (female) (5), (6), (7) and chassis ground Resistance Max. 1 z Resistance Min. 1 Mz Voltage 20 – 30 V 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B12. 3) Connect T-adapter. Between wiring harness between T11 (female) (3) – B12 (male) and chassis ground 1) Turn starting switch OFF. 2) Disconnect V1. 3) Connect T-adapter. 4) Turn starting switch ON. Between T11 (female) (3) and T11 (female) (5), (6), (8) 12 1 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to power source of communication controller GD655-3E0, GD675-3E0 13 SEN01965-00 40 Troubleshooting Failure code [DBF2KK] Voltage of 24 V solenoid power supply system too low Action code Failure code E01 DBF2KK Contents of trouble Action of controller Problem that appears on machine Related information Trouble Voltage of 24 V solenoid power supply system too low (Communication controller system) • C-terminal signal is OFF, battery direct voltage is below 20 V, and solenoid source voltage is below 16 V • None in particular. • System may not operate normally. • Reduction of this voltage does not directly affect functions of controller. Cause 1 Possible causes and standard value in normal state 2 3 Defective contact or open circuit in wiring harness. Grounding fault in wiring harness Defective communication controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B11. 3) Connect T-adapter. Between T11 (female) (2) and B11 (male) Resistance Max. 1 z Between T11 (female) (5), (6), (7) and chassis ground Resistance Max. 1 z Resistance Min. 1 Mz Voltage 20 – 30 V 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B12. 3) Connect T-adapter. Between wiring harness between T11 (female) (2) – B11 (male) and chassis ground 1) Turn starting switch OFF. 2) Disconnect V1. 3) Connect T-adapter. 4) Turn starting switch ON. Between T11 (female) (2) and T11 (female) (5), (6), (8) 14 1 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to 24 V solenoid power supply system GD655-3E0, GD675-3E0 15 SEN01965-00 40 Troubleshooting Failure code [DBFRKR] Communication lost communication controller Action code Failure code E03 DBFRKR Contents of trouble Action of controller Problem that appears on machine Trouble • Flashes warning lamp and turns on alarm buzzer. • Fixes communication values sent through CAN to communication controller to value just before trouble • gear shift points in auto-shift mode are limited. • Articulate gauge and accumulator pressure reduction alarm do not operate. • VHPC is not set to high output side. — Cause 1 2 Defective contact or open circuit in wiring harness. Grounding fault in wiring harness 3 Hot short in wiring harness 4 16 Communication lost communication controller (Machine monitor system) • Machine monitor cannot check communication controller in CAN communication circuit. Related information Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B11. 3) Connect T-adapter. Between FP2 (female) (1) and TCR (female) (38) Resistance Max. 1 z Between FP2 (female) (3) and TCR (female) (28) Resistance Max. 1 z Between FP2 (female) (1) and TCR (female) (38) Resistance Min. 1 Mz Between FP2 (female) (3) and TCR (female) (28) Resistance Min. 1 Mz Between FP2 (female) (1) and TCR (female) (38) Voltage Max. 1 V Between FP2 (female) (3) and TCR (female) (28) Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect battery, T11 and B12. 3) Connect T-adapter. 1) Turn starting switch OFF. 2) Disconnect FP2 and TCR. 3) Connect T-adapter. 4) Turn starting switch ON. If no problem is found in causes 1 to 3, it is suspected that commuDefective communication nication controller or machine monitor is defective. (Troubleshooting controller or machine monitor cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to CAN communication system GD655-3E0, GD675-3E0 17 SEN01965-00 40 Troubleshooting Failure code [DD1PKB] Power supply line short in RPM set switch 1 Action code Failure code E03 DD1PKB Contents of trouble Action of controller Problem that appears on machine Related information Trouble Power supply line short in RPM set switch (Communication controller system) • "SET" and "RESUME" of set switch are turned ON simultaneously. • During setting operation, either or both of "SET" and "RESUME" of set switch are kept ON. • Flashes warning lamp and turns on alarm buzzer • Sets RPM set function in OFF mode. • If RPM set is being used, "SET" is cancelled and it cannot be used any more. • Check in advance that set switch operates normally. Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect TCR. 3) Connect T-adapter. Short circuit in wiring harness a When measuring, operate switch and check that value does not 1 (With another wiring harness) change. Between TCR (female) (15) and (25) Possible causes and standard value in normal state 2 3 18 Hot short in wiring harness (Contact with 24 V circuit) Defective communication controller Resistance Min. 1 Mz Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect SH2 and TCR. 3) Connect T-adapter. 4) Turn starting switch ON. Between wiring harness between TCR (female) (15) – SH2 (female) (3), TCR (female) (25) – SH2 (female) (1) and chassis ground If no problem is found in causes 1, 2, it is suspected that communication controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to RPM set switch GD655-3E0, GD675-3E0 19 SEN01965-00 40 Troubleshooting Failure code [DD1QKB] Short circuit in RPM set mode switch Action code Failure code E03 DD1QKB Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Short circuit in RPM set mode switch (Communication controller system) • "SET" and "RESUME" of set switch are turned ON simultaneously. • Flashes warning lamp and turns on alarm buzzer. • Sets RPM set function in OFF mode. • If RPM set is cancelled and it cannot be used any more. • Check in advance that set switch operates normally. Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect TCR. 3) Connect T-adapter. Short circuit in wiring harness a When measuring, operate switch and check that value does not 1 (With another wiring harness) change. Between TCR (female) (5) and (34) Possible causes and standard value in normal state 2 3 20 Hot short in wiring harness (Contact with 24 V circuit) Defective communication controller Resistance Min. 1 Mz Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect SH1 and TCR. 3) Connect T-adapter. 4) Turn starting switch ON. Between wiring harness between TCR (female) (5) – SH1 (female) (3), (4), TCR (female) (34) – SH1 (female) (1), (6), TCR (female) (5) – TCR (female) (34) and chassis ground If no problem is found in causes 1, 2, it is suspected that communication controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to RPM set switch GD655-3E0, GD675-3E0 21 SEN01965-00 40 Troubleshooting Failure code [DDTGKA] Disconnection in lock-up clutch fill switch 1 Action code Failure code E03 DDTGKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble • While controller sends solenoid output to lock-up clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state Disconnection in lock-up clutch fill switch (Transmission controller system) Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3B, T43. Between T3 (female) (36) and T43 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T43. Defective 2nd clutch fill switch 3) Start engine. 2 (Internal defect) 4) Set TM mode switch in "Manual" While T43 (female) (1) is grounded, [DDTGKA] is displayed. 3 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to RPM set switch 22 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DDTGKB] Fill signal is ON when command current is OFF (lock-up clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTGKB Trouble Fill signal is ON when command current is OFF (lock-up clutch fill switch) (Transmission controller system) • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Possible causes and standard value in normal state Defective lock-up clutch fill 1 switch (Internal defect) Grounding fault in wiring 2 harness 3 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T43. Between T43 (male) (1) and chassis ground. Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3B, T43. Between T3 (female) (36) and chassis ground. If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 23 SEN01965-00 40 Troubleshooting Failure code [DDTHKA] Disconnection in FH clutch fill switch Action code Failure code E03 DDTHKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in FH clutch fill switch (Transmission controller system) • While controller sends solenoid output to FH clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3B, T37. Between T3 (female) (33) and T37 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T37. Defective FH clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F2", "F4", "F6", "F8". While T37 (female) (1) is grounded, [DDTHKA] is displayed. 3 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches 24 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DDTHKB] Fill signal is ON when command current is OFF (FH clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTHKB Trouble Fill signal is ON when command current is OFF (FH clutch fill switch) (Transmission controller system) • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Defective FH clutch fill switch 1 (Internal defect) Possible causes and standard value in normal state Grounding fault in wiring 2 harness 3 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T37. Between T37 (male) (1) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T37. Between T3 (female) (33) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 25 SEN01965-00 40 Troubleshooting Failure code [DDTJKA] Disconnection in FL clutch fill switch Action code Failure code E03 DDTJKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in FL clutch fill switch (Transmission controller system) • While controller sends solenoid output to FL clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T36. Between T3 (female) (25) and T36 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T36. Defective FL clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F1", "F3", "F5", "F7". While T36 (female) (1) is grounded, [DDTJKA] is displayed. 3 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches 26 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DDTJKB] Fill signal is ON when command current is OFF (FL clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTJKB Trouble Fill signal is ON when command current is OFF (FL clutch fill switch) (Transmission controller system) • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Defective FL clutch fill switch 1 (Internal defect) Possible causes and standard value in normal state Grounding fault in wiring 2 harness 3 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T36. Between T36 (male) (1) and chassis ground. Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T36. Between T3 (female) (25) and chassis ground. If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 27 SEN01965-00 40 Troubleshooting Failure code [DDTKKA] Disconnection in 1st clutch fill switch Action code Failure code E03 DDTKKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in 1st clutch fill switch (Transmission controller system) • While controller sends solenoid output to 1st clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T39. Between T3 (female) (34) and T39 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T39. Defective 1st clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F1", "F2", "R1". While T39 (female) (1) is grounded, [DDTKKA] is displayed. 3 28 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 29 SEN01965-00 40 Troubleshooting Failure code [DDTKKB] Fill signal is ON when command current is OFF (1st clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTKKB Trouble • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Defective 1st clutch fill switch 1 (Internal defect) Possible causes and standard value in normal state Grounding fault in wiring 2 harness 3 30 Fill signal is ON when command current is OFF (1st clutch fill switch) (Transmission controller system) Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T39. Between T39 (male) (1) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T39. Between T3 (female) (34) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 31 SEN01965-00 40 Troubleshooting Failure code [DDTLKA] Disconnection in 2nd clutch fill switch Action code Failure code E03 DDTLKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in 2nd clutch fill switch (Transmission controller system) • While controller sends solenoid output to 2nd clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T40. Between T3 (female) (27) and T40 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T40. Defective 2nd clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F3", "F4", "R2". While T40 (female) (1) is grounded, [DDTLKA] is displayed. 3 32 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 33 SEN01965-00 40 Troubleshooting Failure code [DDTLKB] Fill signal is ON when command current is OFF (2nd clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTLKB Trouble • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. Defective 2nd clutch fill switch 2) Disconnect T40. 1 (Internal defect) Between T40 (male) (1) and chassis ground Grounding fault in wiring 2 harness 3 34 Fill signal is ON when command current is OFF (2nd clutch fill switch) (Transmission controller system) Defective transmission controller Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T40. Between T3 (female) (27) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 35 SEN01965-00 40 Troubleshooting Failure code [DDTMKA] Disconnection in 3rd clutch fill switch Action code Failure code E03 DDTMKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in 3rd clutch fill switch (Transmission controller system) • While controller sends solenoid output to 3rd clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T41. Between T3 (female) (35) and T41 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T41. Defective 3rd clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F5", "F6", "R3". While T41 (female) (1) is grounded, [DDTMKA] is displayed. 3 36 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 37 SEN01965-00 40 Troubleshooting Failure code [DDTMKB] Fill signal is ON when command current is OFF (3rd clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTMKB Trouble • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. Defective 3rd clutch fill switch 2) Disconnect T41. 1 (Internal defect) Between T41 (male) (1) and chassis ground Grounding fault in wiring 2 harness 3 38 Fill signal is ON when command current is OFF (3rd clutch fill switch) (Transmission controller system) Defective transmission controller Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T41. Between T3 (female) (35) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 39 SEN01965-00 40 Troubleshooting Failure code [DDTNKA] Disconnection in R clutch fill switch Action code Failure code E03 DDTNKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in R clutch fill switch (Transmission controller system) • While controller sends solenoid output to R clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 2 Defective R clutch fill switch (Internal defect) Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T38. Between T3 (female) (26) and T38 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T38. 3) Start engine. 4) Shift gears in "F2" – "F4". While T38 (female) (1) is grounded, [DDTNKA] is displayed. 3 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches 40 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DDTNKB] Fill signal is ON when command current is OFF (R clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTNKB Trouble Fill signal is ON when command current is OFF (R clutch fill switch) (Transmission controller system) • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Defective R clutch fill switch 1 (Internal defect) Possible causes and standard value in normal state Grounding fault in wiring 2 harness 3 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T38. Between T38 (male) (1) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T38. Between T3 (female) (26) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 41 SEN01965-00 40 Troubleshooting Failure code [DDTPKA] Disconnection in 4th clutch fill switch Action code Failure code E03 DDTPKA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in 4th clutch fill switch (Transmission controller system) • While controller sends solenoid output to 4th clutch ECMV, there is not fill switch signal. • Flashes warning lamp and turns on alarm buzzer. • Selects sudden rise mode. • Gear shift shock is made. • Gear shift time lag is made. • System does not reset itself until starting switch is turned OFF. Cause Defective contact or open 1 circuit in wiring harness. Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T42. Between T3 (female) (28) and T42 (female) (1) Resistance Max. 1 z 1) Turn starting switch ON. 2) Disconnect T42. Defective 4th clutch fill switch 3) Start engine. 2 (Internal defect) 4) Shift gears in "F7", "F8", "R4". While T42 (female) (1) is grounded, [DDTPKA] is displayed. 3 42 Defective transmission controller If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 43 SEN01965-00 40 Troubleshooting Failure code [DDTPKB] Fill signal is ON when command current is OFF (4th clutch fill switch) 1 Action code Failure code E03 Contents of trouble Action of controller Problem that appears on machine Related information DDTPKB Trouble • While there is another clutch pressure switch signal, there are double signals. • Flashes warning lamp and turns on alarm buzzer. • Sets to Neutral. • Machine stops. • System resets itself immediately after signal becomes normal. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. Defective 4th clutch fill switch 2) Disconnect T42. 1 (Internal defect) Between T42 (male) (1) and chassis ground Grounding fault in wiring 2 harness 3 44 Fill signal is ON when command current is OFF (4th clutch fill switch) (Transmission controller system) Defective transmission controller Resistance Min. 1 Mz Resistance Min. 1 Mz 1) Turn starting switch OFF. 2) Disconnect T3, T42. Between T3 (female) (28) and chassis ground If no problem is found in causes 1, 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to clutch fill switches GD655-3E0, GD675-3E0 45 SEN01965-00 40 Troubleshooting Failure code [DF10KA] Disconnection in transmission shift lever switch Action code Failure code E03 DF10KA Contents of trouble Action of controller Problem that appears on machine Trouble 1 Disconnection in transmission shift lever switch (Transmission controller system) • All shift lever switch signals are not input. • Flashes warning lamp and turns on alarm buzzer. • No F, R, N signals o N • Cannot travel. Related information — Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T5 and T13. 1 Disconnection in wiring harness 2 Defective shift lever 3 Defective shift lever Possible causes and standard value in normal state Disconnection in wiring 4 harness 5 Defective shift lever Disconnection in wiring 6 harness 7 Defective shift lever Disconnection in wiring 8 harness 9 Defective shift lever 46 Wiring harness between T5 (female) (6) – T13 (female) (7), T5 (female) (14) – T13 (female) (13) Resistance Max. 1 z Wiring harness between T5 (female) (14) – T13 (female) (13) Resistance Max. 1 z Voltage 20 – 30 V Voltage 20 – 30 V Resistance Max. 1 z Voltage 20 – 30 V Resistance Max. 1 z Voltage 20 – 30 V Resistance Max. 1 z Voltage 20 – 30 V 1) Turn starting switch OFF. 2) Shift gears in "R1" – "R4". Wiring harness between T13 (female) (7) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "R1" – "R4". Wiring harness between T13 (female) (7) – (19), (20), (23) 1) Turn starting switch OFF. 2) Disconnect T3A and T13. Wiring harness between T3A (female) – T13 (female) (2) 1) Turn starting switch OFF. 2) In shift range "N". Wiring harness between T13 (female) (2) – (19), (20), (23) 1) Turn starting switch OFF. 2) Disconnect T3A and T13. Wiring harness between T3A (female) (8) – T13 (female) (4) 1) Turn starting switch ON. 2) Shift gears in "F1" – "F8", "R1" – "R4". Wiring harness between T13 (female) (4) – (19), (20), (23) 1) Turn starting switch OFF. 2) Disconnect T5, T13. Wiring harness between T5 (female) (7) – T13 (female) (5) 1) Turn starting switch ON. 2) Shift gears in "F1", "F5" – "F7". Wiring harness between T13 (female)(5) – (19), (20), (23) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Cause 10 Disconnection in wiring harness 11 Defective shift lever 12 Disconnection in wiring harness Possible causes and standard value in normal 13 Defective shift lever state 14 Disconnection in wiring harness 15 Defective shift lever 16 Defective transmission controller GD655-3E0, GD675-3E0 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T5, T13. Wiring harness between T5 (female) (15) – T13 (female) (12) Resistance Max. 1 z Voltage 20 – 30 V Resistance Max. 1 z Voltage 20 – 30 V Resistance Max. 1 z Voltage 20 – 30 V 1) Turn starting switch OFF. 2) Disconnect T5, T13. Wiring harness between T13 (female) (12) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "F1" – "F8", "R1" – "R4". Wiring harness between T5 (female) (8) – T13 (female) (18) 1) Turn starting switch ON. 2) Shift gears in "F1" – "F3". Wiring harness between T13 (female) (18) – (19), (20), (23) 1) Turn starting switch OFF. 2) Disconnect T5, T13. Wiring harness between T13 (female) (4) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "F1" – "F3". Wiring harness between T13 (female) (3) – (19), (20), (23) If no problem is found in causes 1 to 15, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) 47 SEN01965-00 40 Troubleshooting Circuit diagram related to transmission shift lever switch 48 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 49 SEN01965-00 40 Troubleshooting Failure code [DF10KB] Short circuit in transmission shift lever switch Action code Failure code E03 DF10KB Contents of trouble Action of controller Problem that appears on machine Trouble Short circuit in transmission shift lever switch (Transmission controller system) • Multiple gear shift lever signals are input simultaneously. • Flashes warning lamp and turns on alarm buzzer. • Does not update lever signal but keeps gear speed just before trouble. • Sets gear speed to N, F1 or R2, depending on direction of lever, and continues control after N signal is input. • Travel is limited. Related information — Cause 1 Hot short in wiring harness Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T5, T13. 3) Turn starting switch ON. Between T5 (female) (6), (14) and chassis ground 2 Hot short in wiring harness 3 Hot short in wiring harness 50 Max. 1 V Voltage Max. 1 V Voltage Max. 1 V Voltage Max. 1 V Voltage Max. 1 V Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T5, T13. 3) Turn starting switch ON. Between T5 (female) (16) and chassis ground 8 Defective shift lever Voltage 1) Turn starting switch OFF. 2) Disconnect T5, T13. 3) Turn starting switch ON. Between T5 (female) (8) and chassis ground 7 Hot short in wiring harness Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T5, T13. 3) Turn starting switch ON. Between T5 (female) (15) and chassis ground 6 Hot short in wiring harness Voltage 1) Turn starting switch OFF. 2) Disconnect T3A, T13. 3) Turn starting switch ON. Between T5 (female) (7) and chassis ground 5 Hot short in wiring harness Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T3A, T13. 3) Turn starting switch ON. Between T3A (female) (18) and chassis ground 4 Hot short in wiring harness Voltage 1) Turn starting switch OFF. 2) Disconnect T3A, T13. 3) Turn starting switch ON. Between T3A (female) (8) and chassis ground Possible causes and standard value in normal state 1 1) Turn starting switch ON. 2) Shift gears in "N", "P", "R1" – "R4". Wiring harness between T13 (female) (7) – (19), (20), (23) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Cause 9 Defective shift lever 10 Defective shift lever 11 Defective shift lever 12 Defective contact or open circuit in wiring harness Possible causes and standard value in normal 13 Defective shift lever state 14 Defective shift lever 15 Defective shift lever 16 Defective shift lever 17 Defective transmission controller GD655-3E0, GD675-3E0 Standard value when normal and remarks for troubleshooting 1) Turn starting switch ON. 2) Shift gears in "F1" – "F8", "N", "P". Wiring harness between T13 (female) (13) – (19), (20), (23) Voltage Max. 1 V Voltage Max. 1 V Voltage Max. 1 V 1) Turn starting switch ON. 2) Shift gears in "F1" – "F8", "R1" – "R4". Wiring harness between T13 (female) (2) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "N", "P". Wiring harness between T13 (female) (4) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "N", "P", "F2" – "F4", "F8" – "R4". Wiring harness between T13 (female) (5) – (19), (20), (23) Voltage Max. 1 V 1) Turn starting switch ON. 2) Shift gears in "N", "P", "F6" – "F8", "R2" – "R4". Wiring harness between T13 (female) (12) – (19), (20), (23) Voltage Max. 1 V 1) Turn starting switch ON. 2) Shift gears in "N", "P", "F4" – "F8", "R1" – "R4". Wiring harness between T13 (female) (18) – (19), (20), (23) Voltage Max. 1 V Voltage Max. 1 V 1) Turn starting switch ON. 2) Shift gears in "F1" – "F3". Wiring harness between T13 (female) (3) – (19), (20), (23) 1) Turn starting switch ON. 2) Shift gears in "N", "P", "F1", "F2", "F7", "F8", "R3", "R4". Wiring harness between T13 (female) (3) – (19), (20), (23) Voltage Max. 1 V If no problem is found in causes 1 to 16, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) 51 SEN01965-00 40 Troubleshooting Circuit diagram related to transmission shift lever switch 52 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 53 SEN01965-00 40 Troubleshooting Failure code [DGF1KX] Transmission oil temperature out of range Action code Failure code E03 DGF1KX Contents of trouble Action of controller Problem that appears on machine Trouble 1 Transmission oil temperature out of range (Transmission controller system) • Input voltage of transmission oil temperature sensor is below 0.5 V. • Flashes warning lamp and turns on alarm buzzer. • Outputs with oil temperature map for less than 20°C. • Normal operation. Related information — Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T35. Defective transmission oil 1 temperature sensor (Internal defect) Between T35 (male) (1) and (2) Between T35 (female) (1), (2) and chassis ground Possible causes and standard value in normal state Grounding fault in wiring 2 harness 3 Hot short in wiring harness Defective contact or open 5 circuit in wiring harness 6 54 Defective transmission controller 3.5 – 4.0 kz Resistance (100°C) 38.5 – 47.0 kz Resistance Min. 1 Mz Resistance Min. 1 Mz Voltage Max. 1 V Resistance Max. 1 z Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T3, T35. Between T3 (female) (1) and chassis ground 1) Turn starting switch ON. 2) Disconnect T3, T35. Between T3 (female) (1) and chassis ground Defective contact or open 4 circuit in wiring harness Resistance (normal temp. 25°C) 1) Turn starting switch ON. 2) Disconnect T3, T35. Between T3 (female) (1) and T35 (female) (1) 1) Turn starting switch OFF. 2) Disconnect T35. Between T3 (female) (1) and chassis ground If no problem is found in causes 1 to 5, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to transmission oil temperature sensor GD655-3E0, GD675-3E0 55 SEN01965-00 40 Troubleshooting Failure code [DGT1KX] Torque converter oil temperature out of range Action code Failure code E01 DGT1KX Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Torque converter oil temperature out of range (Transmission controller system) • Input voltage of torque converter oil temperature sensor is below 0.5 V. • Flashes warning lamp and turns on alarm buzzer. • Normal operation. • The input state (voltage) from torque converter oil temperature sensor can be checked with the monitoring function (Code: 30100 TC OIL TEMP). Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T34. Defective torque converter 1 oil temperature sensor (Internal defect) Between T34 (male) (1) and (2) Between T34 (male) (1), (2) and chassis ground Possible causes and standard value in normal state 2 Grounding fault in wiring harness 3 Hot short in wiring harness Defective contact or open 4 circuit in wiring harness 5 6 56 Defective contact or open circuit in wiring harness Defective transmission controller Resistance (normal temp. 25°C) 3.5 – 4.0 kz Resistance (100°C) 38.5 – 47.0 kz Resistance Min. 1 Mz Resistance Min. 1 Mz Voltage Max. 1 V Resistance Max. 1 z Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T3, T34. Between T3 (female) (11) and chassis ground 1) Turn starting switch ON. 2) Disconnect T3, T34. Between T3 (female) (11) and chassis ground 1) Turn starting switch ON. 2) Disconnect T3, T34. Between T3 (female) (11) – T34 (female) (1) 1) Turn starting switch OFF. 2) Disconnect T34. Between T34 (female) (2) and chassis ground If no problem is found in causes 1 to 5, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to torque converter oil temperature sensor GD655-3E0, GD675-3E0 57 SEN01965-00 40 Troubleshooting Failure code [DJF1KA] Disconnection in fuel level sensor Action code Failure code E01 DJF1KA Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Disconnection in fuel level sensor (Machine monitor system) • The signal circuit of fuel level sensor is disconnected and signal is not input. • None in particular. • The fuel level gauge does not indicate normally. • Signal from the fuel level sensor (resistance, voltage) can be checked with monitoring function (Code: 04201-FUEL SENSOR, 04200-FUEL SENSOR) • Method of reproducing failure code: Start engine Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ET39 (male) 1 Possible causes and standard value in normal state Defective fuel level sensor (Internal disconnection) Disconnection in wiring harness 2 (Disconnection or defective contact) Hot short in wiring harness 3 (Contact with 24V circuit) Between (1) – chassis ground Fuel level Resistance FULL Max. 13 z 3/4 (18 z) 1/2 25.5 – 28.8 z 1/4 (46.6 z) EMPTY Min. 69.9 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FP2 (female) (10) and ET39 (female) (1) Resistance Max. 1 z Wiring harness between fuel sensor ground terminal – chassis ground Resistance Max. 1 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between chassis ground and wiring harness between FP2 (female) (10) – ET39 (female) (1) Voltage Max. 1 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FP2 (male) 4 Defective machine monitor Between (10) – chassis ground 58 Fuel level Resistance FULL Max. 13 z 3/4 (18 z) 1/2 25.5 – 28.8 z 1/4 (46.6 z) EMPTY Min. 69.9 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to fuel level sensor GD655-3E0, GD675-3E0 59 SEN01965-00 40 Troubleshooting Failure code [DK10KX] Input of accelerator pedal potentiometer out of normal range 1 Action code Failure code E01 DK10KX Contents of trouble Action of controller Problem that appears on machine Related information Trouble Input of accelerator pedal potentiometer out of normal range (Transmission controller system) • Input voltage of accelerator pedal position sensor is above 4.5 V or below 0.4 V. • Flashes warning lamp and turns on alarm buzzer. • Uses low throttle position map instead of standard set. • No action. • The input state (voltage) from accelerator pedal potentiometer can be checked with the monitoring function (Code: 31707 THROTTLE POS). • The controller interpret the specified potentiometer voltage as the throttle angle. Cause Defective accelerator pedal 1 potentiometer (Internal defect) Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, TCR. Between T3 (female) (3) – TCR (8) Voltage 20 – 30 V Voltage 0.5 – 4.75 V 1) Turn starting switch OFF. Possible causes and standard value in normal state 2 Defective communication controller Between T3 (male) (21) – T2 (male) (21) Voltage 1.0 – 2.0 V (at low idle) Voltage (at low idle 2.1 – 4.3 V to high idle) 3 Defective transmission controller If no problem is found in causes 1 to 2, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to accelerator pedal potentiometer 60 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 61 SEN01965-00 40 Troubleshooting Failure code [DK70KX] Input of inching pedal potentiometer out of normal range 1 Action code Failure code E03 DK70KX Contents of trouble Action of controller Problem that appears on machine Related information Trouble Input of inching pedal potentiometer out of normal range (Transmission controller system) • Signal voltage of inching angle sensor of inching pedal is out of normal range. • Flashes warning lamp and turns on alarm buzzer. • No inching output. • Inching is not available. • The controller interpret the specified potentiometer voltage as the pedal angle. • When adjusting the potentiometer, leave the margin for error judgement field. At low idle, adjust the potentiometer so that voltage is from 1.3 to 1.6 V. Cause Defective contact or open 1 circuit in wiring harness 2 Grounding fault in wiring harness Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T3, T8. Between T3 (female) (7), T8 (female) (A) and chassis ground Resistance Min. 1 Mz Between T3 (female) (7) and chassis ground Resistance Max. 1 z Between T3 (female) (13) and chassis ground Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T3, T8. 3) Ground T8 (female) (B) to the chassis. 1) Turn starting switch ON. Possible causes and standard value in normal state Defective inching pedal 3 potentiometer (Internal defect) Wiring harness between T3 (female) (13) – (16) Voltage 0.5 – 4.75 V Voltage (Inching pedal not depressed) 0.8 – 1.6 V Voltage (When inching pedal not depressed to inch- 2.1 – 4.3 V ing pedal fully depressed) Wiring harness between T3 (female) (7) – (16) 4 Defective contact or open circuit in wiring harness 4.75 – 5.25 V 1) Turn starting switch OFF. 2) Disconnect T3, T8. 3) Ground T8 (female) (C) to the chassis. Between T3 (16) and chassis ground 62 Voltage Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch ON. If voltage is normal, it is suspected that transmission controller is defective. Possible causes and standard value in normal state Defective transmission 5 controller (Internal defect) Wiring harness between T3 (male) (13) – (16) Wiring harness between T3 (male) (7) – (16) 6 Hot short in wiring harness 0.5 – 4.75 V Voltage (Inching pedal not depressed) 0.8 – 1.6 V Voltage (When inching pedal not depressed to inch- 2.1 – 4.0 V ing pedal fully depressed) Voltage 4.75 – 5.25 V 1) Disconnect T8. 2) Turn starting switch ON. Between T3 (male) (13) and (16) Defective inching pedal 7 potentiometer (Internal defect) Voltage Voltage Max. 0.5 V If no problem is found in causes 1 to 6, it is suspected that inching pedal potentiometer is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to inching pedal potentiometer GD655-3E0, GD675-3E0 63 SEN01965-00 40 Troubleshooting Failure code [DKD0KA] Disconnection in articulate sensor Action code Failure code E01 DK10KX Contents of trouble Action of controller Problem that appears on machine Related information Trouble 1 Disconnection in articulate sensor (Communication controller system) • The signal circuit of articulate sensor is disconnected and signal is not input. • If cause of failure disappears and gear shift lever position is N, system resets itself. • The articulate gauge does not indicate normally. • Signal from the articulate sensor (resistance, voltage) can be checked with monitoring function (Code: 43905-ARTICULATE, 43904-ARTICULATE). • Method of reproducing failure code: Start engine and operate the articulated section. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective articulate sensor (Internal disconnection) FL6 (male) Between (1) – (2) Possible causes and standard value in normal state Disconnection in wiring harness 2 (Disconnection or defective contact) Hot short in wiring harness 3 (Contact with 24 V) Articulate angle Resistance Center 96.5 – 106.5 z Left end (23°) 163.8 – 180 z Right end (23°) 17.7 – 37.7 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TCR (female) (24) and FL6 (female) (2) Resistance Max. 1 z Wiring harness between TCR (female) (32) and FL6 (female) (1) Resistance Max. 1 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between chassis ground and wiring harness between TCR (female) (24) – FL6 (female) (2) Voltage Max. 1 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective communication controller TCR (male) Between (24) – (32) 64 Articulate angle Resistance Center 96.5 – 106.5 z Left end (23°) 163.8 – 180 z Right end (23°) 17.7 – 37.7 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to articulate sensor GD655-3E0, GD675-3E0 65 SEN01965-00 40 Troubleshooting Failure code [DLE2KA] Disconnection in engine speed sensor Action code Failure code E03 DLE2KA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in engine speed sensor (Transmission controller system) • There is disconnection in engine speed sensor circuit and engine speed signal is not input. • Flashes warning lamp and turns on alarm buzzer. • Engine speed not displayed on panel. • No action. • System does not reset itself until starting switch is turned OFF. Cause Possible causes and standard value in normal state 1 Defective engine speed 1 sensor (Internal defect) 2 Disconnection in wiring harness Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T46. Between T46 (male) (1) and (2) Resistance 500 – 1000 z Between T46 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T4, T46. Between T4 (female) (20) – T46 (female) (1) Between T5 (female) (1) – T46 (female) (2) Circuit diagram related to engine reverse sensor 66 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DLF1KA] Disconnection in transmission input speed sensor 1 Action code Failure code E03 DLF1KA Contents of trouble Action of controller Problem that appears on machine Related information Trouble Disconnection in transmission input speed sensor (Transmission controller system) • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not input. • Flashes warning lamp and turns on alarm buzzer. • Normal operation. • System does not reset itself until starting switch is turned OFF. Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T32. Defective transmission input 1 speed sensor Between T32 (male) (1) and (2) (Internal defect) Between T32 (male) (1), (2) and chassis ground Possible causes and standard value in normal state Defective contact or open 2 circuit in wiring harness Defective contact or open 3 circuit in wiring harness 4 Defective transmission controller Resistance 500 – 1000 z Resistance Min. 1 Mz Resistance Max. 1 z Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T5, T32. Between T5 (female) (2) and T32 (female) (1) 1) Turn starting switch ON. 2) Disconnect T5, T32. Between T5 (female) (1) and T32 (female) (2) If no problem is found in causes 1 to 3, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to transmission input speed sensor GD655-3E0, GD675-3E0 67 SEN01965-00 40 Troubleshooting Failure code [DLT3KA] Disconnection in transmission output speed sensor 1 Action code Failure code E03 DLT3KA Trouble Disconnection in transmission output speed sensor (Transmission controller system) Contents of trouble • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not input. Action of controller • Flashes warning lamp and turns on alarm buzzer. • When starting switch is ON and gear shift lever kept at N, possible up to 2nd; when traveling, taken as N until starting switch turned OFF Problem that appears on machine Related information • Travel is impossible after stopping the machine. • The input state (voltage) from transmission output speed sensor can be checked with the monitoring function (Code: 31400 T/M SPEED: OUT). • System does not reset itself until starting switch is turned OFF. Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T33. Defective transmission output 1 speed sensor Between T33 (male) (1) and (2) (Internal defect) Between T33 (male) (1), (2) and chassis ground Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Defective contact or open 3 circuit in wiring harness 4 Defective transmission controller Resistance 500 – 1000 z Resistance Min. 1 Mz Resistance Max. 1 z Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T4, T33. Between T4 (female) (1) and T33 (female) (1) 1) Turn starting switch ON. 2) Disconnect T4, T33. Between T4 (female) (9) and T33 (female) (2) If no problem is found in causes 1 to 3, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to transmission output speed sensor 68 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DV00KB] Short circuit in caution buzzer Action code Failure code E01 DV00KB Contents of trouble Action of controller Problem that appears on machine Related information Trouble Short circuit in caution buzzer (Machine monitor system) • Abnormal current flowed when caution buzzer circuit output ground signal. • Stops caution buzzer circuit from outputting ground signal. • Caution buzzer does not sound. • Method of reproducing failure code: Turn starting switch ON (When it is turned ON, buzzer sounds for 2 second). Cause 1 Possible causes and standard value in normal state 1 Defective caution buzzer (Internal short circuit) Short circuit with power 2 source in wiring harness (Contact with 24 V circuit) Standard value when normal and remarks for troubleshooting a Internal defect of caution buzzer is suspected. (It cannot be diagnosed.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between FP1 (female) (18) – SP26 (female) Voltage Max. 1 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor FP1 (male) Between (18) – chassis ground Caution buzzer Voltage When turned OFF 20 – 30 V When turned ON (sounding) Max. 3 V Circuit diagram related to caution buzzer GD655-3E0, GD675-3E0 69 SEN01965-00 40 Troubleshooting Failure code [DW4BKA] Disconnection in parking brake relay Action code Failure code E03 DW4BKA Contents of trouble Trouble Disconnection in parking brake relay (Transmission controller system) • Short circuit with power source or open circuit in the parking signal circuit. Action of controller — Problem that appears on machine — Related information — Cause 1 Defective parking brake relay Grounding fault in wiring 2 harness Standard value when normal and remarks for troubleshooting 1) Replace BR11 with a known good one. If the condition becomes normal, parking brake relay has a defect. 1) Turn starting switch OFF. 2) Disconnect T2 and BR11. 3) Turn starting switch ON. Between T2 (female) (6) and chassis ground Possible causes and standard value in normal state 1) Turn starting switch OFF. Short circuit in wiring 2) Disconnect T2 and BR11. 3 harness (with another wiring harness) Between T2 (female) (6) and BR11 (female) (2) 4 Defective Fuse I-10 5 Defective transmission controller Voltage Max. 1 V Resistance Max. 1 z Voltage 20 – 30 V 1) Turn starting switch OFF. 2) Disconnect BR11. 3) Turn starting switch ON. Between BR11 (female) (1) and chassis ground 70 1 If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to parking brake relay GD655-3E0, GD675-3E0 71 SEN01965-00 40 Troubleshooting Failure code [DXH1KA] Disconnection in lock-up ECMV solenoid Action code Failure code E03 DXH1KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in lock-up ECMV solenoid (Transmission controller system) • When output to lock-up ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Torque converter always drived (Lock-up is not applied). Related information — Cause Defective lock-up clutch 1 ECMV solenoid (Internal defect) Possible causes and standard value in normal state 1 2 Defective contact or open circuit in wiring harness. Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T31. Between T31 (male) (1) and (2) Resistance 5 – 15 z Between T31 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T31. Between T2 (female) (20) – T31 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2,T31. Between T2 (female) (20) and chassis ground. 1) Turn starting switch OFF. 2) Disconnect T2, T31. Between T2 (female) (10) and T31 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to lock-up ECMV solenoid 72 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DXH1KY] Power supply line short in lock-up ECMV solenoid Action code Failure code E03 DXH1KY Contents of trouble Action of controller Problem that appears on machine Related information Trouble Power supply line short in lock-up ECMV solenoid (Transmission controller system) • When output to lock-up ECMV is OFF, current flows to circuit. • Turns lock-up solenoid output OFF. • Flashes warning lamp and turns on alarm buzzer. • Lock-up is always applied. • System does not reset itself until starting switch is turned OFF. Cause Defective lock-up ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 1 Grounding fault in wiring 2 harness Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T31. Between T31 (male) (1) and (2) Resistance 5 – 15 z Between T31 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Between T2 (female) (10) and chassis ground Voltage Max. 1 V Between T2 (female) (20) and chassis ground Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T2, T31. Between T2 (female) (10) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring 2) Disconnect T2. 3 harness (With another wiring harness) Between T2 (female) (10) and (20) 4 Hot short in wiring harness 5 Defective transmission controller 1) Turn starting switch ON. 2) Disconnect T2, T31. If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to lock-up ECMV solenoid GD655-3E0, GD675-3E0 73 SEN01965-00 40 Troubleshooting Failure code [DXH2KA] Disconnection in FH clutch ECMV solenoid 1 Action code Failure code E03 DXH2KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in FH clutch ECMV solenoid (Transmission controller system) • When output to FH clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F2, F4, F6, F8. Related information — Cause Defective FH clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T25. Between T25 (male) (1) and (2) Resistance 5 – 15 z Between T25 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T25. Between T2 (female) (18) – T25 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T25. Between T2 (female) (18) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T25. Between T2 (female) (8) and T25 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to FH clutch ECMV solenoid 74 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 75 SEN01965-00 40 Troubleshooting Failure code [DXH2KY] Power supply line short in FH clutch ECMV solenoid 1 Action code Failure code E03 DXH2KY Contents of trouble Action of controller Problem that appears on machine Related information Trouble Power supply line short in FH clutch ECMV solenoid (Transmission controller system) • When output to FH clutch ECMV is OFF, current flows to circuit. • Turns FL, FH, R solenoid outputs OFF. • When lever position at: N, F1: can not run (1st – 4th solenoids turns OFF) F2, F3: F2 F4, F5: F4 F6, F7: F6 F8: F8 R: 1st thru 4th • Flashes warning lamp and turns on alarm buzzer. • Possible to travel in F2, F4, F6, F8, but will occur some shift shock. • System does not reset itself until starting switch is turned OFF. Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T25. 1 Defective FH clutch solenoid Between T25 (male) (1) and (2) (Internal defect) Resistance 5 – 15 z Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz Between T2 (female) (8) and chassis ground Voltage Max. 1 V Between T2 (female) (18) and chassis ground Voltage Max. 1 V Between T25 (male) (1), (2) and chassis ground Possible causes and standard value in normal state Grounding fault in wiring 2 harness Between T2 (female) (8) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring harness 2) Disconnect T2. 3 (With another wiring harness) Between T2 (female) (8) and (18) 4 Hot short in wiring harness 5 76 1) Turn starting switch OFF. 2) Disconnect T2, T25. Defective transmission controller 1) Turn starting switch ON. 2) Disconnect T2, T25. If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to FH clutch ECMV solenoid GD655-3E0, GD675-3E0 77 SEN01965-00 40 Troubleshooting Failure code [DXH3KA] Disconnection in FL clutch ECMV solenoid 1 Action code Failure code E03 DXH3KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in FL clutch ECMV solenoid (Transmission controller system) • When output to FL clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F1, F3, F5, F7. Related information — Cause Defective FL clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T24. Between T24 (male) (1) and (2) Resistance 5 – 15 z Between T24 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2,T24. Between T2 (female) (17) – T24 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2,T24. Between T2 (female) (7) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T24. Between T2 (female) (7) and T24 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to FL clutch ECMV solenoid 78 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 79 SEN01965-00 40 Troubleshooting Failure code [DXH3KY] Power supply line short in FL clutch ECMV solenoid 1 Action code Failure code E03 DXH3KY Contents of trouble Action of controller Problem that appears on machine Trouble Power supply line short in FL clutch ECMV solenoid (Transmission controller system) • When output to FL clutch ECMV is OFF, current flows to circuit. • Turns FL, FH, R solenoid outputs OFF. • When lever position at: N: 1st – 4th solenoids OFF F1, F2: F1 F3, F4: F3 F5, F6: F5 F7, F8: F7 R: 1st thru 4th solenoids OFF • Flashes warning lamp and turns on alarm buzzer. • Possible to travel in F1, F3, F5, F7, but will occur some shift shock. Related information — Cause Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T24. 1 Possible causes and standard value in normal state Defective FL clutch solenoid (Internal defect) Grounding fault in wiring 2 harness Resistance 5 – 15 z Between T24 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Between T2 (female) (7) and chassis ground Voltage Max. 1 V Between T2 (female) (17) and chassis ground Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T2. Between T2 (female) (7) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring harness 2) Disconnect T2. 3 (With another wiring harness) Between T2 (female) (7) and (17) 4 Hot short in wiring harness 5 80 Between T24 (male) (1) and (2) Defective transmission controller 1) Turn starting switch ON. 2) Disconnect T2 and T24. If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to FL clutch ECMV solenoid GD655-3E0, GD675-3E0 81 SEN01965-00 40 Troubleshooting Failure code [DXH4KA] Disconnection in 1st clutch ECMV solenoid 1 Action code Failure code E03 DXH4KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in 1st clutch ECMV solenoid (Transmission controller system) • When output to 1st clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F1, F2, R1. Related information — Cause Defective 1st clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T27. Between T27 (male) (1) and (2) Resistance 5 – 15 z Between T27 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T27. Between T2 (female) (13) – T27 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T27. Between T2 (female) (13) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2,T27. Between T2 (female) (2) and T27 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch ECMV solenoids 82 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DXH4KY] Power supply line short in 1st, 3rd clutch ECMV solenoid Action code Failure code E03 DXH4KY Contents of trouble Action of controller Problem that appears on machine Related information Trouble Power supply line short in 1st, 3rd clutch ECMV solenoid (Transmission controller system) • When output to 1st, 3rd clutch ECMV is OFF, current flows to circuit. • Turns 1st thru 4th solenoid outputs OFF. • Flashes warning lamp and turns on alarm buzzer. • Possible to travel in F1, F2, F5, F6, R1, R3, but will occur some shift shock. • System does not reset itself until starting switch is turned OFF. Cause Defective 1st, 3rd clutch 1 ECMV solenoid (Internal defect) Grounding fault in wiring 2 harness Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T2, T27, T29. Between T27 (male) (1) and (2), between T29 (male) (1) and (2) Resistance 5 – 15 z Between T27 (male) (1), (2), T29 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Between T2 (female) (2), (3) and chassis ground Voltage Max. 1 V Between T2 (female) (13), (14) and chassis ground Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T2, T27, T29. Between T2 (female) (2), (3) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring harness 2) Disconnect T2. 3 (With another wiring harness) Between T2 (female) (2) and (13), T2 (female) (3) and (14) 1) Turn starting switch ON. 2) Disconnect T2, T27, T29. 4 Hot short in wiring harness 5 Defective transmission controller If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch ECMV solenoids GD655-3E0, GD675-3E0 83 SEN01965-00 40 Troubleshooting Failure code [DXH5KA] Disconnection in 2nd clutch ECMV solenoid1 Action code Failure code E03 DXH5KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in 2nd clutch ECMV solenoid (Transmission controller system) • When output to 2nd clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F3, F4, R2. Related information — Cause Defective 2nd clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T28. Between T28 (male) (1) and (2) Resistance 5 – 15 z Between T28 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T28. Between T2 (female) (15) – T28 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T28. Between T2 (female) (15) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T28. Between T2 (female) (13) and T28 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch ECMV solenoids 84 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DXH5KY] Power supply line short in 2nd, 4th clutch ECMV solenoid Action code Failure code E03 DXH5KY Contents of trouble Action of controller Problem that appears on machine Related information Trouble Power supply line short in 2nd, 4th clutch ECMV solenoid (Transmission controller system) • When output to 2nd, 4th clutch ECMV is OFF, current flows to circuit. • Turns 1st thru 4th solenoid outputs OFF. • Flashes warning lamp and turns on alarm buzzer. • Possible to travel in F3, F4, F7, F8, R2, R4. But will occur some shift shock. • System does not reset itself until starting switch is turned OFF. Cause Defective 1st, 3rd clutch 1 ECMV solenoid (Internal defect) Grounding fault in wiring 2 harness Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T2, T28, T30. Between T28 (male) (1) and (2), T30 (male) (1) and (2) Resistance 5 – 15 z Between T28 (male) (1), (2), T30 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Between T2 (female) (4), (5) and chassis ground Voltage Max. 1 V Between T2 (female) (15), (16) and chassis ground Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T2, T28, T30. Between T2 (female) (4), (5) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring harness 2) Disconnect T2. 3 (With another wiring harness) Between T2 (female) (4) and (15), T2 (female) (5) and (16) 1) Turn starting switch ON. 2) Disconnect T2, T28, T30. 4 Hot short in wiring harness 5 Defective transmission controller If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch ECMV solenoids GD655-3E0, GD675-3E0 85 SEN01965-00 40 Troubleshooting Failure code [DXH6KA] Disconnection in 3rd clutch ECMV solenoid 1 Action code Failure code E03 DXH6KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in 3rd clutch ECMV solenoid (Transmission controller system) • When output to 3rd clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F5, F6, R3. Related information — Cause Defective 3rd clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T29. Between T29 (male) (1) and (2) Resistance 5 – 15 z Between T29 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T29. Between T2 (female) (14) – T29 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T29. Between T2 (female) (14) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T29. Between T2 (female) (3) and T29 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to clutch ECMV solenoids 86 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Failure code [DXH7KA] Disconnection in R clutch ECMV solenoid Action code Failure code E03 DXH7KA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in R clutch ECMV solenoid (Transmission controller system) • When output to R clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in reverse. Related information — Cause Defective R clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 1 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T26. Between T26 (male) (1) and (2) Resistance 5 – 15 z Between T26 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T26. Between T2 (female) (18) – T26 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T26. Between T2 (female) (19) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T26. Between T2 (female) (9) and T26 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to R clutch ECMV solenoid GD655-3E0, GD675-3E0 87 SEN01965-00 40 Troubleshooting Failure code [DXH7KY] Power supply line short in R clutch ECMV solenoid Action code Failure code E03 DXH7KY Contents of trouble Action of controller Problem that appears on machine Related information Trouble • Turns FL,FH,R solenoid outputs OFF. • When lever position at: N, F1-F8: can not run (1st-4th solenoids turns OFF) R1: R1 R2: R2 R3: R3 R4: R4 • Flashes warning lamp and turns on alarm buzzer. • Possible to travel in R1, R2, R3, R4. • System does not reset itself until starting switch is turned OFF. Defective R clutch ECMV 1 solenoid (Internal defect) Grounding fault in wiring 2 harness Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T26. Between T26 (male) (1) and (2) Resistance 5 – 15 z Between T26 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance 5 – 15 z Between T2 (female) (9) and chassis ground Voltage Max. 1 V Between T2 (female) (19) and chassis ground Voltage Max. 1 V 1) Turn starting switch OFF. 2) Disconnect T2, T26. Between wiring harness T2 (female) (9) – T26 (female) (1) and chassis ground 1) Turn starting switch OFF. Short circuit in wiring harness 2) Disconnect T2. 3 (With another wiring harness) Between T2 (female) (9) and (19) 4 Hot short in wiring harness 5 88 Power supply line short in R clutch ECMV solenoid (Transmission controller system) • When output to R clutch ECMV is OFF, current flows to circuit. Cause Possible causes and standard value in normal state 1 Defective transmission controller 1) Turn starting switch ON. 2) Disconnect T2, T26. If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01965-00 Circuit diagram related to R clutch ECMV solenoid GD655-3E0, GD675-3E0 89 SEN01965-00 40 Troubleshooting Failure code [DXHHKA] Disconnection in 4th clutch ECMV solenoid 1 Action code Failure code E03 DXHHKA Contents of trouble Action of controller Problem that appears on machine Trouble Disconnection in 4th clutch ECMV solenoid (Transmission controller system) • When output to 4thd clutch ECMV is OFF, current flows to circuit. • Flashes warning lamp and turns on alarm buzzer. • Can not travel in F7, F8, R4. Related information — Cause Defective 4th clutch ECMV 1 solenoid (Internal defect) Possible causes and standard value in normal state 2 Defective contact or open circuit in wiring harness Grounding fault in wiring 3 harness Defective contact or open 4 circuit in wiring harness 5 Defective transmission controller Standard value when normal and remarks for troubleshooting 1) Turn starting switch OFF. 2) Disconnect T30. Between T30 (male) (1) and (2) Resistance 5 – 15 z Between T30 (male) (1), (2) and chassis ground Resistance Min. 1 Mz Resistance Max. 1 z Resistance Min. 1 Mz Resistance Max. 1 z 1) Turn starting switch OFF. 2) Disconnect T2, T30. Between T2 (female) (16) – T30 (female) (2) 1) Turn starting switch OFF. 2) Disconnect T2, T30. Between T2 (female) (16) and chassis ground 1) Turn starting switch OFF. 2) Disconnect T2, T30. Between T2 (female) (5) and T30 (female) (1) If no problem is found in causes 1 to 4, it is suspected that transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.) Circuit diagram related to lock-up ECMV solenoid 90 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01965-00 91 SEN01841-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 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 SEN01841-00 40 Troubleshooting 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 40 Troubleshooting SEN01841-00 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 failure General information Symptom of failure that has appeared in the machine Information related to troubles occurred or troubleshooting Cause Standard value when normal and remarks for troubleshooting <Described contents> • Standard value when normal required to judge the possible cause • Remarks required to judge whether the cause is right or not 1 2 Possible causes and the standard values when normal Cause by which a trouble is assumed to be caused (The order number indicates a serial number, not a priority sequence.) 3 4 <Symptoms of defective harness> • Disconnection in wiring The connector contact is defective or the wiring harness is disconnected. • Defective grounding A harness not connected to GND (ground) circuit comes into contact with the GND (ground) circuit. • Hot short defect A harness not connected to the electric power supply (24 V) circuit comes into contact with the electric power supply (24 V) circuit. • Short circuit A harness abnormally comes into contact with a harness of separate circuit. <Points to remember when troubleshooting> (1) Method of indicating connector numbers and handling Tadapter For troubleshooting, insert or connect the T- adapter as described below unless especially specified. • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the Tadapter in both the male and female. • When “male”or “female” is indicated for a connector number, 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 specified. • Connect the plus (+) lead to a pin number or harness indicated 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 SEN01841-00 40 Troubleshooting E-1 Engine does not start at all or does not start easily 1 Symptom of failure (1) When starting switch is turned to START, starting motor does not rotate. General information • Since engine start circuit has neutral safety function, engine cannot be started if gear shift lever is not in P position. • 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.) Cause 1 Insufficient battery charge Standard value when normal and remarks for troubleshooting Battery voltage Electrolyte specific gravity 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. 2 3 Defective starting switch (Internal disconnection) Defective safety relay (Internal defect) Starting switch Switch position Resistance Between terminals B – C OFF Min. 1 Mz START Max. 1 z a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace safety relay (Right No.) with another relay (5pin type). If condition becomes normal at this time, safety relay is defective. SP13 a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 5 Possible causes and the standard values when normal Defective cold start aid switch relay (Internal defect) Replace cold start aid switch relay (Right No.) with another relay (5-pin type). If condition becomes normal at this time, cold start aid switch relay is defective. Defective diode (Internal disconnection) Defective alternator 6 (Internal short circuit) [75 A alternator specification] SP14 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R28 (male), R29 (male) Continuity Between (2) – (1) There is continuity a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. R30 (female) Voltage Between 2 – ground Max. 1 V a Prepare with starting switch OFF (with wiring harness connected), then start engine and carry out troubleshooting. Starting motor 7 Defective starting motor (Internal defect) Voltage Between B – E Power supply input 20 – 30 V 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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ET49 – starting motor terminal B Disconnection in wiring harness Wiring harness between starting motor termi8 (Disconnection in wiring or nal E – ground defective contact in connector) Wiring harness between ST8 – SP13 (female) (3) Wiring harness between SP13 (female) (5) – SP14 (female) (5) 4 Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting Wiring harness between SP13 (female) (5) – R28 (female) (2), R29 (female) (2) Resistance Max. 1 z Wiring harness between R28 (female) (1), Disconnection in wiring harness R29 (female) (1) – starting motor terminal S 8 (Disconnection in wiring or defective contact in connector) Wiring harness between T13 (female) (6) – SP14 (female) (1) Resistance Max. 1 z Resistance Max. 1 z Wiring harness between SP14 (female) (2) – ground (FT01) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal 9 10 Wiring harness between ET49 – starting motor terminal B Resistance Min. 1 Mz Wiring harness between ST8 – SP13 (female) (3) or circuit branch end Resistance Min. 1 Mz Wiring harness between SP13 (female) (5) – Ground fault in wiring harness SP14 (female) (5) (Contact with GND circuit) Wiring harness between SP13 (female) (5) – R28 (female) (2), R29 (female) (2) or circuit branch end Resistance Min. 1 Mz Resistance Min. 1 Mz Wiring harness between R28 (female) (1), R29 (female) (1) – starting motor terminal S Resistance Min. 1 Mz Wiring harness between T13 (female) (6) – SP14 (female) (1) Resistance Min. 1 Mz Hot short (Contact with 24V circuit) in wiring harness GD655-3E0, GD675-3E0 a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between R30 (female) (2) – alternator terminal R, R19 (female) (2), FP2 (female) (9) or circuit branch end Voltage Max. 1 V 5 SEN01841-00 40 Troubleshooting Circuit diagram related to auto-preheating, starting, start aid, and charging of engine 6 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01841-00 7 SEN01841-00 40 Troubleshooting Symptom of failure (2) When starting switch is turned to START, starting motor does not rotate. General information • 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 seconds and preheater pilot lamp lights up during that time). • State (Temperature) of engine coolant can be checked with monitoring function (Code: ENGINE04105-COOLANT TEMP). Cause 1 Defective slow blow fuse 2 2 Defective preheater relay (Internal defect) Standard value when normal and remarks for troubleshooting If slow blow fuse is broken, circuit probably has ground fault etc. (See cause 7.) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Replace preheater relay with normal relay. If condition becomes normal 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 3 Defective heater relay (Internal defect) Voltage Between B – E Power supply input 20 – 30 V 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. 4 Possible causes and the standard values when normal Defective intake air heater (Internal disconnection) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Intake air heater Continuity Between terminals There is continuity a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector) Wiring harness between ET53 – heater relay terminal B Resistance Max. 1 z Wiring harness between heater relay terminal A – intake air heater Resistance Max. 1 z Wiring harness between heater relay terminal 5 – EC2 (female) (40) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ET53 – heater relay terminal B 6 Resistance Min. 1 Mz Ground fault in wiring harness Wiring harness between heater relay termi(Contact with GND circuit) nal A – intake air heater Resistance Min. 1 Mz Wiring harness between heater relay terminal 5 – EC2 (female) (40) Resistance Min. 1 Mz Wiring harness between EC2 (female) (40) – heater relay terminal 5 or R31 (female) (1) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7 Defective engine controller EC2 Between (40) – ground 8 Engine coolant temperature Voltage Min. –5°C 20 – 30 V Below –5°C Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to auto-preheating, starting, start aid, and charging of engine GD655-3E0, GD675-3E0 9 SEN01841-00 40 Troubleshooting Symptom of failure (3) Even if start aid switch is pressed when ambient temperature is low, engine does not start easily. General information • If start aid switch is used, load on hydraulic pump is decreased when engine is started so that engine can be started easily. Cause 1 2 Defective fuse A10 of fuse box I (FB1) Defective start aid switch relay (Internal defect) Standard value when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. (See causes 5 and 7.) a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace neutral relay (Right No.) with another relay (6pin type). If condition becomes normal at this time, neutral relay is defective. SP14 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective start aid switch (Internal disconnection) FR19 (male) Start aid switch Resistance Q Min. 1 Mz I Max. 1 z Between (1) – (2) 4 Possible causes and the standard values when normal Defective diode (Internal disconnection) Defective start aid solenoid 5 valve (Internal disconnection or short circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L2 (male) Continuity Between (2) – (1) There is continuity a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L3 (male) Between (1) – (2) Between (1) – (2) 0.5 – 1.0 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A10 of fuse box I (FB1) – FP19 (female) (1) Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP19 (female) (2) – 6 or defective contact in con- SP14 (female) (3) nector) Wiring harness between SP14 (female) (5) – L3 (female) (1) Wiring harness between L3 (female) (2) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 10 Wiring harness between fuse A10 of fuse Ground fault in wiring harness box I (FB1) – FP19 (female) (1) 7 (Contact with GND circuit) Wiring harness between FP19 (female) (2) – SP14 (female) (3) Resistance Min. 1 Mz Resistance Min. 1 Mz Wiring harness between SP14 (female) (5) – L3 (female) (1) or L2 (female) (1) Resistance Min. 1 Mz GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to auto-preheating, starting, start aid, and charging of engine GD655-3E0, GD675-3E0 11 SEN01841-00 40 Troubleshooting E-2 Transmission mode does not change 1 Symptom of failure • Transmission mode does not change. General information • Mode 1: Direct power shift (HYDROSHIFT) mode Mode 2: Torque converter mode • Input state (ON/OFF) from transmission mode selector switch can be checked with monitoring mode (Code: TRANSMISSION-41700-SHIFT MODE SW). Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission mode 1 selector switch (Internal disconnection or short circuit) SP29 (male) Between (1) – (2) Transmission mode selector switch Resistance Mode 1 Min. 1 Mz Mode 2 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between T5 (female) (17) – 2 or defective contact in con- SP29 (female) (2) nector) Wiring harness between SP29 (female) (1) – TCR (female) (2), (12) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between T5 (female) (17) – ResisMax. 