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![Table of contents
00--4 GD555-5,GD655-5,GD675-5
(00)
D R A F T
Testing exhaust gas color.......................................................................................................... 30- 16
Adjusting valve clearance .......................................................................................................... 30- 18
Testing compression pressure................................................................................................... 30- 20
Testing blowby pressure............................................................................................................ 30- 23
Testing engine oil pressure........................................................................................................ 30- 25
Handling fuel system device ...................................................................................................... 30- 26
Releasing remaining pressure from fuel system........................................................................ 30- 27
Testing fuel pressure ................................................................................................................. 30- 28
Bleeding air from fuel circuit....................................................................................................... 30- 29
Testing fuel circuit for leakage ................................................................................................... 30- 30
Cylinder cut-out test mode......................................................................................................... 30- 31
No injection cranking.................................................................................................................. 30- 32
Handling voltage circuit of engine controller .............................................................................. 30- 33
Checking muffler body and muffler stack for looseness and damage ....................................... 30- 34
Checking muffler function .......................................................................................................... 30- 35
Checking cylinder head and manifolds for looseness................................................................ 30- 36
Checking engine piping for damage and looseness .................................................................. 30- 37
Checking fuel delivery, return rate and leakage......................................................................... 30- 38
Replacing alternator belt............................................................................................................ 30- 41
Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]. 30- 42
Power train.................................................................................................................................... 30- 44
Testing power train oil pressure................................................................................................. 30- 44
Adjusting transmission speed sensor ........................................................................................ 30- 56
Emergency escape method in case of transmission valve failure ............................................. 30- 60
Flushing torque converter and trasmission circuits.................................................................... 30- 64
Testing and adjusting toe-in....................................................................................................... 30- 66
Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]......... 30- 68
Steering system ............................................................................................................................ 30- 70
Testing and adjusting steering oil pressure ............................................................................... 30- 70
Testing steering cylinder oil leakage.......................................................................................... 30- 71
Bleeding air from steering circuit................................................................................................ 30- 72
Brake system ................................................................................................................................ 30- 74
Testing and adjusting brake oil pressure ................................................................................... 30- 74
Releasing remaining pressure from brake circuit....................................................................... 30- 78
Bleeding air from brake circuit ................................................................................................... 30- 79
Testing wheel brake disc wear................................................................................................... 30- 80
Testing and adjusting parking brake.......................................................................................... 30- 82
Emergency release method of parking brake ............................................................................ 30- 84
Filling gas into brake accumulator ............................................................................................. 30- 86
Hydraulic system........................................................................................................................... 30- 88
Testing and adjusting work equipment oil pressure................................................................... 30- 88
Testing and adjusting pump LS differential pressure................................................................. 30- 91
Testing lift arm lock cylinder circuit oil pressure [machine with bank cut].................................. 30- 93
Testing work equipment cylinder oil leakage amount ................................................................ 30- 94
Bleeding air from work equipment circuit................................................................................... 30- 97
Work equipment............................................................................................................................ 30- 98
Clearance adjustment of drawbar ball joint................................................................................ 30- 98
Testing and adjusting circle guide clearance............................................................................. 30- 99
Testing and adjusting slip clutch type circle rotator ................................................................... 30- 101
Filling gas into blade accumulator [machine with blade accumulator] ....................................... 30- 103
Electrical system ........................................................................................................................... 30- 104
Procedure for testing diodes...................................................................................................... 30- 104
Special functions of machine monitor (EMMS).......................................................................... 30- 105
Handling high voltage circuit of engine controller ...................................................................... 30- 154
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![GD555-5,GD655-5,GD675-5 00--3
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Table of contents
D R A F T
How to start KOMTRAX terminal operations ............................................................................. 30- 156
Indicator lamps of KOMTRAX terminal...................................................................................... 30- 161
Preparation work for troubleshooting of electrical system ......................................................... 30- 164
Pm clinic ....................................................................................................................................... 30- 166
Pm Clinic- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-166
40 Troubleshooting
General information on troubleshooting........................................................................................ 40- 7
Points to remember when troubleshooting ................................................................................ 40- 7
Sequence of events in troubleshooting...................................................................................... 40- 8
Checks before troubleshooting.................................................................................................. 40- 9
Classification and procedures for troubleshooting..................................................................... 40- 29
Failure codes table .................................................................................................................... 40- 30
Failure and troubleshooting numbers ........................................................................................ 40- 37
Information in troubleshooting table........................................................................................... 40- 39
Troubleshooting method for open circuit in wiring harness of pressure sensor system ............ 40- 41
Connector list and layout ........................................................................................................... 40- 43
Connection table for connector pin numbers ............................................................................. 40- 58
T- branch box and T- branch adapter table ............................................................................... 40- 94
Locations of fuses...................................................................................................................... 40- 97
Troubleshooting by failurecode..................................................................................................... 40- 99
Failure code [1500LO] TORQUEFLOW transmission: Double engagement............................. 40- 99
Failure code [15G0MW] Transmission R clutch: Slip ................................................................ 40- 100
Failure code [15H0MW] Transmission FH clutch: Slip .............................................................. 40- 101
Failure code [15J0MW] Transmission FL clutch: Slip................................................................ 40- 101
Failure code [15K0MW] Transmission 1st clutch: Slip............................................................... 40- 102
Failure code [15L0MW] Transmission 2nd clutch: Slip.............................................................. 40- 103
Failure code [15M0MW] Transmission 3rd speed clutch: Slip................................................... 40- 104
Failure code [15N0MW] Transmission 4th clutch: Slip .............................................................. 40- 105
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF .......... 40- 106
Failure code [15SBMA] ECMV R clutch: Malfunction ................................................................ 40- 108
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF........ 40- 110
Failure code [15SCMA] ECMV FH clutch: Malfunction.............................................................. 40- 112
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF ........ 40- 114
Failure code [15SDMA] ECMV FL clutch: Malfunction .............................................................. 40- 116
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF ........ 40- 118
Failure code [15SEMA] ECMV 1st clutch: Malfunction.............................................................. 40- 120
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF ....... 40- 122
Failure code [15SFMA] ECMV 2nd clutch: Malfunction............................................................. 40- 124
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF ....... 40- 126
Failure code [15SGMA] ECMV 3rd clutch: Malfunction ............................................................. 40- 128
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF........ 40- 130
Failure code [15SHMA] ECMV 4th clutch: Malfunction ............................................................. 40- 132
Failure code [15SJMA] ECMV lockup clutch: Malfunction......................................................... 40- 134
Failure code [15UONT] Inching clutch: Overheating ................................................................. 40- 134
Failure code [2G42ZG] Front accumulater: Oil pressure drop................................................... 40- 135
Failure code [2G43ZG] Rear accumulater: Pressure drop ........................................................ 40- 135
Failure code [AA1ANX] Air cleaner: Clogging ........................................................................... 40- 136
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched. .................. 40- 138
Failure code [AB00MA] Alternator: Malfunction......................................................................... 40- 140
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop ........................... 40- 142
Failure code: [B@BCNS] Engine coolant overheat ................................................................... 40- 142
Failure code: [B@CENS] Torque converter oil overheat........................................................... 40- 143
Failure code: [B@CKNS] Differential case: Overheat ............................................................... 40- 144
Failure code: [B@HANS] Hydraulic oil: Overheating................................................................. 40- 146
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![Table of contents
00--2 GD555-5,GD655-5,GD675-5
(00)
D R A F T
Failure code [CA111] Engine controller internal error................................................................ 40- 148
Failure code [CA115] Engine Ne, Bkup speed sensor error...................................................... 40- 149
Failure code [CA122] Charge pressure sensor high error ......................................................... 40- 150
Failure code [CA123] Charge pressure sensor low error........................................................... 40- 152
Failure code [CA131] Throttle sensor high error........................................................................ 40- 154
Failure code [CA132] Throttle sensor low error ......................................................................... 40- 156
Failure code [CA144] Coolant sensor high error........................................................................ 40- 158
Failure code [CA145] Coolant sensor low error......................................................................... 40- 160
Failure code [CA153] Charge temperature sensor high error.................................................... 40- 162
Failure code [CA154] Charge temperature sensor low error ..................................................... 40- 164
Failure code [CA155] Speed derating error by high charge temperature .................................. 40- 166
Failure code [CA187] Sensor power supply 2 low error............................................................. 40- 168
Failure code [CA221] Atmospheric pressure sensor high error................................................. 40- 170
Failure code [CA222] Atmospheric pressure sensor low error .................................................. 40- 172
Failure code [CA227] Sensor power supply 2 high error ........................................................... 40- 174
Failure code [CA234] Engine overspeed ................................................................................... 40- 174
Failure code [CA238] Ne speed sensor power supply error ...................................................... 40- 175
Failure code [CA271] IMV/IMA: Short circuit ............................................................................. 40- 176
