Gd675-3c (Aps) Shop Manual

SEBM020908

MACHINE MODEL GD555-3C GD655-3C GD675-3C •

•

SERIAL NUMBER 00

00

00

50001 and up 50001 and up 50001 and up

00

00

00

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. GD555-3C mounts the SA6D102E-1 or SAA6D102E-2 engine. GD655-3C, GD675-3C mount the S6D114E-1, SA6D114E-1 or SAA6D114E-2 engine. For details of the engine, see the 102 Series Engine Shop Manual and the 114 Series Engine Shop Manual.

© 2006 All Rights Reserved Printed in Japan 03-06 (01)

00-1 (8)

CONTENTS

No. of page 01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . 10-1

20

TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90

OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 00

00-2 (4)

GD555, 655, 675-3C

The affected pages are indicated by using the following marks. It is requested that necessary actions be taken to these pages according to the table below.

Mark

( )

Indication

Action Required

New page to be added

Add

Page to be replaced

Replace

Page to be deleted

Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES j

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Safety

Safety notice

Safety Safety notice Important safety notice Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two 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 signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. Preparations for work 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. 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.

00-3

Safety

Precautions during work 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. 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, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

Safety notice

19. Be sure to assemble all parts again in their original places. Replace any damaged parts 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 being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. 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.

Foreword

General

Foreword General This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

Structure and function This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.

Testing and adjusting This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.

Disassembly and assembly This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.

Maintenance standard This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.

Others This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

Notice The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

Foreword

General

How to read the shop manual Volumes Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume:

Each issued as one volume to cover all models

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.

Distribution and updating Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work. Filing method 1. See the page number on the bottom of the page. File the pages in correct order.

Revised edition mark W he n a m an ua l i s r ev i s e d, an e di t i on m a r k ((1)(2)(3)....) is recorded on the bottom of the pages.

Revisions Revised pages are shown in the List of revised pages next to the Contents page.

Symbols So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Symbol

Item

Remarks

k

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

4

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

Places that require special attention for the tightening torque during assembly.

2

Coat

Places to be coated with adhesives and lubricants, etc.

5

Oil, water

Places where oil, water or fuel must be added, and the capacity.

6

Drain

Places where oil or water must be drained, and quantity to be drained.

a

2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (–) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5

00-6

Added pages

20-203 12-203-1 12-203-2 12-204

Foreword

Hoisting instructions

Hoisting instructions Hoisting k

•

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the Disassembly and assembly section, every part weighing 25 kg or more is indicated clearly with the symbol 4

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k

Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

Allowable load

mm

kN

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

a The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120? hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

00-7

Foreword

Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type coupler k

k

Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see “Tes ting and adjus ting”, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see “Testing and adjusting”, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

Foreword

Method of disassembling, connecting push-pull type coupler

Type 2

Type 3

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

1)

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2)

Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2)

Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3)

Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3)

Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

•

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Disassembly

1)

00-9

Foreword

Coating materials

Coating materials a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

790-129-9060 (Set of adhesive and hardening agent)

LT-4

790-129-9040

Holtz MH 705

790-126-9120

Three bond 1735

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond 1211

790-129-9090

Three bond 1207B

419-15-18131

Adhesives

Gasket sealant

00-10

Q’ty

Container

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. 20 g Polyethylene Used for plastics (except polyethylene, (2 pcs.) container polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and nonmetal. • Features: Polyethylene Resistance to heat and chemicals 50 g container • Used for anti-loosening and sealant purpose for bolts and plugs. Adhesive: • Used as adhesive or sealant for metal, 1 kg glass and plastic. Can Hardening agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene 2g (max. strength after 30 minutes) container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene 50 cc • Used at joint portions subject to high container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type 1 kg Tube • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g

Tube

Foreword

Molybdenum disulphide lubricant

Komatsu code

Part No.

Q’ty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

Various

G2-LI

G2-CA

Grease

Primer

Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41

Adhesive

Caulking material

SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM

Various

Various

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

• Used for normal temperature, light load bearing at places in contact with water or steam. • Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body.