1 z SP29 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 4 circuit) in wiring harness Wiring harness between T5 (female) (17) – Voltage Max. 1 V SP29 (female) (2) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective transmission controller T5 Between (17) – ground 12 Transmission mode selector switch Voltage Mode 1 20 – 30 V Mode 2 Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to transmission mode selector switch GD655-3E0, GD675-3E0 13 SEN01841-00 40 Troubleshooting E-3 Differential lock function does not work or is not reset [Differential lock specification] 1 Symptom of failure (1) Differential lock function does not work or is not reset. General information • Transmission controller checks coil circuit (primary circuit) of differential lock relay for trouble. (If disconnection, short circuit, etc. occur, failure code [D19CKZ] is displayed.) • Input state (ON/OFF) from differential lock switch can be checked with monitoring function (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). Possible causes and the standard values when normal 14 Cause Standard value when normal and remarks for troubleshooting Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See causes 1 4 and 6.) (FB1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective differential lock Differential lock FP13 (male) Resistance 2 switch (Internal disconnecswitch tion or short circuit) ON Min. 1 Mz Between (1) – (2) OFF Max. 1 z a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective differential lock 3 Replace differential lock relay (Right No.) with another relay (Internal defect) 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 without turning starting switch ON. Defective differential lock R44 (male) Resistance 4 solenoid valve (Internal disconnection or short circuit) Between (1) – (2) Max. 1 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between T5 (female) (9) – ResisMax. 1 z FP13 (female) (2) tance ResisDisconnection in wiring har- Wiring harness between FP13 (female) (1) – Max. 1 z tance ness (Disconnection in wiring A10 of fuse box I (FB1) 5 or defective contact in con- Wiring harness between A6 of fuse box I ResisMax. 1 z nector) (FB1) – BR7 (female) (3) tance Wiring harness between BR7 (female) (6) – ResisMax. 1 z R44 (female) (1) tance Wiring harness between R44 (female) (2) – ResisMax. 1 z ground (ET77) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between T5 (female) (9) – ResisMin. 1 Mz Ground fault in wiring harFP13 (female) (2) tance 6 ness ResisWiring harness between A6 of fuse box I (Contact with GND circuit) Min. 1 Mz (FB1) – BR7 (female) (3) tance Wiring harness between BR7 (female) (6) – ResisMin. 1 Mz R44 (female) (1) tance 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) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Possible causes and the standard values when normal 8 Defective transmission controller Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Differential lock T5 Voltage switch OFF 20 – 30 V Between (9) – ground ON Max. 1 V Symptom of failure (2) Only display of differential lock pilot lamp is abnormal (Function is normal). General information • When differential lock is operated: Pilot lamp lights up When differential lock is reset: Pilot lamp goes off • Operation signal of differential lock pilot lamp is received from transmission controller by communication. Possible causes and the standard values when normal Cause 1 Defective machine monitor 2 Defective transmission controller GD655-3E0, GD675-3E0 Standard value when normal and remarks for troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 15 SEN01841-00 40 Troubleshooting Circuit diagram related to differential lock switch and solenoid valve 16 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01841-00 17 SEN01841-00 40 Troubleshooting E-4 Wheel brake does not work normally 1 Symptom of failure • Wheel brake does not work normally. General information • If engine startup solenoid valve operates (turned ON) continuously, brake accumulator is not charged with air. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective start aid switch (Internal short circuit) FP19 (male) Between (1) – (2) Possible causes and the standard values when normal Defective engine startup 2 solenoid valve (Internal defect) Start aid switch Resistance Q Min. 1 Mz I Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L3 (male) Resistance Between (1) – (2) 0.5 – 1.0 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between FP19 (female) (2) – Hot short (Contact with 24 V SP14 (female) (3) 3 circuit) in wiring harness Wiring harness between SP14 (female) (2) – L2 (female) (2) or circuit branch end Wiring harness between L3 (female) (1) – L2 (female) (1) 18 Voltage Max. 1 V Voltage Max. 1 V Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to auto-preheating, starting, start aid, and charging of engine GD655-3E0, GD675-3E0 19 SEN01841-00 40 Troubleshooting E-5 Parking brake does not work or is not reset 1 Symptom of failure (1) Parking brake does not work or is not reset. General information • Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If disconnection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.) • Before starting troubleshooting, check that wheel brake operates normally. (If wheel brake does not operate normally, carry out troubleshooting for wheel brake first.) Cause Possible causes and the standard values when normal Defective parking brake sole1 noid valve (Internal disconnection or short circuit) Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL8 (male) Resistance Between (1) – (2) 40 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between FL8 (female) (1) – 2 or defective contact in con- circuit branch end nector) Wiring harness between FL8 (female) (2) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z Symptom of failure (2) Only display of parking brake pilot lamp is abnormal (Function is normal). General information • When parking brake is operated: Pilot lamp lights up When parking brake is reset: Pilot lamp goes off • Operation signal of parking brake pilot lamp is received from transmission controller by communication. Possible causes and the standard values when normal 20 Cause 1 Defective machine monitor 2 Defective transmission controller Standard value when normal and remarks for troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to parking brake solenoid valve GD655-3E0, GD675-3E0 21 SEN01841-00 40 Troubleshooting E-6 Lift arm lock pin is not locked or reset [Lift arm specification] 1 Symptom of failure (1) Lift arm lock pin is not locked or reset. General information • Lift arm lock switch is turned ON (Pin is reset) when pushed in, and turned OFF (Pin is locked) when pushed back. Cause Standard value when normal and remarks for troubleshooting Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. 1 (FB1) (See causes 3 and 5.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm lock switch a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 (Internal disconnection or short circuit) SP30 (male) Lift arm lock switch Resistance Between (1) – (2) Defective lift arm lock sole3 noid valve (Internal disconnection or short circuit) Possible causes and the standard values when normal OFF Min. 1 Mz ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL7 (male) Resistance Between (1) – (2) 40 – 60 z Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector) Wiring harness between fuse A6 of fuse box I (FB1) – SP30 (female) (1) Resistance Max. 1 z Wiring harness between SP30 (female) (2) – FL7 (female) (1) Resistance Max. 1 z Wiring harness between SP30 (female) (2) – ground (FT01) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Wiring harness between fuse A6 of fuse box I Ground fault in wiring harness (FB1) – SP30 (female) (1) or circuit branch (Contact with GND circuit) end Resistance Min. 1 Mz Wiring harness between SP30 (female) (2) – FL7 (female) (1) or FP3 (female) (9) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 6 circuit) in wiring harness Wiring harness between SP30 (female) (2) – Voltage Max. 1 V FL7 (female) (1) or FP3 (female) (9) 22 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Symptom of failure (2) Only display of lift arm lock pin pilot lamp is abnormal (Function is normal). General information • When lift arm pin is locked: Pilot lamp goes off When lift arm pin is reset: Pilot lamp lights up Cause 1 Broken bulb 2 Defective lamp assembly (Internal defect) Standard value when normal and remarks for troubleshooting Lift arm lock pin pilot lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP3 (female) (9) – 3 or defective contact in con- circuit branch end nector) Wiring harness between FP3 (female) (12) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between FP3 (female) (9) – ResisMin. 1 Mz circuit branch end tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between FP3 (female) (9) – Voltage Max. 1 V circuit branch end GD655-3E0, GD675-3E0 23 SEN01841-00 40 Troubleshooting Circuit diagram related to lift arm lock switch and solenoid valve 24 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-7 Blade accumulator function does not work or is not reset [Blade accumulator and float specification] Symptom of failure 1 (1) Blade accumulator function of both right and left sides does not work or is not reset. General information Cause 1 Standard value when normal and remarks for troubleshooting Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. (FB1) (See causes 3, 4, 5 and 7.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade accumulator/ 2 float switch (Internal disconnection or short circuit) SP18 (male) Blade accumulator/ float switch Resistance OFF Min. 1 Mz Accumulator Max. 1 z Between (B) – (A) Defective left blade accumu3 lator solenoid valve (Internal short circuit) Defective right blade accu4 mulator solenoid valve (Internal short circuit) Possible causes and the standard values when normal Defective diode (Internal 5 short circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL10 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL9 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL15 (male), FL16 (male) Continuity (Resistance) Between (1) – (2) There is no continuity (Min. 1 Mz) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harResisness (Disconnection in wiring Wiring harness between fuse A6 of fuse box I Max. 1 z 6 tance or defective contact in con- (FB1) – SP18 (female) (B) nector) Wiring harness between SP18 (female) (A) – ResisMax. 1 z circuit branch end tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A6 of fuse box I (FB1) -– SP18 (female) (B), L4 (female) (B), Ground fault in wiring harness or L5 (female) (B) 7 (Contact with GND circuit) Wiring harness between SP18 (female) (A) – FL9 (female) (1), FL10 (female) (1), FL15 (female) (1), FL16 (female) (1), or FP3 (female) (7) Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 8 Hot short (Contact with 24 V Wiring harness between SP18 (female) (A) – circuit) in wiring harness FL9 (female) (1), FL10 (female) (1), FL15 (female) (1), FL16 (female) (1), or FP3 (female) (7) GD655-3E0, GD675-3E0 Voltage Max. 1 V 25 SEN01841-00 Symptom of failure 40 Troubleshooting (2) Blade accumulator function of only left side does not work or is not reset. General information Cause Possible causes and the standard values when normal Symptom of failure Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left blade accumuwithout turning starting switch ON. 1 lator solenoid valve (Internal FL10 (male) Resistance disconnection) Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between FL10 (female) (1) – Resis2 Max. 1 z or defective contact in con- circuit branch end tance nector) Wiring harness between FL10 (female) (2) – ResisMax. 1 z ground (FT10) tance (3) Blade accumulator function of only right side does not work or is not reset. General information Cause Possible causes and the standard values when normal Defective right blade accu1 mulator solenoid valve (Internal disconnection) Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL9 (male) Resistance Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between FL9 (female) (1) – 2 or defective contact in con- circuit branch end nector) Wiring harness between FL9 (female) (2) – ground (FT01) Symptom of failure (4) Only display of blade accumulator pilot lamp is abnormal (Function is normal). General information • When blade accumulator is operated: Pilot lamp lights up When blade accumulator is reset: Pilot lamp goes off Cause 1 Broken bulb 2 Defective lamp assembly (Internal defect) Resistance Max. 1 z Resistance Max. 1 z Standard value when normal and remarks for troubleshooting Blade accumulator pilot lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal 3 Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP3 (female) (7) – or defective contact in con- circuit branch end nector) Wiring harness between FP3 (female) (12) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between FP3 (female) (7) – ResisMin. 1 Mz circuit branch end tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between FP3 (female) (7) – Voltage Max. 1 V circuit branch end 26 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to blade accumulator and float switch and solenoid valve GD655-3E0, GD675-3E0 27 SEN01841-00 40 Troubleshooting E-8 Blade float function does not work or is not reset [Blade accumulator and float specification] Symptom of failure 1 (1) Blade float function of both right and left sides does not work or is not reset. General information Cause 1 Standard value when normal and remarks for troubleshooting Defective fuse A6 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See causes (FB1) 3, 4, 5, 6, 7 and 9.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade accumulator/ 2 float switch (Internal disconnection or short circuit) SP18 (male) Blade accumulator/ float switch Resistance OFF Min. 1 Mz Float Max. 1 z Between (B) – (C) Defective left blade float 3 solenoid valve 1 (Internal short circuit) Defective left blade float 4 solenoid valve 2 (Internal short circuit) Possible causes and the standard values when normal Defective right blade float 5 solenoid valve 1 (Internal short circuit) Defective right blade float 6 solenoid valve 2 (Internal short circuit) 7 Defective diode (Internal short circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL13 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL14 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL11 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL12 (male) Resistance Between (1) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL17 (male), LF18 (male), FL19 (male), FL20 (male) Continuity (Resistance) Between (1) – (2) There is no continuity (Min. 1 Mz) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse A6 of fuse box I 8 or defective contact in con- (FB1) – SP18 (female) (B) nector) Wiring harness between SP18 (female) (C) – SP7 (female) (1) 28 Resistance Max. 1 z Resistance Min. 1 Mz GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Wiring harness between fuse A6 of fuse box I (FB1) – SP18 (female) (B), L4 (female) (B), or L5 (female) (B) Resistance Min. 1 Mz Wiring harness between SP18 (female) (C) – Ground fault in wiring harness SP7 (female) (1), (2), SP8 (female) (1), (2), 9 (Contact with GND circuit) or FP3 (female) (8) Resistance Min. 1 Mz Wiring harness between SP7 (female) (5) – FL13 (female) (1), LF14 (female) (1), FL19 (female) (1), or FL20 (female) (1) Resistance Min. 1 Mz Wiring harness between SP8 (female) (5) – FL11 (female) (1), FL12 (female) (1), FL17 (female) (1), or FL18 (female) (1) Resistance Min. 1 Mz Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 10 Hot short (Contact with 24 V Wiring harness between SP18 (female) (C) – circuit) in wiring harness SP7 (female) (1), (2), SP8 (female) (1), (2), or FP3 (female) (8) GD655-3E0, GD675-3E0 Voltage Max. 1 V 29 SEN01841-00 Symptom of failure 40 Troubleshooting (2) Blade float function of only left side does not work or is not reset. General information Cause 1 2 Defective left blade float relay (Internal defect) Defective diode (Internal disconnection) Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace left blade float relay (Right No.) with another relay (5-pin type). If condition becomes normal at this time, left blade float relay is defective. SP7 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SP33 (male) Continuity Between (2) – (1) There is continuity a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective left float cancel switch (Internal defect) L5 Left blade lift cylinder control lever Voltage Between (B) – (C) All range 20 – 30 V Neutral 20 – 30 V Raise operation Lower operation Max. 1 V Between (B) – (A) Left float cancel switch voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness, too, for another cause of trouble, and then judge. Possible causes and the standard values when normal Defective left blade float 4 solenoid valve 1 (Internal disconnection) Defective left blade float 5 solenoid valve 2 (Internal disconnection) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL13 (male) Resistance Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL14 (male) Resistance Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 6 or defective contact in connector) 30 Wiring harness between SP7 (female) (1) – (3) Resistance Max. 1 z Wiring harness between SP7 (female) (3) – SP33 (female) (2) Resistance Max. 1 z Wiring harness between SP33 (female) (1) – L5 (female) (A) Resistance Max. 1 z Wiring harness between L5 (female) (B) – circuit branch end Resistance Max. 1 z Wiring harness between L5 (female) (C) – ground (FT01) Resistance Max. 1 z Wiring harness between SP7 (female) (5) – FL13 (female) (1) or FL14 (female) (1) Resistance Max. 1 z Wiring harness between FL13 (female) (2), FL14 (female) (2) – ground (FT01) Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between SP7 (female) (3) – SP33 (female) (2) Possible causes and the standard values when normal 7 Ground fault in wiring harness Wiring harness between SP33 (female) (1) – (Contact with GND circuit) L5 (female) (A) or circuit branch end Wiring harness between SP7 (female) (5) – FL13 (female) (1), FL14 (female) (1), FL19 (female) (1), or FL20 (female) (1) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 8 Hot short (Contact with 24 V Wiring harness between SP7 (female) (5) – circuit) in wiring harness FL13 (female) (1), FL14 (female) (1), FL19 (female) (1), or FL20 (female) (1) GD655-3E0, GD675-3E0 Voltage Max. 1 V 31 SEN01841-00 Symptom of failure 40 Troubleshooting (3) Blade float function of only right side does not work or is not reset. General information Cause 1 2 Defective right blade float relay (Internal defect) Defective diode (Internal disconnection) Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace right blade float relay (Right No.) with another relay (5-pin type). If condition becomes normal at this time, right blade float relay is defective. SP8 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SP32 (male) Continuity Between (2) – (1) There is continuity a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective right float cancel switch (Internal defect) L5 Right blade lift cylinder control lever Voltage Between (B) – (C) All range 20 – 30 V Neutral 20 – 30 V Between (B) – (A) Raise operation Lower operation Max. 1 V Right float cancel switch voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness, too, for another cause of trouble, and then judge. Possible causes and the standard values when normal Defective right blade float 4 solenoid valve 1 (Internal disconnection) Defective right blade float 5 solenoid valve 2 (Internal disconnection) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL11 (male) Resistance Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FL12 (male) Resistance Between (1) – (2) 20 – 30 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 6 or defective contact in connector) 32 Wiring harness between SP7 (female) (3) – SP8 (female) (1), (3) Resistance Max. 1 z Wiring harness between SP8 (female) (3) – SP32 (female) (2) Resistance Max. 1 z Wiring harness between SP32 (female) (1) – L4 (female) (A) Resistance Max. 1 z Wiring harness between L4 (female) (B) – circuit branch end Resistance Max. 1 z Wiring harness between L4 (female) (C) – ground (FT01) Resistance Max. 1 z Wiring harness between SP8 (female) (5) – FL11 (female) (1) or FL12 (female) (1) Resistance Max. 1 z Wiring harness between FL11 (female) (2), FL12 (female) (2) – ground (FT01) Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between SP8 (female) (3) – SP32 (female) (2) Possible causes and the standard values when normal 7 Ground fault in wiring harness Wiring harness between SP32 (female) (1) – (Contact with GND circuit) L4 (female) (A) or circuit branch end Wiring harness between SP8 (female) (5) – FL11 (female) (1), FL12 (female) (1), FL17 (female) (1), or FL18 (female) (1) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 8 Hot short (Contact with 24 V Wiring harness between SP8 (female) (5) – circuit) in wiring harness FL11 (female) (1), FL12 (female) (1), FL17 (female) (1), or FL18 (female) (1) Symptom of failure (4) Only display of blade float pilot lamp is abnormal (Function is normal). General information • When blade float is operated: Pilot lamp lights up When blade float is reset: Pilot lamp goes off Cause 1 Broken bulb 2 Possible causes and the standard values when normal Defective lamp assembly (Internal defect) Voltage Max. 1 V Standard value when normal and remarks for troubleshooting Blade float pilot lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP3 (female) (8) – Resis3 Max. 1 z or defective contact in con- circuit branch end tance nector) Wiring harness between FP3 (female) (12) – ResisMax. 1 z ground (FT01) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between FP3 (female) (8) – ResisMin. 1 Mz circuit branch end tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between FP3 (female) (8) – Voltage Max. 1 V circuit branch end GD655-3E0, GD675-3E0 33 SEN01841-00 40 Troubleshooting Circuit diagram related to blade accumulator and float switch and solenoid valve 34 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01841-00 35 SEN01841-00 40 Troubleshooting E-9 When starting switch is turned ON, machine monitor does not operate normally 1 Symptom of failure • When starting switch is turned ON, machine monitor does not operate normally. General information • 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. 3) Speedometer displays “88” for 2 seconds, then is turned OFF for 1 second and displayed normally. 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. Cause 1 Standard value when normal and remarks for troubleshooting Defective fuses No. 12 or 14 If fuse is broken, circuit probably has ground fault etc. (See cause 4.) of fuse box III a Prepare with starting switch OFF, then turn starting switch ON and OFF and carry out troubleshooting in each case. 2 Defective starting switch (Internal defect) Starting switch Switch position Resistance Between terminals B – ACC OFF Min. 1 Mz ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between fuse A3 of fuse box I (FB1) – ST6 Resistance Max. 1 z Wiring harness between ST9 – FP1 (female) (1), (2) Resistance Max. 1 z Wiring harness between fuse A1 of fuse box I (FB1) – FP1 (female) (5), (6) Resistance Max. 1 z Wiring harness between FP1 (female) (3), (4) – TCR (21), (31) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A3 of fuse box I (FB1) – ST6 or circuit branch end Ground fault in wiring harness 4 Wiring harness between ST9 – FP1 (female) (Contact with GND circuit) (1), (2) or circuit branch end Wiring harness between fuse A1 of fuse box I (FB1) – FP1 (female) (5), (6) or circuit branch end Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective machine monitor 36 FP1 Voltage Between (1), (2) – (3), (4) 20 – 30 V Between (5), (6) – (3), (4) 20 – 30 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to machine monitor power supply GD655-3E0, GD675-3E0 37 SEN01841-00 40 Troubleshooting E-10 When starting switch is turned ON, machine monitor is not reset to ordinary display 1 Symptom of failure • When starting switch is turned ON, machine monitor is not reset to ordinary display General information • 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. 3) Speedometer displays “88” for 2 seconds, then is turned OFF for 1 second and displayed normally. 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 causes and the standard values when normal 38 Cause Standard value when normal and remarks for troubleshooting 1 Defective machine monitor Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-11 When starting switch is turned ON, caution item lights up Symptom of failure (1) Parking brake pilot lamp does not display normally. General information • When parking brake is operated: Pilot lamp lights up When parking brake is reset: Pilot lamp goes off Possible causes and the standard values when normal Cause 1 Standard value when normal and remarks for troubleshooting 1 Carry out troubleshooting “E-7 Parking brake does not work or is not reset”. Symptom of failure (2) Maintenance caution monitor blinks or lights up. General information • Maintenance caution lamp blinks in 30 hours before replacement time and lights up after replacement time (for 30 seconds after starting switch is turned ON). Cause Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting An item is near or after mainCheck character display. If any item needs maintenance, carry out 1 tenance time maintenance. (When system is normal) 2 Defective machine monitor GD655-3E0, GD675-3E0 If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 39 SEN01841-00 40 Troubleshooting E-12 While engine is running, emergency stop item lights up 1 Symptom of failure (1) While engine is running, battery charge circuit caution lamp lights up. General information • If battery charge circuit has trouble while engine is running, battery charge circuit caution lamp lights up and alarm buzzer sounds. • Generation signal of alternator is received from transmission controller by communication. • Generation state (ON/OFF) of alternator can be checked with monitoring function (Code: TRANSMISSION-04301-ALTERNATOR R). Cause Defective alternator (Defective generation) [75 A alternator specification] 1 Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. R36 (female) Engine speed Voltage Between (1) – ground Min. medium (half) 20 – 30 V Defective alternator or regu- a Prepare with starting switch OFF, then start engine and carry out troubleshooting. lator R36 (female) (Defective generation) [140 A alternator specification] Between (1) – ground Possible causes and the standard values when normal Voltage Min. medium (half) 20 – 30 V Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con- Wiring harness between R10 (female) (15) – ResisMax. 1 z nector) R36 (male) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between R10 (female) (15) – ResisMin. 1 Mz R36 (male) (1) or circuit branch end tance 4 Defective transmission controller 5 Defective machine monitor 40 Engine speed a Prepare with starting switch OFF, then start engine and carry out troubleshooting. R10 Engine speed Voltage Between (15) – ground Min. medium (half) 20 – 30 V If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to auto-preheating, starting, start aid, and charging of engine GD655-3E0, GD675-3E0 41 SEN01841-00 40 Troubleshooting Symptom of failure (2) Engine oil pressure caution lamp lights up. General information • If engine oil pressure is abnormal while engine is running, engine oil pressure caution lamp lights up and alarm buzzer sounds. • Signal of engine oil pressure switch is received from engine controller by communication. Cause 1 Standard value when normal and remarks for troubleshooting Engine oil pressure reduction Engine oil pressure reduction is detected. Check engine oil pres(When system is normal) sure. a Prepare with starting switch OFF, then keep starting switch OFF and start engine and carry out troubleshooting in each case. 2 Possible causes and the standard values when normal Defective engine oil pressure switch (Internal short circuit) C2 Engine Resistance Between terminal – ground Stopped Max. 1 z Min. 600 rpm Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between EC1 (female) (17) – ResisMax. 1 z C2 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 5 Defective machine monitor 42 EC1 Engine Voltage Between (17) – ground Stopped Max. 1 V Min. 600 rpm 20 – 30 V If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to engine oil pressure switch GD655-3E0, GD675-3E0 43 SEN01841-00 40 Troubleshooting Symptom of failure (3) Brake oil pressure caution lamp lights up. General information • If brake oil pressure is abnormal while engine is running, brake oil pressure caution lamp lights up and alarm buzzer sounds. • Signal of brake oil pressure switch (Front/Rear) is received from communication controller by communication. • Input state (ON/OFF) from brake oil pressure switch (Front/Rear) can be checked with monitoring function (Code: TRANSMISSION1-35500-ACC OIL PRE F, TRANSMISSION1-35501-ACC OIL PRE R). Cause Standard value when normal and remarks for troubleshooting 1 Brake oil pressure reduction Brake oil pressure reduction is detected. Check brake oil pressure. (When system is normal) 2 Defective fuse A12 of fuse box I (FB1) If fuse is broken, circuit probably has ground fault etc. (See cause 6.) a Prepare with starting switch OFF, then turn starting switch ON and start engine and carry out troubleshooting in each case. Defective front brake oil 3 pressure switch (Internal defect) R15 Accumulator oil pressure Voltage Between (A) – (C) All range 20 – 30 V Below approx. 4.2 MPa {Below approx. 42.5 kg/cm2} Max. 1 V Above approx. 4.2 MPa {Above approx. 42.5 kg/cm2} 20 – 30 V Between (B) – (C) Front brake oil pressure switch voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Possible causes and the standard values when normal Defective rear brake oil pres4 sure switch (Internal defect) R16 Accumulator oil pressure Voltage Between (A) – (C) All range 20 – 30 V Below approx. 4.2 MPa {Below approx. 42.5 kg/cm2} Max. 1 V Above approx. 4.2 MPa {Above approx. 42.5 kg/cm2} 20 – 30 V Between (B) – (C) Rear brake oil pressure switch voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A12 of fuse box I (FB1) – R15 (female) (A) or R16 (female) (A) Disconnection in wiring harness (Disconnection in wiring Wiring harness between R15 (female) (C), 5 or defective contact in con- R16 (female) (C) – ground (ET89) nector) Wiring harness between R15 (female) (B) – TCR (female) (35) Wiring harness between R16 (female) (B) – TCR (female) (26) 44 Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A12 of fuse box I Ground fault in wiring harness (FB1) – R15 (female) (A) or R16 (female) (A) 6 (Contact with GND circuit) Wiring harness between R15 (female) (B) – TCR (female) (35) Wiring harness between R16 (female) (B) – TCR (female) (26) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and start engine and carry out troubleshooting in each case. TCR Possible causes and the standard values when normal 7 Defective communication controller Between (35) – ground Between (26) – ground 8 Defective machine monitor GD655-3E0, GD675-3E0 Engine Voltage Below approx. 4.2 MPa {Below approx. 42.5 kg/cm2} Max. 1 V Above approx. 4.2 MPa {Above approx. 42.5 kg/cm2} 20 – 30 V Below approx. 4.2 MPa {Below approx. 42.5 kg/cm2} Max. 1 V Above approx. 4.2 MPa {Above approx. 42.5 kg/cm2} 20 – 30 V If causes 1 – 7 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 45 SEN01841-00 40 Troubleshooting Circuit diagram related to front brake oil pressure switch and rear brake oil pressure switch 46 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Symptom of failure (4) Torque converter oil temperature caution lamp lights up. General information • If torque converter oil temperature is abnormal while engine is running, torque converter oil temperature caution lamp lights up and alarm buzzer sounds. • Torque converter oil temperature caution lamp lights up and goes off according to the display of torque converter oil temperature gauge. • Signal of torque converter oil temperature sensor is received from transmission controller by communication. • State (Temperature) of torque converter oil can be checked with monitoring function (Code: TRANSMISSION1-30100-T/C OIL TEMP). Cause 1 Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting Torque converter oil overheat Torque converter oil overheat is detected. Check torque converter (When system is normal) oil temperature. If indication of torque converter oil temperature gauge is abnormal, carry out troubleshooting for “E-18 Indication of torque converter oil temperature gauge is abnormal”. 2 Defective torque converter oil temperature system Oil temperature gauge Oil temperature lamp 3 Defective machine monitor See following figure White range Red range OFF ON If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Torque converter oil temperature gauge GD655-3E0, GD675-3E0 47 SEN01841-00 40 Troubleshooting Symptom of failure (5) Differential oil temperature caution lamp lights up. General information • If differential oil temperature is abnormal while engine is running, differential oil temperature caution lamp lights up and alarm buzzer sounds. • Signal of differential oil temperature sensor is received from transmission controller by communication. 1 Cause Standard value when normal and remarks for troubleshooting Differential oil overheat (When system is normal) Differential oil overheat is detected. Check differential oil temperature. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective differential oil tem2 perature switch (Internal short circuit) R43 (male) Between (1) – (2) Possible causes and the standard values when normal Differential oil temperature Resistance Below 120 °C Min. 1 Mz Above 120 °C Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between R12 (female) (30) – ResisMin. 1 Mz R43 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective transmission controller T3-2 Between (10) – ground 5 Defective machine monitor Differential oil temperature Voltage Below 120 °C 20 – 30 V Above 120 °C Max. 1 V If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to differential oil temperature switch 48 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-13 Indication of speedometer and engine tachometer is abnormal 1 Symptom of failure (1) Indication of speedometer is abnormal. General information • Speedometer signal (transmission output shaft speed sensor signal) is received from transmission controller by communication. Cause Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting Abnormality in transmission 1 output shaft speed sensor system Check occurrence record of failure code [DLT3KA]. If it is displayed, carry out troubleshooting for it. 2 Defective machine monitor If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 3 Defective transmission controller If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Symptom of failure (2) Display of speedometer display pilot lamp is abnormal. General information • Speedometer pilot lamp lights up when km/h is selected and goes off when MPH is selected. • Speedometer pilot lamp signal is processed in machine monitor. Possible causes and the standard values when normal Cause 1 Defective machine monitor Standard value when normal and remarks for troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Symptom of failure (3) Indication of engine tachometer is abnormal. General information • Engine tachometer signal (Engine Ne speed sensor signal) is received from transmission controller by communication. Cause Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting Abnormality in engine Ne 1 speed sensor system Check occurrence record of failure code [DLE3LC]. If it is displayed, carry out troubleshooting for it. 2 Defective machine monitor If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 3 Defective engine controller If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 49 SEN01841-00 40 Troubleshooting E-14 Indication of engine coolant temperature gauge is abnormal 1 Symptom of failure • Indication of engine coolant temperature gauge is abnormal. General information • If engine coolant high temperature sensor system has abnormality, failure code [B@BCNS] may be displayed and recorded. • Engine coolant temperature gauge signal (Engine coolant high temperature sensor signal) is received from engine controller by communication. • State (Temperature) of engine coolant can be checked with monitoring function (Code: MONITOR PANEL-04104-COOLANT TEMP). Cause Defective engine coolant high temperature sensor 1 (Internal disconnection or short circuit) Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CS (male) Resistance Between (1) – (2) 3.5 k – 90 kz Between (1), (2) – ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between EC1 (female) (15) – 2 or defective contact in con- C3 (female) (1) nector) Wiring harness between EC1 (female) (38) – C3 (female) (2) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between EC1 (female) (15) – ResisMin. 