Failure code [CA272] IMV/IMA open circuit............................................................................... 40- 178
Failure code [CA322] Injector #1 (L#1) open/short.................................................................... 40- 180
Failure code [CA323] Injector #5 (L#5) open/short.................................................................... 40- 182
Failure code [CA324] Injector #3 (L#3) open/short.................................................................... 40- 184
Failure code [CA325] Injector #6 (L#6) open/short.................................................................... 40- 186
Failure code [CA331] Injector #2 (L#2) open/short.................................................................... 40- 188
Failure code [CA332] Injector #4 (L#4) open/short.................................................................... 40- 190
Failure code [CA342] Data compatibility error in engine controller............................................ 40- 192
Failure code [CA351] Injector drive circuit error......................................................................... 40- 193
Failure code [CA352] Sensor power supply 1 low error............................................................. 40- 194
Failure code [CA386] Sensor power supply 1 high error ........................................................... 40- 195
Failure code [CA428] Water-in-fuel sensor high error ............................................................... 40- 196
Failure code [CA429] Water-in-fuel sensor low error................................................................. 40- 198
Failure code [CA431] Idle validation switch error....................................................................... 40- 200
Failure code [CA432] Idle validation action error....................................................................... 40- 204
Failure code [CA435] Engine oil pressure switch error.............................................................. 40- 207
Failure code [CA441] Power supply voltage low error............................................................... 40- 208
Failure code [CA442] Power supply voltage high error.............................................................. 40- 210
Failure code [CA449] Common rail pressure high error 2 ......................................................... 40- 211
Failure code [CA451] Common rail pressure sensor high error................................................. 40- 212
Failure code [CA452] Common rail pressure sensor low error.................................................. 40- 214
Failure code [CA488] Torque derating error by high charge temperature ................................. 40- 216
Failure code [CA553] Common rail pressure high error 1 ......................................................... 40- 217
Failure code [CA559] Supply pump pressure low error 1 .......................................................... 40- 218
Failure code [CA689] Engine Ne speed sensor error ................................................................ 40- 219
Failure code [CA731] Engine Bkup speed sensor phase error.................................................. 40- 221
Failure code [CA757] All continuous data lost error................................................................... 40- 222
Failure code [CA778] Engine Bkup speed sensor error............................................................. 40- 223
Failure code [CA1633] KOMNET (CAN communication) error.................................................. 40- 226
Failure code [CA2185] Throttle sensor power supply high error................................................ 40- 228
Failure code [CA2186] Throttle sensor power supply low error................................................. 40- 230
Failure code [CA2249] Supply pump pressure low error 2 ........................................................ 40- 232
Failure code [CA2311] Abnormality in IMV (IMA) solenoid........................................................ 40- 233
Failure code [CA2555] Intake heater relay open circuit............................................................. 40- 234
Failure code [CA2556] Intake heater relay short circuit............................................................. 40- 236
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness..... 40- 238
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![GD555-5,GD655-5,GD675-5 00--1
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Table of contents
D R A F T
Failure code [D160KB] Backup lamp relay: Ground fault .......................................................... 40- 240
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault.................................. 40- 242
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state .......... 40- 244
Failure code [DAFRKR] CAN communication failure (monitor panel) ....................................... 40- 246
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)......... 40- 248
Failure code [DAQOKT] Transmission controller: Non-volatile memory error ........................... 40- 250
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)
................................................................................................................................................... 40- 252
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement
................................................................................................................................................... 40- 254
Failure code [DAQRKR] Transmission controller CAN communication: Communication error . 40- 256
Failure code [DAQRMA] Transmission controller option setting: Malfunction ........................... 40- 260
Failure code [DB2RKR] Engine controller CAN communication: Communication error ............ 40- 261
Failure code [DD1NLD] Fan reverse switch signal: Short circuit ............................................... 40- 268
Failure code [DD1PKB] RPM set switch power supply short circuit .......................................... 40- 270
Failure code [DD1QKB] RPM set mode switch short circuit ...................................................... 40- 272
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error ..................... 40- 274
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit .................................................. 40- 276
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit ................................................... 40- 276
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit .................................................. 40- 277
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit ................................................. 40- 277
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit ................................................. 40- 278
Failure code [DDTNKA] Fill switch for R clutch: Open circuit .................................................... 40- 279
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit .................................................. 40- 280
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input ................ 40- 281
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error . 40- 285
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range.......... 40- 288
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault................................... 40- 290
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range.... 40- 292
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault................................. 40- 294
Failure code [DJF1KA] Fuel level sensor: Open circuit ............................................................. 40- 296
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range.......................... 40- 298
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range............................. 40- 300
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit........................... 40- 302
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match 40- 303
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit............... 40- 304
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match
................................................................................................................................................... 40- 305
Failure code [DLM3KA] Fan speed sensor: Open circuit........................................................... 40- 306
Failure code [DLM3LC] Fan speed sensor: Short circuit........................................................... 40- 307
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit ........................ 40- 308
Failure code [DV00KB] Buzzer: Short circuit............................................................................. 40- 310
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit......................................... 40- 312
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit......................................... 40- 314
Failure code [DW7BKA] Fan reverse solenoid: Open circuit..................................................... 40- 315
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..................................................... 40- 316
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line .................... 40- 318
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit................................................. 40- 320
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit................................................. 40- 321
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line ................ 40- 322
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit.................................................. 40- 324
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit .................................................. 40- 325
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line ................. 40- 326
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit .............................................. 40- 328
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![Table of contents
00-0 GD555-5,GD655-5,GD675-5
(00)
D R A F T
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit............................................... 40- 329
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line.............. 40- 330
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit ............................................... 40- 332
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit ............................................... 40- 334
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line............... 40- 336
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit............................................... 40- 338
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit............................................... 40- 340
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line.............. 40- 342
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit ............................................. 40- 344
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.............................................. 40- 346
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line............. 40- 348
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit .............................................. 40- 350
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit .............................................. 40- 352
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line.............. 40- 354
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit................................................. 40- 356
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit................................................. 40- 357
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line ................ 40- 358
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit.............................................. 40- 360
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.............................................. 40- 362
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line ............. 40- 364
Troubleshooting of electrical system (E-mode)............................................................................. 40- 366
E-1 Engine does not start (starting motor does not turn)........................................................... 40- 366
E-2 Preheating does not work.................................................................................................... 40- 372
E-3 When starting switch is turned to ON position, machine monitor displays nothing ............. 40- 377
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen
................................................................................................................................................... 40- 380
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine mon-
itor does not display correct screen ........................................................................................... 40- 380
E-6 Emergency stop monitor lights up while engine is running ................................................. 40- 381
E-7 Speedometer or engine tachometer does not indicate correctly......................................... 40- 385
E-8 Engine coolant temperature gauge does not indicate correctly .......................................... 40- 386
E-9 Articulation angle indicator does not indicate correctly ....................................................... 40- 388
E-10 Torque converter oil temperature gauge does not indicate correctly ................................ 40- 390
E-11 Fuel level gauge does not indicate correctly ..................................................................... 40- 392
E-12 Character display does not display correctly..................................................................... 40- 394
E-13 Centralized warning lamp does not light up or does not go off ......................................... 40- 396
E-14 Alarm buzzer does not sound or does not stop sounding ................................................. 40- 398
E-15 Machine monitor mode selector switch does not work...................................................... 40- 400
E-16 Transmission mode does not switch ................................................................................. 40- 404
E-17 Engine mode does not switch ........................................................................................... 40- 406
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock spec-
ification]...................................................................................................................................... 40- 408
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]
................................................................................................................................................... 40- 412
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator
specification] .............................................................................................................................. 40- 414
E-21 Horn does not sound or does not stop sounding............................................................... 40- 418
E-22 Backup alarm does not sound or does not stop sounding ................................................ 40- 420
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off ......................... 40- 423
E-24 Working lamp does not light up or does not go off............................................................ 40- 430
E-25 Turn signal lamp and hazard lamp do not flash. ............................................................... 40- 436