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

400 g 16 kg

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

400 g 16 kg

Bellows type Can

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass container

22M-54-27210

320 ml

Ecocart (Special container)

• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months)

417-926-3910

417-926-3910

320 ml

Polyethylene container

20Y-54-39850

310 ml


417-926-3920

320 ml


20Y-54-55130

333 ml


22M-54-27220

333 ml

Cartridge

• Used as primer for glass side (Using limit: 4 months)

Adhesive for cab glass

Category

Coating materials

• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

00-11

Foreword

Standard tightening torque

Standard tightening torque Standard tightening torque table (when using torque wrench) a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. SAD00483

Thread diameter

Width across flats

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

Foreword


Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter

Width across flats

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

Table of tightening torques for o-ring boss piping joints a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Norminal No. 02 03, 04 05, 06 10, 12 14

Thread diameter

Width across flats

mm

mm

14 20 24 33 42

Varies depending on type of connector.

Tightening torque (Nm {kgm}) Range 35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1010 {76.0 – 103}

Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Table of tightening torques for o-ring boss plugs a Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter

Width across flats

Tightening torque (Nm {kgm})

mm

mm

Range

Target

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 {9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

Foreword


Tightening torque for 102 and 114 engine series 1) Bolt and nuts Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12

10 ± 2 24 ± 4 43 ± 6 77 ± 12

1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22

2) Eye joints Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

6 8 10 12 14

8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

3) Tapered screws Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

kgm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

Tightening torque table for hoses (taper seal type and face seal type) a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm})

Nominal size of hose

Width across flats

02

19

Range

Target

Taper seal type

Face seal type

Thread size Nominal thread size Root diameter – Threads per inch, (mm) (mm) (Reference) Thread series 9 — – 18UN 14.3 16

34 – 54 {3.5 – 5.5}

44 {4.5}

34 – 63 {3.5 – 6.5}

44 {4.5}

14

—

—

22

54 – 93 {5.5 – 9.5}

74 {7.5}

—

11 – 16UN 16

17.5

24

59 – 98 {6.0 – 10.0}

78 {8.0}

18

—

—

04

27

84 – 132 {8.5 – 13.5}

103 {10.5}

22

13 – 16UN 16

20.6

05

32

128 – 186 {13.0 – 19.0}

157 {16.0}

24

1 – 14UNS

25.4

3 1 – 12UN 16

30.2

03

06

36

177 – 245 {18.0 – 25.0}

216 {22.0}

30

(10)

41

177 – 245 {18.0 – 25.0}

216 {22.0}

33

—

—

(12)

46

197 – 294 {20.0 – 30.0}

245 {25.0}

36

—

—

(14)

55

246 – 343 {25.0 – 35.0}

294 {30.0}

42

—

—

00-14

Foreword

Electric wire code

Electric wire code In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

Classification by thickness Norminal number

Copper wire Number of strands

Dia. of Cross section strands (mm2) (mm2)

Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.85

11

0.32

0.88

2.4

12

Starting, lighting, signal etc.

2

26

0.32

2.09

3.1

20

Lighting, signal etc.

5

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Classification by color and code Priority

1

Circuits

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

—

BW

RW

YR

GW

LW

Color

White & Red

—

White & Black

Red & White

Rellow & Red

Green & White

Blue & White

Code

WB

—

BY

RB

YB

GR

LR

Color

White & Black

—

Black & Yellow

Red & Black

Yellow & Black

Green & Red

Blue & Yellow

Code

WL

—

BR

RY

YG

GY

LY

Color

White & Blue

—

Black & Red

Red & Yellow

Yellow & Green

Green & Yellow

Blue & Yellow

Code

WG

—

—

RG

YL

GB

LB

Color

White & Green

—

—

Red & Green

Yellow & Blue

Green & Black

Blue & Black

Code

—

—

—

RL

YW

GL

—

Color

—

—

—

Red & Blue

Yellow & White

Green & Blue

—

Classification Primary

2

3

4

Auxiliary

5

6

00-15

Foreword

Conversion table

Conversion table Method of using the conversion table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

(B)

Millimeters to inches

1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

(C) (A)

00-16

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Foreword

Conversion table

Millimeters to Inches 1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound 1 kg = 2.2046 lb 0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

Foreword

Conversion table

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

Foreword

Conversion table

kgm to ft. lb 1 kgm = 7.233 ft. lb 0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

Foreword

Conversion table

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2 0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

Foreword

Conversion table

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F °C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

Foreword

Units

Units In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {

}.

Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

04-05

01 GENERAL GENERAL ASSEMBLY DRAWING ..............................................................................................................01- 2 SPECIFICATIONS ........................................................................................................................................01- 3 WEIGHT TABLE............................................................................................................................................01- 15 FUEL, COOLANT, AND LUBRICANT SELECTION......................................................................................01- 17

GD555, 655, 675-3C

01-1 (4)

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

(Unit: mm) GD555-3C

GD655-3C

GD675-3C

Overall length

8,350

8,595

8,611

Overall height (with full height cab)

3,330

3,350

3,350

Overall height (with low height cab)

3,100

3,120

3,120

Overall width

2,525

2,550

2,550

Item A B C

01-2 (4)

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

SPECIFICATIONS GD555-3C GD555-3C

Machine Model

VHP Engine

Serial Number

50001 – 51000

51001 and up

13,850

14,040

3,950

4,000

On rear axle

9,900

10,040

Overall length

8,370

8,350

Machine weight

Dimensions

On front axle

kg

Overall width

2,525

Overall height (top of muffler)

2,980

Overall height (with ROPS cab)

3,100

Wheel base

5,850

mm

Distance between centers of tandem wheels

1,535

Tread (Front)

2,130

Tread (Rear)

2,130

Ground clearance

350

Forward

Performance

Travel speed

1st

3.3

2nd

4.8

3rd

6.8

4th 5th

21.6

7th

29.6

8th

42.9

2nd 3rd

km/h

4th Maximum drawbar pull Gradeability Min. Turning radius Static stability

•

14.9

6th

1st Reverse

9.8

km/h

kN {kg}

4.4

4.4

8.9

9.0

18.7

19.7

36.1

39.1

77.7 {7,920}

78.7 {8,030}

deg.

24

m

6.8

deg.

35

VHP engine: Variable horsepower engine.

GD555, 655, 675-3C

01-3 (4)

GENERAL

SPECIFICATIONS

GD555-3C

Machine Model

VHP Engine

Serial Number Engine model

Cylinder number - bore x stroke

l {cc}

5.88 {5,880}

Flywheel horsepower

kW/rpm {HP/rpm}

104.4 to 119.3/2,000 {140 to 160/2,000}

Maximum torque

Nm/rpm {kgm/rpm}

606.3 to 741.6/1,400 {60.9 to 74.5/1,400}

575.4 to 728.6/1,500 {58.7 to 74.3/1,500}

Max. speed at no load

rpm

2,200

2,200

Min. speed at no load

rpm

800

850

Fuel consumption ratio

g/kWh {g/HPh}

229.4 to 232.4 {171.1 to 173.3}

214.3 {159.7}

24 V, 7.5 kW

24 V, 5.5 kW

Performance

Engine

Alternator

24 V, 50 A

Battery

12 V, 112 Ah x 2

Radiator type

CF19-4 3-element, single-stage Automatic shifting, wet-type clutch

Torque converter

Power train

SAA6D102E-2

6 - 102 x 120

Starting motor

Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds

Transmission

Reduction gear

Spiral bevel gear, single-stage reduction

Rear axle

Fully floating tandem type

Front axle

Type

Steering system

Tandem

Steering

SA6D102E-1

mm

Piston displacement

(4)

51001 and up

4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler

Type

01-4

50001 – 51000

Type

Max. leaning angle

Double-row chain drive Reverse Elliott, angle type deg.

16 Fully hydraulic type

Steering angle

deg.

49

Articulate angle

deg.

23

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

GD555-3C

Machine Model

VHP Engine

13.00-24-10PR

Tires (rear)

13.00-24-10PR 275 {2.75}

Inflation pressure (rear)

kPa {kg/cm2}

275 {2.75}

Brakes

kPa {kg/cm2}

Hydraulic pump

Inflation pressure (front)

Type x no.

Control valve

Tires

50001 and up

Tires (front)

Main brake

Type x no.

Steering related cylinders

Hydraulic system

Steering, operating system

Serial Number

Rear 4-wheel braking, multiple-disc wet type

Parking brake

Discharge Set pressure

Dry disc type Komatsu LPV90 Variable swash plate type x 1 l/min.

