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Komatsu GD655-6 Shop Manual
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Komatsu GD655-6 Shop Manual

Komatsu GD655-6 Shop Manual

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MOTOR GRADER
GD655
GD675
SERIAL NUMBERS
SEN06523-06
-6
-6
GD655- 60001
and up
GD675- 60001

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Summary of Contents for Komatsu GD655-6

  • Page 1 SEN06523-06 MOTOR GRADER GD655 GD675 GD655- 60001 SERIAL NUMBERS and up GD675- 60001...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD GD655-6, GD675-6 00-1 Find manuals at https://best-manuals.com...
  • Page 4 ENGINE SYSTEM ..........................10-48 LAYOUT DRAWING OF ENGINE SYSTEM ................... 10-48 ENGINE CONTROL SYSTEM ....................... 10-51 ENGINE POWER MODE SELECTOR SYSTEM................10-54 AUTOMATIC IDLE STOP SYSTEM ....................10-55 COMPONENT PARTS OF ENGINE SYSTEM ................10-56 00-2 GD655-6, GD675-6 Find manuals at https://best-manuals.com...
  • Page 5 CONTENTS ............................20-2 ABBREVIATION LIST ..........................20-3 STANDARD VALUE TABLE FOR ENGINE ..................... 20-9 STANDARD VALUE TABLE FOR ENGINE: GD655-6 ..............20-9 STANDARD VALUE TABLE FOR ENGINE: GD675-6 ..............20-13 STANDARD VALUE TABLE FOR MACHINE..................20-17 STANDARD VALUE TABLE FOR MACHINE: GD655-6 ..............20-17 STANDARD VALUE TABLE FOR MACHINE: GD675-6 ..............
  • Page 6 BLEED AIR FROM BRAKE CIRCUIT ...................30-169 TEST LOWERING OF WHEEL BRAKE PRESSURE..............30-171 TEST WEAR OF WHEEL BRAKE DISC ..................30-172 TEST PARKING BRAKE OIL PRESSURE ..................30-173 RELEASE PARKING BRAKE MANUALLY ..................30-175 TEST AND ADJUST PARKING BRAKE PAD................30-176 HYDRAULIC SYSTEM.........................30-179 00-4 GD655-6, GD675-6 Find manuals at https://best-manuals.com...
  • Page 7 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .............40-178 FAILURE CODE [1500L0] ......................40-178 FAILURE CODE [15G0MW]......................40-179 FAILURE CODE [15H0MW] ......................40-180 FAILURE CODE [15J0MW]......................40-181 FAILURE CODE [15K0MW] ......................40-182 FAILURE CODE [15L0MW]......................40-184 FAILURE CODE [15M0MW]......................40-186 FAILURE CODE [15N0MW] ......................40-188 GD655-6, GD675-6 00-5 Find manuals at https://best-manuals.com...
  • Page 8 FAILURE CODE [CA144] ......................40-271 FAILURE CODE [CA145] ......................40-273 FAILURE CODE [CA153] ......................40-275 FAILURE CODE [CA154] ......................40-278 FAILURE CODE [CA187] ......................40-280 FAILURE CODE [CA221] ......................40-282 FAILURE CODE [CA222] ......................40-284 FAILURE CODE [CA227] ......................40-286 FAILURE CODE [CA234] ......................40-287 00-6 GD655-6, GD675-6 Find manuals at https://best-manuals.com...
  • Page 9 FAILURE CODE [CA1678] ......................40-381 FAILURE CODE [CA1682] ......................40-382 FAILURE CODE [CA1683] ......................40-386 FAILURE CODE [CA1684] ......................40-388 FAILURE CODE [CA1686] ......................40-390 FAILURE CODE [CA1691] ......................40-391 FAILURE CODE [CA1694] ......................40-394 FAILURE CODE [CA1695] ......................40-397 FAILURE CODE [CA1696] ......................40-398 GD655-6, GD675-6 00-7 Find manuals at https://best-manuals.com...
  • Page 10 FAILURE CODE [CA3165] ......................40-519 FAILURE CODE [CA3229] ......................40-521 FAILURE CODE [CA3231] ......................40-523 FAILURE CODE [CA3232] ......................40-525 FAILURE CODE [CA3235] ......................40-529 FAILURE CODE [CA3239] ......................40-531 FAILURE CODE [CA3241] ......................40-534 FAILURE CODE [CA3242] ......................40-537 FAILURE CODE [CA3251] ......................40-540 00-8 GD655-6, GD675-6 Find manuals at https://best-manuals.com...