E-26 Stop lamp does not light up or does not go off.................................................................. 40- 442
E-27 Backup lamp does not light up or does not go off ............................................................. 40- 444
E-28 Windshield wiper does not operate ................................................................................... 40- 446
00-3-5
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![GD555-5,GD655-5,GD675-5 00-9
Foreword and general information
Safety notice
D R A F T
8. Precautions for disconnecting and
connecting hoses and tubes in air condi-
tioner circuit
1) Disconnection
k For the environment, the air condition-
er of this machine uses the refrigerant
(air conditioner gas: R134a) which has
fewer factors of the depletion of the
ozone layer. However, it does not
mean that you may discharge the re-
frigerant into the atmosphere as it is.
Be sure to recover the refrigerant
when disconnecting the refrigerant
gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight and your skin may be fro-
zen. Accordingly, put on safety glass-
es, safety gloves and safety clothes
when recovering or adding the refrig-
erant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring (1) is not
damaged or deteriorated.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings (1).
a Example of O-ring (Fitted to every
joint of hoses and tubes)
a For tightening torque, see the precau-
tions for installation in each section of
"Disassembly and assembly".](https://image.slidesharecdn.com/001-028komatsugd655-5workshopmanual1-200828071901/75/Komatsu-Gd655-5-Workshop-Manual-28-2048.jpg)
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Komatsu Gd655 5 Workshop Manual
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- 3. GD555-5, GD655-5, GD675-51 (05) Notice of revision Notice of revision 6th. revision The affected pages are indicated by the use of the following marks. It is requested that necessary ac- tions must be taken to these pages according to the list below. 2011/11 List of revised pages Mark Indication Action required Q Page to be newly added Add q Page to be replaced Replace ( ) Page to be deleted Discard Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number q 1 (06) 00-26 10-7 10-48 q 2 (06) 00-27 10-8 10-49 3 (05) 00-28 10-9 10-50 4 (05) 00-29 10-10 10-51 5 (05) 00-30 10-11 10-52 6 (05) 00-31 10-12 10-53 7 (05) 00-32 10-13 10-54 q 8 (06) 00-33 10-14 10-55 00-1 00-34 10-15 10-56 00-2 00-35 10-16 10-57 00-3 (05) 00-36 10-17 10-58 00-3-1 (03) 00-37 10-18 10-59 00-3-2 (01) 00-38 10-19 10-60 00-3-3 (01) 00-39 10-20 10-61 00-3-4 (01) 00-40 10-21 10-62 00-3-5 (01) 00-41 10-22 10-63 00-3-6 (01) 00-42 10-23 10-64 00-3-7 (02) 00-43 10-24 10-65 00-3-8 (02) 00-44 10-25 10-66 00-4 (02) 00-45 10-26 10-67 00-5 00-46 10-27 10-68 00-6 00-47 10-28 10-69 00-7 00-48 10-29 10-70 00-8 01-1 10-30 10-71 00-9 01-2 10-31 10-72 00-10 01-3 10-32 10-73 00-11 01-4 10-33 10-74 00-12 01-5 10-34 10-75 00-13 01-6 10-35 10-76 00-14 01-7 10-36 10-77 00-15 01-8 10-37 10-78 00-16 01-9 10-38 10-79 00-17 01-10 10-39 10-80 00-18 01-11 10-40 10-81 00-19 01-12 10-41 10-82 00-20 10-1 10-42 10-83 00-21 10-2 (05) 10-43 10-84 00-22 10-3 10-44 10-85 00-23 10-4 10-45 10-86 00-24 10-5 10-46 10-87 00-25 10-6 10-47 10-88 (06)
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- 5. Notice of revision 2GD555-5, GD655-5, GD675-5 (05) 10-89 10-135 10-187 20-5 (01) 10-90 10-136 10-188 20-6 (01) 10-91 10-137 10-189 20-7 (01) 10-92 10-138 10-190 20-8 (01) 10-93 10-139 10-191 20-9 (04) 10-94 10-140 10-192 q 20-10 (06) 10-95 10-141 10-193 20-11 (01) 10-96 10-142 10-194 20-12 (01) 10-97 10-143 10-195 30-1 (01) 10-98 10-144 10-196 30-2 (03) 10-99 (05) 10-145 10-197 30-3 (01) 10-99-1 (05) 10-146 10-198 30-4 (01) 10-99-2 (05) 10-147 10-199 30-5 (01) 10-99-3 (05) 10-148 10-200 30-6 (01) 10-99-4 (05) 10-149 10-201 30-7 (01) 10-99-5 (05) 10-150 10-202 30-8 (01) 10-99-6 (05) 10-151 10-203 30-9 (01) 10-100 10-152 10-204 30-10 (01) 10-101 10-153 10-205 30-11 (01) 10-102 10-154 10-206 (03) 30-12 (01) 10-103 10-155 10-207 30-13 (01) 10-104 10-156 10-207-1 (03) 30-14 (01) 10-105 10-157 10-207-2 (03) 30-15 (01) 10-106 10-158 10-208 30-16 (01) 10-107 10-159 10-209 30-17 (01) 10-108 10-160 10-210 30-18 (01) 10-109 10-161 10-211 30-19 (01) 10-110 10-162 10-212 30-20 (01) 10-111 10-163 10-213 30-21 (01) 10-112 10-164 10-214 30-22 (01) 10-113 10-165 10-215 30-23 (01) 10-114 10-166 10-216 30-24 (01) 10-115 10-167 10-217 30-25 (01) 10-116 10-168 10-218 30-26 (01) 10-117 10-169 10-219 30-27 (01) 10-118 10-170 10-220 30-28 (01) 10-119 10-171 10-221 30-29 (01) 10-120 10-172 10-222 30-30 (01) 10-121 10-173 10-223 30-31 (01) 10-122 10-174 10-224 30-32 (01) 10-123 10-175 10-225 30-33 (01) 10-124 10-176 10-226 30-34 (01) 10-125 10-177 10-227 30-35 (01) 10-126 10-178 10-228 30-36 (01) 10-127 10-179 10-229 30-37 (01) 10-128 10-180 10-230 30-38 (01) 10-129 10-181 10-231 30-39 (01) 10-130 10-182 10-232 30-40 (01) 10-131 10-183 20-1 (01) 30-41 (03) 10-132 10-184 20-2 (01) 30-42 (01) 10-133 10-185 20-3 (01) 30-43 (01) 10-134 10-186 20-4 (01) 30-44 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number (06)
- 6. GD555-5, GD655-5, GD675-53 (05) Notice of revision 30-45 (01) 30-97 (01) 30-149 (01) 40-19 (01) 30-46 (01) 30-98 (01) 30-150 (01) 40-20 (01) 30-47 (01) 30-99 (01) 30-151 (01) 40-21 (01) 30-48 (01) 30-100 (01) 30-152 (01) 40-22 (01) 30-49 (01) 30-101 (01) 30-153 (01) 40-23 (01) 30-50 (01) 30-102 (01) 30-154 (01) 40-24 (01) 30-51 (01) 30-103 (01) 30-155 (01) 40-25 (01) 30-52 (01) 30-104 (01) 30-156 (01) 40-26 (01) 30-53 (01) 30-105 (01) 30-157 (03) 40-27 (01) 30-54 (01) 30-106 (01) 30-158 (01) 40-28 (01) 30-55 (01) 30-107 (01) 30-159 (01) 40-29 (01) 30-56 (01) 30-108 (01) 30-160 (01) 40-30 (01) 30-57 (01) 30-109 (01) 30-160-1 (03) 40-31 (01) 30-58 (01) 30-110 (01) 30-160-2 (03) 40-32 (01) 30-59 (01) 30-111 (01) 30-160-3 (03) 40-33 (01) 30-60 (01) 30-112 (01) 30-160-4 (03) 40-34 (01) 30-61 (01) 30-113 (01) 30-161 (03) 40-35 (01) 30-62 (01) 30-114 (01) 30-162 (01) 40-36 (01) 30-63 (01) 30-115 (01) 30-163 (01) 40-37 (01) 30-64 (01) 30-116 (01) 30-163-1 (03) 40-38 (01) 30-65 (01) 30-117 (01) 30-163-2 (03) 40-39 (01) 30-66 (01) 30-118 (01) 30-163-3 (03) 40-40 (01) 30-67 (01) 30-119 (01) 30-163-4 (03) 40-41 (01) 30-68 (01) 30-120 (01) 30-164 (01) 40-42 (01) 30-69 (01) 30-121 (01) 30-165 (01) 40-43 (01) 30-70 (01) 30-122 (01) 30-166 (01) 40-44 (01) 30-71 (01) 30-123 (01) 30-167 (01) 40-45 (01) 30-72 (01) 30-124 (01) 30-168 (01) 40-46 (01) 30-73 (01) 30-125 (01) 30-169 (01) 40-47 (01) 30-74 (01) 30-126 (01) 30-170 (01) 40-48 (01) 30-75 (01) 30-127 (01) 30-171 (01) 40-49 (01) 30-76 (01) 30-128 (01) 30-172 (01) 40-50 (01) 30-77 (04) 30-129 (01) 30-173 (01) 40-51 (01) 30-78 (01) 30-130 (01) 30-174 (01) 40-52 (01) 30-79 (01) 30-131 (01) 40-1 (01) 40-53 (01) 30-80 (01) 30-132 (01) 40-2 (01) 40-54 (01) 30-81 (01) 30-133 (01) 40-3 (01) 40-55 (01) 30-82 (01) 30-134 (01) 40-4 (01) 40-56 (01) 30-83 (01) 30-135 (01) 40-5 (01) 40-57 (01) 30-84 (01) 30-136 (01) 40-6 (01) 40-58 (01) 30-85 (01) 30-137 (01) 40-7 (01) 40-59 (01) 30-86 (01) 30-138 (01) 40-8 (01) 40-60 (01) 30-87 (01) 30-139 (01) 40-9 (01) 40-61 (01) 30-88 (01) 30-140 (01) 40-10 (01) 40-62 (01) 30-89 (04) 30-141 (01) 40-11 (01) 40-63 (01) 30-90 (01) 30-142 (01) 40-12 (01) 40-64 (01) 30-91 (01) 30-143 (01) 40-13 (01) 40-65 (01) 30-92 (01) 30-144 (01) 40-14 (01) 40-66 (01) 30-93 (01) 30-145 (01) 40-15 (01) 40-67 (01) 30-94 (01) 30-146 (01) 40-16 (01) 40-68 (01) 30-95 (01) 30-147 (01) 40-17 (01) 40-69 (01) 30-96 (01) 30-148 (01) 40-18 (01) 40-70 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number
- 7. Notice of revision 4GD555-5, GD655-5, GD675-5 (05) 40-71 (01) 40-123 (01) 40-175 (01) 40-227 (01) 40-72 (01) 40-124 (01) 40-176 (01) 40-228 (01) 40-73 (01) 40-125 (01) 40-177 (01) 40-229 (01) 40-74 (01) 40-126 (01) 40-178 (01) 40-230 (01) 40-75 (01) 40-127 (01) 40-179 (01) 40-231 (01) 40-76 (01) 40-128 (01) 40-180 (01) 40-232 (01) 40-77 (01) 40-129 (01) 40-181 (01) 40-233 (01) 40-78 (01) 40-130 (01) 40-182 (01) 40-234 (01) 40-79 (01) 40-131 (01) 40-183 (01) 40-235 (01) 40-80 (01) 40-132 (01) 40-184 (01) 40-236 (01) 40-81 (01) 40-133 (01) 40-185 (01) 40-237 (01) 40-82 (01) 40-134 (01) 40-186 (01) 40-238 (01) 40-83 (01) 40-135 (01) 40-187 (01) 40-239 (01) 40-84 (01) 40-136 (01) 40-188 (01) 40-240 (01) 40-85 (01) 40-137 (01) 40-189 (01) 40-241 (01) 40-86 (01) 40-138 (01) 40-190 (01) 40-242 (01) 40-87 (01) 40-139 (01) 40-191 (01) 40-243 (01) 40-88 (01) 40-140 (01) 40-192 (01) 40-244 (01) 40-89 (01) 40-141 (01) 40-193 (01) 40-245 (01) 40-90 (01) 40-142 (01) 40-194 (01) 40-246 (01) 40-91 (01) 40-143 (01) 40-195 (01) 40-247 (01) 40-92 (01) 40-144 (01) 40-196 (01) 40-248 (01) 40-93 (01) 40-145 (01) 40-197 (01) 40-249 (01) 40-94 (01) 40-146 (01) 40-198 (01) 40-250 (01) 40-95 (01) 40-147 (01) 40-199 (01) 40-251 (01) 40-96 (01) 40-148 (01) 40-200 (01) 40-252 (01) 40-97 (01) 40-149 (01) 40-201 (01) 40-253 (01) 40-98 (01) 40-150 (01) 40-202 (01) 40-254 (01) 40-99 (01) 40-151 (01) 40-203 (01) 40-255 (01) 40-100 (01) 40-152 (01) 40-204 (01) 40-256 (01) 40-101 (01) 40-153 (01) 40-205 (01) 40-257 (01) 40-102 (01) 40-154 (01) 40-206 (01) 40-258 (01) 40-103 (01) 40-155 (01) 40-207 (01) 40-259 (01) 40-104 (01) 40-156 (01) 40-208 (01) 40-260 (01) 40-105 (01) 40-157 (01) 40-209 (01) 40-261 (01) 40-106 (01) 40-158 (01) 40-210 (01) 40-262 (01) 40-107 (01) 40-159 (01) 40-211 (01) 40-263 (01) 40-108 (01) 40-160 (01) 40-212 (01) 40-264 (01) 40-109 (01) 40-161 (01) 40-213 (01) 40-265 (01) 40-110 (01) 40-162 (01) 40-214 (01) 40-266 (01) 40-111 (01) 40-163 (01) 40-215 (01) 40-267 (01) 40-112 (01) 40-164 (01) 40-216 (01) 40-268 (01) 40-113 (01) 40-165 (01) 40-217 (01) 40-269 (01) 40-114 (01) 40-166 (01) 40-218 (01) 40-270 (01) 40-115 (01) 40-167 (01) 40-219 (01) 40-271 (01) 40-116 (01) 40-168 (01) 40-220 (01) 40-272 (01) 40-117 (01) 40-169 (01) 40-221 (01) 40-273 (01) 40-118 (01) 40-170 (01) 40-222 (01) 40-274 (01) 40-119 (01) 40-171 (01) 40-223 (01) 40-275 (01) 40-120 (01) 40-172 (01) 40-224 (01) 40-276 (01) 40-121 (01) 40-173 (01) 40-225 (01) 40-277 (01) 40-122 (01) 40-174 (01) 40-226 (01) 40-278 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number
- 8. GD555-5, GD655-5, GD675-55 (05) Notice of revision 40-279 (01) 40-331 (01) 40-383 (01) 40-435 (01) 40-280 (01) 40-332 (01) 40-384 (01) 40-436 (01) 40-281 (01) 40-333 (01) 40-385 (01) 40-437 (01) 40-282 (01) 40-334 (01) 40-386 (01) 40-438 (01) 40-283 (01) 40-335 (01) 40-387 (01) 40-439 (01) 40-284 (01) 40-336 (01) 40-388 (01) 40-440 (01) 40-285 (01) 40-337 (01) 40-389 (01) 40-441 (01) 40-286 (01) 40-338 (01) 40-390 (01) 40-442 (01) 40-287 (01) 40-339 (01) 40-391 (01) 40-443 (01) 40-288 (01) 40-340 (01) 40-392 (01) 40-444 (01) 40-289 (01) 40-341 (01) 40-393 (01) 40-445 (01) 40-290 (01) 40-342 (01) 40-394 (01) 40-446 (01) 40-291 (01) 40-343 (01) 40-395 (01) 40-447 (01) 40-292 (01) 40-344 (01) 40-396 (01) 40-448 (01) 40-293 (01) 40-345 (01) 40-397 (01) 40-449 (01) 40-294 (01) 40-346 (01) 40-398 (01) 40-450 (01) 40-295 (01) 40-347 (01) 40-399 (01) 40-451 (01) 40-296 (01) 40-348 (01) 40-400 (01) 40-452 (01) 40-297 (01) 40-349 (01) 40-401 (01) 40-453 (01) 40-298 (01) 40-350 (01) 40-402 (01) 40-454 (01) 40-299 (01) 40-351 (01) 40-403 (01) 40-455 (01) 40-300 (01) 40-352 (01) 40-404 (01) 40-456 (01) 40-301 (01) 40-353 (01) 40-405 (01) 40-457 (01) 40-302 (01) 40-354 (01) 40-406 (01) 40-458 (03) 40-303 (01) 40-355 (01) 40-407 (01) 40-459 (03) 40-304 (01) 40-356 (01) 40-408 (01) 40-459-1 (03) 40-305 (01) 40-357 (01) 40-409 (01) 40-459-2 (03) 40-306 (01) 40-358 (01) 40-410 (01) 40-460 (01) 40-307 (01) 40-359 (01) 40-411 (01) 40-461 (01) 40-308 (01) 40-360 (01) 40-412 (01) 40-462 (01) 40-309 (01) 40-361 (01) 40-413 (01) 40-463 (01) 40-310 (01) 40-362 (01) 40-414 (01) 40-464 (01) 40-311 (01) 40-363 (01) 40-415 (01) 40-465 (01) 40-312 (01) 40-364 (01) 40-416 (01) 40-466 (01) 40-313 (01) 40-365 (01) 40-417 (01) 40-467 (01) 40-314 (01) 40-366 (01) 40-418 (01) 40-468 (01) 40-315 (01) 40-367 (01) 40-419 (01) 40-469 (01) 40-316 (01) 40-368 (01) 40-420 (01) 40-470 (01) 40-317 (01) 40-369 (01) 40-421 (01) 40-471 (01) 40-318 (01) 40-370 (01) 40-422 (01) 40-472 (01) 40-319 (01) 40-371 (01) 40-423 (01) 40-473 (01) 40-320 (01) 40-372 (01) 40-424 (01) 40-474 (01) 40-321 (01) 40-373 (01) 40-425 (01) 40-475 (01) 40-322 (01) 40-374 (01) 40-426 (01) 40-476 (01) 40-323 (01) 40-375 (01) 40-427 (01) 40-477 (01) 40-324 (01) 40-376 (01) 40-428 (01) 40-478 (01) 40-325 (01) 40-377 (01) 40-429 (01) 40-479 (01) 40-326 (01) 40-378 (01) 40-430 (01) 40-480 (01) 40-327 (01) 40-379 (01) 40-431 (01) 40-481 (01) 40-328 (01) 40-380 (01) 40-432 (01) 40-482 (01) 40-329 (01) 40-381 (01) 40-433 (01) 40-483 (01) 40-330 (01) 40-382 (01) 40-434 (01) 40-484 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number
- 9. Notice of revision 6GD555-5, GD655-5, GD675-5 (05) 40-485 (01) 50-7 (02) 50-59 (02) 50-111 (02) 40-486 (01) 50-8 (02) 50-60 (02) 50-112 (02) 40-487 (01) 50-9 (02) 50-61 (02) 50-113 (02) 40-488 (01) 50-10 (02) 50-62 (02) 50-114 (02) 40-489 (01) 50-11 (02) 50-63 (02) 50-115 (02) 40-490 (01) 50-12 (02) 50-64 (02) 50-116 (02) 40-491 (01) 50-13 (02) 50-65 (02) 50-117 (02) 40-492 (01) 50-14 (02) 50-66 (02) 50-118 (02) 40-493 (01) 50-15 (02) 50-67 (02) 50-119 (02) 40-494 (01) 50-16 (02) 50-68 (02) 50-120 (02) 40-495 (01) 50-17 (02) 50-69 (02) 50-121 (02) 40-496 (01) 50-18 (02) 50-70 (02) 50-122 (02) 40-497 (01) 50-19 (02) 50-71 (02) 50-123 (02) 40-498 (01) 50-20 (02) 50-72 (02) 50-124 (02) 40-499 (01) 50-21 (02) 50-73 (02) 50-125 (02) 40-500 (01) 50-22 (02) 50-74 (02) 50-126 (02) 40-501 (01) 50-23 (02) 50-75 (02) 50-127 (02) 40-502 (01) 50-24 (02) 50-76 (02) 50-128 (02) 40-503 (01) 50-25 (02) 50-77 (02) 50-129 (02) 40-504 (01) 50-26 (02) 50-78 (02) 50-130 (02) 40-505 (01) 50-27 (02) 50-79 (02) 50-131 (02) 40-506 (01) 50-28 (02) 50-80 (02) 50-132 (02) 40-507 (01) 50-29 (02) 50-81 (02) 50-133 (02) 40-508 (01) 50-30 (02) 50-82 (02) 50-134 (02) 40-509 (01) 50-31 (02) 50-83 (02) 50-135 (02) 40-510 (01) 50-32 (02) 50-84 (02) 50-136 (02) 40-511 (01) 50-33 (02) 50-85 (02) 50-137 (02) 40-512 (01) 50-34 (02) 50-86 (02) 50-138 (02) 40-513 (01) 50-35 (02) 50-87 (02) 50-139 (02) 40-514 (01) 50-36 (02) 50-88 (02) 50-140 (02) 40-515 (01) 50-37 (02) 50-89 (02) 50-141 (02) 40-516 (01) 50-38 (02) 50-90 (02) 50-142 (02) 40-517 (01) 50-39 (02) 50-91 (02) 50-143 (02) 40-518 (01) 50-40 (02) 50-92 (02) 50-144 (02) 40-519 (01) 50-41 (02) 50-93 (02) 50-145 (02) 40-520 (01) 50-42 (02) 50-94 (02) 50-146 (02) 40-521 (01) 50-43 (02) 50-95 (02) 50-147 (02) 40-522 (01) 50-44 (02) 50-96 (02) 50-148 (02) 40-523 (01) 50-45 (02) 50-97 (02) 50-149 (02) 40-524 (01) 50-46 (02) 50-98 (02) 50-150 (02) 40-525 (01) 50-47 (02) 50-99 (02) 50-151 (02) 40-526 (01) 50-48 (02) 50-100 (02) 50-152 (02) 40-527 (01) 50-49 (02) 50-101 (02) 50-153 (02) 40-528 (01) 50-50 (02) 50-102 (02) 50-154 (02) 40-529 (01) 50-51 (02) 50-103 (02) 50-155 (02) 40-530 (01) 50-52 (02) 50-104 (02) 50-156 (02) 50-1 (02) 50-53 (02) 50-105 (02) 50-157 (02) 50-2 (02) 50-54 (02) 50-106 (02) 50-158 (02) 50-3 (02) 50-55 (02) 50-107 (02) 50-159 (02) 50-4 (02) 50-56 (02) 50-108 (02) 50-160 (02) 50-5 (02) 50-57 (02) 50-109 (02) 50-161 (02) 50-6 (02) 50-58 (02) 50-110 (02) 50-162 (02) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number