205

MPa {kg/cm2}

206 {210}

4-spool type x 2 (CLSS)

Control method

Hydraulic type Steering

Type

Articulating

Double-acting piston type

Cylinder bore

mm

50

70

90

Piston rod outside diameter

mm

35

35

50

Piston stroke

mm

330

160

325

Blade lift

Type Work equipment cylinders

Leaning

Blade side shift

Blade tilt

Drawbar side shift

Ripper

Double-acting piston type Cylinder bore

mm

80

80

80

80

100


mm

50

50

40

45

50

Piston stroke

mm

1,160

1,250

300

585

600

Scarifier

Type


Cylinder bore

mm

80


mm

50

Piston stroke

mm

345

GD555, 655, 675-3C

01-5 (4)

GENERAL

SPECIFICATIONS

Machine Model

GD555-3C

Serial Number

50001 – 51000

Blade dimension (Length x Height x Thickness)

3,660 x 660 x 22

Cutting edge dimension (Length x Width x Thickness – Number) Max. lift above ground

1,830 x 153 x 16 – 2 mm

460

Max. cutting depth

635

Blade

Blade base Blade load Turning angle (with scarifier) Max. side shift distance (left) Max. side shift distance (right)

2,500 kN {kg} deg. mm

Cutting angle [Standard] [Adjustable]

01-6 (4)

51001 and up

68 {6,939}

68.5 {6,985} 360 (130) 625 625 —

deg.

37 32 to 81

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

GD655-3C GD655-3C Machine Model

Standard HP Engine

Serial Number Machine weight On front axle

kg

Dimensions

On rear axle

VHP Engine

50001 – 51000

51001 and up

14,800

15,000

4,220

4,270

10,580

10,730

Overall length

8,595

Overall width

2,550


3,000


3,120

Wheel base

mm

6,070


1,535

Tread (Front)

2,130

Tread (Rear)

2,130

Forward

Travel speed

370 1st

3.3

2nd

4.7

3rd

6.7

4th 5th

21.2

7th

29.1

8th

42.1

2nd 3rd

Maximum drawbar pull

Min. Turning radius Static stability

GD555, 655, 675-3C

14.6

6th

km/h

4th

Gradeability

9.7

km/h

1st Reverse

Performance

Ground clearance

kN {kg}

4.3

4.3

8.8

8.8

18.1

18.1

35.1

38.4

83.0 {8,460}

84.1 {8,580}

deg.

24

m

6.9

deg.

35

01-7 (4)

GENERAL

SPECIFICATIONS

GD655-3C Machine Model

Standard HP Engine

Serial Number

50001 – 51000 S6D114E-1 Standard

Engine model

Type

Performance

Engine

Piston displacement

l {cc}

8.27 {8,270}

kW/rpm {HP/rpm}

123/1,900 {165/1,900}

Maximum torque

Nm/rpm {kgm/rpm}

793.4/1,300 {80.9/1,300}

2,200


rpm

800

g/kWh {g/HPh}

Radiator type

159 {213.2}

218 {162.8}

24 V, 7.5 kW

24 V, 7.5 kW

24 V, 50 A

24 V, 60 A

12 V, 112 Ah x 2

12 V, 112 Ah x 2

CF19-4

CF19-5


Transmission

Reduction gear


Rear axle


Tandem Front axle

749.7 to 926.2/ 1,400 {76.4 to 94.4/1,400}

3-element, single-stage Automatic shifting, wet-type clutch

Torque converter

Steering system

794.3 to 913.0/ 1,300 {81.0 to 93.1/1,300}

rpm

Battery

Power train

123.3 to 141.7/1,900 {165 to 190/1,900}


Alternator

Steering

4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler 6 - 114 x 135

Starting motor

(4)

SAA6D114E-2

mm

Flywheel horsepower


01-8

51001 and up

SA6D114E-1 VHP

4-cycle, water cooled, overhead valve, direct-injection type with turbocharger


VHP Engine

Double-row chain drive Type

Reverse Elliott, angle type

Max. leaning angle

16

Type

Fully hydraulic type

Steering angle

deg.

49

Articulate angle

deg.

23

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

GD655-3C

Machine Model

Standard HP Engine

14.00-24-10PR

Tires (rear)

14.00-24-10PR 250 {2.5}


kPa {kg/cm2}

250 {2.5}

Brakes

kPa {kg/cm2}

Hydraulic pump


Type x no.

Control valve

Tires

50001 and up

Tires (front)

Main brake

Type x no.