1 Mz C3 (female) (1) tance Hot short in wiring harness 4 (Contact with 24 V circuit) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between EC1 (female) (15) – C3 (female) (1) Voltage Max. 1 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller 6 Defective machine monitor 50 EC1 (female) Resistance Between (15) – (38) 3.5 k – 90 kz Between (15), (38) – ground Min. 1 Mz If causes 1 – 5 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to engine coolant high temperature sensor GD655-3E0, GD675-3E0 51 SEN01841-00 40 Troubleshooting E-15 Indication of articulate gauge is abnormal 1 Symptom of failure • Indication of articulate gauge is abnormal. General information • If articulate angle sensor system has abnormality, failure code [DKD0KA] may be displayed and recorded. • Articulate gauge signal (Articulate angle sensor signal) is received from transmission controller by communication. • Input state (Resistance/Voltage) from articulate angle sensor can be checked with monitoring function (Code: TRANSMISSION1-43905-ARTICULATE, TRANSMSSION1-43904-ARTICULATE). Cause 1 Abnormality in articulate angle sensor system Standard value when normal and remarks for troubleshooting Check occurrence record of failure code [DKD0KA]. If it is displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Possible causes and the standard values when normal Defective articulate angle sensor (Internal short circuit) FL6 (male) Articulate Resistance Center 96.5 – 106.5 z Between (1) – (2) Left end (23°) 163.8 – 180 z Right end (23°) 17.7 – 37.7 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between TCR (female) (24) – ResisMin. 1 Mz FL6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective communication controller 5 Defective machine monitor TCR (male) Between (24) – ground Articulate Resistance Center 96.5 – 106.5 z Left end (23°) 163.8 – 180 z Right end (23°) 17.7 – 37.7 z If causes 1 – 4 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) Circuit diagram related to articulate angle sensor 52 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-16 Indication of torque converter oil temperature gauge is abnormal 1 Symptom of failure • Indication of torque converter oil temperature gauge is abnormal. General information • If torque converter oil temperature sensor system has abnormality, failure code [DGT1KX] may be displayed and recorded. • Torque converter oil temperature gauge signal (Torque converter oil temperature sensor signal) is 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.) Cause Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting Abnormality in torque con1 verter oil temperature sensor system Check occurrence record of failure code [DGT1KX]. If it is displayed, carry out troubleshooting for it. 2 Defective machine monitor If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 3 Defective transmission controller GD655-3E0, GD675-3E0 If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) 53 SEN01841-00 40 Troubleshooting E-17 Indication of fuel level gauge is abnormal 1 Symptom of failure • Indication of fuel level gauge is abnormal. General information • If fuel level sensor system has abnormality, failure code [DJF1KA] may be displayed and recorded. • 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). Cause Standard value when normal and remarks for troubleshooting Abnormality in fuel level sen- Check occurrence record of failure code [DJF1KA]. If it is displayed, 1 carry out troubleshooting for it. sor system a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ET39 (male) 2 Defective fuel level sensor (Internal short circuit) Between (1) – 011 Possible causes and the standard values when normal Fuel level Resistance FULL 10 ± 5 z 3/4 (19 z) 1/2 32 ± 0.5 z 1/4 (49.5 z) EMPTY 80 ± 0.5 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between FP2 (female) (10) – ResisMin. 1 Mz ET39 (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FP2 (female) 4 Defective machine monitor Between (10) – ground 54 Fuel level Resistance FULL 10 ± 5 z 3/4 (19 z) 1/2 32 ± 0.5 z 1/4 (49.5 z) EMPTY 80 ± 0.5 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to fuel level sensor GD655-3E0, GD675-3E0 55 SEN01841-00 40 Troubleshooting E-18 Display of character display is abnormal 1 Symptom of failure (1) Service meter does not operate while engine is running. (2) Trip odometer does not operate while machine is traveling. (3) Character display displays nothing. General information • Service meter measures time by engine Ne speed sensor signal. While it is in operation, hourglass mark blinks. • Trip odometer integrates travel distance by transmission output shaft speed sensor signal. Possible causes and the standard values when normal 56 Cause 1 Defective machine monitor Standard value when normal and remarks for troubleshooting Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-19 Centralized warning lamp does not light up or go off Symptom of failure • Centralized warning lamp does not light up or go off. General information • Centralized warning lamp lights up under following conditions. 1) When emergency stop item has abnormality 2) When character display displays action code [E02] or [E03] 3) When machine overruns • If centralized warning lamp lights up, alarm buzzer sounds intermittently. Cause 1 Defective fuse A10 of fuse box I (FB1) 2 Broken bulb 3 Defective lamp assembly (Internal defect) 1 Standard value when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. (See cause 5.) Centralized warning lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse A10 of fuse 4 or defective contact in con- box I (FB1) – FP3 (female) (1) nector) Wiring harness between FP3 (female) (11) – FP1 (female) (19) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Wiring harness between fuse A10 of fuse Ground fault in wiring harness box I (FB1) – FP3 (female) (1) or circuit (Contact with GND circuit) branch end Wiring harness between FP3 (female) (11) – FP1 (female) (19) Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF. 6 Defective machine monitor FP1 Starting switch Voltage Between (19) – ground ON (for 2 sec after ON) Max. 1 V ON (after 2 sec after ON) 20 – 30 V Circuit diagram related to centralized warning lamp GD655-3E0, GD675-3E0 57 SEN01841-00 40 Troubleshooting E-20 Alarm buzzer does not sound or stop 1 Symptom of failure • Alarm buzzer does not sound or stop. General information • If alarm buzzer system has abnormality, failure code [DV00KB] may be displayed and recorded. Cause Standard value when normal and remarks for troubleshooting 1 Abnormality in alarm buzzer Check occurrence record of failure code [DV00KB]. If it is dissystem played, carry out troubleshooting for it. 2 Defective fuse A10 of fuse box I (FB1) If fuse is broken, circuit probably has ground fault etc. (See causes 3 and 5.) a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch ON and carry out troubleshooting. 3 Defective alarm buzzer (Internal defect) SP26 Between (1) – (2) Starting switch Voltage ON (for 2 sec after ON) 20 – 30 V ON (after 2 sec after ON) Max. 3 V If voltage is normal but alarm buzzer does not sound, alarm buzzer is defective. Possible causes and the standard values when normal a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between fuse A10 of fuse 4 or defective contact in con- box I (FB1) – SP26 (female) (1) nector) Wiring harness between SP26 (female) (2) – FP1 (female) (18) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Wiring harness between fuse A10 of fuse Ground fault in wiring harness box I (FB1) – SP26 (female) (1) or circuit (Contact with GND circuit) branch end Wiring harness between SP26 (female) (2) – FP1 (female) (18) Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective machine monitor 58 FP1 Starting switch Voltage Between (18) – ground ON (for 2 sec after ON) Max. 3 V ON (after 2 sec after ON) 20 – 30 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to alarm buzzer GD655-3E0, GD675-3E0 59 SEN01841-00 40 Troubleshooting E-21 Machine monitor mode selector switch does not function Symptom of failure (1) Machine monitor mode selector switch 1 does not function General information • t (Left) position: Used to cancel various modes and operations • U(Right) position: Used to select (enter) various modes and operations Cause 1 Standard value when normal and remarks for troubleshooting Defective fuse A1 of fuse box I 1 If fuse is broken, circuit probably has ground fault etc. (See cause 4.) (FB1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective machine monitor mode selector switch 1 2 (Internal disconnection or short circuit) FP15 (male) Between (2) – (3) Between (2) – (1) Machine monitor mode selector switch 1 Resistance Neutral Min. 1 Mz t (Left) Max. 1 z Neutral Min. 1 Mz U (Right) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and the standard values when normal Wiring harness between fuse A1 of fuse box I (FB1) – FP15 (female) (2) Resistance Max. 1 z Wiring harness between FP15 (female) (3) – FP1 (female) (17) Resistance Max. 1 z Wiring harness between FP15 (female) (1) – FP1 (female) (16) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A1 of fuse box I (FB1) – FP15 (female) (2) or circuit branch Ground fault in wiring harness end 4 (Contact with GND circuit) Wiring harness between FP15 (female) (3) – FP1 (female) (17) Wiring harness between FP15 (female) (1) – FP1 (female) (16) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Hot short (Contact with 24 V Wiring harness between FP15 (female) (3) – circuit) in wiring harness FP1 (female) (17) Voltage Max. 1 V Wiring harness between FP15 (female) (1) – FP1 (female) (16) Voltage Max. 1 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. FP1 6 Defective machine monitor 60 Machine monitor mode selector switch 1 Voltage Between (17) – ground Neutral Max. 1 V t (Left) 20 – 30 V Between (16) – ground Neutral Max. 1 V U (Right) 20 – 30 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Symptom of failure (2) Machine monitor mode selector switch 2 does not function General information • > (Left) position : Used to display next screen or increase number to be input • < (Right) position : Used to display previous page or decrease number to be input Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective machine monitor mode selector switch 2 1 (Internal disconnection or short circuit) FP14 (male) Between (2) – (1) Between (2) – (3) Machine monitor mode selector switch 2 Resistance Neutral Min. 1 Mz > (Left) Max. 1 z Neutral Min. 1 Mz < (Right) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and the standard values when normal Wiring harness between FP14 (female) (2) – ground (FT01) Resistance Max. 1 z Wiring harness between FP14 (female) (1) – FP1 (female) (15) Resistance Max. 1 z Wiring harness between FP14 (female) (3) – FP1 (female) (14) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Ground fault in wiring harness Wiring harness between FP14 (female) (1) – (Contact with GND circuit) FP1 (female) (15) Resistance Min. 1 Mz Wiring harness between FP14 (female) (3) – FP1 (female) (14) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Hot short (Contact with 24 V Wiring harness between FP14 (female) (1) – circuit) in wiring harness FP1 (female) (15) Voltage Max. 1 V Wiring harness between FP14 (female) (3) – FP1 (female) (14) Voltage Max. 1 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. FP1 5 Defective machine monitor Between (15) – ground Between (14) – ground GD655-3E0, GD675-3E0 Machine monitor mode selector switch 2 Voltage Neutral Max. 1 V > (Left) 20 – 30 V Neutral Max. 1 V < (Right) 20 – 30 V 61 SEN01841-00 40 Troubleshooting Circuit diagram related to machine monitor mode selector switches 1 and 2 62 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 E-22 Headlamp, clearance lamp and tail lamp do not light up or go off 1 Symptom of failure (1) None of headlamp, clearance lamp, tail lamp, machine monitor night lamp and switch panel lamp [Cabless specification] lights up or goes off. General information • Clearance lamp ON position: Clearance lamp, tail lamp, machine monitor night lamp and switch panel lamp [Cabless specification] light up. • Headlamp ON position: Above lamps and headlamp light up. Cause 1 Defective fuse A11 of fuse box I (FB1) Standard value when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. (See cause 4 and troubles (2), (3) and (5).) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Defective headlamp switch 2 (Internal disconnection or short circuit) SP19 (female) Between (2) – (3) Between (5) – (6) Headlamp switch Resistance OFF Min. 1 Mz Clearance lamp ON Max. 1 z OFF Min. 1 Mz Headlamp ON Max. 1 z Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 3 or defective contact in con- Wiring harness between fuse A11 of fuse ResisMax. 1 z nector) box I (FB1) – SP19 (female) (2), (5) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between fuse A11 of fuse ResisMin. 1 Mz box I (FB1) – SP19 (female) (2), (5) tance GD655-3E0, GD675-3E0 63 SEN01841-00 Symptom of failure 40 Troubleshooting (2) Headlamp does not light up or go off. (3) High beam or low beam of headlamp cannot be selected. General information Cause 1 Broken bulb Standard value when normal and remarks for troubleshooting If only specific headlamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Dimmer switch Defective dimmer switch 2 (Internal disconnection) Low High FP12 (male) Resistance Between (A) – (B) Max. 1 z Between (A) – (C) Min. 1 Mz Between (A) – (B) Max. 1 z Between (A) – (C) Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and the standard values when normal Wiring harness between SP19 (female) (6) – FP12 (female) (A) Resistance Max. 1 z Wiring harness between FP12 (female) (B) – FL1 (female) (1), FL2 (female) (1), C27 (female) (1), or C28 (female) (1) Resistance Max. 1 z Wiring harness between FP12 (female) (C) – FL1 (female) (3), FL2 (female) (3), C27 (female) (3), or C28 (female) (3) Resistance Max. 1 z Wiring harness between FL1 (female) (2), FL2 (female) (2) – ground (FT01) Resistance Max. 1 z Wiring harness between C27 (female) (2), C28 (female) (2) – ground (CT41) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Wiring harness between SP19 (female) (6) – FP12 (female) (A) Resistance Min. 1 Mz Ground fault in wiring harness Wiring harness between FP12 (female) (B) – FL1 (female) (1), FL2 (female) (1), C27 (Contact with GND circuit) (female) (1), or C28 (female) (1) Resistance Min. 1 Mz Wiring harness between FP12 (female) (C) – FL1 (female) (3), FL2 (female) (3), C27 (female) (3), C28 (female) (3), or FP3 (female) (3) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 64 Wiring harness between SP19 (female) (6) – FP12 (female) (A) Voltage Max. 1 V Hot short (Contact with 24 V Wiring harness between FP12 (female) (B) – FL1 (female) (1), FL2 (female) (1), C27 circuit) in wiring harness (female) (1), or C28 (female) (1) Voltage Max. 1 V Wiring harness between FP12 (female) (C) – FL1 (female) (3), FL2 (female) (3), C27 (female) (3), C28 (female) (3), or FP3 (female) (3) Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting Symptom of failure SEN01841-00 (4) High beam pilot lamp does not light up or go off. General information Cause 1 Broken bulb 2 Defective lamp assembly (Internal defect) Standard value when normal and remarks for troubleshooting High beam pilot lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP3 (female) (3) – 3 or defective contact in con- circuit branch point nector) Wiring harness between FP3 (female) (12) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between FP3 (female) (3) – ResisMin. 1 Mz circuit branch point tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between FP3 (female) (3) – Voltage Max. 1 V circuit branch point GD655-3E0, GD675-3E0 65 SEN01841-00 Symptom of failure 40 Troubleshooting (5) Clearance lamp, tail lamp, machine monitor night lamp and switch panel lamp [Cabless specification] do not light up or go off. General information Cause Standard value when normal and remarks for troubleshooting 1 Broken clearance lamp bulb If only specific clearance lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. 2 Broken tail lamp bulb If only specific tail lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor (Internal defect) FP1 Between (8) – ground 4 Broken switch panel lamp bulb [Cabless specification] Headlamp switch Voltage OFF Max. 1 V Clearance lamp ON 20 – 30 V If only switch panel lamp does not light up, its bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector) Wiring harness between SP19 (female) (3) – FL22 (female) (1), FL23 (female) (1), RL2 (female) (4), RL3 (female) (4), FP1 (female) (8), or ST10 (female) Resistance Max. 1 z Wiring harness between FL22 (female) (2), FL23 (female) (2) – ground (FT01) Resistance Max. 1 z Wiring harness between RL2 (female) (6), RL3 (female) (6) – ground (ET77) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 6 Ground fault in wiring harness Wiring harness between SP19 (female) (3) – (Contact with GND circuit) FL22 (female) (1), FL23 (female) (1), RL2 (female) (4), RL3 (female) (4), FP1 (female) (8), ST10 (female), or SP9 (female) (1) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7 66 Hot short (Contact with 24 V Wiring harness between SP19 (female) (3) – circuit) in wiring harness FL22 (female) (1), FL23 (female) (1), RL2 (female) (4), RL3 (female) (4), FP1 (female) (8), ST10 (female), or SP20 (female) (8) Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to headlamp, clearance lamp, tail lamp GD655-3E0, GD675-3E0 67 SEN01841-00 40 Troubleshooting E-23 Working lamp does not light up or go off Symptom of failure 1 (1) None of front working lamps and rear working lamps lights up or goes off. General information Cause 1 Defective fuse A9 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See cause 4 (FB1) and troubles (2) and (3).) Defective working lamp 2 switch (Internal disconnection or short circuit) Possible causes and the standard values when normal Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SP23 (male) Working lamp switch Resistance Between (A) – (B) Between (C) – (B) OFF Min. 1 Mz ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between fuse A8 of fuse box I (FB1) – SP23 (female) (B) or SP10 (female) (1) Resistance Max. 1 z Wiring harness between SP23 (female) (B) – SP10 (female) (1) Resistance Max. 1 z Wiring harness between SP10 (female) (6) – ground (FT01) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 68 Ground fault in wiring harness Wiring harness between fuse A9 of fuse box I (Contact with GND circuit) (FB1) – SP23 (female) (C) or SP11 (female) (5) Resistance Min. 1 Mz Wiring harness between SP23 (female) (C) – SP11 (female) (5) Resistance Min. 1 Mz GD655-3E0, GD675-3E0 40 Troubleshooting Symptom of failure SEN01841-00 (2) Front working lamps do not light up or go off General information Cause 1 Broken bulb Standard value when normal and remarks for troubleshooting If only specific front working lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2 Defective front working lamp Replace front working lamp relay (Right No.) with relay (Internal defect) another relay (6-pin type). If condition becomes normal at this time, front working lamp relay is defective. SP10 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Wiring harness between SP10 (female) (3) – (1) Disconnection in wiring harness (Disconnection in wiring Wiring harness between SP10 (female) (2) – 3 or defective contact in con- FL26 (female) (1) nector) Wiring harness between SP10 (female) (4) – FL27 (female) (1) Wiring harness between FL26 (female) (2), FL27 (female) (2) – ground (FT01) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Ground fault in wiring harness Wiring harness between SP10 (female) (2) – (Contact with GND circuit) FL26 (female) (1) Resistance Min. 1 Mz Wiring harness between SP10 (female) (4) – FL27 (female) (1) or FP3 (female) (5) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Hot short (Contact with 24 V Wiring harness between SP10 (female) (2) – circuit) in wiring harness FL26 (female) (1) Voltage Max. 1 V Wiring harness between SP10 (female) (4) – FL27 (female) (1) or FP3 (female) (5) Voltage Max. 1 V GD655-3E0, GD675-3E0 69 SEN01841-00 Symptom of failure 40 Troubleshooting (3) Rear working lamps do not light up or go off General information Cause 1 Broken bulb Standard value when normal and remarks for troubleshooting Rear working lamp bulbs may be broken or may have defective contact. Check them directly. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2 Defective rear working lamp Replace rear working lamp relay (Right No.) with relay (Internal defect) another relay (6-pin type). If condition becomes normal at this time, rear working lamp relay is defective. SP11 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Wiring harness between SP11 (female) (3) – SP11 (female) (1) Disconnection in wiring harness (Disconnection in wiring Wiring harness between SP11 (female) (6) – 3 or defective contact in con- SP10 (6) nector) Wiring harness between SP11 (female) (4) – RL4 (female) (1) or RL5 (female) (1) Wiring harness between RL4 (female) (2), RL5 (female) (2) – ground (ET77) Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between SP11 (female) (4) – ResisMin. 1 Mz RL4 (female) (1) or RL5 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between SP11 (female) (4) – Voltage Max. 1 V RL4 (female) (1) or RL5 (female) (1) Symptom of failure (4) Working lamp pilot lamp does not light up or go off. General information Cause 1 Broken bulb 2 Defective lamp assembly (Internal defect) Standard value when normal and remarks for troubleshooting Working lamp pilot lamp bulb may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between FP3 (female) (5) – 3 or defective contact in con- circuit branch point nector) Wiring harness between FP3 (female) (12) – ground (FT01) Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Contact with GND circuit) Wiring harness between FP3 (female) (5) – ResisMin. 1 Mz circuit branch point tance Hot short (Contact with 24 V 5 circuit) in wiring harness 70 Resistance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between FP3 (female) (5) – circuit branch point Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to working lamp GD655-3E0, GD675-3E0 71 SEN01841-00 40 Troubleshooting E-24 Turn signal lamp and hazard lamp do not blink or go off Symptom of failure 1 (1) None of turn signal lamp and hazard lamp blinks or goes off. General information Cause 1 Standard value when normal and remarks for troubleshooting Defective fuse A2 of fuse box I If fuse is broken, circuit probably has ground fault etc. (See cause 4 (FB1) and troubles (2) and (3).) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2 Defective flasher (Internal defect) SP22 Voltage Between (3) – (1) 20 – 30 V Between (4) – (1) 20 – 30 V Max. 1 V (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. Possible causes and the standard values when normal a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between fuse A2 of fuse box I (FB1) – SP22 (female) (3) Resistance Max. 1 z Wiring harness between SP22 (female) (1) – ground (FT01) Resistance Max. 1 z Wiring harness between SP22 (female) (4) – circuit branch point Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Ground fault in wiring harness Wiring harness between fuse A2 of fuse box I (Contact with GND circuit) (FB1) – SP22 (female) (3) Resistance Min. 1 Mz Wiring harness between SP22 (female) (4) – SP20 (female) (2), (5) or FP11 (female) (A) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 5 circuit) in wiring harness Wiring harness between SP22 (female) (4) – Voltage Max. 1 V SP20 (female) (2), (5) or FP11 (female) (A) 72 GD655-3E0, GD675-3E0 40 Troubleshooting Symptom of failure SEN01841-00 (2) Turn signal lamp does not blink or go off. General information Cause 1 Broken bulb Standard value when normal and remarks for troubleshooting If only specific turn signal lamp or hazard lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective turn signal lever 2 (Internal disconnection or short circuit) FP11 (male) Between (A) – (B) Between (A) – (C) Turn signal lever Resistance Neutral Min. 1 Mz Left turn (Upper side) Max. 1 z Neutral Min. 1 Mz Right turn (Lower side) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between FP11 (female) (A) – circuit branch point Resistance Max. 1 z Wiring harness between FP11 (female) (B) – FL23 (female) (3) or RL3 (female) (1) Resistance Max. 1 z Wiring harness between FP11 (female) (C) – FL22 (female) (3) or RL2 (female) (1) Resistance Max. 1 z Wiring harness between FL23 (female) (2), FL22 (female) (2) – ground (FT01) Resistance Max. 1 z Wiring harness between RL3 (female) (6), RL2 (female) (6) – ground (ET77) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FP11 (female) (B) – Ground fault in wiring harness FL23 (female) (3), RL3 (female) (1), FP3 4 (Contact with GND circuit) (female) (4), or SP20 (female) (6) Resistance Min. 1 Mz Wiring harness between FP11 (female) (C) – FL22 (female) (3), RL2 (female) (1), FP3 (female) (2), or SP20 (female) (3) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between FP11 (female) (B) – Hot short (Contact with 24 V FL23 (female) (3), RL3 (female) (1), FP3 5 circuit) in wiring harness (female) (4), or SP20 (female) (6) Voltage Max. 1 V Wiring harness between FP11 (female) (C) – FL22 (female) (3), RL2 (female) (1), FP3 (female) (2), or SP20 (female) (3) Voltage Max. 1 V GD655-3E0, GD675-3E0 73 SEN01841-00 Symptom of failure 40 Troubleshooting (3) Hazard lamp does not blink or go off. General information Cause 1 Broken bulb Defective hazard lamp 2 switch (Internal disconnection or short circuit) Standard value when normal and remarks for troubleshooting If only specific turn signal lamp or hazard lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SP20 (male) Hazard lamp switch Resistance Between (2) – (3) Between (5) – (6) OFF Min. 1 Mz ON Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between SP20 (female) (2), (5) – circuit branch point Resistance Max. 1 z Wiring harness between SP20 (female) (6) – FL23 (female) (3) or RL3 (female) (1) Resistance Max. 1 z Wiring harness between SP20 (female) (3) – FL22 (female) (3) or RL2 (female) (1) Resistance Max. 1 z Wiring harness between FL23 (female) (2), FL22 (female) (2) or ground (FT01) Resistance Max. 1 z Wiring harness between RL3 (female) (6), RL2 (female) (6) or ground (ET77) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between SP20 (female) (6) – Ground fault in wiring harness FL23 (female) (3), RL3 (female) (1), FP3 4 (Contact with GND circuit) (female) (4), or FP11 (female) (B) Resistance Min. 1 Mz Wiring harness between SP20 (female) (3) – FL22 (female) (3), RL2 (female) (1), FP3 (female) (2), or FP11 (female) (C) Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 74 Wiring harness between SP20 (female) (6) – Hot short (Contact with 24 V FL23 (female) (3), RL3 (female) (1), FP3 5 circuit) in wiring harness (female) (4), or FP11 (female) (B) Voltage Max. 1 V Wiring harness between SP20 (female) (3) – FL22 (female) (3), RL2 (female) (1), FP3 (female) (2), or FP11 (female) (C) Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting Symptom of failure SEN01841-00 (4) Turn signal pilot lamp does not light up or go off. General information Cause 1 Broken bulb 2 Defective lamp assembly (Internal defect) Standard value when normal and remarks for troubleshooting Turn signal pilot lamp bulb which does not light up may be broken or may have defective contact. Check it directly. Lamp assembly may have defect (disconnection or short circuit) in it. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Possible causes and the standard values when normal Wiring harness between FP3 (female) (4) – circuit branch point Resistance Max. 1 z Wiring harness between FP3 (female) (2) – circuit branch point Resistance Max. 1 z Wiring harness between FP3 (female) (12) – ground (FT01) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Ground fault in wiring harness Wiring harness between FP3 (female) (4) – (Contact with GND circuit) circuit branch point Resistance Min. 1 Mz Wiring harness between FP3 (female) (2) – circuit branch point Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Hot short (Contact with 24 V Wiring harness between FP3 (female) (4) – circuit) in wiring harness circuit branch point Voltage Max. 1 V Wiring harness between FP3 (female) (2) – circuit branch point Voltage Max. 1 V GD655-3E0, GD675-3E0 75 SEN01841-00 40 Troubleshooting Circuit diagram related to turn signal lamp and hazard lamp 76 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01841-00 77 SEN01841-00 40 Troubleshooting E-25 Brake lamp does not light up or go off Symptom of failure 1 • Brake lamp does not light up or go off. General information Cause 1 Defective fuse A12 of fuse box I (FB1) 2 Broken brake lamp bulb Defective brake lamp switch 3 (Internal disconnection or short circuit) 4 Defective stop lamp relay (Internal defect) Standard value when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. (See causes 4 and 6.) If only specific brake lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. B13 (male) Between (1) – (2) Brake pedal Resistance Released Min. 1 Mz Pressed Max. 1 z a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Replace stop lamp relay (Right No.) with another relay (5-pin type). If condition becomes normal at this time, stop lamp relay is defective. SP12 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Wiring harness between fuse A12 of fuse box I (FB1) – B13 (female) (1) or SP12 (female) (3) Resistance Max. 1 z Disconnection in wiring har- Wiring harness between B13 (female) (2) – ness (Disconnection in wiring SP12 (female) (1) 5 or defective contact in conWiring harness between SP12 (female) (2) – nector) ground (FT01) Resistance Max. 1 z Resistance Max. 1 z Wiring harness between SP12 (female) (5) – RL3 (female) (5) or RL2 (female) (6) Resistance Max. 1 z Wiring harness between RL3 (female) (6), RL2 (female) (5) – ground (ET77) Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse A12 of fuse box I (FB1) – B13 (female) (1) or SP12 Ground fault in wiring harness (female) (3) 6 (Contact with GND circuit) Wiring harness between B13 (female) (2) – SP12 (female) (1) Wiring harness between SP12 (female) (5) – RL3 (female) (5) or RL2 (female) (6) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7 Hot short (Contact with 24 V Wiring harness between B13 (female) (2) – circuit) in wiring harness SP12 (female) (1) Wiring harness between SP12 (female) (5) – RL3 (female) (5) or RL2 (female) (6) 78 Voltage Max. 1 V Voltage Max. 1 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Circuit diagram related to brake lamp GD655-3E0, GD675-3E0 79 SEN01841-00 40 Troubleshooting E-26 Backup lamp does not light up or go off 1 Symptom of failure • Backup lamp does not light up or go off. General information • Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If disconnection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.) Cause 1 Broken brake lamp bulb Standard value when normal and remarks for troubleshooting If only specific backup lamp does not light up, that lamp bulb may be broken or may have defective contact. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wiring Wiring harness between RL3 (female) (2), 2 or defective contact in con- RL2 (female) (2) – circuit branch point nector) Wiring harness between RL3 (female) (6), RL2 (female) (6) – ground (ET77) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) Wiring harness between RL3 (female) (2), ResisMin. 1Mz RL2 (female) (2) – circuit branch point tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 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 40 Troubleshooting SEN01841-00 E-27 Backup buzzer does not sound or stop 1 Symptom of failure • Backup buzzer does not sound or stop. General information • Transmission controller checks signal circuit between gear shift lever and itself for trouble. (If disconnection, short circuit, etc. occur, failure code [DW4BKA] or [DW4BKB] is displayed.) Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch ON and carry out troubleshooting. 1 Defective backup buzzer (Internal defect) RTS, RT2 Gear shift lever Voltage R1 – R4 Max. 1 V Between terminals Other than between R1 – R4 20 – 30 V If voltage is normal but backup buzzer does not sound, backup buzzer is defective. Possible causes and the standard values when normal a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between RT3 – circuit branch 2 or defective contact in con- point nector) Wiring harness between RT2 – ground (ET77) Resistance Max. 1 z Resistance Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Contact with GND circuit) ResisWiring harness between RT3 – circuit branch Min. 1 Mz point tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 V 4 circuit) in wiring harness ResisWiring harness between RT3 – circuit branch Min. 1 Mz point tance Circuit diagram related to backup lamp and backup buzzer GD655-3E0, GD675-3E0 81 SEN01841-00 40 Troubleshooting E-28 Air conditioner does not work or stop 1 Symptom of failure • Air conditioner does not work or stop. General information • Following is troubleshooting for only power supply circuit and ground circuit between air conditioner and operator’s cab. For troubleshooting for air conditioner unit, see Shop Manual for air conditioner. Cause Standard value when normal and remarks for troubleshooting Defective fuse No. 3 or No. 4 of fuse box A or 5A or 15A 1 If fuse is broken, circuit probably has ground fault etc. (See cause 2.) fuse of main circuit in air conditioner a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 8 of fuse box A is broken Wiring harness between fuse No. 8 of fuse box A – 5A fuse of main circuit in air conditioner unit or 15A fuse in air conditioner unit Resistance Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 7 of fuse box A is broken Possible causes and the standard values when normal Wiring harness between fuse No. 7 of fuse box A – compressor clutch relay Resistance Wiring harness between 5A fuse of main circuit in air conditioner unit – C48 (female) (7), pressure switch, or primary side of blower OFF relay Resistance Min. 1 Mz Ground fault in wiring harness 2 a Prepare with starting switch OFF, then carry out troubleshooting (Contact with GND circuit) without turning starting switch ON. • When 5A fuse of main circuit in air conditioner unit is broken Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When 15A fuse in air conditioner unit is broken Wiring harness between 15A fuse in air conditioner unit – blower OFF relay Resistance Min. 1 Mz a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C48 Starting switch Voltage Disconnection in air condiON 20 – 30 V Between (7) – (1) tioner control panel power OFF Max. 1 V supply or ground wiring har3 a Prepare with starting switch OFF, then carry out troubleshooting ness (Disconnection in wiring without turning starting switch ON. or defective contact in connector) Wiring harness between fuse No. 8 of fuse ResisMax. 