- 10. GD555-5, GD655-5, GD675-57 (05) Notice of revision 50-163 (02) 50-215 (02) 50-267 (02) 60-39 50-164 (02) 50-216 (02) 50-268 (02) 60-40 50-165 (02) 50-217 (02) 50-269 (02) 60-41 50-166 (02) 50-218 (02) 50-270 (02) 60-42 50-167 (02) 50-219 (02) 50-271 (02) 60-43 50-168 (02) 50-220 (02) 50-272 (02) 60-44 50-169 (02) 50-221 (02) 50-273 (02) 60-45 50-170 (02) 50-222 (02) 50-274 (02) 60-46 50-171 (02) 50-223 (02) 50-275 (02) 60-47 50-172 (02) 50-224 (02) 50-276 (02) 60-48 50-173 (02) 50-225 (02) 50-277 (02) 60-49 50-174 (02) 50-226 (02) 50-278 (02) 60-50 50-175 (02) 50-227 (02) 50-279 (02) 60-51 50-176 (02) 50-228 (02) 50-280 (02) 60-52 50-177 (02) 50-229 (02) 60-1 60-53 50-178 (02) 50-230 (02) 60-2 60-54 50-179 (02) 50-231 (02) 60-3 60-55 50-180 (02) 50-232 (02) 60-4 60-56 50-181 (02) 50-233 (02) 60-5 60-57 50-182 (02) 50-234 (02) 60-6 60-58 50-183 (02) 50-235 (02) 60-7 60-59 50-184 (02) 50-236 (02) 60-8 60-60 50-185 (02) 50-237 (02) 60-9 60-61 50-186 (02) 50-238 (02) 60-10 60-62 50-187 (02) 50-239 (02) 60-11 60-63 50-188 (02) 50-240 (02) 60-12 60-64 50-189 (02) 50-241 (02) 60-13 80-1 (01) 50-190 (02) 50-242 (02) 60-14 80-2 (01) 50-191 (02) 50-243 (02) 60-15 80-3 (01) 50-192 (02) 50-244 (02) 60-16 80-4 (01) 50-193 (02) 50-245 (02) 60-17 80-5 (01) 50-194 (02) 50-246 (02) 60-18 80-6 (01) 50-195 (02) 50-247 (02) 60-19 80-7 (01) 50-196 (02) 50-248 (02) 60-20 80-8 (01) 50-197 (02) 50-249 (02) 60-21 80-9 (01) 50-198 (02) 50-250 (02) 60-22 80-10 (01) 50-199 (02) 50-251 (02) 60-23 80-11 (01) 50-200 (02) 50-252 (02) 60-24 80-12 (01) 50-201 (02) 50-253 (02) 60-25 80-13 (01) 50-202 (02) 50-254 (02) 60-26 80-14 (01) 50-203 (02) 50-255 (02) 60-27 80-15 (01) 50-204 (02) 50-256 (02) 60-28 80-16 (01) 50-205 (02) 50-257 (02) 60-29 80-17 (01) 50-206 (02) 50-258 (02) 60-30 80-18 (01) 50-207 (02) 50-259 (02) 60-31 80-19 (01) 50-208 (02) 50-260 (02) 60-32 80-20 (01) 50-209 (02) 50-261 (02) 60-33 80-21 (01) 50-210 (02) 50-262 (02) 60-34 80-22 (01) 50-211 (02) 50-263 (02) 60-35 80-23 (01) 50-212 (02) 50-264 (02) 60-36 80-24 (01) 50-213 (02) 50-265 (02) 60-37 80-25 (01) 50-214 (02) 50-266 (02) 60-38 80-26 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number
- 11. Notice of revision 8GD555-5, GD655-5, GD675-5 (05) 80-27 (01) 90-33 (01) 80-28 (01) 90-35 (03) 80-29 (01) 1 (05) 80-30 (01) 2 (02) 80-31 (01) 3 (02) 80-32 (01) 4 (02) 80-33 (01) 5 (02) 80-34 (01) 6 (03) 80-35 (01) q Colo- phon (06) 80-36 (01) 80-37 (01) 80-38 (01) 80-39 (01) 80-40 (01) 80-41 (01) 80-42 (01) 80-43 (01) 80-44 (01) 80-45 (01) 80-46 (01) 80-47 (01) 80-48 (01) 80-49 (01) 80-50 (01) 80-51 (01) 80-52 (01) 80-53 (01) 80-54 (01) 80-55 (01) 80-56 (01) 80-57 (01) 80-58 (01) 90-1 90-2 (01) 90-3 90-4 90-5 90-7 (01) 90-9 (01) 90-11 (01) 90-13 (01) 90-14 (01) 90-15 (01) 90-16 (01) 90-17 (01) 90-19 (01) 90-21 (01) 90-23 (01) 90-25 (01) 90-27 (01) 90-29 (01) 90-31 (01) Mark Page Revision number Mark Page Revision number Mark Page Revision number Mark Page Revision number (06)
- 12. GD555-5,GD655-5,GD675-5 00-1 D RA F T SEN0521502-00 GD555-5,GD655-5,GD675-5 Shop Manual MOTOR GRADER GD555-5 GD655-5 GD675-5 Machine model Serial number GD555-5 55001 and up GD655-5 55001 and up GD675-5 55001 and up 00 Index and foreword4
- 13. Table of contents 00-2GD555-5,GD655-5,GD675-5 D R A F T Table of contents Composition of shop manual 00 Index and foreword Table of contents .......................................................................................................................... 00 - 2 Table of contents ....................................................................................................................... 00 - 2 Foreword and general information................................................................................................ 00 - 5 Safety notice .............................................................................................................................. 00 - 5 How to read the shop manual.................................................................................................... 00 - 10 Explanation of terms for maintenance standard ........................................................................ 00 - 12 Handling of electric equipment and hydraulic components........................................................ 00 - 14 Handling of connectors newly used for engines ........................................................................ 00 - 23 How to read electric wire code................................................................................................... 00 - 26 Precautions when carrying out work.......................................................................................... 00 - 29 Method of disassembling and connecting push-pull type coupler.............................................. 00 - 32 Standard tightening torque table................................................................................................ 00 - 35 List of Abbreviation .................................................................................................................... 00 - 39 Conversion table........................................................................................................................ 00 - 43 01 Specification Specification drawing................................................................................................................. 01 - 3 Specifications............................................................................................................................. 01 - 4 Weight table............................................................................................................................... 01 - 10 Table of fuel, coolant and lubricants .......................................................................................... 01 - 11 10 Structure, function and maintenance standard Engine and Cooling....................................................................................................................... 10 - 4 Cooling system .......................................................................................................................... 10 - 4 Cooling fan pump....................................................................................................................... 10 - 6 Power train system ....................................................................................................................... 10 - 14 Power train system drawing....................................................................................................... 10 - 14 Power train piping drawing......................................................................................................... 10 - 16 Transmission control.................................................................................................................. 10 - 18 Torque converter........................................................................................................................ 10 - 20 Transmission.............................................................................................................................. 10 - 24 Transmission control valve ........................................................................................................ 10 - 46 ECMV......................................................................................................................................... 10 - 50 Main relief and torque converter relief valve.............................................................................. 10 - 58 Front axle................................................................................................................................... 10 - 60 Final drive (no differential specification)..................................................................................... 10 - 64 Final drive (differential/ differential lock specification)................................................................ 10 - 66 Differential lock solenoid valve................................................................................................... 10 - 68 Tandem drive............................................................................................................................. 10 - 70 Steering system ............................................................................................................................ 10 - 72 Steering piping diagram............................................................................................................. 10 - 72 Priority valve .............................................................................................................................. 10 - 74 Steering valve ............................................................................................................................ 10 - 80 Brake system ................................................................................................................................ 10 - 88 Brake hydraulic piping diagram.................................................................................................. 10 - 88 Brake valve ................................................................................................................................ 10 - 89 Slack adjuster ............................................................................................................................ 10 - 96 Accumulator (for brake) ............................................................................................................. 10 - 98 Wheel brake............................................................................................................................... 10 -100
- 14. GD555-5,GD655-5,GD675-5 00--5 (00) Table ofcontents D R A F T Charge valve.............................................................................................................................. 10- 99 Wheel brake............................................................................................................................... 10 -100 Parking brake and bank control valve........................................................................................ 10 -102 Parking brake............................................................................................................................. 10 -104 Undercarriage frame..................................................................................................................... 10 -106 Frame ........................................................................................................................................ 10 -106 Tire............................................................................................................................................. 10 -108 Hydraulic system .......................................................................................................................... 10 -110 Hydraulic system ....................................................................................................................... 10 -110 Work equipment hydraulic piping diagram................................................................................. 10 -114 Work equipment control............................................................................................................. 10 -118 Hydraulic tank............................................................................................................................ 10 -120 Main pump................................................................................................................................. 10 -122 Power train pump....................................................................................................................... 10 -134 Control valve.............................................................................................................................. 10 -136 CLSS ......................................................................................................................................... 10 -146 Functions and operation by valve.............................................................................................. 10 -150 Hydraulic cylinder ...................................................................................................................... 10 -160 Swivel joint................................................................................................................................. 10 -162 Pilot check valve........................................................................................................................ 10 -164 Accumulator (for blade) ............................................................................................................. 10 -172 Work equipment............................................................................................................................ 10 -174 Circle and drawbar..................................................................................................................... 10 -174 Blade.......................................................................................................................................... 10 -176 Lifter........................................................................................................................................... 10 -178 Circle rotation motor .................................................................................................................. 10 -180 Circle rotation gear .................................................................................................................... 10 -182 Cab ............................................................................................................................................... 10 -184 Cab ............................................................................................................................................ 10 -184 Electrical ststem............................................................................................................................ 10 -186 Machine monitor ........................................................................................................................ 10 -186 Automatic shift control system................................................................................................... 10 -190 Transmission controller.............................................................................................................. 10 -198 Engine controller........................................................................................................................ 10 -202 KOMTRAX system..................................................................................................................... 10 -206 Starting engine circuit ................................................................................................................ 10 -208 Stopping engine circuit .............................................................................................................. 10 -210 Preheating circuit....................................................................................................................... 10 -212 Sensor ....................................................................................................................................... 10 -214 Engine power mode select circuit.............................................................................................. 10 -226 Cooling fan control function ....................................................................................................... 10 -228 20 Standard value table Standard value table..................................................................................................................... 20- 3 Standard value table for engine................................................................................................. 20- 3 Standard value table for machine.............................................................................................. 20- 5 30 Testing and adjusting Tools for testing, adjusting, and troubleshooting .......................................................................... 30- 4 Tools for testing, adjusting, and troubleshooting ....................................................................... 30- 4 Engine and cooling system........................................................................................................... 30- 10 Testing engine speed ................................................................................................................ 30- 10 Testing intake air pressure (boost pressure) ............................................................................. 30- 12 Testing exhaust gas temperature .............................................................................................. 30- 14 00-3 (05)