Hydraulic system


Serial Number


Parking brake

Discharge at rated rpm Set pressure


194

MPa {kg/cm2}

206 {210}


Control method


Type

Leaning

Articulating


Cylinder bore

mm

50

80

90


mm

35

40

50

Piston stroke

mm

330

160

325

Blade lift


VHP Engine

Blade side shift

Blade tilt

Drawbar side shift

Ripper


mm

80

80

80

80

120


mm

50

40

40

45

55

Piston stroke

mm

1,160

1,250

300

585

540

Scarifier

Type


Cylinder bore

mm

90


mm

50

Piston stroke

mm

300

GD555, 655, 675-3C

01-9 (4)

GENERAL

SPECIFICATIONS

Machine Model

GD655-3C

Serial Number

50001 – 51000


3,660 x 660 x 22


1,829 x 153 x 16 – 2 mm

480

Max. cutting depth

815

Blade




01-10 (4)

51001 and up

72.4 {7,378}

73.2 {7,469} 360 (130) 625 625 —

deg.

37 32 to 81

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

GD675-3C GD675-3C

Machine Model

VHP Engine

Serial Number

50001 – 51000

51001 and up

15,600

15,810

4,450

4,500

On rear axle

11,150

11,310

Overall length

8,620

8,595

Machine weight

Dimensions

On front axle

kg

Overall width

2,550


2,995


3,115

Wheel base

6,070

mm


1,535

Tread (Front)

2,130

Tread (Rear)

2,130

Ground clearance

365

Forward

Performance

Travel speed

Reverse

1st

3.3

2nd

4.7

3rd

6.7

4th 5th

9.7

km/h

14.6

6th

21.2

7th

29.1

8th

42.1

1st

4.3

2nd 3rd

8.8

km/h

18.1

4th Maximum drawbar pull Gradeability Min. Turning radius Static stability

GD555, 655, 675-3C

35.1 kN {kg}

83.0 {8,460}

88.8 {9,050}

deg.

24

m

6.9

deg.

35

01-11 (4)

GENERAL

SPECIFICATIONS

GD675-3C

Machine Model

VHP Engine

Serial Number Engine model


l {cc}

8.27 {8,270}

Flywheel horsepower

kW/rpm {HP/rpm}

134.2 to 149.2/1,900 {180 to 200/1,900}

Maximum torque

Nm/rpm {kgm/rpm}

Performance

Engine

856.2 to 974.8/1,300 {86.1 to 98.0/1,300}

785 to 974.6/1,400 {80.0 to 99.4/1,400}


rpm

2,200


rpm

800


g/kW•h {g/HP•h}

Alternator Battery Radiator type

Reduction gear

Front axle

24V, 7.5kW

24V, 50A

24V, 60A

12V, 112Ah x 2

12V, 112Ah x 2

CF19-4

CF19-5


Tandem

Steering system

24V, 7.5 kW


Rear axle

Type

218.1 {162.7}


Transmission

Type

236.5 to 237.6 {176.4 to 177.2}

3-element, single-stage Automatic shifting, wet-type clutch

Torque converter

Power train

SAA6D114E-2

6 - 114 x 135

Starting motor

Steering

SA6D114E-1

mm

Piston displacement

(4)

51001 and up

4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler

Type

01-12

50001 – 51000

Double-row chain drive Reverse Elliott, angle type

Max. leaning angle

16 Fully hydraulic type

Steering angle

deg.

49

Articulate angle

deg.

23

GD555, 655, 675-3C

GENERAL

SPECIFICATIONS

GD675-3C

Machine Model

VHP Engine

Tires (rear)

14.00-24-12PR 275 {2.75}


kPa {kg/cm2}

275 {2.75}

Brakes

kPa {kg/cm2}

Hydraulic pump


Type x no.

Type x no.


Parking brake

Discharge at rated rpm Set pressure


194

MPa {kg/cm2}

206 {210}


Control method


Type

Leaning

Articulating


Cylinder bore

mm

50

80

90


mm

35

40

50

Piston stroke

mm

330

160

325

Blade lift


51001 and up

14.00-24-12PR

Control valve

Tires

50001 – 51000

Tires (front)

Main brake


Hydraulic system


Serial Number

Blade side shift

Blade tilt

Drawbar side shift

Ripper


mm

80

80

80

80

120


mm

50

40

40

45

55

Piston stroke

mm

1,160

1,250

300

585

540

Scarifier

Type


Cylinder bore

mm

90


mm

50

Piston stroke

mm

300

GD555, 655, 675-3C

01-13 (4)

GENERAL

SPECIFICATIONS

Machine Model

GD675-3C

Serial Number

50001 – 51000


3,660 x 660 x 25


1,830 x 153 x 16 – 2 mm

480

Max. cutting depth

615

Blade




01-14 (4)

51001 and up

76.3 {7,777}

77.2 {7,872} 360 (130) 625 625 —

deg.