  • Page 11 FAILURE CODE [CA3866] ......................40-658 FAILURE CODE [CA3867] ......................40-661 FAILURE CODE [CA3868] ......................40-664 FAILURE CODE [CA3899] ......................40-668 FAILURE CODE [CA3911] ......................40-670 FAILURE CODE [CA3912] ......................40-674 FAILURE CODE [CA3932] ......................40-676 FAILURE CODE [CA3933] ......................40-678 FAILURE CODE [CA3934] ......................40-680 FAILURE CODE [CA3935] ......................40-683 GD655-6, GD675-6 00-9...
  • Page 12 FAILURE CODE [D8ALKB] ......................40-794 FAILURE CODE [D8AQK4]......................40-796 FAILURE CODE [D8AQKR] ......................40-797 FAILURE CODE [DAF0KT] ......................40-799 FAILURE CODE [DAF0MB] ......................40-800 FAILURE CODE [DAF0MC] ......................40-801 FAILURE CODE [DAF3KK] ......................40-802 FAILURE CODE [DAF8KB] ......................40-804 FAILURE CODE [DAFDKB] ......................40-806 FAILURE CODE [DAFLKA] ......................40-808 00-10 GD655-6, GD675-6...
  • Page 13 FAILURE CODE [DPQ3KR] ......................40-901 FAILURE CODE [DV00KB] ......................40-904 FAILURE CODE [DW4BKA]......................40-906 FAILURE CODE [DW4BKB]......................40-908 FAILURE CODE [DW4BKY]......................40-910 FAILURE CODE [DW7BKA]......................40-912 FAILURE CODE [DW7BKB]......................40-914 FAILURE CODE [DW7BKY]......................40-916 FAILURE CODE [DX16KA] ......................40-918 FAILURE CODE [DX16KB] ......................40-920 FAILURE CODE [DX16KY] ......................40-922 GD655-6, GD675-6 00-11...
  • Page 14 E-23 ENGINE TACHOMETER DOES NOT INDICATE NORMALLY ...........40-1029 E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL ........40-1031 E-25 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY .................................40-1033 E-26 ARTICULATION INDICATOR DOES NOT INDICATE ACTUAL ARTICULATED ANGLE ..40-1035 00-12 GD655-6, GD675-6...
  • Page 15 H-12 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..........40-1156 H-13 STEERING WHEEL CANNOT BE OPERATED..............40-1157 H-14 STEERING SPEED OR POWER IS INSUFFICIENT............40-1158 H-15 WHEEL BRAKES DO NOT WORK OR ARE WEAK............40-1159 H-16 WHEEL BRAKES ARE NOT RELEASED OR DRAG ............40-1160 GD655-6, GD675-6 00-13...
  • Page 16 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ............50-13 HOW TO READ THIS MANUAL..................... 50-13 COATING MATERIALS LIST......................50-15 SPECIAL TOOLS LIST ........................50-20 SKETCHES OF SPECIAL TOOLS....................50-38 ENGINE AND COOLING SYSTEM....................... 50-70 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ..............50-70 00-14 GD655-6, GD675-6...
  • Page 17 REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY............50-546 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............50-549 WORK EQUIPMENT..........................50-556 REMOVE AND INSTALL RIPPER ASSEMBLY ................50-556 REMOVE AND INSTALL BLADE ASSEMBLY ................50-562 REMOVE AND INSTALL CIRCLE AND DRAWBAR ASSEMBLY..........50-564 REMOVE AND INSTALL CIRCLE ROTATION GEAR ASSEMBLY ..........50-569 GD655-6, GD675-6 00-15...
  • Page 18 MAINTENANCE STANDARD OF POWER TRAIN PUMP AND DIFFERENTIAL LOCK PUMP..60-51 MAINTENANCE STANDARD OF CONTROL VALVE..............60-52 MAINTENANCE STANDARD OF DIFFERENTIAL LOCK SOLENOID VALVE ....... 60-62 MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE AND LIFTER LOCK PIN CONTROL VALVE ........................60-63 00-16 GD655-6, GD675-6...
  • Page 19 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) ............................. 80-63 A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .......... 80-66 A-5 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER..........80-69 A-6 TROUBLESHOOTING FOR HOT WATER CUT VALVE ..............80-72 GD655-6, GD675-6 00-17...
  • Page 20 ELECTRICAL CIRCUIT DIAGRAM (6/12)..................90-33 ELECTRICAL CIRCUIT DIAGRAM (7/12)..................90-35 ELECTRICAL CIRCUIT DIAGRAM (8/12)..................90-37 ELECTRICAL CIRCUIT DIAGRAM (9/12)..................90-39 ELECTRICAL CIRCUIT DIAGRAM (10/12) ..................90-41 ELECTRICAL CIRCUIT DIAGRAM (11/12) ..................90-43 ELECTRICAL CIRCUIT DIAGRAM (12/12) ..................90-45 INDEX..................................1 00-18 GD655-6, GD675-6...