- 15. Table of contents 00--4GD555-5,GD655-5,GD675-5 (00) D R A F T Testing exhaust gas color.......................................................................................................... 30- 16 Adjusting valve clearance .......................................................................................................... 30- 18 Testing compression pressure................................................................................................... 30- 20 Testing blowby pressure............................................................................................................ 30- 23 Testing engine oil pressure........................................................................................................ 30- 25 Handling fuel system device ...................................................................................................... 30- 26 Releasing remaining pressure from fuel system........................................................................ 30- 27 Testing fuel pressure ................................................................................................................. 30- 28 Bleeding air from fuel circuit....................................................................................................... 30- 29 Testing fuel circuit for leakage ................................................................................................... 30- 30 Cylinder cut-out test mode......................................................................................................... 30- 31 No injection cranking.................................................................................................................. 30- 32 Handling voltage circuit of engine controller .............................................................................. 30- 33 Checking muffler body and muffler stack for looseness and damage ....................................... 30- 34 Checking muffler function .......................................................................................................... 30- 35 Checking cylinder head and manifolds for looseness................................................................ 30- 36 Checking engine piping for damage and looseness .................................................................. 30- 37 Checking fuel delivery, return rate and leakage......................................................................... 30- 38 Replacing alternator belt............................................................................................................ 30- 41 Testing and adjusting air conditioner compressor belt tension [machines with air conditioner]. 30- 42 Power train.................................................................................................................................... 30- 44 Testing power train oil pressure................................................................................................. 30- 44 Adjusting transmission speed sensor ........................................................................................ 30- 56 Emergency escape method in case of transmission valve failure ............................................. 30- 60 Flushing torque converter and trasmission circuits.................................................................... 30- 64 Testing and adjusting toe-in....................................................................................................... 30- 66 Testing and adjusting differential lock-up oil pressure [machine with differential lock-up]......... 30- 68 Steering system ............................................................................................................................ 30- 70 Testing and adjusting steering oil pressure ............................................................................... 30- 70 Testing steering cylinder oil leakage.......................................................................................... 30- 71 Bleeding air from steering circuit................................................................................................ 30- 72 Brake system ................................................................................................................................ 30- 74 Testing and adjusting brake oil pressure ................................................................................... 30- 74 Releasing remaining pressure from brake circuit....................................................................... 30- 78 Bleeding air from brake circuit ................................................................................................... 30- 79 Testing wheel brake disc wear................................................................................................... 30- 80 Testing and adjusting parking brake.......................................................................................... 30- 82 Emergency release method of parking brake ............................................................................ 30- 84 Filling gas into brake accumulator ............................................................................................. 30- 86 Hydraulic system........................................................................................................................... 30- 88 Testing and adjusting work equipment oil pressure................................................................... 30- 88 Testing and adjusting pump LS differential pressure................................................................. 30- 91 Testing lift arm lock cylinder circuit oil pressure [machine with bank cut].................................. 30- 93 Testing work equipment cylinder oil leakage amount ................................................................ 30- 94 Bleeding air from work equipment circuit................................................................................... 30- 97 Work equipment............................................................................................................................ 30- 98 Clearance adjustment of drawbar ball joint................................................................................ 30- 98 Testing and adjusting circle guide clearance............................................................................. 30- 99 Testing and adjusting slip clutch type circle rotator ................................................................... 30- 101 Filling gas into blade accumulator [machine with blade accumulator] ....................................... 30- 103 Electrical system ........................................................................................................................... 30- 104 Procedure for testing diodes...................................................................................................... 30- 104 Special functions of machine monitor (EMMS).......................................................................... 30- 105 Handling high voltage circuit of engine controller ...................................................................... 30- 154 00-3-1 (05)
- 16. GD555-5,GD655-5,GD675-5 00--3 (00) Table ofcontents D R A F T How to start KOMTRAX terminal operations ............................................................................. 30- 156 Indicator lamps of KOMTRAX terminal...................................................................................... 30- 161 Preparation work for troubleshooting of electrical system ......................................................... 30- 164 Pm clinic ....................................................................................................................................... 30- 166 Pm Clinic- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-166 40 Troubleshooting General information on troubleshooting........................................................................................ 40- 7 Points to remember when troubleshooting ................................................................................ 40- 7 Sequence of events in troubleshooting...................................................................................... 40- 8 Checks before troubleshooting.................................................................................................. 40- 9 Classification and procedures for troubleshooting..................................................................... 40- 29 Failure codes table .................................................................................................................... 40- 30 Failure and troubleshooting numbers ........................................................................................ 40- 37 Information in troubleshooting table........................................................................................... 40- 39 Troubleshooting method for open circuit in wiring harness of pressure sensor system ............ 40- 41 Connector list and layout ........................................................................................................... 40- 43 Connection table for connector pin numbers ............................................................................. 40- 58 T- branch box and T- branch adapter table ............................................................................... 40- 94 Locations of fuses...................................................................................................................... 40- 97 Troubleshooting by failurecode..................................................................................................... 40- 99 Failure code [1500LO] TORQUEFLOW transmission: Double engagement............................. 40- 99 Failure code [15G0MW] Transmission R clutch: Slip ................................................................ 40- 100 Failure code [15H0MW] Transmission FH clutch: Slip .............................................................. 40- 101 Failure code [15J0MW] Transmission FL clutch: Slip................................................................ 40- 101 Failure code [15K0MW] Transmission 1st clutch: Slip............................................................... 40- 102 Failure code [15L0MW] Transmission 2nd clutch: Slip.............................................................. 40- 103 Failure code [15M0MW] Transmission 3rd speed clutch: Slip................................................... 40- 104 Failure code [15N0MW] Transmission 4th clutch: Slip .............................................................. 40- 105 Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF .......... 40- 106 Failure code [15SBMA] ECMV R clutch: Malfunction ................................................................ 40- 108 Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF........ 40- 110 Failure code [15SCMA] ECMV FH clutch: Malfunction.............................................................. 40- 112 Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF ........ 40- 114 Failure code [15SDMA] ECMV FL clutch: Malfunction .............................................................. 40- 116 Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF ........ 40- 118 Failure code [15SEMA] ECMV 1st clutch: Malfunction.............................................................. 40- 120 Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF ....... 40- 122 Failure code [15SFMA] ECMV 2nd clutch: Malfunction............................................................. 40- 124 Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF ....... 40- 126 Failure code [15SGMA] ECMV 3rd clutch: Malfunction ............................................................. 40- 128 Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF........ 40- 130 Failure code [15SHMA] ECMV 4th clutch: Malfunction ............................................................. 40- 132 Failure code [15SJMA] ECMV lockup clutch: Malfunction......................................................... 40- 134 Failure code [15UONT] Inching clutch: Overheating ................................................................. 40- 134 Failure code [2G42ZG] Front accumulater: Oil pressure drop................................................... 40- 135 Failure code [2G43ZG] Rear accumulater: Pressure drop ........................................................ 40- 135 Failure code [AA1ANX] Air cleaner: Clogging ........................................................................... 40- 136 Failure code [AB00L6] Alternator; Engine start and stop signals are not matched. .................. 40- 138 Failure code [AB00MA] Alternator: Malfunction......................................................................... 40- 140 Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop ........................... 40- 142 Failure code: [B@BCNS] Engine coolant overheat ................................................................... 40- 142 Failure code: [B@CENS] Torque converter oil overheat........................................................... 40- 143 Failure code: [B@CKNS] Differential case: Overheat ............................................................... 40- 144 Failure code: [B@HANS] Hydraulic oil: Overheating................................................................. 40- 146 00-3-2 (05)