1 z box A – C48 (female) (7) tance Wiring harness between C48 (female) (1) – ground 82 Resistance Max. 1 z GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Blower OFF relay and pressure switch Between blower OFF relay (15A fuse line) – ground Between blower OFF relay (5A fuse line of main circuit) – ground Possible causes and the standard values when normal Starting switch Voltage ON 20 – 30 V OFF Max. 1 V ON 20 – 30 V OFF Max. 1 V Pressure switch ON 20 – 30 V Disconnection in relay power (5A fuse line of main supply wiring harness (DisOFF Max. 1 V circuit) – ground 4 connection in wiring or defeca Prepare with starting switch OFF, then carry out troubleshooting tive contact in connector) without turning starting switch ON. GD655-3E0, GD675-3E0 Wiring harness between fuse No. 8 of fuse box A – blower OFF relay (15A fuse line side) Resistance Max. 1 z Wiring harness between fuse No. 8 of fuse box A – blower OFF relay (5A fuse line side of main circuit) Resistance Max. 1 z Wiring harness between fuse No. 8 of fuse box A – pressure switch (5A fuse line side of main circuit) Resistance Max. 1 z Wiring harness between pressure switch – compressor clutch relay Resistance Max. 1 z 83 SEN01841-00 40 Troubleshooting Circuit diagram related to air conditioner 84 GD655-3E0, GD675-3E0 40 Troubleshooting GD655-3E0, GD675-3E0 SEN01841-00 85 SEN01841-00 40 Troubleshooting E-29 KOMTRAX system does not operate normally 1 Symptom of failure • KOMTRAX system does not operate normally. General information • If KOMTRAX system administrator asks if there is trouble in system on machine side, carry out troubleshooting. • Even if KOMTRAX system has trouble, it does not appear on machine. Cause Standard value when normal and remarks for troubleshooting a Prepare with starting switch OFF. 1 Defective power supply Defective communication 2 environment LED (1) Normal condition LED-A1 ON a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. G01 Signal Voltage Between (39), (40) – (37), (38) Unswitched power supply 20 – 30 V a Prepare with starting switch ON. LED (6) Normal condition LED-A2 ON a Prepare with engine started. Possible causes and the standard values when normal Starting switch signal ACC or 3 alternator signal R LED (6) Normal condition LED-C1 ON a Prepare with starting switch OFF, then start engine and carry out troubleshooting. C01 Signal Voltage Between (36) – (37), (38) Starting switch ACC 20 – 30 V Between (28) – (37), (38) Alternator R 20 – 30 V a Prepare with starting switch ON. LED (8) Normal condition LED-C3 OFF a Turn starting switch to START and carry out troubleshooting. 4 Defective network type or starting switch signal C LED (8) Normal condition LED-C3 Fast blink (Period: 1 sec) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. G01 Signal Continuity Between (24), (25) – (37), (38) Network type There is continuity a Prepare with starting switch OFF, then start engine and carry out troubleshooting. 86 G01 Signal Voltage Between (27) – (37), (38) Starting switch C 20 – 30 V GD655-3E0, GD675-3E0 40 Troubleshooting SEN01841-00 a Prepare with starting switch ON. Defective fuel sensor con5 nection or pattern Possible causes and the standard values when normal LED (9) Normal condition LED-C4 Slow blink (Period: 4 sec) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. G01 Signal Voltage Between (32) – (37), (38) Fuel sensor Max. 5 V Between (17) – (37), (38) Fuel sensor pattern selection 20 – 30 V a Prepare with starting switch ON. 6 Defective transmission of data LED (12) 7-segment Normal condition If letters at right are not displayed, condition is normal. [–] [C] [H] a Prepare with starting switch ON. Defective GPS measuring 7 condition LED display section GD655-3E0, GD675-3E0 LED (13) Normal condition Dot ON (See *) *: 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. G01 connector 87 SEN01842-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 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 SEN01842-00 40 Troubleshooting 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 2 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 Troubleshooting of hydraulic and mechanical system (H-mode)1 Contents of troubleshooting table a 1 Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Trouble Related information Phenomenon occurring on machine Information on the failure occurred as well as the troubleshooting Cause Standard value when normal and remarks for troubleshooting 1 Possible causes and standard value in normal state 2 Cause for presumed failure <Contents> (The attached No. is for fil• The standard values in normalcy by which to judge "Good" or "No ing and reference purpose Good" about presumed causes. only. It does not stand for • References for making judgement of "Good" or "No Good" any priority.) 3 4 GD655-3E0, GD675-3E0 3 SEN01842-00 40 Troubleshooting H-1 Excessive drop in engine speed, or engine stalls Trouble Related information • Excessive drop in engine speed, or engine stalls • Before starting troubleshooting, check that oil level in hydraulic tank is normal. Cause Malfunction or improper 1 adjustment of piston pump (PC valve) Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. If condition does not become normal after adjustment, PC valve of piston pump may be malfunctioning or may have defect in it. Check piston pump directly. 2 Clogged piston pump (orifice Orifice plug of piston pump may be clogged. Check it directly. plug) 3 Malfunction of piston pump (servo piston) 4 Defect in piston pump (pump Piston pump may have defect in it. Check it directly. unit) 5 Defective engine 4 1 Servo piston of piston pump may be malfunctioning. Check it directly. Engine may be defective. Carry out troubleshooting for engine (S mode). GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-2 Machine does not move in either forward or reverse direction Trouble Related information 1 • Machine does not move in either forward or reverse direction • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. Cause 1 Defect in PTO Standard value when normal and remarks for troubleshooting Power train pump may not be rotating because of defect in PTO. Check PTO directly. 2 Defective coupling of power train pump (drive system) Power train pump may not be rotating because of defective coupling of its drive system. Check drive system directly. 3 Clogged suction strainer of transmission case Suction strainer of transmission case may be clogged. Check it directly. 4 Air in suction circuit of power Suction circuit of power train pump may have sucked air. Check it train pump directly. 5 Defect in power train pump (pump unit) Power train pump may have defect in it. Check it directly. a Prepare with engine stopped, then start engine and carry out troubleshooting. Possible causes and standard value in normal state Malfunction of power train 6 main relief valve Gear shift lever Engine Power train main relief pressure Low idle 2.4 ± 0.1 MPa {24.5 ± 1.0 kg/cm2} High idle 2.46 ± 0.2 MPa {25.1 ± 2.0 kg/cm2} P position a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 7 Malfunction of torque converter main relief valve Gear shift lever Torque converter inlet pressure P position 0.88 ± 0.05 MPa {9.0 ± 0.5 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 8 Defect in torque converter Gear shift lever Torque converter outlet pressure P position 0.59 ± 0.05 MPa {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 GD655-3E0, GD675-3E0 Transmission may have defect in it. Check it directly. 5 SEN01842-00 40 Troubleshooting H-3 Transmission does not shift up or shift down Trouble Related information 1 (1) Machine does not move in forward or reverse direction • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • Before starting troubleshooting, set gear shift lever in each gear speed and check that machine does not move in only forward or reverse direction. Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Possible causes and standard value in normal state Trouble Related information 1 Measured clutch Clutch pressure FL, FH 1.96 – 2.45 MPa {20 – 25 kg/cm2} R 2.25 ± 0.2 MPa {23.0 ± 2.0 kg/cm2} Malfunction of transmission clutch valve (ECMV) If oil pressure is abnormal, replace clutch valve (ECMV) with one of normal side and check again, then judge. 2 Defective transmission clutch Transmission clutch piston seal may be defective. Check it directly. piston seal 3 Worn or broken transmission clutch disc/plate Transmission clutch disc/plate may be worn or broken. Check it directly. (2) Transmission does not shift up or shift down • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • Before starting troubleshooting, set gear shift lever in each gear speed and check that machine does not move in only specific gear speed. Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Possible causes and standard value in normal state 6 Malfunction of transmission 1 clutch valve (ECMV) Measured clutch Clutch pressure FL, FH, 1st, 2nd, 3rd, 4th 1.96 – 2.45 MPa {20 – 25 kg/cm2} If oil pressure is abnormal, replace clutch valve (ECMV) with one of same set pressure and check again, then judge. 2 Defective transmission clutch Transmission clutch piston seal may be defective. Check it directly. piston seal 3 Worn or broken transmission clutch disc/plate Transmission clutch disc/plate may be worn or broken. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-4 Machine is slow or lacks power when traveling Trouble Related information 1 (1) Machine is slow or lacks power in all gear speeds • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • 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). Cause Standard value when normal and remarks for troubleshooting 1 Clogged suction strainer of transmission case Suction strainer of transmission case may be clogged. Check it directly. 2 Air in suction circuit of power Suction circuit of power train pump may have sucked air. Check it train pump directly. 3 Defect in power train pump (pump unit) Power train pump may have defect in it. Check it directly. a Prepare with engine stopped, then start engine and carry out troubleshooting. 4 Malfunction of power train main relief valve Gear shift lever Engine Power train main relief pressure Low idle 2.4 ± 0.1 MPa {24.5 ± 1.0 kg/cm2} High idle 2.46 ± 0.2 MPa {25.1 ± 2.0 kg/cm2} P position Possible causes and standard value in normal state a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 5 Malfunction of torque converter main relief valve Gear shift lever Torque converter inlet pressure P position 0.88 ± 0.05 MPa {9.0 ± 0.5 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 6 Defect in torque converter Gear shift lever Torque converter outlet pressure P position 0.59 ± 0.05 MPa {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. 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 SEN01842-00 Trouble Related information 40 Troubleshooting (2) Machine is slow or lacks power in specific gear speed • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • Torque converter lockup clutch operates in specific gear speed according to position of transmission mode selector switch (See table of "Transmission mode selector switch and torque converter lockup function"). Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Malfunction of torque con1 verter lockup clutch valve (ECMV) 2 Possible causes and standard value in normal state Defective torque converter lockup clutch piston seal Worn or broken torque con3 verter lockup clutch disc/ plate Transmission mode selector switch Gear shift lever Clutch pressure Mode 1 F1 position 2.01 ± 0.15 MPa {20.5 ± 1.5 kg/cm2} Torque converter lockup clutch piston seal may be defective. Check it directly. Torque converter lockup clutch disc/plate may be worn or broken. Check it directly. a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. 4 Malfunction of transmission clutch valve (ECMV) Measured clutch Clutch pressure FL, FH, 1st, 2nd, 3rd, 4th 1.96 – 2.45 MPa {20 – 25 kg/cm2} R 2.06 – 2.45 MPa {21 – 25 kg/cm2} If oil pressure is abnormal, replace clutch valve (ECMV) with one of same set pressure and check again, then judge. 5 Defective transmission clutch Transmission clutch piston seal may be defective. Check it directly. piston seal 6 Worn or broken transmission clutch disc/plate Transmission clutch disc/plate may be worn or broken. Check it directly. Transmission mode selector switch and torque converter lockup function Gear shift lever Gear speed Transmission mode selector switch F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 Mode 1 D D D D D D D D D D TC TC 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 40 Troubleshooting SEN01842-00 H-5 Torque converter lockup function cannot be actuated or canceled1 Trouble Related information • Torque converter lockup function cannot be actuated or canceled • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • Torque converter lockup clutch operates in specific gear speed according to position of transmission mode selector switch (See table of "Transmission mode selector switch and torque converter lockup function"). Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Possible causes and standard value in normal state Malfunction of torque con1 verter lockup clutch valve (ECMV) 2 Defective torque converter lockup clutch piston seal Worn or broken torque con3 verter lockup clutch disc/ plate Transmission mode selector switch Gear shift lever Clutch pressure Mode 1 F1 position 2.01 ± 0.15 MPa {20.5 ± 1.5 kg/cm2} Torque converter lockup clutch piston seal may be defective. Check it directly. Torque converter lockup clutch disc/plate may be worn or broken. Check it directly. Transmission mode selector switch and torque converter lockup function Gear shift lever Gear speed Transmission mode selector switch F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 Mode 1 D D D D D D D D D D TC TC 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 SEN01842-00 40 Troubleshooting H-6 Excessive time lag when starting or shifting gear Trouble Related information 1 • Excessive time lag when starting or shifting gear • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • Before starting troubleshooting, set gear shift lever in each gear speed and check which gear speed or travel direction has excessive time lag. • Before starting troubleshooting, check that travel speed is normal. (If abnormal, carry out troubleshooting for "H-4 Machine is slow or lacks power when traveling" first.) Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Possible causes and standard value in normal state 10 1 Malfunction of transmission clutch valve (ECMV) Measured clutch Clutch pressure FL, FH, 1st, 2nd, 3rd, 4th 1.96 – 2.45 MPa {20 – 25 kg/cm2} R 2.06 – 2.45 MPa {21 – 25 kg/cm2} If oil pressure is abnormal, replace clutch valve (ECMV) with one of same set pressure and check again, then judge. 2 Defective transmission clutch Transmission clutch piston seal may be defective. Check it directly. piston seal 3 Worn or broken transmission clutch disc/plate Transmission clutch disc/plate may be worn or broken. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-7 Torque converter oil temperature is high Trouble Related information 1 • Torque converter oil temperature is high • Before starting troubleshooting, check that oil level in transmission case is normal. • Check oil pressure while torque converter oil temperature gauge is reading 60 – 80°C. • 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). Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then start engine and carry out troubleshooting. Malfunction of power train 1 main relief valve Gear shift lever Engine Power train main relief pressure Low idle 2.4 ± 0.1 MPa {24.5 ± 1.0 kg/cm2} High idle 2.46 ± 0.2 MPa {25.1 ± 2.0 kg/cm2} P position a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 2 Malfunction of torque converter main relief valve Gear shift lever Torque converter inlet pressure P position 0.88 ± 0.05 MPa {9.0 ± 0.5 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 3 Defect in torque converter Gear shift lever Torque converter outlet pressure P position 0.59 ± 0.05 MPa {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. Possible causes and standard value in normal state a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. Malfunction of torque 4 converter lockup clutch valve (ECMV) 5 Defective torque converter lockup clutch piston seal Transmission mode selector switch Gear shift lever Clutch pressure Mode 1 F1 position 2.01 ± 0.15 MPa {20.5 ± 1.5 kg/cm2} Torque converter lockup clutch piston seal may be defective. Check it directly. Worn or broken torque Torque converter lockup clutch disc/plate may be worn or broken. 6 converter lockup clutch disc/ Check it directly. plate a Prepare with engine stopped, then run engine at high idle (noload travel) and carry out troubleshooting. 7 Malfunction of transmission clutch valve (ECMV) Measured clutch Clutch pressure FL, FH, 1st, 2nd, 3rd, 4th 1.96 – 2.45 MPa {20 – 25 kg/cm2} R 2.06 – 2.45 MPa {21 – 25 kg/cm2} If oil pressure is abnormal, replace clutch valve (ECMV) with one of same set pressure and check again, then judge. 8 Defective transmission clutch Transmission clutch piston seal may be defective. Check it directly. piston seal GD655-3E0, GD675-3E0 11 SEN01842-00 Cause Possible causes and standard Worn or broken transmission 9 value in normal clutch disc/plate state 10 Defect in transmission 12 40 Troubleshooting Standard value when normal and remarks for troubleshooting Transmission clutch disc/plate may be worn or broken. Check it directly. Transmission may have defect in it. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-8 Differential lock function is not operated or reset [Differential lock specification] 1 Trouble Related information • Differential lock function does not work or is not reset • Before starting troubleshooting, check that oil level in final drive case is normal. • Check oil pressure while final drive case oil temperature gauge is reading 45 – 55°C. Cause Defective coupling of 1 differential lock pump (drive system) Standard value when normal and remarks for troubleshooting Differential lock pump may not be rotating because of defective coupling of its drive system. Check drive system directly. 2 Clogged suction strainer of final drive case Suction strainer of final drive case may be clogged. Check it directly. 3 Air in suction circuit of differential lock pump Suction circuit of differential lock pump may have sucked air. Check it directly. 4 Defect in differential lock pump (pump unit) Differential lock pump may have defect in it. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state Malfunction or improper 5 adjustment of differential lock valve Differential lock switch Differential lock pressure (Pump outlet, valve outlet) OFF Approx. 0 MPa {Approx. 0 kg/cm2} ON Max. 2.84 MPa {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. 6 Defective differential lock clutch piston seal Differential lock clutch piston seal may be defective. Check it directly. 7 Worn or broken differential lock clutch disc/plate Differential lock clutch disc/plate may be worn or broken. Check it directly. GD655-3E0, GD675-3E0 13 SEN01842-00 40 Troubleshooting H-9 Machine is slow or lacks power when steering Trouble Related information 1 • Machine is slow or lacks power when steering • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check oil pressure and cylinder leakage while hydraulic oil temperature is 45 – 55°C. • Before starting troubleshooting, check that work equipment operates normally (If not, carry out troubleshooting 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. Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 1 Possible causes and standard value in normal state Steering cylinder Steering oil pressure When relieved 18.1 +0.7 +0 MPa +7 {185 +0 kg/cm2} 2 Malfunction of steering valve Steering valve (Orbit-roll) may be malfunctioning. Check it directly. 3 14 Malfunction of priority valve (relief valve) Defective steering cylinder seal a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Steering cylinder Cylinder leakage When relieved in extending operation 0 cc/min GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-10 Wheel brake does not work normally Trouble Related information 1 • Wheel brake does not work normally • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check oil pressure while hydraulic oil temperature is 45 – 55°C. • Before starting troubleshooting, check that work equipment operates normally (If not, carry out troubleshooting for "H-13 No work equipment moves" first). Cause Standard value when normal and remarks for troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction or improper adjustment of brake 1 accumulator charge valve (pressure governor valve) Malfunction of brake 2 accumulator charge valve (LS relief valve) Gas pressure reduction in 3 brake accumulator Possible causes and standard value in normal state Cut-in pressure 9.36 +0.2 +0 MPa 2 {95.5 +2 +0 kg/cm } Cut-out pressure 12.26 +0.98 MPa +0 2 {125 +10 +10 kg/cm } If oil pressure does not become normal after adjustment, pressure governor valve of brake accumulator charge valve may be malfunctioning or may have defect in it. Check pressure governor valve directly. LS relief valve of brake accumulator charge valve may be malfunctioning. Check it directly. Gas pressure in brake accumulator (2 units of front and rear) may be low. Check it directly. Accumulator gas pressure (Nitrogen gas) 3.4 ± 0.1 MPa {35 ± 1 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. 4 Malfunction of brake valve Brake pedal Wheel brake actuating pressure Pressed (to stroke end) +0.10 3.9 –0.31 MPa +1 {40 –3 kg/cm2} 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 without starting engine (Increase accumulator pressure before starting check). 6 Defective brake piston seal Brake pedal Wheel brake actuating pressure reduction (in 5 min) Pressed (to stroke end) 98 kPa {1.0 kg/cm2} 7 Worn or broken brake disc/ plate Brake disc/plate may be worn or broken. Check it directly. 8 Defective air bleeding from brake circuit Air may not be bled from brake circuit normally. Bleed air (Slack adjuster section and wheel brake section). GD655-3E0, GD675-3E0 15 SEN01842-00 40 Troubleshooting H-11 Parking brake is not applied or released Trouble Related information 1 • Parking brake is not applied or released • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check oil pressure while hydraulic oil temperature is 45 – 55°C. • Before starting troubleshooting, check that wheel brake operates normally (If not, carry out troubleshooting for "H-10 Wheel brake does not work normally" first). Cause 1 Standard value when normal and remarks for troubleshooting Clogged parking brake bank 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. Possible causes and standard value in normal state Malfunction of parking brake 2 bank valve (parking solenoid valve) 3 Clogged elbow filter Gear shift lever Parking brake actuating pressure P position 0 MPa {0 kg/cm2} Position other than P 9.36 – 13.24 MPa {95.5 – 135 kg/cm2} Elbow filter may be clogged. Check it directly. Malfunction of parking brake 4 Parking brake calipers may be malfunctioning. Check it directly. calipers 5 16 Improper adjustment of parking brake Parking brake may be adjusted improperly. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-12 All work equipment is slow or lacks power Trouble Related information 1 • All work equipment is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check oil pressure while hydraulic oil temperature is 45 – 55°C. Cause 1 Clogged suction strainer of hydraulic tank Standard value when normal and remarks for troubleshooting Suction strainer of hydraulic tank may be clogged. Check it directly. 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 Malfunction or improper 3 adjustment of piston pump (PC valve) a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. If condition does not become normal after adjustment, PC valve of piston pump may be malfunctioning or may have defect in it. Check piston pump directly. a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction or improper 4 adjustment of piston pump (LS valve) Possible causes and standard value in normal state Work equipment LS differential pressure All work equipment in neutral 2.8 ± 0.98 MPa {29 ± 10 kg/cm2} While blade is turning (Lever at stroke end) 2.35 ± 0.1 MPa {24 ± 1 kg/cm2} If differential pressure does not become normal after adjustment, LS valve of piston pump may be malfunctioning or may have defect in it. Check LS valve directly. 5 Clogged piston pump (orifice plug) Orifice plug of piston pump may be clogged. Check it directly. 6 Malfunction of piston pump (servo piston) Servo piston of piston pump may be malfunctioning. Check it directly. 7 Defect in piston pump (pump unit) Piston pump may have defect in it. Check it directly. a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. 8 Malfunction of left 5-spool control valve (unload valve) Work equipment Unload pressure All work equipment in neutral 2.8 ± 0.98 MPa {29 ± 10 kg/cm2} a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction or improper adjustment of right 4-spool 9 control valve (main relief valve/LS relief valve) Work equipment Work equipment circuit relief pressure When relieved (Check each actuator singly) 20.6 ± 1 MPa {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 malfunctioning or may have defect in it. Check them directly. GD655-3E0, GD675-3E0 17 SEN01842-00 40 Troubleshooting H-13 No work equipment moves Trouble Related information 1 • No work equipment moves • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check oil pressure while hydraulic oil temperature is 45 – 55°C. Cause 1 Defect in PTO Standard value when normal and remarks for troubleshooting Piston pump may not be rotating because of defect in PTO. Check PTO directly. 2 Defective piston pump (drive system) Piston pump may not be rotating because of defective coupling of its drive system. Check drive system directly. 3 Defect in piston pump (pump unit) Piston pump may have defect in it. Check it directly. a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state 4 Malfunction of left 5-spool control valve (unload valve) Work equipment Unload pressure All work equipment in neutral 2.8 ± 0.98 MPa {29 ± 10 kg/cm2} a Adjust with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction or improper adjustment of right 4-spool 5 control valve (main relief valve/LS relief valve) Work equipment Work equipment circuit relief pressure When relieved (Check each actuator singly) 20.6 ± 1 MPa {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 malfunctioning or may have defect in it. Check them directly. 18 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-14 Abnormal noise generated around pump Trouble Related information • Abnormal noise generated around pump • Causes 1 – 5 are in piston pump system and causes 6 – 9 are in power train pump system. Cause 1 Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting Oil level reduction in hydraulic 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. 3 Clogged hydraulic tank cap Hydraulic tank cap may be clogged and pressure in tank may be negative. Check tank cap directly. 4 Clogged hydraulic tank strainer 5 Defect in piston pump 6 Oil level reduction in transmission case 7 Air in transmission oil 8 Clogged transmission case strainer Hydraulic tank strainer may be clogged and pressure in suction circuit may be negative. Check tank strainer directly. Piston pump may have defect in it. Check it directly. Oil level in transmission case may be low. Check it directly. Transmission oil may contain air. Check it directly. Transmission case strainer may be clogged and pressure in suction 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. – When cause cannot be found If causes 1 – 9 are not detected, operate machine for a while to see if condition changes. GD655-3E0, GD675-3E0 19 SEN01842-00 40 Troubleshooting H-15 Blade is slow or lacks power in lifting Trouble Related information 1 • Blade is slow or lacks power in lifting • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Standard value when normal and remarks for troubleshooting 1 Insufficient stroke of blade lift a Carry out troubleshooting with engine stopped. control valve (spool) Spool stroke (Each side) 6 mm 2 Malfunction of pilot check valve (check valve) Check valve of pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state Malfunction of pilot check 3 valve (relief valve) [Only right blade lift] 4 Defective blade lift cylinder seal 5 Deformed blade lift cylinder 20 Right blade lift cylinder Work equipment circuit relief pressure When relieved in raising operation 20.6 ± 1 MPa {210 ± 10 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Blade lift cylinder Cylinder oil leakage When relieved in lowering operation 0 cc/min Blade lift cylinder may be deformed. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-16 Excessive blade drift Trouble Related information 1 • Excessive blade drift • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause 1 Malfunction of pilot check valve (check valve) Standard value when normal and remarks for troubleshooting Check valve of pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state Malfunction of pilot check 2 valve (relief valve) [Only right blade lift] 3 Defective blade lift cylinder seal GD655-3E0, GD675-3E0 Right blade lift cylinder Work equipment circuit relief pressure When relieved in raising operation 20.6 ± 1 MPa {210 ± 10 kg/cm2} a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Blade lift cylinder Cylinder oil leakage When relieved in lowering operation 0 cc/min 21 SEN01842-00 40 Troubleshooting H-17 Drawbar side shift operation is slow or lacks power Trouble Related information • Drawbar side shift operation is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Possible causes and standard value in normal state Standard value when normal and remarks for troubleshooting 1 Insufficient stroke of drawbar a Carry out troubleshooting with engine stopped. side shift control valve (spool) Spool stroke (Each side) 6 mm 2 Malfunction of pilot check valve 3 4 22 1 Defective drawbar side shift cylinder seal Pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Drawbar side shift cylinder Cylinder oil leakage When relieved in right shift operation 0 cc/min Deformed drawbar side shift Drawbar side shift cylinder may be deformed. Check it directly. cylinder GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-18 Blade side shift operation is slow or lacks power Trouble Related information • Blade side shift operation is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause 1 Possible causes and standard value in normal state 1 a Carry out troubleshooting with engine stopped. Insufficient stroke of blade side shift control valve (spool) Spool stroke (Each side) 6 mm 2 Defective swivel joint seal 3 4 Standard value when normal and remarks for troubleshooting Defective blade side shift cylinder seal Deformed blade side shift cylinder GD655-3E0, GD675-3E0 Swivel joint seal may be defective. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Blade side shift cylinder Cylinder oil leakage When relieved in left shift operation 0 cc/min Blade side shift cylinder may be deformed. Check it directly. 23 SEN01842-00 40 Troubleshooting H-19 Power tilt operation is slow or lacks power Trouble Related information 1 • Power tilt operation is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Standard value when normal and remarks for troubleshooting 1 Insufficient stroke of power tilt control valve (spool) a Carry out troubleshooting with engine stopped. 2 Malfunction of pilot check valve (check valve) Check valve of pilot check valve may be malfunctioning. Check it directly. Spool stroke (Each side) 6 mm a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible causes and standard value in normal state 3 Malfunction of pilot check valve (relief valve) 4 Defective swivel joint seal 5 Defective power tilt cylinder seal Power tilt cylinder Work equipment circuit relief pressure When relieved in cutting angle reducing operation 20.6 ± 1 MPa {210 ± 10 kg/cm2} Swivel joint seal may be defective. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Power tilt cylinder Cylinder oil leakage When relieved in cutting angle increasing operation 0 cc/min 6 Deformed power tilt cylinder Power tilt cylinder may be deformed. Check it directly. 24 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-20 Articulate operation is slow or lacks power Trouble Related information • Articulate operation is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1 Insufficient stroke of articulate a Carry out troubleshooting with engine stopped. control valve (spool) Spool stroke (Each side) 6 mm 2 Malfunction of pilot check valve 3 Defective articulate cylinder seal Pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Articulate cylinder Cylinder oil leakage When relieved in extension operation 0 cc/min 4 Deformed articulate cylinder Articulate cylinder may be deformed. Check it directly. GD655-3E0, GD675-3E0 25 SEN01842-00 40 Troubleshooting H-21 Leaning operation is slow or lacks power Trouble Related information • Leaning operation is slow or lacks power • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Possible causes and standard value in normal state 1 Insufficient stroke of leaning control valve (spool) 2 Malfunction of pilot check valve 3 Defective leaning cylinder seal 4 Deformed leaning cylinder 26 1 Standard value when normal and remarks for troubleshooting a Carry out troubleshooting with engine stopped. Spool stroke (Each side) 6 mm Pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Leaning cylinder Cylinder oil leakage When relieved in right leaning operation 0 cc/min Leaning cylinder may be deformed. Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-22 Excessive drift of leaning Trouble Related information • Excessive drift of leaning • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Check cylinder oil leakage while hydraulic oil temperature is 45 – 55°C. Cause Possible causes and standard value in normal state 1 1 2 Malfunction of pilot check valve Defective leaning cylinder seal GD655-3E0, GD675-3E0 Standard value when normal and remarks for troubleshooting Pilot check valve may be malfunctioning. Check it directly. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Leaning cylinder Cylinder oil leakage When relieved in right leaning operation 0 cc/min 27 SEN01842-00 40 Troubleshooting H-23 Blade does not rotate Trouble Related information • Blade does not rotate • Before starting troubleshooting, check that oil level in hydraulic tank is normal. • Before starting troubleshooting, check that oil level in circle rotation gear case is normal. Cause Possible causes and standard value in normal state 28 1 Standard value when normal and remarks for troubleshooting 1 a Carry out troubleshooting with engine stopped. Insufficient stroke of blade rotation control valve (spool) Spool stroke (Each side) 5 mm 2 Broken circle rotation gear (shear pin) [Shear pin type] Shear pin of circle rotation gear may be broken. Check it directly. Improper adjustment of circle Clutch of circle rotation gear may be adjusted improperly. Check it 3 rotation gear (clutch) directly. [Clutch type] 4 Defect in circle rotation gear Gear of circle rotation gear may have defect in it. Check it directly. (gear) 5 Malfunction or internal defect Circle rotation motor may be malfunctioning or may have defect in it. of circle rotation motor Check it directly. GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-24 Lift arm lock pin is not locked or reset [Lift arm specification] Trouble Related information • Lift arm lock pin is not locked or reset • Check oil pressure while hydraulic oil temperature is 45 – 55°C. Cause Possible causes and standard value in normal state 1 Standard value when normal and remarks for troubleshooting 1 Misalignment of lift arm and lock pin 2 Clogged parking brake bank Parking brake valve filter may be clogged. Check it directly. valve (filter) Lift arm and lock pin may be misaligned. Align them. a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Malfunction of parking brake Lift arm lock pin lamp 3 bank valve (bank solenoid valve) When OFF When ON Cylinder head pressure Cylinder bottom pressure 9.36 – 13.24 MPa {95.5 – 135 kg/cm2} 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 SEN01842-00 40 Troubleshooting H-25 Blade accumulator function is not operated or reset [Blade accumulator and float specification] Trouble • Blade accumulator function is not operated or reset Related information — Cause Possible causes and standard value in normal state 30 1 Standard value when normal and remarks for troubleshooting Malfunction or internal defect Blade accumulator solenoid valves (2 units of right and left) may be 1 of blade accumulator solenoid malfunctioning or may have defect in them. Check them directly. valve Gas pressure reduction in 2 blade accumulator Gas pressure in blade accumulators (2 units of right and left) may be low. Check it directly. Accumulator gas pressure (Nitrogen gas) 2.0 ± 0.1 MPa {20 ± 1 kg/cm2} GD655-3E0, GD675-3E0 40 Troubleshooting SEN01842-00 H-26 Blade float function is not operated or reset [Blade accumulator and float specification] Trouble • Blade float function is not operated or reset Related information Possible causes and standard value in normal state 1 — Cause 1 Standard value when normal and remarks for troubleshooting Malfunction or internal defect Blade float solenoid valves (4 units of right and left) may be malfuncof blade float solenoid valve tioning or may have defect in them. Check them directly. GD655-3E0, GD675-3E0 31 SEN01843-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 40 Troubleshooting 1 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 SEN01843-00 40 Troubleshooting S-15 Abnormal noise is made ............................................................................................................ 