  • Page 21: Abbreviation List

    (provides better Sensing System combined operation than OLSS). Engine controller electronically controls supply pump, common rail, and injector. This function Common Rail Injection Engine maintains optimum fuel injection amount and fuel injection timing. GD655-6, GD675-6 00-19...
  • Page 22 Technology tronic control and communication. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel Inlet Metering Actuator Engine discharged volume of supply pump. (Same as IMV) 00-20 GD655-6, GD675-6...
  • Page 23 Inlet Metering Valve Engine discharged volume of supply pump. (Same as IMA) This mechanism separates oil in blowby gas and Komatsu Closed Crank- KCCV Engine returns it to the intake side to combust it there. It case Ventilation primarily consists of filters.
  • Page 24 Tip-Over Protectuive chine when it is overtuned.(Hydraulic excavator TOPS Cab and canopy Structure tip-over protective structure) Structure which is standardized as ISO 12117. Solenoid valve that switches over direction of 2-Way Valve Hydraulic system flow. 00-22 GD655-6, GD675-6...
  • Page 25 Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature GD655-6, GD675-6 00-23...
  • Page 26 ABBREVIATION LIST 00 INDEX AND FOREWORD Abbreviation Actual word spelled out Torque Converter Transmission 00-24 GD655-6, GD675-6...

  • Page 27: Troubleshooting

    REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.

  • Page 28: Signal Word

    REMARK Remark This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. 00-26 GD655-6, GD675-6...

  • Page 29: Safety Matters

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...

  • Page 30: Precautions During Work

    Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-). 00-28 GD655-6, GD675-6...
  • Page 31 • Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic- ular. GD655-6, GD675-6 00-29...
  • Page 32 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. 00-30 GD655-6, GD675-6...
  • Page 33 Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane When raising a heavy component (heavier than 25 kg), use a hoist or crane. GD655-6, GD675-6 00-31...
  • Page 34 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 318.3 {32.4} 00-32 GD655-6, GD675-6...
  • Page 35 When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). GD655-6, GD675-6 00-33...
  • Page 36 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". 00-34 GD655-6, GD675-6...
  • Page 37 Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 38 When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual. 00-36 GD655-6, GD675-6...
  • Page 39 Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them. GD655-6, GD675-6 00-37...
  • Page 40 Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. 00-38 GD655-6, GD675-6...
  • Page 41 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 42 If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws. 00-40 GD655-6, GD675-6...
  • Page 43 If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper- ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze. Drain AdBlue/DEF to prevent it from freezing. GD655-6, GD675-6 00-41...
  • Page 44 Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap- propriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs. 00-42 GD655-6, GD675-6...
  • Page 45 Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. GD655-6, GD675-6 00-43...
  • Page 46 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. 00-44 GD655-6, GD675-6...
  • Page 47 Introduction of parts for the disassembly of the face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 GD655-6, GD675-6 00-45...
  • Page 48 Split flange Sleeve head Flange (1) 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032 00-46 GD655-6, GD675-6...
  • Page 49 Introduction of parts for the removal of O-ring boss type joint Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 GD655-6, GD675-6 00-47...
  • Page 50 When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. 00-48 GD655-6, GD675-6...
  • Page 51 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 52 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". 00-50 GD655-6, GD675-6...
  • Page 53 The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage. GD655-6, GD675-6 00-51...
  • Page 54 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. 00-52 GD655-6, GD675-6...
  • Page 55 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 56 Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it. 00-54 GD655-6, GD675-6...
  • Page 57 To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor. GD655-6, GD675-6 00-55...
  • Page 58 Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). 00-56 GD655-6, GD675-6...
  • Page 59 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. GD655-6, GD675-6 00-57...
  • Page 60 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-58 GD655-6, GD675-6...
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This manual is also suitable for:

Gd675-6Gd655- 60001Gd675- 60001