- 17. Table of contents 00--2GD555-5,GD655-5,GD675-5 (00) D R A F T Failure code [CA111] Engine controller internal error................................................................ 40- 148 Failure code [CA115] Engine Ne, Bkup speed sensor error...................................................... 40- 149 Failure code [CA122] Charge pressure sensor high error ......................................................... 40- 150 Failure code [CA123] Charge pressure sensor low error........................................................... 40- 152 Failure code [CA131] Throttle sensor high error........................................................................ 40- 154 Failure code [CA132] Throttle sensor low error ......................................................................... 40- 156 Failure code [CA144] Coolant sensor high error........................................................................ 40- 158 Failure code [CA145] Coolant sensor low error......................................................................... 40- 160 Failure code [CA153] Charge temperature sensor high error.................................................... 40- 162 Failure code [CA154] Charge temperature sensor low error ..................................................... 40- 164 Failure code [CA155] Speed derating error by high charge temperature .................................. 40- 166 Failure code [CA187] Sensor power supply 2 low error............................................................. 40- 168 Failure code [CA221] Atmospheric pressure sensor high error................................................. 40- 170 Failure code [CA222] Atmospheric pressure sensor low error .................................................. 40- 172 Failure code [CA227] Sensor power supply 2 high error ........................................................... 40- 174 Failure code [CA234] Engine overspeed ................................................................................... 40- 174 Failure code [CA238] Ne speed sensor power supply error ...................................................... 40- 175 Failure code [CA271] IMV/IMA: Short circuit ............................................................................. 40- 176 Failure code [CA272] IMV/IMA open circuit............................................................................... 40- 178 Failure code [CA322] Injector #1 (L#1) open/short.................................................................... 40- 180 Failure code [CA323] Injector #5 (L#5) open/short.................................................................... 40- 182 Failure code [CA324] Injector #3 (L#3) open/short.................................................................... 40- 184 Failure code [CA325] Injector #6 (L#6) open/short.................................................................... 40- 186 Failure code [CA331] Injector #2 (L#2) open/short.................................................................... 40- 188 Failure code [CA332] Injector #4 (L#4) open/short.................................................................... 40- 190 Failure code [CA342] Data compatibility error in engine controller............................................ 40- 192 Failure code [CA351] Injector drive circuit error......................................................................... 40- 193 Failure code [CA352] Sensor power supply 1 low error............................................................. 40- 194 Failure code [CA386] Sensor power supply 1 high error ........................................................... 40- 195 Failure code [CA428] Water-in-fuel sensor high error ............................................................... 40- 196 Failure code [CA429] Water-in-fuel sensor low error................................................................. 40- 198 Failure code [CA431] Idle validation switch error....................................................................... 40- 200 Failure code [CA432] Idle validation action error....................................................................... 40- 204 Failure code [CA435] Engine oil pressure switch error.............................................................. 40- 207 Failure code [CA441] Power supply voltage low error............................................................... 40- 208 Failure code [CA442] Power supply voltage high error.............................................................. 40- 210 Failure code [CA449] Common rail pressure high error 2 ......................................................... 40- 211 Failure code [CA451] Common rail pressure sensor high error................................................. 40- 212 Failure code [CA452] Common rail pressure sensor low error.................................................. 40- 214 Failure code [CA488] Torque derating error by high charge temperature ................................. 40- 216 Failure code [CA553] Common rail pressure high error 1 ......................................................... 40- 217 Failure code [CA559] Supply pump pressure low error 1 .......................................................... 40- 218 Failure code [CA689] Engine Ne speed sensor error ................................................................ 40- 219 Failure code [CA731] Engine Bkup speed sensor phase error.................................................. 40- 221 Failure code [CA757] All continuous data lost error................................................................... 40- 222 Failure code [CA778] Engine Bkup speed sensor error............................................................. 40- 223 Failure code [CA1633] KOMNET (CAN communication) error.................................................. 40- 226 Failure code [CA2185] Throttle sensor power supply high error................................................ 40- 228 Failure code [CA2186] Throttle sensor power supply low error................................................. 40- 230 Failure code [CA2249] Supply pump pressure low error 2 ........................................................ 40- 232 Failure code [CA2311] Abnormality in IMV (IMA) solenoid........................................................ 40- 233 Failure code [CA2555] Intake heater relay open circuit............................................................. 40- 234 Failure code [CA2556] Intake heater relay short circuit............................................................. 40- 236 Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness..... 40- 238 00-3-3 (05)
- 18. GD555-5,GD655-5,GD675-5 00--1 (00) Table ofcontents D R A F T Failure code [D160KB] Backup lamp relay: Ground fault .......................................................... 40- 240 Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault.................................. 40- 242 Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state .......... 40- 244 Failure code [DAFRKR] CAN communication failure (monitor panel) ....................................... 40- 246 Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)......... 40- 248 Failure code [DAQOKT] Transmission controller: Non-volatile memory error ........................... 40- 250 Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input) ................................................................................................................................................... 40- 252 Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement ................................................................................................................................................... 40- 254 Failure code [DAQRKR] Transmission controller CAN communication: Communication error . 40- 256 Failure code [DAQRMA] Transmission controller option setting: Malfunction ........................... 40- 260 Failure code [DB2RKR] Engine controller CAN communication: Communication error ............ 40- 261 Failure code [DD1NLD] Fan reverse switch signal: Short circuit ............................................... 40- 268 Failure code [DD1PKB] RPM set switch power supply short circuit .......................................... 40- 270 Failure code [DD1QKB] RPM set mode switch short circuit ...................................................... 40- 272 Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error ..................... 40- 274 Failure code [DDTHKA] Fill switch for FH clutch: Open circuit .................................................. 40- 276 Failure code [DDTJKA] Fill switch for FL clutch: Open circuit ................................................... 40- 276 Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit .................................................. 40- 277 Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit ................................................. 40- 277 Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit ................................................. 40- 278 Failure code [DDTNKA] Fill switch for R clutch: Open circuit .................................................... 40- 279 Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit .................................................. 40- 280 Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input ................ 40- 281 Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error . 40- 285 Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range.......... 40- 288 Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault................................... 40- 290 Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range.... 40- 292 Failure code [DGT7KB] Differential oil temperature sensor: Ground fault................................. 40- 294 Failure code [DJF1KA] Fuel level sensor: Open circuit ............................................................. 40- 296 Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range.......................... 40- 298 Failure code [DKD0KX] Articulation angle sensor: Input signal out of range............................. 40- 300 Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit........................... 40- 302 Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match 40- 303 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit............... 40- 304 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match ................................................................................................................................................... 40- 305 Failure code [DLM3KA] Fan speed sensor: Open circuit........................................................... 40- 306 Failure code [DLM3LC] Fan speed sensor: Short circuit........................................................... 40- 307 Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit ........................ 40- 308 Failure code [DV00KB] Buzzer: Short circuit............................................................................. 40- 310 Failure code [DW4BKA] Parking brake solenoid valve: Open circuit......................................... 40- 312 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit......................................... 40- 314 Failure code [DW7BKA] Fan reverse solenoid: Open circuit..................................................... 40- 315 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..................................................... 40- 316 Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line .................... 40- 318 Failure code [DX16KA] Fan motor EPC solenoid: Open circuit................................................. 40- 320 Failure code [DX16KB] Fan motor EPC solenoid: Short circuit................................................. 40- 321 Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line ................ 40- 322 Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit.................................................. 40- 324 Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit .................................................. 40- 325 Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line ................. 40- 326 Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit .............................................. 40- 328 00-3-4 (05)
- 19. Table of contents 00-0GD555-5,GD655-5,GD675-5 (00) D R A F T Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit............................................... 40- 329 Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line.............. 40- 330 Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit ............................................... 40- 332 Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit ............................................... 40- 334 Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line............... 40- 336 Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit............................................... 40- 338 Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit............................................... 40- 340 Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line.............. 40- 342 Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit ............................................. 40- 344 Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit.............................................. 40- 346 Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line............. 40- 348 Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit .............................................. 40- 350 Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit .............................................. 40- 352 Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line.............. 40- 354 Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit................................................. 40- 356 Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit................................................. 40- 357 Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line ................ 40- 358 Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit.............................................. 40- 360 Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit.............................................. 40- 362 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line ............. 40- 364 Troubleshooting of electrical system (E-mode)............................................................................. 40- 366 E-1 Engine does not start (starting motor does not turn)........................................................... 40- 366 E-2 Preheating does not work.................................................................................................... 40- 372 E-3 When starting switch is turned to ON position, machine monitor displays nothing ............. 40- 377 E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen ................................................................................................................................................... 40- 380 E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine mon- itor does not display correct screen ........................................................................................... 40- 380 E-6 Emergency stop monitor lights up while engine is running ................................................. 40- 381 E-7 Speedometer or engine tachometer does not indicate correctly......................................... 40- 385 E-8 Engine coolant temperature gauge does not indicate correctly .......................................... 40- 386 E-9 Articulation angle indicator does not indicate correctly ....................................................... 40- 388 E-10 Torque converter oil temperature gauge does not indicate correctly ................................ 40- 390 E-11 Fuel level gauge does not indicate correctly ..................................................................... 40- 392 E-12 Character display does not display correctly..................................................................... 40- 394 E-13 Centralized warning lamp does not light up or does not go off ......................................... 40- 396 E-14 Alarm buzzer does not sound or does not stop sounding ................................................. 40- 398 E-15 Machine monitor mode selector switch does not work...................................................... 40- 400 E-16 Transmission mode does not switch ................................................................................. 40- 404 E-17 Engine mode does not switch ........................................................................................... 40- 406 E-18 Differential lock function does not work or cannot be reset [for machine with differential lock spec- ification]...................................................................................................................................... 40- 408 E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification] ................................................................................................................................................... 40- 412 E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification] .............................................................................................................................. 40- 414 E-21 Horn does not sound or does not stop sounding............................................................... 40- 418 E-22 Backup alarm does not sound or does not stop sounding ................................................ 40- 420 E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off ......................... 40- 423 E-24 Working lamp does not light up or does not go off............................................................ 40- 430 E-25 Turn signal lamp and hazard lamp do not flash. ............................................................... 40- 436 E-26 Stop lamp does not light up or does not go off.................................................................. 40- 442 E-27 Backup lamp does not light up or does not go off ............................................................. 40- 444 E-28 Windshield wiper does not operate ................................................................................... 40- 446 00-3-5 (05)