22 S-16 Vibration is excessive ................................................................................................................ 23 2 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 Troubleshooting of engine (S-mode) 1 Method of using troubleshooting charts 1 The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” 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 SEN01843-00 40 Troubleshooting <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 gradually], and [Air cleaner clogging caution lamp is flashing]. 4 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 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 SEN01843-00 40 Troubleshooting S-1 Starting performance is poor. 1 General causes why starting performance is poor Defective or deteriorated battery Defective alternator (generator unit) Defective alternator (regulator unit) Defective intake air heater system Defective injector Defective electric lift pump Stuck and seized fuel supply pump plunger Clogged fuel filter, element Leakage, clogging, air in fuel piping Clogged air breather hole in fuel tank cap Worn piston ring, cylinder With the common rail fuel injection system (CRI), the fuel injection timing is recognized electrically, so even when the starting operation is carried out, the engine may not start until the crankshaft has completed two rotations. However, this does not indicate any abnormality. Defective contact of valve, valve seat a Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel Clogged air cleaner element • • • • Cause Confirm recent repair history Questions Ease of starting Operated for long period E E Gradually became worse Q w w Q E w Starts when warm Non-specified fuel is being used Replacement of filters has not been carried out according to Operation & Maintenance Manual w Q Q Q w Q Q w w Engine oil must be added more frequently Preheating monitor does not work normally during preheating or in low temperatures (when monitor is installed) w w w Charging monitor shows abnormality in charging while driving (when monitor is installed) 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 Q w Starting motor cranks engine slowly w Check items No fuel comes out even when fuel filter air bleed plug is removed When engine is cranked with starting When hose at collection portion for spill flow from fuel injector is motor disconnected, spill flow is small w When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w Q Q Engine does not pick up smoothly and combustion is irregular w Q w Q There is hunting from engine (rotation is irregular) Q w Blow-by gas is excessive q Check air cleaner directly q q When compression pressure is measured, it is found to be low q Check fuel filter, strainer directly Troubleshooting Q q Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q Carry out troubleshooting for code display “Defective electric lift pump (*2)“ Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode q q Intake air heater mount does not become warm during operation of preheating Is voltage between alternator terminal B and terminal E with engine at low idle? (20 – 30V) q Yes q No q Replace Replace Replace Replace Replace Replace Replace Correct Clean Replace Replace Action Clean When specific gravity of electrolyte or voltage of battery is measured, it is found to be low Replace Degree of use of machine *1: Failure code of code display [CA559] and [CA2249] *2: Failure code of code display [CA2265] and [CA2266] 6 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-2 Engine does not start 1 a) Engine does not turn Defective steering circuit wiring Defective starting motor (motor section) Defective safety relay Defective starting switch Defective battery relay Defective connection of battery terminal Broken flywheel ring gear General causes why engine does not turn • Seized parts inside engine: See "S-4 Engine stops during operations" • Defective electrical system • Problem in drive devices on applicable machine side: Carry out troubleshooting for devices on applicable machine Defective or deteriorated battery Causes Degree of use of machine Operated for long period Condition of horn when starting switch is turned ON Horn does not sound E E Q Q Q w Speed of rotation is low w Makes grating noise w w Soon disengages again q Inspect flywheel ring gear directly q When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E q When terminal B and terminal C of starting switch are connected, engine starts q When terminal B and terminal C at safety relay outlet are connected, engine starts q Replace Remedy Replace q Correct When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace q Replace Even if terminal B and terminal C at safety relay outlet are connected, engine does not start Carry out troubleshooting on applicable machine Q Q — Q Makes rattling noise and does not turn Troubleshooting w w Replace Check items When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out GD655-3E0, GD675-3E0 Q w Battery terminal is loose Turn starting switch OFF, connect cord, and carry out troubleshooting at ON w w Battery electrolyte is low When starting switch is turned to START, starting pinion moves out, but Q w Horn volume is low Replace Questions Confirm recent repair history 7 Cause Defective electric lift pump Defective fuel supply pump IMV solenoid Stuck, seized fuel supply pump plunger Broken fuel supply pump shaft Seized, abnormally worn fuel feed pump Clogged fuel filter, element Leakage, clogging, air in fuel piping Clogged air breather hole in fuel tank cap Insufficient fuel in tank Improper fuel used 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 injector b) Engine turns but no exhaust smoke comes out Defective common rail pressure limiter 40 Troubleshooting Defective actuation of fuel overflow valve (does not close) SEN01843-00 Degree of use of machine E E Operated for long period w Q w w Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation & Maintenance 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 w Check items When fuel filter is removed, there is no fuel in filter w E Q E E E Q w Q w There is a leakage from fuel piping Q No fuel comes out even when fuel filter air bleed plug is removed When engine is cranked with start- When hose at collection portion for spill flow from fuel injector is ing motor disconnected, spill flow is small Q w Q Q Q w w w Q q Check fuel filter directly q Check fuel feed pump directly Troubleshooting E q q Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q Carry out troubleshooting for code display “Abnormality in IMV solenoid (*2)“ q Carry out troubleshooting for code display “Defective electric lift pump (*3)“ q Check fuel overflow valve directly q Possible to start in reduced cylinder mode Replace Replace Replace Replace Replace Replace Replace Correct Clean Add Replace Action Replace q When pressure limiter return pipe is removed, fuel comes out Replace Questions Confirm recent repair history *1: Failure code of code display [CA559] and [CA2249] *2: Failure code of code display [CA2311] *3: Failure code of code display [CA2265] and [CA2266] 8 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 c) Exhaust smoke comes out but engine does not start (Fuel is being injected) Defective intake air heater system Defective coolant temperature sensor, defective wiring harness Defective or deteriorated battery Clogged injector, defective spray Defective electric lift pump Stuck, seized fuel supply pump plunger Clogged fuel filter Leakage, clogging, air in fuel system Clogged air breather hole in fuel tank cap Improper fuel used Worn piston ring, cylinder liner Clogged air cleaner element General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel Worn dynamic valve system (valve, rocker lever, etc.) Cause Confirm recent repair history E Operated for long period E w Suddenly failed to start w w Non-specified fuel is being used Replacement of filters has not been carried out according to Operation & Maintenance Manual E Q Q w Q w w Engine oil must be added more frequently Preheating monitor does not work normally during preheating or in low temperatures (when monitor is installed) w w Dust indicator lamp is red (when indicator is installed) Q Air breather hole in fuel tank cap is clogged w Rust and water are found when fuel tank is drained w When fuel filter is removed, there is no fuel in filter Q w There is a leakage from fuel piping w Starting motor cranks engine slowly w Check items When engine is cranked, abnormal noise is heard from around cylinder head When engine is cranked with starting motor Q No fuel comes out even when fuel filter air bleed plug is removed Q w When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w q Check air cleaner directly q Check dynamic valve system directly q When compression pressure is measured, it is found to be low Troubleshooting w When hose at collection portion for spill flow from fuel injector is disconnected, spill flow is small q When air is bled from fuel line, air comes out q Check fuel filter directly q Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q Carry out troubleshooting for code display “Defective electric lift pump (*2)“ 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 Replace Replace Replace Replace Replace Replace Correct Clean Replace Replace Replace Action Clean Intake air heater mount does not become warm during preheating Replace Questions Degree of use of machine *1: Failure code of code display [CA559] and [CA2249] *2: Failure code of code display [CA2265] and [CA2266] GD655-3E0, GD675-3E0 9 SEN01843-00 40 Troubleshooting S-3 Engine does not pick up smoothly 1 General causes why engine does not pick up smoothly Clogged injector, defective spray Stuck, seized fuel supply pump plunger Clogged fuel filter Leakage, clogging, air in fuel piping Clogged air breather hole in fuel tank cap Worn piston ring, cylinder liner Seized turbocharger, interference Improper valve clearance Defective contact of valve and valve seat Insufficient intake of air Insufficient supply of fuel Abnormal fuel injection condition Improper selection of fuel Controller controlled by derate mode (The injection amount (output) is limited because a failure has occurred in the electrical system.) Clogged air cleaner element • • • • • Cause Degree of use of machine E E Operated for long period E w Engine pick-up suddenly becomes poor E Q Q Q Non-specified fuel is being used w w w Replacement of filters has not been carried out according to Operation & Maintenance Manual w w w Engine oil must be added more frequently w Dust indicator lamp is red (when indicator is installed) w Air breather hole in fuel tank cap is clogged w Rust and water are found when fuel in fuel tank is drained w There is a leakage from fuel piping Check items When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas Q w w Blue under light load w Q Black w 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 High idle speed is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) w Q Q Q w Blow-by gas is excessive q Check air cleaner directly q When compression pressure is measured, it is found to be low Troubleshooting Q q q Check valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel line, air comes out q Check fuel filter, strainer directly q 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 mode Replace Replace Correct Clean Replace Replace Adjust Replace Clean Action q Replace Questions Confirm recent repair history *1: Failure code of code display [CA559] and [CA2249] 10 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-4 Engine stops during operations 1 General causes why engine stops Failure in power train mounted on the machine Broken auxiliary equipment (pump, compressor, etc.) Stuck, seized fuel supply pump plunger Broken fuel supply pump shaft Broken, seized fuel feed pump Clogged fuel filter Clogged, leaking fuel piping Clogged air breather hole in fuel tank cap Insufficient fuel in tank Broken, seized gear train Broken, seized crankshaft bearing Internal part of engine seized Insufficient supply of fuel Engine overheating Failure in power train on the machine: Carry out troubleshooting on the machine. Broken, seized piston, connecting rod Broken dynamic valve system (valve, rocker lever, etc.) • • • • Cause Confirm recent repair history E Operated for long period Condition when engine stopped w w w w Q w Q w w w Q Engine overheated and stopped Q Engine stopped slowly w Q There was hunting and engine stopped w Q Q Q Non-specified fuel is being used 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 Fuel tank is found to be empty w w Air breather hole in fuel tank cap is clogged w There is a leakage from fuel piping w Rust and water are found when fuel in fuel tank is drained w w w Check items Metal particles are found when oil in oil pan is drained Q w w Does not turn at all When it is attempted to turn engine by hand Q w Turns in opposite direction w Moves amount of backlash w w Fuel supply pump shaft does not run w Engine rotates but stops when load is applied to machine q Check dynamic valve system directly q Check piston and connecting rod directly q q Check gear train directly q Check fuel filter, strainer directly q Check fuel feed pump directly q q Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q Replace Replace Replace Replace Correct Clean Add Replace Replace Replace Action Replace When auxiliary equipment (pump, air compressor, etc.) is removed, engine turns Replace Troubleshooting Check crankshaft bearing directly Carry out troubleshooting on the machine Questions Abnormal noise was heard and engine stopped suddenly — Degree of use of machine *1: Failure code of code display [CA559] and [CA2249] GD655-3E0, GD675-3E0 11 SEN01843-00 40 Troubleshooting S-5 Engine does not rotate smoothly 1 General causes why engine does not rotate smoothly Defective Bkup speed sensor, defective wiring harness Defective Ne speed sensor, defective wiring harness Clogged fuel filter Leakage, clogging, air in fuel piping Clogged air breather hole in fuel tank cap Insufficient fuel in tank • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate failure display Clogged fuel injector, defective spray (dirt caught) Cause E Operated for long period Q Q Occurs at a certain speed range Condition of hunting Q Q Q Q Q Occurs at low idle Q Occurs even when speed is raised Q Q w Occurs on slopes w w Fuel tank is found to be empty w Air breather hole in fuel tank cap is clogged Q Rust and water are found when fuel in fuel tank is drained w There is a leakage from fuel piping q Check fuel filter, strainer directly q 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 Replace Replace Correct Action Clean Carry out troubleshooting for code display “Abnormality in Bkup speed sensor (*2)“ Add Troubleshooting Check items Replacement of filters has not been carried out according to Operation & Maintenance Manual Replace Degree of use of machine Replace Questions Confirm recent repair history *1: Failure code of code display [CA689] *2: Failure code of code display [CA778] 12 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-6 Engine lacks output (or lacks power) 1 General causes why engine lacks output Defective mount of boost pressure sensor (air leakage) Defective boost pressure sensor, defective wiring harness Clogged fuel spill piping Defective injector drive (signal, solenoid) Clogged fuel injector, defective spray (dirt caught) Stuck, seized fuel supply pump plunger Clogged fuel filter Clogged, leaking fuel piping Clogged air breather hole in fuel tank cap Worn piston ring, cylinder liner Improper valve clearance Seized turbocharger, interference Leakage in air intake piping Insufficient intake of air Insufficient supply of fuel Abnormal fuel injection condition Improper selection of fuel Engine overheating: See “S-14 Coolant temperature becomes too high (overheating)“ • Controller controlled by derate mode (The injection amount (output) is limited because a failure has occurred in the electrical system.) Clogged air cleaner element • • • • • Defective contact of valve and valve seat Cause Q Q Q Confirm recent repair history Q Suddenly E E Q Q Q w Q Gradually E Q Q Non-specified fuel is being used Replacement of filters has not been carried out according to Operation & Maintenance Manual w Q w Q w w There is a leakage from fuel piping w Power is lacking after short stop in operations w Black w w Blue under light load Check items When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w w w When engine is running, noise of interference is heard from around turbocharger w When engine is running, abnormal noise is heard from around cylinder head Q High idle speed of engine is high Q High idle speed is normal, but speed suddenly drops when load is applied w Engine does not pick up smoothly and combustion is irregular w There is hunting from engine (rotation is irregular) w Blow-by gas is excessive w Q Q Q Q Q Q w Q Q Q w q Check air cleaner directly q Check air intake piping directly q When boost pressure is measured, it is found to be low q q q When compression pressure is measured, it is found to be low Troubleshooting Q w Air breather hole in fuel tank cap is clogged Color of exhaust gas Q Q w Engine oil must be added more frequently Dust indicator lamp is red (when indicator is installed) Q q q Check valve clearance directly q Check fuel piping q Check fuel filter, strainer directly q Check spill port check valve directly q 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 mode q q q Check mounting of boost pressure sensor directly q Correct Replace Replace Replace Replace Correct Clean Replace Adjust Replace Replace Correct Action Clean Carry out troubleshooting for code display “Abnormality in boost pressure sensor (*2)“ Replace Power was lost E Operated for long period Replace Questions Degree of use of machine *1: Failure code of code display [CA559] and [CA2249] *2: Failure code of code display [CA112] and [CA123] GD655-3E0, GD675-3E0 13 SEN01843-00 40 Troubleshooting S-7 Exhaust smoke is black (incomplete combustion) 1 General causes why exhaust smoke is black Defective fuel injection timing Defective fuel injection pressure Defective coolant temperature sensor, defective wiring harness Q Q q q Replace Worn fuel injector Q Adjust Clogged, seized fuel injector Stuck, seized fuel supply pump plunger Worn piston ring, cylinder liner Crushed, clogged muffler Improper valve clearance Defective contact of valve, valve seat Seized turbocharger, interference Insufficient intake of air Abnormal fuel injection condition Improper selection of fuel Engine overheating: See “S-14 Coolant temperature becomes too high (overheating)“ • Controller controlled by derate mode (The injection amount (output) is limited because a failure has occurred in the electrical system.) Clogged air cleaner element • • • • Leakage of air between turbocharger and cylinder head Cause Confirm recent repair history E Operated for long period E w Suddenly became black Questions E w w Color of exhaust gas Gradually became black Q Q Q Q Q w Blue under light load Non-specified fuel is being used Q Q Q Q w Engine oil must be added more frequently Power was lost E w Suddenly Gradually Q Dust indicator lamp is red (when indicator is installed) w Q Q Q Q w Muffler is crushed w Leakage of air between turbocharger and cylinder head, loose clamp Operates in low-temperature mode even at normal temperatures When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Q w When engine is running, noise of interference is heard from around turbocharger Check items w w When engine is running, abnormal noise is heard from around cylinder head Q Rotation speed of torque converter stall and pump relief is high (excessive injection of fuel) Exhaust noise is abnormal Q Engine does not pick up smoothly and combustion is irregular Q w Q Q Q Q Q w w Blow-by gas is excessive When hose from injector to spill collection portion is disconnected, spill flow is found to be abnormally high w q Check air cleaner directly q When turbocharger is rotated by hand, it is found to be heavy q Troubleshooting When compression pressure is measured, it is found to be low q q Check valve clearance directly q When muffler is removed, exhaust color returns to normal q 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 mode q q q Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)“ Replace Replace Replace Replace Replace Correct Adjust Replace Replace Action Clean Confirm with monitoring function of INSITE or on the machine Replace Degree of use of machine *1:Failure code of code display [CA559] and [CA2249] *2:Failure code of code display [CA114] and [CA145] 14 GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive 1 Leakage from oil pan, cylinder head, etc. Leakage from oil drain plug Leakage from oil piping Leakage from oil filter Leakage from oil cooler Broken oil cooler Worn, broken rear oil seal Worn piston ring, cylinder liner Broken piston ring Clogged breather, breather hose Turbocharger Worn seal at the side of blower Worn seal at the side of turbine Dust stuck in from intake system • Abnormal combustion of oil • The engine has been run at low or high idle for a long time continuously (more than 20 minutes continuous operation is not allowed) • External leakage of oil • Wear of lubrication system Worn, broken valve (stem, guide, seal) Cause E E E Operated for long period E w Oil consumption suddenly increased Q w Engine oil must be added more frequently Q Q Q w Oil gets contaminated quickly w w w w w Outside of engine is dirty with oil w Loose piping clamp in air intake system w Inside of turbocharger air supply pipe is dirty with oil Q w w There is oil in engine coolant w Oil level in clutch or damper chamber rises w w Exhaust smoke is blue under light load w w w None q When intake manifold is removed, dust is found inside q When intake manifold is removed, inside is found to be extremely dirty Troubleshooting Q q q Excessive play of turbocharger shaft q Check breather, breather hose directly q q When compression pressure is measured, it is found to be low q Check rear oil seal directly q q Pressure-tightness test of oil cooler shows there is leakage q q q q GD655-3E0, GD675-3E0 Replace Replace Replace Replace Replace Clean Replace Replace Replace Action Correct There is external leakage of oil from engine Correct Amount of blow-by gas Q Excessive Correct Check items Inside of turbocharger exhaust pipe is dirty with oil Correct Degree of use of machine Correct Questions Confirm recent repair history 15 SEN01843-00 40 Troubleshooting S-9 Oil becomes contaminated quickly 1 General causes why oil becomes contaminated quickly Non-specified fuel is being used Q Engine oil must be added more frequently w Metal particles are found when oil inside oil filter is drained Q Q Inside of exhaust pipe is dirty with oil w Exhaust smoke color is poor Q w w Amount of blow-by gas w Black Q Q w Excessive Q w None q q q When compression pressure is measured, it is found to be low q Check breather, breather hose directly See S-7 Color of exhaust gas w Blue under light load Excessive play of turbocharger shaft q Check oil cooler directly q Check oil filter directly q Spring of oil filter safety valve catching or broken q Replace Replace Clean Clean Replace Replace Action Replace Check turbocharger drain tube directly 16 Clogged turbocharger lubrication drain tube Defective oil filter safety valve E E E Operated for long period — Degree of use of machine Clean Check items Clogged oil filter Confirm recent repair history Engine oil temperature rises quickly Troubleshooting Clogged oil cooler Clogged breather, breather hose Worn piston ring, cylinder liner Worn valve, valve guide Defective seal at turbocharger turbine end Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Improper fuel used Improper oil used Operation under excessive load Questions • • • • • Cause GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-10 Fuel consumption is excessive 1 General causes why fuel consumption is excessive Defective fuel injection timing Defective actuation of fuel injector Defective fuel injector spray Defective common rail fuel pressure Defective supply pump plunger Defective fuel feed pump oil seal External leakage from fuel piping, fuel filter Leakage of fuel inside head cover • Leakage of fuel • Improper condition of fuel injection (injection pressure, injection timing) • Excessive injection of fuel Defective coolant temperature sensor, defective wiring harness Cause Degree of use of machine E E Operated for long period Q Is more than for other machines of same model Condition of fuel consumption E Q Gradually increased Q Q Q Suddenly increased w There is external leakage of fuel from engine w There is irregular combustion w Check items Engine oil level rises and smells of diesel fuel w When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w Q Low idle speed is high Q Rotation speed of torque converter stall and pump relief is high Color of exhaust gas Q Q Black Q Q Q White q Remove head cover and check directly q Check fuel feed pump oil seal directly Troubleshooting Q Q Q q 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 mode q When flow of oil from fuel injector at spill return collection portion is measured, it is found to be excessive q q Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)” Adjust Replace q Replace Replace Replace Correct Correct Action Correct q Confirm with monitoring function of INSITE or on the machine Replace Questions Confirm recent repair history *1: Failure code of code display [CA559] and [CA2249] *2: Failure code of code display [CA114] and [CA145] GD655-3E0, GD675-3E0 17 SEN01843-00 40 Troubleshooting S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)1 General causes why oil is in coolant Broken hydraulic oil cooler or power train oil cooler on applicable machine side Broken oil cooler core, O-ring Holes caused by pitting Broken cylinder head, head gasket • Internal leakage in lubrication system • Internal leakage in cooling system Cracks inside cylinder block Causes Degree of use of machine Oil level E E Operated for long period Q Suddenly rose Q Q Q Hard water is being used as coolant Q Q w w 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 Troubleshooting q q Inspect cylinder block, liner directly q Replace Replace Remedy Replace Pressure-tightness test of oil cooler shows there is leakage — q Pressure-tightness test of cylinder head shows there is leakage Carry out troubleshooting on applicable machine Check items Oil level has risen and oil is milky 18 Q Q Q Gradually rose Replace Questions Confirm recent repair history GD655-3E0, GD675-3E0 40 Troubleshooting 1 General causes why oil pressure drops Defective oil level sensor, defective wiring harness Clogged oil filter Defective regulator valve Defective oil pump Clogged, broken pipe inside oil pan Clogged strainer inside oil pan Water, fuel in oil Lack oil in oil pan Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating Worn bearing journal • • • • Cause Leaking, crushed, clogged hydraulic piping S-12 Oil pressure drops SEN01843-00 Degree of use of machine E Operated for long period E E Q w Oil level monitor indicates drop in oil pressure (when monitor is installed) Q Non-specified oil is being used Q w Replacement of filters has not been carried out according to Operation & Maintenance Manual w Q w w w Q w w Oil level monitor indicates low amount of oil (when monitor is installed) w Oil level in oil pan is low w Q w w There is crushing, external leakage from hydraulic piping w Oil is cloudy white and smells of diesel oil Metal particles are found when oil in oil pan is drained w Metal particles are found when oil inside oil filter is drained w Metal particles are found in oil filter q Q Check oil pan strainer and pipe directly See S-13 Troubleshooting Check items indicates oil pressure drop at low idle Oil pressure moni- indicates oil pressure drop at low idle and high idle tor (when monitor indicates oil pressure drop on slopes is installed) sometimes indicates oil pressure drop Oil pump rotation is heavy, there is play Deterioration, damage of valve, spring in regulator valve Check oil filter directly q q q q q q GD655-3E0, GD675-3E0 Correct Replace Adjust Replace Correct Clean — Add Action Replace When oil level sensor is replaced, oil level monitor displays normally Replace Questions Confirm recent repair history 19 SEN01843-00 40 Troubleshooting S-13 Oil level rises (water, fuel in oil) 1 General causes why oil level rises Defective part inside fuel supply pump Broken oil cooler core, O-ring Worn, broken rear oil seal Holes made by pitting Cracks inside cylinder block Broken injector O-ring Broken cylinder head, head gasket • 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 auxiliary equipment seal (pump, air compressor) Cause Degree of use of machine E Operated for long period Check items E w Fuel consumption has increased w Coolant must be added more frequently Q There is oil in engine coolant Q Q Q Q Q w w Oil smells of diesel fuel Oil is cloudy white 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 appear, or water spurts back w w Q Q Q Exhaust smoke is white w Oil level goes down in clutch chamber or damper chamber w Oil level goes down in hydraulic tank q When compression pressure is measured, it is found to be low Troubleshooting E E q Remove injector and check O-ring q q Check cylinder block, liner directly 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 20 Replace Replace Replace Replace Replace Correct Action Replace Check auxiliary equipment seal directly Replace Questions Confirm recent repair history GD655-3E0, GD675-3E0 40 Troubleshooting SEN01843-00 S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high Rise in power train oil temperature Defective coolant temperature gauge Fan belt slipping, worn fan pulley Defective radiator cap (pressure valve) Clogged radiator core Clogged, crushed radiator fins Defective actuation of thermostat Broken water pump Lack of coolant Clogged, broken oil cooler Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature in power train: Carry out troubleshooting on the machine. Holes made by pitting Cause Broken cylinder head, head gasket • • • • 1 Confirm recent repair history E E Operated for long period E E Condition of over- Suddenly overheated heating Always tends to overheat Q w Coolant tempera- Rises quickly ture gauge (when coolant Does not go down from red range temperature gauge is installed) Q Q Q w w Q w w w Radiator coolant level monitor indicates low coolant level (when monitor is installed) w Q Engine oil level has risen, oil is cloudy white w Fan belt tension is loose w There is play when fan pulley is rotated w Cloudy white oil is floating on coolant w When light bulb is held behind radiator, no light passes through w Radiator shroud, inside of underguard are clogged with dirt or mud w 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 Power train oil temperature enters red range faster than coolant temperature (when oil and coolant temperature gauges are installed) w q When compression pressure is measured, it is found to be low q Check cylinder liner directly q q Temperature difference between top and bottom radiator tanks is excessive When function test is carried out on thermostat, it does not open even at cracking temperature q q 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 GD655-3E0, GD675-3E0 Correct Replace Correct Correct Replace Replace Add Replace Replace Action Replace When coolant temperature is measured, it is found to be normal Replace Troubleshooting Check oil cooler directly Carry out troubleshooting on the machine Check items Excessive air bubbles inside radiator, water spurts back — Questions Degree of use of machine 21 SEN01843-00 40 Troubleshooting 1 General causes why abnormal noise is made Defective fuel injection timing (abnormal coolant temperature low temperature sensor, boost temperature sensor) Dirt caught in fuel injector Clogged, seized fuel injector Deformed fan, loose fan belt, interference Missing, seized bushing Improper gear train backlash Improper valve clearance Defect inside muffler (dividing board out of position) a Judge if the noise is an internal one or an external one. If the engine is not thoroughly warmed up, the engine sound becomes slightly louder because it is operated in the low temperature mode, but this is not an abnormality. When the engine is accelerated, it enters the acceleration mode and the engine noise is a little bit higher for 3 seconds at a maximum, but this is not an abnormality. Broken dynamic valve system (valve, rocker lever, etc.) a a Leakage of air between turbocharger and cylinder head • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system Seized turbocharger, interference Cause Excessive wear of piston ring, cylinder liner S-15 Abnormal noise is made Degree of use of machine Condition of abnormal noise E Operated for long period Q Gradually occurred Q Q Q Suddenly occurred Q Q Non-specified fuel is being used w Engine oil must be added more frequently w Metal particles are found when oil inside oil filter is drained w When engine is running, noise of interference is heard from around turbocharger 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 Check items w w Leakage of air between turbocharger and cylinder head When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas w Q w Blue under light load Q w Black Q w Engine does not pick up smoothly and combustion is irregular Q Abnormal noise is loud when accelerating Q Q w Blow-by gas is excessive q When turbocharger is rotated by hand, it is found to be heavy q Check dynamic valve system directly q When muffler is removed, abnormal noise disappears Troubleshooting Q q Check valve clearance directly q When compression pressure is measured, it is found to be low q q Check gear train directly q Check fan, fan belt directly Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode q q q Abnormal noise is made only when starting q 22 Replace Replace Correct Replace Replace Replace Adjust Replace Replace Replace Action Correct Confirm with monitoring function of INSITE or on the machine Replace Questions Confirm recent repair history GD655-3E0, GD675-3E0 40 Troubleshooting 1 General causes why vibration is excessive Broken part inside output shaft and damper on the machine Misalignment between engine and equipment on the machine Loose engine mounting bolts, broken cushion Defective fuel injection timing (abnormal coolant temperature, boost temperature sensor) If there is abnormal noise together with the vibration, carry out troubleshooting also for “S-15 Abnormal noise is made“. Improper gear train backlash a Stuck dynamic valve system (valve, rocker lever, etc.) • Defective parts (abnormal wear, breakage, etc,) • Improper alignment with machine • Abnormal combustion Worn main bearing, connecting rod Cause Worn cam bushing S-16 Vibration is excessive SEN01843-00 Degree of use of machine E E E 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 Operated for long period Q Condition of vibra- Suddenly increased tion Gradually increased Q Vibration occurs at mid-range speed Q Vibration follows engine speed Exhaust smoke is black w Check dynamic valve system directly q Q Q Q Q Q q Check main bearing, connecting rod bearing directly Troubleshooting Q q 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 GD655-3E0, GD675-3E0 Adjust Replace Replace Replace Replace Replace Action Replace Check inside of output shaft and damper directly Replace Check items Questions Confirm recent repair history 23 SEN01914-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 50 Disassembly and assembly1 General information on disassembly and assembly General information on disassembly and assembly ....................................................................................... 