- 20. GD555-5,GD655-5,GD675-5 00-1 (00) Table ofcontents D R A F T E-29 Window washer does not operate..................................................................................... 40- 454 E-30 KOMTRAX system does not operate correctly ................................................................. 40- 458 Troubleshooting of hydraulic and mechanical system (H-mode).................................................. 40- 460 How to read troubleshooting matrix........................................................................................... 40- 460 H-1 Engine speed lowers significantly or engine stalls.............................................................. 40- 466 H-2 Machine does not start........................................................................................................ 40- 467 H-3 Gear is not shifted............................................................................................................... 40- 468 H-4 Travel lacks speed or power............................................................................................... 40- 469 H-5 Torque converter lockup does not work or is not released. ................................................ 40- 474 H-6 A large time lag results at start or in gear shift.................................................................... 40- 475 H-7 Oil temperature of torque converter is high......................................................................... 40- 480 H-8 Differential lock-up function does not work or is not released............................................. 40- 485 H-9 Steering lacks speed or power............................................................................................ 40- 486 H-10 Steering wheel does not move.......................................................................................... 40- 487 H-11 Wheel brake does not work at all or sufficiently................................................................ 40- 488 H-12 Wheel brake cannot be released or drags........................................................................ 40- 489 H-13 Parking brake does not work at all or insufficiently ........................................................... 40- 490 H-14 Parking brake (including emergency release system) cannot be released or drags. ....... 40- 491 H-15 All work equipment operation lacks speed or power......................................................... 40- 492 H-16 Work equipment does not work at all................................................................................ 40- 493 H-17 Unusual noise comes out from around hydraulic pump.................................................... 40- 494 H-18 Blade lift operation lacks speed or power ......................................................................... 40- 495 H-19 Hydraulic drift of blade lift cylinders is large...................................................................... 40- 496 H-20 Drawbar side shift operation lacks speed or power .......................................................... 40- 497 H-21 Blade side shift operation lacks speed or power............................................................... 40- 498 H-22 Power tilt operation lacks speed or power ........................................................................ 40- 499 H-23 Articulate operation lacks speed or power........................................................................ 40- 500 H-24 Leaning operation lacks speed or power .......................................................................... 40- 501 H-25 Hydraulic drift of leaning cylinders (leaning) is large......................................................... 40- 502 H-26 Blade does not rotate........................................................................................................ 40- 503 H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification) ................................................................................................................................................... 40- 504 H-28 Blade accumulator function does not work or cannot be released (for machine with blade accumu- lator float specification).............................................................................................................. 40- 505 H-29 Blade float function does not work or cannot be released ................................................ 40- 506 H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................................................................................................................................................... 40- 507 Troubleshooting of engine (S-mode) ............................................................................................ 40- 508 Method of using troubleshooting chart....................................................................................... 40- 508 S-1 Startability is poor................................................................................................................ 40- 512 S-2 Engine does not start .......................................................................................................... 40- 513 S-3 Engine does not pick up smoothly ...................................................................................... 40- 516 S-4 Engine stops during operation ............................................................................................ 40- 517 S-5 Engine runs rough or is unstable ........................................................................................ 40- 518 S-6 Engine lacks power............................................................................................................. 40- 519 S-7 Exhaust smoke is black (incomplete combustion) .............................................................. 40- 520 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................... 40- 521 S-9 Oil becomes contaminated early......................................................................................... 40- 522 S-10 Fuel consumption is excessive ......................................................................................... 40- 523 S-11 Oil is in coolant (or coolant spurts or coolant level goes down) ........................................ 40- 524 S-12 Oil pressure drops............................................................................................................. 40- 525 S-13 Oil level rises (coolant or fuel in oil) .................................................................................. 40- 526 S-14 Coolant temperature rises too high (overheating)............................................................. 40- 527 S-15 Unusual noise is made...................................................................................................... 40- 528 00-3-6 (05)
- 21. Table of contents 00-2GD555-5,GD655-5,GD675-5 (00) D R A F T S-16 Vibration is excessive........................................................................................................ 40- 529 50 Disassembly and assembly General information on disassembly and assembly ..................................................................... 50 - 4 How to read this manual ............................................................................................................ 50- 4 Coating materials list.................................................................................................................. 50- 6 Special tools list ......................................................................................................................... 50- 9 Sketches of special tools ........................................................................................................... 50- 13 Engine and cooling system ........................................................................................................... 50- 17 Removal and installation of fuel supply pump assembly ........................................................... 50- 17 Removal and installation of fuel injector assembly .................................................................... 50- 22 Removal and installation of cylinder head assembly ................................................................. 50- 32 Removal and installation of engine front oil seal........................................................................ 50- 50 Removal and installation of engine rear oil seal ........................................................................ 50- 53 Removal and installation of cooling fan pump assembly ........................................................... 50- 57 Removal and installation of cooling fan and fan motor assembly.............................................. 50- 59 Removal and installation of radiator assembly .......................................................................... 50- 63 Removal and installation of aftercooler assembly...................................................................... 50- 67 Removal and installation of power train oil cooler assembly ..................................................... 50- 70 Removal and installation of fuel tank assembly......................................................................... 50- 73 Removal and installation of engine hood assembly................................................................... 50- 77 Power train.................................................................................................................................... 50- 79 Removal and installation of engine and transmission/torque converter assembly .................... 50- 79 Disassembly and assembly of engine and transmission/torque converter assembly................ 50- 87 Disassembly and assembly of torque converter assembly........................................................ 50- 89 Disassembly and assembly of transmission assembly.............................................................. 50- 97 Removal and installation of tandem drive and final drive assembly .......................................... 50- 135 Disassembly and assembly of tandem drive assembly ............................................................. 50- 139 Disassembly and assembly of final drive assembly................................................................... 50- 144 Steering system ............................................................................................................................ 50- 163 Removal and installation of steering valve (orbit-roll) assembly................................................ 50- 163 Disassembly and assembly of steering valve (orbit-roll) assembly............................................ 50- 169 Brake system ................................................................................................................................ 50- 180 Disassembly and assembly of wheel brake assembly............................................................... 50- 180 Undercarriage and frame .............................................................................................................. 50- 185 Removal and installation of center hinge pin ............................................................................. 50- 185 Hydraulic system........................................................................................................................... 50- 198 Removal and installation of hydraulic tank, battery and frame assembly .................................. 50- 198 Removal and installation of hydraulic tank assembly ................................................................ 50- 205 Removal and installation of control valve assembly .................................................................. 50- 212 Disassembly and assembly of control valve assembly.............................................................. 50- 218 Disassembly and assembly of hydraulic cylinder assembly ...................................................... 50- 221 Work equipment............................................................................................................................ 50- 226 Removal and installation of blade assembly.............................................................................. 50- 226 Removal and installation of circle drawbar assembly ................................................................ 50- 228 Removal and installation of circle rotation gear assembly......................................................... 50- 231 Disassembly and assembly of circle rotation gear assembly..................................................... 50- 238 Removal and installation of ripper assembly ............................................................................. 50- 238 Cab and its attachments ............................................................................................................... 50- 241 Removal and installation of operator cab assembly .................................................................. 50- 241 Removal and installation of floor frame assembly ..................................................................... 50- 253 Removal and installation of operator cab glass (adhered glass) ............................................... 50- 257 Removal and installation of air conditioner unit assembly ......................................................... 50- 267 00-3-7 (05)
- 22. GD555-5,GD655-5,GD675-5 00-3 (00) Table ofcontents D R A F T Electrical system........................................................................................................................... 50- 273 Removal and installation of engine controller assembly............................................................ 50- 273 Removal and installation of machine monitor assembly............................................................ 50- 275 Removal and installation of transmission controller assembly .................................................. 50- 277 Removal and installation of KOMTRAX terminal assembly....................................................... 50- 279 60 Maintenance standard Engine and Cooling ...................................................................................................................... 60 - 4 Engine mount and transmission mount ..................................................................................... 60 - 4 Cooling system .......................................................................................................................... 60 - 6 Cooling fan motor ...................................................................................................................... 60 - 8 Power train system ....................................................................................................................... 60 - 12 Transmission control.................................................................................................................. 60 - 12 Torque converter ....................................................................................................................... 60 - 14 Transmission ............................................................................................................................. 60 - 16 Main relief valve and torque converter relief valve .................................................................... 60 - 24 Front axle................................................................................................................................... 60 - 26 Final drive (no differential specification) .................................................................................... 60 - 30 Final drive (differential/ differential lock specification) ............................................................... 60 - 32 Differential lock solenoid valve .................................................................................................. 60 - 34 Tandem drive............................................................................................................................. 60 - 36 Brake system ................................................................................................................................ 60 - 38 Slack adjuster ............................................................................................................................ 60 - 38 Wheel brake............................................................................................................................... 60 - 40 Parking brake............................................................................................................................. 60 - 42 Hydraulic system .......................................................................................................................... 60 - 44 Power train pump....................................................................................................................... 60 - 44 Control valve.............................................................................................................................. 60 - 46 Hydraulic cylinder ...................................................................................................................... 60 - 54 Work equipment............................................................................................................................ 60 - 56 Circle and drawbar..................................................................................................................... 60 - 56 Blade.......................................................................................................................................... 60 - 58 Lifter........................................................................................................................................... 60 - 60 Circle rotation gear .................................................................................................................... 60 - 62 80 Appendix Air conditioner............................................................................................................................... 80- 3 Precautions for refrigerant ......................................................................................................... 80- 3 Air Conditioner Components...................................................................................................... 80- 4 Structure and Function of Refrigeration System........................................................................ 80- 6 Overview of Refrigeration System ............................................................................................. 80- 7 Air Conditioner Unit.................................................................................................................... 80- 8 Compressor ............................................................................................................................... 80- 11 Condenser ................................................................................................................................. 80- 12 Receiver drier ............................................................................................................................ 80- 13 Air conditioner control panel ...................................................................................................... 80- 14 Procedure for check and troubleshooting.................................................................................. 80- 16 Circuit diagram and layout of connector pins............................................................................. 80- 18 System diagram......................................................................................................................... 80- 20 Detail of air conditioner unit ....................................................................................................... 80- 22 Parts and connectors layout ...................................................................................................... 80- 24 Testing air leakage (ducts) ........................................................................................................ 80- 26 Check with self-diagnosis (control panel display) ...................................................................... 80- 27 Testing temperature control....................................................................................................... 80- 28 (05) 00-3-8
- 23. Table of contents 00-4GD555-5,GD655-5,GD675-5 (00) D R A F T Testing Fresh/Recirc air changeover......................................................................................... 80- 29 Testing evaporator temperature sensor..................................................................................... 80- 30 Testing relays............................................................................................................................. 80- 31 Testing blower amp.................................................................................................................... 80- 32 Troubleshooting Chart 1 ............................................................................................................ 80- 33 Troubleshooting Chart 2 ............................................................................................................ 80- 35 Information in troubleshooting table........................................................................................... 80- 37 Troubleshooting for power supply system (Air conditioner does not operate)........................... 80- 38 Troubleshooting of compressor and refrigerant system (Air is not cooled)................................ 80- 40 Troubleshooting for blower motor system (Air does not come out or air flow is improper)........ 80- 44 Troubleshooting for temperature control.................................................................................... 80- 46 Troubleshooting for FRESH/RECIRC air changeover ............................................................... 80- 48 Troubleshooting with gauge pressure........................................................................................ 80- 50 Connection of service tool.......................................................................................................... 80- 52 Precautions for disconnecting and connecting air conditioner piping ........................................ 80- 54 Handling compressor oil ............................................................................................................ 80- 56 90 Diagrams and drawings Hydraulic diagrams and drawings................................................................................................. 90 - 3 Symbols used in hydraulic circuit diagrams............................................................................... 90 - 3 Hydraulic circuit diagram............................................................................................................ 90 - 5 Power train hydraulic circuit diagram......................................................................................... 90 - 9 Differential hydraulic circuit diagram.......................................................................................... 90 - 11 Electrical diagrams and drawings ................................................................................................. 90 - 13 Symbols used in electric circuit diagrams.................................................................................. 90 - 13 Electrical circuit diagram............................................................................................................ 90 - 17 Index ............................................................................................................................................. 1 (05)
- 24. GD555-5,GD655-5,GD675-5 00-5 Foreword andgeneral information Safety notice D R A F T Foreword and general information Safety notice Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific pur- pose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situa- tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dan- gerous. Read the Operation and Mainte- nance Manual carefully before operating the machine. In addition, read this manu- al and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precau- tions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grind- ing parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the oper- ator's compartment. 5) Only qualified workers must carry out work and operation which require license or quali- fication. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places. (Rev. 2009/9) Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals 5 Prohibition of operation and handling by unli- censed workers 6 Safety check before starting work 7 Wearing protective goggles(for cleaning or grind- ing work) 8 Wearing shielding goggles and protectors(for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
- 25. Foreword and generalinformation Safety notice 00-6 GD555-5,GD655-5,GD675-5 D R A F T 2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equip- ment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equip- ment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing compo- nents of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in partic- ular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal posi- tions. Loosen those bolts gradually and alter- nately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is oper- ated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
- 26. GD555-5,GD655-5,GD675-5 00-7 Foreword andgeneral information Safety notice D R A F T 4. Precautions for sling work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 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. It may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turn- ing of the load during hoisting, un- twisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dan- gerous accident. 7) Limit the hanging angle to 60 °, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8kN {1,000kg} vertically, at various hanging angles. When the 2 ropes sling a load verti- cally, up to 19.6kN {2,000kg} of total weight can be suspended. This weight is reduced to 9.8kN {1,000kg} when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 19.6kN {2,000kg } load at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2kN {4,000kg}. 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 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.
- 27. Foreword and generalinformation Safety notice 00-8 GD555-5,GD655-5,GD675-5 D R A F T q 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 at an angle. 13)When lowering a load, observe the following. q When lowering a load, stop it temporarily at 30cm above the floor, and then lower it slowly. q Check that the load is stable, and then re- move 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. 5. Precautions for using mobile crane a Read the Operation and Maintenance Manu- al of the crane carefully in advance and oper- ate the crane safely. 6. Precautions for using overhead hoist crane kWhen raising a heavy part (heavier than 25), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 is indicated after the mark of4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power appli- cation warning lamp, and check safety. 2) Observe the signals 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 at an angle. 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 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. 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 ground fault circuit interrupter, check that the devices related to that switch are not in oper- ation 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 2mabove the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below. a The allowable load is one-sixth of the breaking strength of the rope used (Safe- ty coefficient: 6). Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter of rope Allowable load 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
- 28. GD555-5,GD655-5,GD675-5 00-9 Foreword andgeneral information Safety notice D R A F T 8. Precautions for disconnecting and connecting hoses and tubes in air condi- tioner circuit 1) Disconnection k For the environment, the air condition- er of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the re- frigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be fro- zen. Accordingly, put on safety glass- es, safety gloves and safety clothes when recovering or adding the refrig- erant. Refrigerant gas must be recovered and added by a qualified person. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring (1) is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings (1). a Example of O-ring (Fitted to every joint of hoses and tubes) a For tightening torque, see the precau- tions for installation in each section of "Disassembly and assembly".
- 29. Foreword and generalinformation How to read the shop manual 00-10 GD555-5,GD655-5,GD675-5 D R A F T How to read the shop manual Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section contains table of contents, and safety and basic information. If any revision of the shop man- ual is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjust- ing and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and meth- od of adjusting each part. The standard values and judgment criteria for testing and adjusting are ex- plained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assem- bling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-sec- tion explains the criteria and remedies for disassembly and service. 80. Appendix The section explains the equipment which can not be included in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting fo the equipment. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of remanufacturing and repairing engine and replacing parts. q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. q Materials and specifications are subject to change without notice. q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol- ume of the engine model mounted on the machine.
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