2 How to read this manual ...................................................................................................................... 2 Coating materials list............................................................................................................................ 4 Special tool list ..................................................................................................................................... 7 Sketches of special tools.....................................................................................................................11 GD655-3E0, GD675-3E0 1 SEN01914-00 50 Disassembly and assembly General information on disassembly and assembly How to read this manual 1. 1 1 Removal and installation of assemblies Special tools q The special tools necessary for the removal and installation work are indicated by symbols as A1 ••• X1 and their part Nos., part names, and quantity are described in the table. q In the special tools table, the following information is described, as well as the above items. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts). * *** **** a General tools that are necessary for removal or installation are described as [1],[2]•••etc. and their part names, part numbers and quantities are not described. Removal q The [Removal] section contains procedures and precautions for implementing the work, know how and the amount of oil or coolant to be drained. q The common tools necessary for the removal work are indicated [1],[2]••• and their part Nos., part names, and quantity are not described. q Various symbols used in the Removal Section are explained and listed below. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work [*1] : This mark shows that there are instructions or precautions for installing parts. 6 : This mark shows the amount of oil or coolant to be drained. 4 : Weight of part or component Installation q Except where otherwise instructed, installation of parts is done in the r evers e order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which step the instructions are intended for. q The common tools necessary for the installation work are indicated [1],[2]••• and their part Nos ., pa rt nam es, and qu anti ty ar e n ot described. q Marks shown in the Installation Section stand for the following. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5 : Quantity of oil or coolant to be added Sketches of special tools Various special tools are illustrated for the convenience of local manufacture. q 2 GD655-3E0, GD675-3E0 50 Disassembly and assembly 2. SEN01914-00 Disassembly and assembly of assemblies Special tools q The special tools necessary for the disassembly and assembly work are indicated by symbols as A1 ••• X1 and their part Nos ., par t na me s, a nd q ua nti ty ar e described in the table. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used (installed). q : Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already available tools for other models. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of "Sketches of special tools". q Part No. of special tools starting with 79 T: means that they can not be supplied from Komatsu in Japan (i.e. locally made parts). * *** **** a General tools that are necessary for removal or installation are described as [1],[2]•••etc. and their part names, part numbers and quantities are not described. GD655-3E0, GD675-3E0 Disassembly q In Disassembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant drained are described. q The common tools necessary for the disassembly work are indicated [1],[2]••• and their part Nos., part names, and quantity are not described. q The meanings of the symbols used in Disassembly section are as follows. k : This mark indicates safety-related precautions that must be followed when implementing the work. a : Know-how or precautions for work 6 : Quantity of oil or coolant drained Assembly q In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The common tools necessary for the assembly work are indicated [1],[2]••• and their part Nos., part names, and quantity are not described. q The meanings of the symbols used in Assembly section are as follows. k : Precautions related to safety in execution of work a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque 5 : Quantity of oil or coolant to be added Sketches of special tools Various special tools are illustrated for the convenience of local manufacture. q 3 SEN01914-00 50 Disassembly and assembly Coating materials list a a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual. Category Komatsu code Part number Q'ty Container Main features and applications LT-1A 790-129-9030 150 g Tube • Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. LT-1B 790-129-9050 20 g (2 pcs.) • Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion. LT-2 09940-00030 50 g Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs. Adhesive LT-3 790-129-9040 250 g Holtz MH 705 790-129-9120 75 g 790-129-9140 • Used to stick and seal metal, glass, and plastics. Polyethylene • Used to seal plugs. container Tube • Heat-resistant seal used to repair engines. 50 g • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals. 790-129-9130 2g Loctite 648-50 79A-129-9110 50 cc LG-1 790-129-9010 200 g 790-129-9080 Can • Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. Aron-alpha 201 LG-5 Gasket sealant 790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener) LT-4 ThreeBond 1735 1 kg • Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures. Tube • Used to stick or seal gaskets and packings of power train case, etc. • Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping. LG-6 790-129-9020 200 g Tube • Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc. LG-7 790-129-9070 1 kg Tube • Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. ThreeBond 1211 790-129-9090 100 g Tube • Gasket sealant used to repair engine. Tube • Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc. ThreeBond 1207B 4 1 419-15-18131 100 g GD655-3E0, GD675-3E0 50 Disassembly and assembly Part number Q'ty Container 09940-00051 60 g Can • Used to lubricate sliding portions. (to prevent squeaking) 200 g Tube • Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc. SYG2-400LI SYG2-350LI SYG2-400LI-A G0-LI (*), G2-LI SYG2-160LI *: For cold district SYGA-160CNLI SYG0-400LI-A (*) SYG0-16CNLI (*) Various Various • General purpose type. SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA Various Various • Used for bearings used at normal temperature under light load in contact with water or steam. LM-G LM-P Grease G2-CA 09940-00040 Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*) Hyper White Grease G2-T, G0-T (*) SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) SUNSTAR PAINT PRIMER 580 SUPER Primer SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 Main features and applications 400 g x 10 Bellows-type 400 g x 20 container • Used for parts under heavy load. 16 kg Can 400 g 16 kg 400 g 16 kg • Seizure resistance and heat resistance higher Bellows-type than molybdenum disulfide grease. container • Not conspicuous on machine since color is Can white. Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants. 20 ml Glass container • Used as primer for cab side. (Using limit: 4 months after date of manufacture) 20 ml Glass container • Used as primer for glass side. (Using limit: 4 months after date of manufacture) 20 ml Glass container 417-926-3910 22M-54-27230 SUNSTAR GLASS PRIMER 435-41 22M-54-27240 150 ml Steel can SUNSTAR SASH PRIMER GP-402 22M-54-27250 20 ml Glass container GD655-3E0, GD675-3E0 Adhesive for cab glass Molybdenum disulfide lubricant CateKomatsu code gory SEN01914-00 • Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture) • Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture) 5 SEN01914-00 6 Part number Q'ty Container Main features and applications SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” 417-926-3910 320 ml Polyethylene container • “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture) Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml Polyethylene container • Used as adhesive for glass. (Using limit: 6 months after date of manufacture) SUNSTAR PENGUINE SUPER 560 22M-54-27210 320 ml Ecocart (Special container) SUNSTAR PENGUINE SEAL No. 2505 417-926-3920 320 ml Polyethylene container SEKISUI SILICONE SEALANT 20Y-54-55130 333 ml Polyethylene container • Used to seal front window. (Using limit: 6 months after date of manufacture) Cartridge • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture) GE TOSHIBA SILICONES TOSSEAL 381 22M-54-27220 333 ml Adhesive for cab glass Caulking material Adhesive CateKomatsu code gory 50 Disassembly and assembly • Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture) GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01914-00 Special tool list a a Tool part number 79QT-QQQ-QQQQ indicates an interchangeable part (locally produced) Necessity : t . . . . . Special tools which cannot be substituted and should be always installed (used) : q . . . . . Special tools which are very useful if available. They can be substituted with commercially available tools. Distinction of new and existing special tools. : N . . . . . Tools with new part numbers. They are newly developed for this model. : R . . . . . Tools with upgraded part numbers. They are remodeled from already available tools for other models. : Blank . . Tools already available for other models and usable without any modification. Circle (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches of special tools. Work item Symbol Part number Part name Necessity Q'ty N/R Sketch a a 1 Work content Removal and installation of fuel supply pump, fuel injector and cylinder head assembly 1 795-799-1131 Gear t 1 Setting of 1.6TOP Removal and installation of fuel supply pump assembly 2 795-799-1390 Remover t 1 Removal and installation of fuel supply pump assembly 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1 Removal of fuel injector assembly 5 795-931-1100 Removal of engine rear seal Removal and installation of fuel injector A Removal and installation of engine rear seal 7 Seal puller q 1 795-799-1150 Repair stand q 1 795-799-2280 Adapter q 1 Fixing of engine assembly Removal and installation of engine front seal 6 795-799-8120 Oil seal driver q 1 N Press fitting of engine front seal Removal and installation of cylinder head assembly 8 790-331-1120 Wrench (angle) q 1 Tightening of cylinder head bolt 790-501-5000 Repair stand (AC100 V) q 1 790-501-5200 Repair stand (AC110 V, 220 V) q 1 Bracket q 1 793-310-2131 Plate q 1 793-310-2141 Plate q 1 Wrench t 1 790-201-2740 Spacer t 1 790-201-2750 Spacer t 1 Wrench t 1 1 790-901-2110 Disassembly and assembly of torque con- C verter 2 792-390-1210 3 4 790-102-1871 Disassembly and assembly of transmission assembly D 790-201-2740 Spacer t 1 1 790-201-2750 Spacer t 1 790-101-5201 Push tool kit t 1 790-201-2740 Spacer t 1 790-101-5201 Push tool kit t 1 797T-423-1320 Push tool t 1 790-101-5201 Push tool kit t 1 2 3 GD655-3E0, GD675-3E0 Disassembly, assembly of torque converter Removal, installation of stator shaft round nut Press fitting of bearing Removal, installation of PTO bearing locknut Press fitting of 4th clutch bearing Press fitting of FH, 1st, 2nd and 3rd clutch bearings Q Press fitting of FL and R clutch bearings 7 Work item 50 Disassembly and assembly Symbol Part number Push tool t 1 N Q Grip t 1 01010-51225 Bolt t 1 794T-423-1130 Push tool t 1 794T-423-1130 4 790-101-5221 5 D 7 t 1 01010-51225 Bolt t 1 794T-423-1110 Push tool t 1 N Q Grip t 1 01010-51225 Bolt t 1 794T-423-1110 Push tool t 1 794T-423-1120 Spacer Q 790-101-5221 Grip t 1 N Q Press fitting of coupling cage dust seal t 1 01010-51225 Bolt t 1 794T-423-1180 Push tool t 1 N Q Grip Bolt 1 Press fitting of coupling cover 1 Lifting tool t 1 Lifting of clutch assembly 10 792-271-2000 Centering tool t 1 Centering of transmission and final drive 11 799-301-1600 Oil leak tester t 1 Operation check of piston 793T-659-1110 Push tool t 1 790-201-2240 Plate t 1 Q Press fitting of shaft bearing inner race 790-101-5401 Push tool kit t 1 790-101-5531 • Plate 1 790-101-5421 • Grip 1 01010-51240 • Bolt 1 H 2 Disassembly and assembly of final drive assembly 1 792-571-1600 Chain puller t 1 t 1 2 J 3 790-101-5401 Push tool kit 790-101-5551 • Plate 1 790-101-5421 • Grip 1 01010-51240 • Bolt 1 Push tool Push tool t 1 Oil leak tester t 1 Spacer t 1 Plate t 1 790-201-2740 Spacer t 1 796-460-1210 Oil stopper t 1 23B-60-32121 Rod t 1 790-201-2850 Disassembly and assembly of bevel pinion assembly 5 790-201-2230 S Press fitting of housing oil seal Removal and installation of chain Press fitting of cage oil seal t 1 N Q Press fitting of drive shaft Q bearing inner race 794T-425-1110 793T-659-1110 4 799-301-1600 8 Press fitting of coupling cage oil seal 9 793-310-2100 1 Removal and installation of work equipment pump assembly t 1 N Q Press fitting of case dust seal on pulley side Spacer Grip 01010-51225 Disassembly and assembly of final brake case assembly Q 794T-423-1140 8 790-101-5221 Disassembly and assembly of axle assembly Work content Press fitting of case oil seal on pulley side 790-101-5221 6 790-101-5221 Disassembly and assembly of transmission assembly Part name Necessity Q'ty N/R Sketch SEN01914-00 Operation check of piston Press fitting of bevel pinion bearing inner race Stopping of hydraulic oil GD655-3E0, GD675-3E0 Work item Symbol 1 SEN01914-00 Part number Part name Necessity Q'ty N/R Sketch 50 Disassembly and assembly 790-502-1003 Cylinder repair stand t 1 790-101-1102 Hydraulic pump t 1 Removal and installation of hydraulic cylinder assembly Wrench assembly t 1 Removal and installation of cylinder head 2 790-330-1100 Commercially available Socket (Width across flats: t 1 30 mm) For blade lift, blade side shift, power tilt, drawbar shift and Removal and leaning installation of nut For scarifier Socket (Width across flats: t 1 41 mm) Commercially available Socket (Width across flats: t 1 46 mm) 790-302-1280 Socket (Width across flats: t 1 55 mm) For articulate 790-302-1290 Socket (Width across flats: t 1 60 mm) For ripper 790-201-1702 Push tool kit 790-101-5021 • Grip 01010-50816 • Bolt 1 790-201-1731 • Push tool 1 For steering 4 790-201-1751 • Push tool 1 For leaning 1 For blade lift, blade side shift, drawbar shift and articulate For power tilt U 790-201-1771 • Push tool t 1 1 Press fitting of cylinder head bushing 790-201-1761 • Push tool 1 790-201-1500 Push tool kit t 1 790-101-5021 • Grip 1 01010-50816 • Bolt 1 790-201-1540 • Plate 1 For steering 5 790-201-1560 • Plate 1 For leaning Press fitting of cylinder head dust seal 790-201-1580 • Plate 1 For blade lift, blade side shift, drawbar shift and articulate 790-201-1570 • Plate 1 For power tilt Expander t 1 796-720-1620 Ring t 1 07281-00609 Clamp t 1 796-720-1650 Ring t 1 07281-01029 Clamp q 1 6 790-720-1000 7 GD655-3E0, GD675-3E0 For steering Commercially available 3 Disassembly and assembly of hydraulic cylinder assembly Work content Installation of piston ring For steering For leaning, blade lift, blade side shift, drawbar shift, articulate and power tilt 9 Work item 50 Disassembly and assembly Symbol Part number 1 791-342-1310 Disassembly and assembly of bank pin assembly t 1 t 1 Clamp t 1 Push tool t 1 Push tool t 1 N Q Grip t 1 01010-51225 Bolt t 1 799-703-1200 Service tool kit t 1 799-703-1100 Vacuum pump (100 V) t 1 799-703-1111 Vacuum pump (220 V) t 1 799-703-1121 Vacuum pump (240 V) t 1 799-703-1401 Gas leak detector t 1 3 796-460-1110 Collection and addition of refrigerant 10 794T-470-1110 4 790-101-5221 X t 1 Expander 07281-00809 Disassembly and assembly of circle rotation gear assembly Wrench Ring 790-720-1000 2 790-720-1740 V Part name Necessity Q'ty N/R Sketch SEN01914-00 Work content Removal and installation of cover Installation of piston ring Press fitting of worm bearing inner race Press fitting of hosing oil seal Collection and addition of air conditioner refrigerant GD655-3E0, GD675-3E0 50 Disassembly and assembly Sketches of special tools SEN01914-00 1 Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. D3 Push tool D4, D5 Push tool GD655-3E0, GD675-3E0 11 SEN01914-00 50 Disassembly and assembly Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. D5 Spacer D6, D7 Push tool 12 GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01914-00 Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. D7 Spacer D8 Push tool GD655-3E0, GD675-3E0 13 SEN01914-00 50 Disassembly and assembly Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. J3 Push tool J3, H1 Push tool 14 GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01914-00 Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. V4 Push tool GD655-3E0, GD675-3E0 15 SEN01914-00 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01914-00 16 SEN01915-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 50 Disassembly and assembly1 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 ..................................................................................... 25 Removal and installation of engine assembly .................................................................................... 30 Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly ....................... 33 Removal and installation of air conditioner condenser....................................................................... 37 Removal and installation of oil cooler assembly ................................................................................ 39 Removal and installation of aftercooler assembly .............................................................................. 41 Removal and installation of radiator assembly................................................................................... 44 Removal and installation of engine hood ........................................................................................... 47 GD655-3E0, GD675-3E0 1 SEN01915-00 50 Disassembly and assembly Engine and cooling system 1 Removal and installation of fuel supply pump assembly 1 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. a Remove the front cover to remove the mounting bolts of the fuel supply pump bracket from the front of the engine. 4. Pipings and wiring harnesses 1) Disconnect connector (5). 2) Remove bracket (6). 3) Disconnect fuel tube (7) from the fuel supply 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. 2 795-799-1390 A 3 795-799-6700 4 795-799-8150 Remover t 1 Puller t 1 Remover q 1 Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools Removal k k k 1. 2. 2 Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Close the fuel stop valve. Set lock pin (1) to the frame. Open engine left side cover (2). GD655-3E0, GD675-3E0 50 Disassembly and assembly 5. Fuel supply pump assembly 1) Remove cap (14). a Use a filter wrench to remove the cap. 2) Remove nut (15) and washer (16) from the shaft (SH) of the fuel supply pump. a Take care not to drop the nut and washer into the case. 3) Tighten tool A2 evenly to disconnect the shaft (SH) of the fuel supply pump from the drive gear (GY). 4) 5) SEN01915-00 Installation q 1. Install the fuel supply pump assembly according to the following procedure. Install fuel supply pump assembly (19), setting projection (P) of its shaft (SH) to the groove (G) of the gear (GY). 2. Install bracket (17) to fuel supply pump assembly (19). 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} 3 Mounting bolt (21): 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} Remove bracket (17). Remove 4 nuts (18) and fuel supply pump assembly (19). GD655-3E0, GD675-3E0 3 SEN01915-00 q 4 50 Disassembly and assembly Carry out the following installation in the reverse order to removal. GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Removal and installation of fuel injector assembly 1 2) Using a sling, lift up muffler assembly (3) temporarily and remove 4 mounting bolts (4) and 3 mounting bolts (5). 3) Using sling [1], remove muffler assembly (3). [*1] A 1 795-799-1131 Gear t 1 2 795-799-1390 Remover t 1 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1 Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools Removal k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Close the fuel stop valve. 4 Muffler assembly: 35 kg Set lock pin (1) to the frame. 4. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Muffler assembly 1) Remove muffler drain tube (2). GD655-3E0, GD675-3E0 Air conditioner compressor [*2] 1) Loosen 4 bolts (4), bolt (5) and bolt (6). 2) Loosen adjustment nut (7) and remove air conditioner compressor drive belt. 3) Remove air conditioner compressor (8) and fix it with ropes to a place where it will not be an obstacle. 5 SEN01915-00 5. 50 Disassembly and assembly 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 clearance". 7. 2) 3) 6. 6 Remove cap (11). a Use a filter wrench to remove the cap. Crank the engine to set stamp (M) of the drive gear (GY) to the TDC position. a Use a mirror to set the stamp. a See Testing and adjusting volume, "Testing and adjusting valve clearance". Rocker arm and crosshead 1) Remove wiring harness nut (14) from the injector. a Wiring harness locations 2) 3) Wiring harness color Cylinder No. Yellow, orange (Exchangeable) 1, 3, 5 Red, brown (Exchangeable) 2, 4, 6 Loosen locknut (15) and then loosen adjustment screw (16) 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. 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.) Cylinder head cover 1) Remove bracket (12). 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". GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Installation q a 1. 8. Fuel injector 1) Remove retainer (19) and inlet connector (20). a Before removing retainer (19), clean it and around it thoroughly. a Tool A4 (Remover) is set for removal of inlet connector (20). (See the tool table.) 2) 3) Remove 2 fuel injector assembly mounting bolts (21). Using tool A3, remove fuel injector assembly (22). a Take care that foreign matter will not enter the mounting part of the fuel injector assembly. GD655-3E0, GD675-3E0 Fuel injector assembly Check that the fuel injector sleeve is free from flaws and foreign matter. Fit gasket (23) and O-ring (24) to fuel injector (22). 2 O-ring (24) of fuel injector (22) and cylinder head surface: Engine oil (EO15W-40) 2. Install holder (25) to fuel injector (22). a Match the projection and concave (B) and (A). 3. Insert fuel injector (22) in the cylinder head with the fuel inlet hole on the air intake manifold side. 4. Tighten mounting bolts (21) of holder (25) by 3 – 4 threads with the fingers. 5. Fit O-ring (26) to inlet connector (20). 2 O-ring (26) of inlet connector (20) and cylinder head surface: Engine oil (EO15W-40) 6. Install inlet connector (20) temporarily with nut (19). (Set the projection (C) and insert the inlet connector in the fuel injector hole.) 3 Nut: 14.7 ± 5.0 Nm {1.5 ± 0.5 kgm} 7 SEN01915-00 7. Tighten mounting bolts (21) of holder (25) alternately. 3 Mounting bolt: 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm} a The top of holder (25) must be in parallel with the top of the cylinder head. Allowable inclination: 2.4° 8. Tighten nut (19) of inlet connector (20) permanently. 3 Nut: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm} q Precautions for installing inlet connector When replacing the fuel injector assembly with new one, be sure to replace inlet connector (20), too. 1. 2. 8 50 Disassembly and assembly 3. Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal surface has fine streaks or cracks. 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 installed in either direction.) a Check that 2 valves are inserted in holes (a) and (b). q Carry out the following installation in the reverse order to removal. Check the inlet connector visually. If it has any of the following faults, replace it. 1) There is a bur or a worn part at front end (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. GD655-3E0, GD675-3E0 50 Disassembly and assembly [*1] Tighten the muffler-related bolts according to the following procedure. 1) Tighten bolts (1) – (4) and (5) – (14) to the specified torque (4 places marked with *1). 2) Temporarily tighten bolts (15) – (22), (23) – (25) and (26) – (28) (5 places marked with *2 and 2 places marked with *3). 3) Tighten bolts (29) – (32) and (33) – (36) to the specified torque (2 places marked with *4). SEN01915-00 4) 5) 6) a Tighten bolts (37) – (39) to the specified torque (3 places marked with *5). Tighten bolts (15) – (22) to the specified torque (5 places marked with *6). Tighten bolts (23) – (25) to the specified torque (2 places marked with *7). When tightening the bolts in steps 5) and 6), adjust the muffler, exhaust elbow, etc. so that they will not be installed forcibly. [*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 SEN01915-00 50 Disassembly and assembly Removal and installation of cylinder head assembly 2) Using a sling, lift up muffler assembly (3) temporarily and remove 4 mounting bolts (4) and 3 mounting bolts (5). 3) Using sling [1], remove muffler assembly (3). [*1] 1 A 8 790-331-1120 Wrench (angle) Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools q 1 Removal k k k 1. 2. 3. 10 Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Close the fuel stop valve. Set lock pin (1) to the frame. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". Muffler assembly 1) Remove muffler drain tube (2). 4 4. Muffler assembly: 35 kg Air conditioner compressor [*2] 1) Loosen 4 bolts (4), bolt (5) and bolt (6). 2) Loosen adjustment nut (7) and remove air conditioner compressor drive belt. 3) Remove air conditioner compressor (8) and fix it with ropes to a place where it will not be an obstacle. GD655-3E0, GD675-3E0 50 Disassembly and assembly 5. 6. Air intake connector and electrical intake air heater 1) Remove electrical intake air heater connector (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] Pipings, hoses and connectors [*5] 1) Remove high-pressure pipe clamp (14). 2) Remove bellows (15). (Remove both bellows 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). 6) Remove bracket (24). 7) Remove fuel return tube (25). 8) Remove 12 bellows (26) of each highpressure pipe. 9) Remove 6 high-pressure pipes (27) (between the common rail and cylinder head). 10) Remove common rail (28). 11) Remove clamp (29). 12) Remove bracket (30). GD655-3E0, GD675-3E0 SEN01915-00 7. Heater hose Disconnect heater hose (31). 8. Blow-by duct cover 1) Remove bracket (32). 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 top position. For details, see Testing and adjusting volume, "Testing and adjusting valve clearance". 9. Turbocharger and exhaust manifold assembly 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] 11 SEN01915-00 50 Disassembly and assembly 11. Adjusting valve timing 1) Remove bracket (40) and cap (41) together and install cranking tool A1 (See the tool table). a See Testing and adjusting volume, "Testing and adjusting valve clearance". 4) Using sling [1], remove turbocharger and exhaust manifold assembly (37). 4 Turbocharger and exhaust manifold assembly: 38 kg 2) 3) Remove cap (42). a Use a filter wrench to remove the cap. Crank the engine to set stamp (M) of the drive gear (GY) to the TDC position. a Use a mirror to set the stamp. a See Testing and adjusting volume, "Testing and adjusting valve clearance". 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). 12 [*9] GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 13. Rocker arm and crosshead 1) Remove wiring harness nut (44) from the injector. a Wiring harness locations 2) 3) Wiring harness color Cylinder No. Yellow, orange (Exchangeable) 1, 3, 5 Red, brown (Exchangeable) 2, 4, 6 14. Fuel injector 1) Remove retainer (49) and inlet connector (50). a Before removing retainer (49), clean it and around it thoroughly. a Tool A4 (Remover) is set for removal of inlet connector (50). (See the tool table.) 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. 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 direction.) 2) 3) GD655-3E0, GD675-3E0 Remove 2 fuel injector assembly mounting bolts (51). Using tool A3, remove fuel injector assembly (52). a Take care that foreign matter will not enter the mounting part of the fuel injector assembly. 13 SEN01915-00 50 Disassembly and assembly 15. Rocker housing 1) Remove push rod (53). 2) Remove spacer (54). a Remove the spacers of other cylinders, too. 3) Remove rocker housing assembly (55). Installation q a 1. Cylinder head assembly Check that there is not foreign matter on the cylinder head mounting face and inside the cylinders. 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 2) Cylinder head assembly: 85 kg Remove cylinder head gasket (57). 2. Sling cylinder head assembly (56) and set it to the cylinder block. 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 gasket (57) are set to those of the cylinder block. 4 14 Cylinder head assembly: 85 kg GD655-3E0, GD675-3E0 50 Disassembly and assembly 3. SEN01915-00 Before tightening the cylinder head mounting bolts, check the following. 1) Measure stem length (a) of every bolt and check that it is less than the using limit. 2) Using limit of length bolt stem: 162.6 mm 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. 3) 4) q 1. 4. Method of tightening cylinder head mounting bolts 1) Tighten each cylinder head mounting bolt 2 – 3 turns with the fingers. 2) Tighten the cylinder head mounting bolts according to the following procedure in the order shown in the figure. 1] 150 ± 9.8 Nm {15.3 ± 1.0 kgm} 2] Return all the bolts 360°. 3] 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 4] Check the tightening torque of 115 ± 4.9 Nm {11.7 ± 0.5 kgm}. 5] 120 ± 5° GD655-3E0, GD675-3E0 Tool A8 (See the tool table) is set for angle tightening. When not using angle tightening tool A8 Make marks on the cylinder head and each bolt and then tighten the bolt 120 ± 5°. Rocker housing Install push rod (53). a Check that the push rod is set in the tappet securely. 2 Apply engine oil (SAE15W-40) to the push rod socket. 2. Fit the gasket and install rocker housing assembly (55). 3. Tighten the mounting bolts in the order shown in the following figure. ([1] o [7]) 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 4. Install spacer (54). 15 SEN01915-00 q a 1. 2. 50 Disassembly and assembly 5. Fit O-ring (56) to inlet connector (50). 2 O-ring (56) of inlet connector (50) and cylinder head surface: Engine oil (EO15W-40) 6. Install inlet connector (50) temporarily with nut (49). (Set the projection (C) and insert the inlet connector in the fuel injector hole.) 3 Nut: 14.7 ± 5.0 Nm {1.5 ± 0.5 kgm} 7. Tighten mounting bolts (51) of holder (55) alternately. 3 Mounting bolt: 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm} a The top of holder (55) must be in parallel with the top of the cylinder head. Allowable inclination: 2.4° 8. Tighten nut (49) of inlet connector (50) permanently. 3 Nut: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm} q Precautions for installing inlet connector When replacing the fuel injector assembly with new one, be sure to replace inlet connector (50), too. Fuel injector assembly Check that the fuel injector sleeve is free from flaws and foreign matter. Fit gasket (53) and O-ring (54) to fuel injector (52). 2 O-ring (54) of fuel injector (52) and cylinder head surface: Engine oil (EO15W-40) Install holder (55) to fuel injector (52). a Match the projection and concave (B) and (A). 3. Insert fuel injector (52) in the cylinder head with the fuel inlet hole on the air intake manifold side. 4. Tighten mounting bolts (51) of holder (55) by 3 – 4 threads with the fingers. 1. 16 GD655-3E0, GD675-3E0 50 Disassembly and assembly 2. Check the inlet connector visually. If it has any of the following faults, replace it. 1) There is a bur or a worn part at front end (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. 3. Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal surface has fine streaks or cracks. GD655-3E0, GD675-3E0 SEN01915-00 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 installed in either direction.) a Check that 2 valves are inserted in holes (a) and (b). 1. Install rocker arm and crosshead assembly (48) and tighten mounting bolts (47) with the fingers. a Check that the ball of adjustment screw ( 44) is fitted in the push rod socket securely. 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} 17 SEN01915-00 3. 18 50 Disassembly and assembly 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 interfere 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 Red, brown (Exchangeable) 2, 4, 6 q Carry out the following installation in the reverse order to removal. GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 [*1] Tighten the muffler-related bolts according to the following procedure. 1) Tighten bolts (1) – (4) and (5) – (14) to the specified torque (4 places marked with *1). 2) Temporarily tighten bolts (15) – (22), (23) – (25) and (26) – (28) (5 places marked with *2 and 2 places marked with *3). 3) Tighten bolts (29) – (32) and (33) – (36) to the specified torque (2 places marked with *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 4) 5) 6) a Tighten bolts (37) – (39) to the specified torque (3 places marked with *5). Tighten bolts (15) – (22) to the specified torque (5 places marked with *6). Tighten bolts (23) – (25) to the specified torque (2 places marked with *7). When tightening the bolts in steps 5) and 6), adjust the muffler, exhaust elbow, etc. so that they will not be installed forcibly. [*3] 3 Clamp of air hose (11): 24 ± 4 Nm {2.45 ± 0.41 kgm} 19 SEN01915-00 [*4] q Air intake connector Fit the gasket and install air intake connector (13). 2 Both sides of gasket: Gasket sealant (LG-7) 3 Mounting bolt (12): 24 ± 4 Nm {2.4 ± 0.41 kgm} 50 Disassembly and assembly 5. Install 6 high-pressure pipes (27) between the common rail and fuel injector. 3 Nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm} 6. Tighten fuel return tube (25) permanently. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 7. Tighten common rail (28) permanently. 3 Joint bolt: 43.1 ± 4.0 Nm {4.4 ± 0.4 kgm} 8. Tighten clamp (14) and bracket (24) permanently. 9. Apply caulking material (e) (hatched part) to nut (49) of inlet connector (50) and cylinder head. 2 Caulking material: GE TOSHIBA SILICONE TOSSEAL 381 [*5] q k k k a High-pressure pipe and common rail Do not bend the high-pressure pipe to collect before installing. Be sure to use the genuine high-pressure pipe clamps and observe the tightening torque. Install each high-pressure pipe and wiring harness at least 10 mm apart from each other. 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 (part at 2 mm from end) caused by fatigue which your nail can feel 1. Install common rail (28) lightly with the fingers. 2. Tighten fuel return tube (25) lightly with the fingers. 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 50 Disassembly and assembly 10. Install 12 bellows (26). SEN01915-00 [*7] q 11. Install right and left bellows (15). a Install each bellows with the slits out and down. a The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. Exhaust manifold and turbocharger Tightening procedure for mounting bolts: 1) Tighten all the bolts to 24 ± 4 Nm {2.4 ± 0.4 kgm} in the order of [1] – [12] shown in the figure. 2) Tighten only bolts [1] – [4] to 24 ± 4 Nm {2.4 ± 0.4 kgm} in order. 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. 3 [*6] 3 3 Mounting bolt of turbocharger lubrication hose (35): 35 ± 5 Nm {3.6 ± 0.5 kgm} 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 adjusting alternator belt tension". [*9] 3 q Cylinder head cover mounting bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm} 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 GD655-3E0, GD675-3E0 Coolant: 39.5 l 21 SEN01915-00 50 Disassembly and assembly k Removal and installation of engine front seal 1 Take care not catch your fingers between the tensioner and pulley. A 6 795-799-8120 Oil seal driver Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools q 1 N Removal k k k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, hydraulic oil and fuel. Collect the air conditioner refrigerant (R134a). If the refrigerant 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. Remove 4 mounting bolts (4) and crankshaft pulley/damper (5). [*2] a Make a match mark on the crankshaft pulley and front cover (since the stamp of 1.6TOP is made on the crankshaft pulley). 7. Remove the 5 mounting bolts and seal carrier (6). 8. Remove dust seal (7) and engine front seal from seal carrier (6). Set lock pin (1) to the frame. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Remove the hydraulic tank, fuel tank and rese r v oi r ta nk a s se m bl y. F o r d e ta il s , s e e "Removal and installation of hydraulic tank, fuel tank and reservoir tank assembly". 4. Remove the engine assembly. For details, see "Removal and installation of engine assembly". 5. Insert a wrench in square hole (A) of tensioner (2) and loosen and remove alternator belt (3). [*1] 22 6. GD655-3E0, GD675-3E0 50 Disassembly and assembly Installation 1. 5. Remove pilot (P). 6. Install seal carrier (6). 2 Apply gasket sealant to the following parts.: Gasket sealant (Threebond 1207D or equivalent) 1) All inside surface (a) of seal carrier (6) 2) Threaded part (b) and periphery (c) of bolt (10) 3) Threaded part (d) of nut (11) q Tighten the mounting bolts in the order [1] o [5] shown in the figure. 3 Seal carrier mounting bolt: 9.8 ± 2 Nm {1 ± 0.2 kgm} a Check the installed dimension of 0.5 – 1 mm. 7. Install dust seal (7). a Push in the dust seal until it touches the oil seal. Wipe off foreign matter from the crankshaft flange portion (A) with clean cloths. a 2. SEN01915-00 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. 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 SEN01915-00 a q 50 Disassembly and assembly Install the crankshaft pulley/damper temporarily and install the alternator belt, and then tighten to the specified torque. Carry out the following installation in the reverse order to removal. [*1] Adjust the alternator belt tension. For details, see "Testing and adjusting alternator belt tension". [*2] 3 q Mounting bolt of crankshaft pulley/damper: 200 ± 10 Nm {20.4 ± 1 kgm} 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 q Refilling with coolant 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 q 24 Hydraulic tank: 45 l Coolant: 39.5 l Charging air conditioner with refrigerant Using tool X, charge the air conditioner circuit with refrigerant (R134a). GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Removal and installation of engine rear seal 6. 1 4 7 q 1 795-799-1150 Repair stand q 1 795-799-2280 Adapter q 1 Flywheel assembly: 45 kg Sketch N/R Q’ty Seal puller 5 795-931-1100 A Part name Necessity Symbol Special tools Part number Remove mounting bolts (2), set guide bolts, and lift off flywheel (3). [*1] Removal k k k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, hydraulic oil and fuel. Collect the air conditioner refrigerant (R134a). If the refrigerant 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. 7. Sling flywheel housing (5), remove mounting bolts (4), and lift off the flywheel housing (5). 4 Flywheel housing (5): 70 kg Set lock pin (1) to the frame. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Remove the hydraulic tank, fuel tank and rese r v oi r ta nk a s se m bl y. F o r d e ta il s , s e e "Removal and installation of hydraulic tank, fuel tank and reservoir tank assembly". 4. Remove the engine assembly. For details, see "Removal and installation of engine assembly". 5. Place the engine assembly on block [1]. a The repair stand and adapter A7 are set (See tool table). GD655-3E0, GD675-3E0 8. Remove rear cover (6). 9. Remove rear seal (7) from rear cover (6). a Take care not to scratch the seal fitting face of the flywheel housing and seal contact face of the crankshaft. 25 SEN01915-00 a 26 If engine rear seal (7) is stuck to the crankshaft and cannot be removed, make holes (about 3 mm in diameter) on its right and left sides with a drill. Then, using seal puller A5, remove the seal with impacts of slide hammer (SH). 50 Disassembly and assembly Installation 1. Clean, degrease, and dry the faces of the gasket between the rear cover and cylinder block. 2. Clean, degrease, and dry the seal lip face (periphery of the crankshaft). 3. Apply neutral detergent to the periphery of the engine rear seal. a Since plastic part (P) on the inside of the engine rear seal is a pilot (guide tool) for 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 50 Disassembly and assembly 5. Using alignment tool (A) attached to the engine rear seal, push rear seal (7) into rear cover (6). 6. Remove alignment tool (A). 7. Set pilot (P) to the crankshaft and push it and rear cover (6) together into the crankshaft with the hands. a Do not forget gasket (G). a Use guide pin [2]. 8. Remove pilot (P). SEN01915-00 12. Cut off gasket (G). (Right and left) a Take care that the cut gasket will not fall in the engine. 9. Install alignment tool (A) again and check that rear seal (7) is inserted to a proper depth. a Evenly set the heights of rear cover (6) and both sides (B) of the oil pan rail. a Keep alignment tool (A) installed. 10. 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} 11. Remove alignment tool (A). GD655-3E0, GD675-3E0 27 SEN01915-00 13. 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} q Carry out the following installation in the reverse order to removal. [*1] a Fix the flywheel to the flywheel housing with ring wrench [3]. 28 50 Disassembly and assembly a Tighten the mounting bolts in the order shown in the following figure. 3 Flywheel mounting bolt: 137 ± 7 Nm {14.0 ± 0.7 kgm} a Measure the facial runout and radial runout of the flywheel housing. (Check with dial gauge [4].) q Facial runout: Max. 0.20 mm q Radial runout: Max. 0.20 mm q Measuring radial runout 1) Install dial gauge [4] to the end of the crankshaft. 2) Set the probe of the dial gauge perpendicular to the socket of the flywheel housing. 3) Set the dial gauge to "0", rotate the crankshaft 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. GD655-3E0, GD675-3E0 50 Disassembly and assembly 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 crankshaft 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 crankshaft 1 turn, and measure the difference between the lowest and highest values. 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 q Hydraulic tank: 45 l Refilling with coolant 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 q SEN01915-00 Coolant: 39.5 l Charging air conditioner with refrigerant Using tool X, charge the air conditioner circuit with refrigerant (R134a). GD655-3E0, GD675-3E0 29 SEN01915-00 Removal and installation of engine assembly 50 Disassembly and assembly 5. Hoses and pipings 1) Disconnect radiator hose (7). 2) Disconnect heater hose (8). 6. Air intake connector 1) Disconnect air hose (9). [*2] 2) Remove fuel prefilter assembly (10) and its bracket together. 7. Disconnect engine oil drain hose (11) from the drain valve at lower part. 1 Removal k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, fuel and hydraulic oil. Set lock pin (1) to the frame. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Remove the fuel tank, hydraulic tank and coolant reservoir tank assembly. For details, see "Removal and installation of fuel tank, hydraulic tank and reservoir tank assembly". 4. 30 Air conditioner compressor [*1] 1) Loosen 4 bolts (2), bolt (3) and bolt (4). 2) Loosen adjustment nut (5) and remove air conditioner compressor drive belt. 3) Remove air conditioner compressor (6) and fix it with ropes to a place where it will not be an obstacle. GD655-3E0, GD675-3E0 50 Disassembly and assembly 8. Remove hose (12) from the flywheel housing bottom. 9. Relay wiring harness on right side of engine 1) Remove cover (13). SEN01915-00 10. Engine mounting bolts [*3] 1) Using the sling, lift up the engine assembly temporarily. 2) Loosen 2 mounting bolts (15) on the mounting bar at the engine block bottom. 3) Remove left engine mounting bolt (16). 4) 2) Remove right engine mounting bolt (17). Disconnect 2 wiring harnesses (14). 11. Engine assembly 1) Using the sling, lift up the engine assembly and remove 12 mounting bolts (18). 2) Move engine assembly (19) forward to disconnect it from the transmission. [*4] a Using a forcing screw (M10, P1.5 mm), disconnect the engine from the transmission. GD655-3E0, GD675-3E0 31 SEN01915-00 3) 50 Disassembly and assembly Using sling [1], remove engine assembly (20). 4 Installation q Engine assembly: 850 kg Carry out installation in the reverse order to removal. [*1] Adjust the air conditioner compressor belt tension. For details, see Testing and adjusting volume, "Testing and adjusting air conditioner compressor belt". [*2] 3 Clamp of air hose (9): 8 ± 1.0 Nm {0.8 ± 0.1 kgm} [*3] 2 3 Engine mounting bolt: Adhesive (LT-2) Engine mounting bolt: 610 – 765 Nm {62.5 – 78 kgm} [*4] 3 a q Engine and transmission case mounting bolt: 54 – 74 Nm {6 – 7.5 kgm} Take care not to damage the O-ring between the engine assembly and transmission assembly. 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 q Refilling with coolant 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 circulate the coolant through the system. Then, check the coolant level again. 6 32 Hydraulic tank: 45 l Coolant: 39.5 l GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Removal and installation of fuel tank, hydraulic tank and coolant sub tank assembly 1 4) Loosen the clamp on the tank side and disconnect air intake connector hose (5). [*1] Removal k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, hydraulic oil and fuel. Set lock pin (1) to the frame. 4. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Hoses and tubes on engine side 1) Loosen the clamp on the tank side and disconnect turbocharger outlet hose (2). 2) Disconnect heater hose (3) from the tank. 3) Loosen the clamp on the tank side and disconnect radiator hose (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. 3) Loosen the clamp on the tank side and disconnect radiator hose (8). 4) GD655-3E0, GD675-3E0 Disconnect hose (9) between the radiator and coolant sub tank. 33 SEN01915-00 5. 6. 34 Upper hoses and tubes 1) Loosen the clamp on the tank side and disconnect aftercooler outlet hose (10). 2) Remove 2 coolant return hose clamps (11). 3) Remove air intake tube (12). 4) Disconnect radiator sub tank overflow hose (13). 5) Disconnect hydraulic tank overflow hose (13a). 50 Disassembly and assembly 4) 5) Disconnect connectors (18), (19), (20) and (21). Disconnect wiring harness clamps (22), (23) and (24). 6) 7) Disconnect connector (25). Disconnect wiring harness clamps (26) and (27). 8) 9) Disconnect connectors (28). Disconnect wiring harness clamps (29) and (30). Wires and connectors on right side 1) Disconnect ground wire D11 (14). 2) Disconnect connector ET39 (15). 3) Disconnect wiring harness clamps (16) and (17). GD655-3E0, GD675-3E0 50 Disassembly and assembly 7. Corrosion resistor Disconnect the related hoses and remove corrosion resistor (31) and its bracket together. 8. Hoses and wiring connectors at tank bottom 1) Disconnect connectors T32 (32) and T34 (33). SEN01915-00 3) 9. 2) Disconnect work equipment pump speed sensor wiring connector (35). Related hoses and clamps 1) Disconnect oil cooler hose clamps (36) and (37). 2) Disconnect coolant sub tank drain hose (38). 3) Disconnect hydraulic tank outlet hose (39). 4) Disconnect hydraulic tank return hose (40). Disconnect 2 fuel tube clamps (34). 5) 6) 7) GD655-3E0, GD675-3E0 Disconnect fuel hose (41). Disconnect 2 hydraulic oil return hoses (42). Disconnect hydraulic tube (43). 35 SEN01915-00 8) 50 Disassembly and assembly 11. Using sling [1], remove fuel tank, hydraulic tank and coolant sub tank assembly (47). Disconnect breather hose (44). 4 9) Fuel tank, hydraulic tank and coolant sub tank assembly: 310 kg 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 10. Tank assembly mount Remove 4 mount bolts (46). 3 [*2] q Tank mount bolt: Adhesive (LT-2) Tank mount bolt: 245 – 309 Nm {25 – 31.5 kgm} 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 q Refilling with coolant 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 circulate the coolant through the system. Then, check the coolant level again. 5 36 Hydraulic tank: 45 l Coolant: 39.5 l GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Removal and installation of air conditioner condenser a Since the air conditioner condenser piping is installed through the right lower part of the shroud, disconnect it. 4) Remove 3 radiator guard mounting bolts (4). a Mounting bolt (4a) is used to secure the engine hood, too. a Work on the right side similarly. 5) Using sling [1], remove radiator guard (5). 1 X 799-703-1200 Service tool kit t 1 799-703-1100 Vacuum pump (100 V) t 1 799-703-1110 Vacuum pump (220 V) t 1 799-703-1120 Vacuum pump (240 V) t 1 799-703-1400 Gas leak tester t 1 Sketch Part name Q’ty Part number N/R Necessity Symbol Special tools Removal k k k k 1. 2. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Collect the air conditioner refrigerant (R134a). If the refrigerant 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. Set lock pin (1) to the frame. 4 Radiator guard: 75 kg Engine hood and radiator guard 1) Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2) Disconnect rear light connector (2). 3) Disconnect air conditioner condenser piping (3). GD655-3E0, GD675-3E0 37 SEN01915-00 3. Fan 1) Remove fan guard (6). 50 Disassembly and assembly Installation q Carry out installation in the reverse order to removal. [*1] 3 q 2) 4. 38 Fan mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} Charging air conditioner with refrigerant Using tool X, charge the air conditioner circuit with refrigerant (R134a). Remove the 6 mounting bolts and fan (7). [*1] Air conditioner condenser 1) Disconnect 2 air conditioner condenser pipings (8). 2) Remove 4 mounting bolts (9) and air conditioner condenser (10). GD655-3E0, GD675-3E0 50 Disassembly and assembly Removal and installation of oil cooler assembly SEN01915-00 3) Remove 3 radiator guard mounting bolts (4). a Mounting bolt (4a) is used to secure the engine hood, too. a Work on the right side similarly. 4) Using sling [1], remove radiator guard (5). 1 Removal k k 1. 2. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Set lock pin (1) to the frame. 4 Radiator guard: 75 kg Engine hood and radiator guard 1) Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2) Disconnect rear light connector (2). 3. GD655-3E0, GD675-3E0 Oil cooler hoses 1) Disconnect upper hose (6) from the oil cooler. 39 SEN01915-00 2) 50 Disassembly and assembly 4) Disconnect lower hose (7) from the oil cooler. 5) 6) 4. Remove left radiator mount (10). a The radiator mount must be removed since it is an obstacle to removal of mounting bolt (11) on the lower left side. Remove 2 mounting bolts (11) from the lower left side. Remove mounting bolt (12) from the lower left rear side. 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 3) Oil cooler: 17 kg Set a jack [2] under the left part of the radiator to support the radiator. a Set the jack to remove the left radiator mount. Installation Carry out installation in the reverse order to removal. 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 40 Hydraulic tank: 45 l GD655-3E0, GD675-3E0 50 Disassembly and assembly Removal and installation of aftercooler assembly SEN01915-00 3) 1 Using sling [1], remove radiator guard (5). 4 Radiator guard: 75 kg Removal k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant and hydraulic oil. Set lock pin (1) to the frame. 3. 2. Engine hood and radiator guard 1) Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2) Remove 3 radiator guard mounting bolts (4). a Mounting bolt (4a) is used to secure the engine hood, too. a Work on the right side similarly. GD655-3E0, GD675-3E0 Fan 1) Remove fan guard (6). 2) Remove the 6 mounting bolts and fan (7). 41 SEN01915-00 4. 5. Upper piping 1) Remove air hoses (8) and (9). 2) Remove radiator upper hose (10). 3) Disconnect overflow tube (11). 4) Disconnect oil cooler hose (12). 50 Disassembly and assembly 7. Disconnect rear light connector (17) and remove bracket (18). 8. Aftercooler 1) Remove 6 aftercooler mounting bolts (19). 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) 6. 42 Air conditioner condenser Remove the 4 air conditioner condenser bolts (15) and move air conditioner condenser (16) toward the fan. Using sling [1], remove aftercooler assembly (20). a When slinging the aftercooler, take care not to break the sponge around it. 4 Aftercooler assembly: 28 kg GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01915-00 Installation Carry out installation in the reverse order to removal. 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 q Hydraulic tank: 45 l Refilling with coolant 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. 5 Coolant: 39.5 l GD655-3E0, GD675-3E0 43 SEN01915-00 Removal and installation of radiator assembly 50 Disassembly and assembly 3) 1 Using sling [1], remove radiator guard (5). 4 Radiator guard: 75 kg Removal k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant. Set lock pin (1) to the frame. 3. 2. 44 Engine hood and radiator guard 1) Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2) Remove 3 radiator guard mounting bolts (4). a Mounting bolt (4a) is used to secure the engine hood, too. a Work on the right side similarly. Piping 1) Remove radiator upper hose (6). 2) Disconnect overflow tube (7). 3) Disconnect radiator lower hose (8). GD655-3E0, GD675-3E0 50 Disassembly and assembly 4. 5. SEN01915-00 Fan 1) Remove fan guard (9). 7. Disconnect rear light connector (15) and remove bracket (16). 2) 8. Radiator 1) Remove 2 radiator mounting bolts (17). Remove 6 mounting bolts and fan (10). 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) a 6. Air conditioner condenser Remove 4 air conditioner condenser mounting bolts (13) and move air conditioner condenser (14) toward the transmission. GD655-3E0, GD675-3E0 Using sling [1], remove radiator assembly (18). When slinging the radiator, take care not to damage the sponge around it. 4 Radiator assembly: 22 kg 45 SEN01915-00 50 Disassembly and assembly Installation Carry out installation in the reverse order to removal. q Refilling with coolant 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 46 Coolant: 39.5 l GD655-3E0, GD675-3E0 50 Disassembly and assembly Removal and installation of engine hood SEN01915-00 1 Removal k k 1. 2. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Set lock pin (1) to the frame. 4) Remove air conditioner compressor wiring harness clamp (7). 5) Loosen the V-belt, remove the air conditioner compressor mounting bracket, and move air conditioner compressor (8) back and fix it. [*1] The air conditioner compressor must be removed back since it interferes with the engine hood. Open engine left side cover (2). a 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 piping. GD655-3E0, GD675-3E0 47 SEN01915-00 4. Left engine hood cover 1) Remove the rubber cap and 6 mounting bolts (9). 2) Remove engine hood left cover (10). a Work on the right side similarly. 3) a 4) 48 50 Disassembly and assembly 5. Remove the 2 mounting bolts (13) from the front lower part of the engine hood. a Work on the right side similarly. 6. Remove the 2 mounting bolts (14) from the lower part of the engine hood. a Work on the right side similarly. 7. Engine hood top cover 1) Remove the rubber cap and 6 mounting bolts (15). 2) Remove cover (16). Remove 3 mounting bolts (11) on the radiator guard. Work on the right side similarly. Remove wiring harness clamp (12) from the right rear part. GD655-3E0, GD675-3E0 50 Disassembly and assembly 3) Remove 3 mounting bolts (17) on the radiator cover. 8. Remove the clamp and air duct (18). 9. Using sling [1], lift off engine hood (19). 4 a SEN01915-00 Installation Carry out installation in the reverse order to removal. [*2] Engine hood: 240 kg 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 49 SEN01915-00 GD655-3E0, GD675-3E0 Motor grader Form No. SEN01915-00 50 SEN01916-00 MOTOR GRADER 1SHOP MANUAL GD655-3E0, GD675-3E0 Machine model Serial number GD655-3E0 GD675-3E0 51501 and up 51301 and up 50 Disassembly and assembly1 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 SEN01916-00 50 Disassembly and assembly Power train, Part 1 1 Removal and installation of engine and transmission assembly 3) Disconnect air conditioner condenser piping (3). 1 X 799-703-1200 Service tool kit t 1 799-703-1100 Vacuum pump (100 V) t 1 799-703-1110 Vacuum pump (220 V) t 1 799-703-1120 Vacuum pump (240 V) t 1 799-703-1400 Gas leak tester t 1 Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools 3. Remove the hydraulic tank, fuel tank and reser 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, fuel tank and reservoir tank assembly". 4. Fan 1) Remove fan guard (4). Removal k k k k k 1. Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, hydraulic oil, fuel and transmission oil. Collect the air conditioner refrigerant (R134a). If the refrigerant 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. Set lock pin (1) to the frame. 2) 3) 2. 2 Loosen and remove fan belt (5). [*1] a See Testing and adjusting volume, "Testing and adjusting fan belt tension". Remove the 6 mounting bolts and fan (6). Engine hood 1) Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2) Disconnect rear light connector (2). GD655-3E0, GD675-3E0 50 Disassembly and assembly 5. Cooler hoses 1) Disconnect lower hose (7) from the radiator bottom. 2) Disconnect hose (8) from the oil cooler bottom. 3) Disconnect hose (9) from the oil cooler top. SEN01916-00 7. Disconnect the clamp of hydraulic tank drain valve hose (12) from the transmission and fix it to the frame. 8. Transmission control wiring harness 1) Disconnect connectors (13), (14) and (15). 2) Remove bracket (16). 3) 6. Work equipment pump piping 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 Disconnect connectors CN-T31 (17) and CN-T43 (18) and remove clamp (19). 3 SEN01916-00 9. Transmission pump 1) Remove outlet hose elbow (20) from the transmission pump. 2) Disconnect hoses (21) and (22) from the transmission pump. a Stop the disconnected hoes and elbow with plugs. 3) Remove bracket (23). 4) Remove elbow (24) and suction hose (25). 5) Remove 3 mounting bolts and transmission pump (26). a The transmission pump must be removed since it is an obstacle to removal of the transmission mounting bolts. 50 Disassembly and assembly 11. Transmission lower piping 1) Disconnect hose (28) from the transmission filter. 2) Remove clamp (29) and disconnect hose (30). 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 50 Disassembly and assembly 14. Relay wiring harness on right side of engine 1) Remove cover (33). 2) Disconnect 2 wiring harnesses (34). 15. Remove the upper mounting nut of the solenoid cover and 2 stud bolts (35). a These parts must be removed since they interfere with the shroud when the transmission is removed. GD655-3E0, GD675-3E0 SEN01916-00 16. Transmission mounting bolts [*3] 1) Remove 2 left transmission mounting bolts (36). 2) Remove 2 right transmission mounting bolts (37). 17. Engine mounting bolts [*4] 1) Using the sling, lift up the transmission assembly temporarily. 2) Loosen 2 mounting bolts (38) on the mounting bar at the engine block bottom. 3) Remove left engine mounting bolt (39). 5 SEN01916-00 4) Remove right engine mounting bolt (40). 50 Disassembly and assembly 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 transmission 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 transmission assembly (41). a Check that all the hydraulic pipes and electric wires are disconnected. 4 6 Engine and transmission assembly: 1,840 kg GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01916-00 Installation Carry out installation in the reverse order to 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 3 Transmission mounting bolt: Adhesive (LT-2) Transmission mounting bolt: 610 – 765 Nm {62.5 – 78 kgm} [*4] 2 3 Engine mounting bolt: Adhesive (LT-2) 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. 3 Engine and transmission case mounting bolt: 54 – 74 Nm {6 – 7.5 kgm} q Refilling with oil (Hydraulic tank and transmission 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 6 q Transmission case: 45 l Refilling with coolant 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. 5 q Hydraulic tank: 45 l Coolant: 39.5 l Charging air conditioner with refrigerant Using tool X, charge the air conditioner circuit with refrigerant (R134a). GD655-3E0, GD675-3E0 7 SEN01916-00 50 Disassembly and assembly Removal and installation of transmission assembly 4. 1 Fan 1) Remove fan guard (2). X 799-703-1200 Service tool kit t 1 799-703-1100 Vacuum pump (100 V) t 1 799-703-1110 Vacuum pump (220 V) t 1 799-703-1120 Vacuum pump (240 V) t 1 799-703-1400 Gas leak tester t 1 Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools 2) Removal k k k k k Stop the machine on a level ground, apply the parking brake, and lock the tires with chocks. Disconnect the cable from the negative (–) terminal of the battery. Drain the coolant, hydraulic oil, fuel and transmission oil. Collect the air conditioner refrigerant (R134a). If the refrigerant 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. 1. Set lock pin (1) to the frame. 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Remove the hydraulic tank, fuel tank and reservoir tank assembly. For details, see "Removal and installation of hydraulic tank, fuel tank and reservoir tank assembly". 8 3) 5. Loosen and remove fan belt (3). [*1] a See Testing and adjusting volume, "Testing and adjusting fan belt tension". Remove the 6 mounting bolts and fan (4). Radiator and cooler assembly a Remove the radiator assembly to secure a "space" to move and disconnect the transmission assembly backward. 1) Disconnect rear light connector (5). 2) Disconnect air conditioner condenser piping (6). a Disconnect the air conditioner condenser piping since it is installed through the right bottom of the shroud. GD655-3E0, GD675-3E0 50 Disassembly and assembly 3) 4) Remove 3 radiator guard mounting bolts (7). a Mounting bolt (7a) is used to secure the engine hood, too. a Work on the right side similarly. SEN01916-00 7) Disconnect hose (11) from the oil cooler top. 8) 9) Remove radiator mount bolt (12). Remove stay mounting bolt (13). Using sling [1], remove radiator guard (8). 4 Radiator guard: 75 kg 10) Using sling [2], remove radiator and cooler assembly (14). 4 5) 6) Disconnect lower hose (9) from the radiator bottom. Disconnect hose (10) from the oil cooler bottom. GD655-3E0, GD675-3E0 Radiator and cooler assembly: 130 kg 9 SEN01916-00 6. 50 Disassembly and assembly Work equipment pump piping 1) Disconnect outlet hose (15) from the work equipment pump. 2) Disconnect 2 LS pressure hoses (16) from the work equipment pump. 3) 9. 7. Disconnect the clamp of hydraulic tank drain valve hose (17) from the transmission and fix it to the frame. 8. Transmission control wiring harness 1) Disconnect connectors (18), (19) and (20). 2) Remove bracket (21). 10 Disconnect connectors CN-T31 (22) and CN-T43 (23) and remove clamp (24). Transmission pump 1) Remove outlet hose elbow (25) from the transmission pump. 2) Disconnect hoses (26) and (27) from the transmission pump. a Stop the disconnected hoes and elbow with plugs. 3) Remove bracket (28). 4) Remove elbow (29) and suction hose (30). 5) Remove 3 mounting bolts and transmission pump (31). a The transmission pump must be removed since it is an obstacle to removal of the transmission mounting bolts. GD655-3E0, GD675-3E0 50 Disassembly and assembly 10. Remove oil feed pipe (32). 11. Transmission lower piping 1) Disconnect hose (33) from the transmission filter. 2) Remove clamp (34) and disconnect hose (35). 12. Remove universal joint (36) from the lower part. [*2] GD655-3E0, GD675-3E0 SEN01916-00 13. Transmission mounting bolts [*3] 1) Remove 2 left transmission mounting bolts (37). 2) Remove 2 right transmission mounting bolts (38). 14. Transmission assembly 1) Using sling [3], lift up transmission assembly (39) temporarily. 11 SEN01916-00 2) 50 Disassembly and assembly Support the flywheel housing with jack [4]. 15. Related components 1) Using sling [5], remove fan pulley assembly (42). 4 3) 4) 5) Using the sling, lift up the transmission assembly temporarily and remove 12 mounting bolts (40). Move and disconnect transmission assembly (41) backward. [*4] a Using a forcing screw (M10, P1.5 mm), disconnect the transmission assembly from the engine. 2) Using sling [3], lift off transmission assembly (39). 3) 4 12 Transmission assembly: 1,000 kg Remove the 2 mounting bolts. Using sling [6], remove work equipment pump assembly (43). 4 4) Fan pulley assembly: 34 kg Work equipment pump assembly: 57 kg Remove right and mounts (44). Remove pulley (45). left transmission GD655-3E0, GD675-3E0 50 Disassembly and assembly SEN01916-00 Installation Carry out installation in the reverse order to 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 3 Transmission mount bolt: Adhesive (LT-2) 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 assembly. 3 Engine and transmission case mounting bolt: 54 – 74 Nm {6 – 7.5 kgm} q Refilling with oil (Hydraulic tank and transmission 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 6 q Transmission case: 45 l Refilling with coolant 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 q Hydraulic tank: 45 l Coolant: 39.5 l Charging air conditioner with refrigerant Using tool X, charge the air conditioner circuit with refrigerant (R134a). GD655-3E0, GD675-3E0 13 SEN01916-00 50 Disassembly and assembly Disassembly and assembly of torque converter assembly 2. 1 Torque converter lock-up housing 1) Remove snap ring (4), then remove spacer (5). 1 C 790-501-5000 Repair stand (AC100 V) 790-501-5200 Repair stand (AC110 V, 220 V) q 1 790-901-2110 Bracket q 1 793-310-2131 Plate q 1 793-310-2141 Plate q 1 Wrench t 1 Spacer t 1 Spacer t 1 Wrench t 1 2 792-390-1210 3 790-201-2740 790-201-2750 4 790-102-1871 Sketch N/R Part name Q’ty Part number Necessity Symbol Special tools q 1 2) Remove housing mounting bolts (6). 3) Using puller [1], remove torque converter lock-up housing (7). Disassembly 1. 14 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). GD655-3E0, GD675-3E0 50 Disassembly and assembly 3. SEN01916-00 4) 5) Remove bearing (8) from housing (7). Remove piston (9) from housing (7). 4. Turbine assembly Remove turbine assembly (24). 6) 7) Remove seal ring (10) from piston (9). Remove seal ring (11) from housing (7). 5. Stator assembly 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). Drive case 1) Remove disc (12). 2) Remove mounting bolts (22), then using eyebolts [2], remove drive case (23). 2] 3] GD655-3E0, GD675-3E0 Remove snap ring (17) from stator (16). Remove bushings (18) and (19), then remove free wheel (20) from race (21). 15 SEN01916-00 6. Stator shaft 1) Using tool C2, remove nut (25). 2) 3) 4) 16 Remove spacer (29). Turn over pump and stator shaft assembly (26), support gear (27) with block [3], then remove stator shaft (28) with push tool [4]. 50 Disassembly and assembly 7. Disassembly of pump assembly 1) Remove mounting bolts (31), then push bearing (32) from opposite side, and remove together with gear (27) from pump assembly (35). 2) 3) Remove bearing (32) from gear (27). Using forcing screws [5], remove collar (34) from gear (27). Remove seal ring (30) from stator shaft (28). GD655-3E0, GD675-3E0 50 Disassembly and assembly Assembly a a 1. Wash all the parts clean and check that there is no dirt or damage before assembling. Check that the snap ring is securely fitted in the groove. SEN01916-00 2. Stator shaft 1) Install seal ring (30) to stator shaft (28). 2 Outside circumference of seal ring: Grease (G2-LI) Pump assembly 1) Install collar (34) to gear (27). a Align the bolt holes. 2) Install bearing (32) to collar (34). 2) 3) 3) Set stator shaft (28) on work stand, and install to pump assembly (35). a Press fit the inner race end of the bearing. Install spacer (29). 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) GD655-3E0, GD675-3E0 Using tool C2, tighten nut (25). 2 Nut: Thread tightener (LT-2) 3 Nut: 161.8 ± 14.7 Nm {16.5 ± 1.5 kgm} 17 SEN01916-00 3. 50 Disassembly and assembly Stator assembly 1) Assembly of stator assembly 1] Assemble free wheel (20) to race (21), then expand fit bushings (18) and (19). a Coat the sliding surface of the bushing and free wheel with engine oil. a Be careful not to damage the sprag of the free wheel. 2] 2) Install snap ring (17) to stator (16). 4. 3] 18 Rotate stator assembly (13) to right (clockwise) to install. a Check the direction of rotation of the stator from the turbine end (input end). q Clockwise: Free q Counterclockwise: Locked a If the direction of rotation of the stator is not as given above, reverse the race and freewheel assembly, reassemble the stator assembly, then check the direction of rotation again. Turbine assembly Install turbine assembly (24). Fit race and free wheel assembly (15) to stator (16), then install snap ring (14). GD655-3E0, GD675-3E0 50 Disassembly and assembly 5. 6. Drive case 1) Using eyebolt [2], install drive case (23). 2) Tighten mounting bolts (22). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} 3) Install disc (12). SEN01916-00 5) Install bearing (8) with push tool [6]. a Press fit the outer race and inner race at the same time. a Take care that push tool [6] will not touch cage groove (a) of bearing (8). 6) Fit spacer (5) and install snap ring (4). a Check that the snap ring is securely fitted in the groove. 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} 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) 2) 3) 4) Install piston (9) to housing (7). Using eyebolts [2], install housing (7). Temporarily assemble several mounting bolts (6). GD655-3E0, GD675-3E0 19 SEN01916-00 7. 20 50 Disassembly and assembly Pilot Install pilot (3), then tighten mounting bolts (2). 2 Mounting bolt: Thread tightener (LT-2) 3

SEN01775-02D

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