37 32 to 81

GD555, 655, 675-3C

GENERAL

WEIGHT TABLE

WEIGHT TABLE

k Use the weight table when handling individual parts or when transporting the entire machine. Serial No. 50001 – 51000 Machine model

Unit: kg GD555-3C

Serial Number

GD655-3C

GD675-3C

50001 – 51000

Engine assembly (dry)

453

616

616

Radiator assembly (dry)

51

51

51

Transmission assembly (dry)

755

755

755

Transmission pump

9

9

9

Final drive assembly

1,012

1,012

1,012

Tandem drive (one side)

876

876

876

Front axle assembly, except leaning cylinder

418

548

548

Parking brake assembly

26

26

26

Wheel assembly (front)

138 x 2

151 x 2

179 x 2

Wheel assembly (rear)

138 x 4

151 x 4

179 x 4

Scarifier assembly

450

530

530

Hydraulic pump

49

49

49

Fuel tank and hydraulic tank (both dry)

160

160

160

Circle rotation motor

10

10

10

Steering cylinder assembly

12 x 2

12 x 2

12 x 2

Leaning cylinder assembly

11

15

15

Articulating cylinder assembly

25 x 2

25 x 2

25 x 2

Blade lift cylinder assembly

49 x 2

49 x 2

49 x 2

Blade side-shift cylinder assembly

48

48

48

Blade power tilt cylinder assembly

19

19

19

Drawbar side-shift cylinder assembly

32

32

32

Scarifier cylinder assembly

22

24

24

Drawbar assembly

538

557

557

Blade assembly

625

625

675

Circle gear

252

272

272

Circle rotation gear assembly

119

119

119

Front frame assembly

1,613

1,814

1,814

Rear frame assembly

883

980

980

Ripper

595

900

900

Operator's compartment assembly and controls

200

200

200

GD555, 655, 675-3C

01-15 (4)

GENERAL

WEIGHT TABLE

Serial No. 51001 and up Machine model

Unit: kg GD555-3C

Serial Number

GD655-3C

GD675-3C

51001 and up

Engine assembly (dry)

550

750

750

Radiator assembly (dry)

115

115

115

Transmission assembly (dry)

755

755

755

Transmission pump

9

9

9

Final drive assembly

1,012

1,012

1,012

Tandem drive (one side)

876

876

876

Front axle assembly, except leaning cylinder

418

548

548

Parking brake assembly

26

26

26

Wheel assembly (front)

138 x 2

151 x 2

179 x 2

Wheel assembly (rear)

138 x 4

151 x 4

179 x 4

Scarifier assembly

450

530

530

Hydraulic pump

49

49

49

Fuel tank and hydraulic tank (both dry)

160

160

160

Circle rotation motor

10

10

10

Steering cylinder assembly

12 x 2

12 x 2

12 x 2

Leaning cylinder assembly

11

15

15

Articulating cylinder assembly

25 x 2

25 x 2

25 x 2

Blade lift cylinder assembly

49 x 2

49 x 2

49 x 2

Blade side-shift cylinder assembly

48

48

48

Blade power tilt cylinder assembly

19

19

19

Drawbar side-shift cylinder assembly

32

32

32

Scarifier cylinder assembly

22

24

24

Drawbar assembly

538

557

557

Blade assembly

625

625

675

Circle gear

252

272

272

Circle rotation gear assembly

119

119

119

Front frame assembly

1,613

1,814

1,814

Rear frame assembly

883

980

980

Ripper

595

900

900

Operator's compartment assembly and controls

200

200

200

01-16 (4)

GD555, 655, 675-3C

GENERAL

FUEL, COOLANT, AND LUBRICANT SELECTION

FUEL, COOLANT, AND LUBRICANT SELECTION According to temperature Ambient temperature Reservoir

Fluid

-22 -30

-4 -20

14 -10

32 0

50 10

68 20

Capacity (l) 86 30

104 40

122ºF 50ºC

Specified

Refill

GD555-3C 16

GD555-3C 14

GD655-3C GD675-3C 24

GD655-3C GD675-3C 19

60

45

18

16

80

75

4

4

7

7

85

45

340

—

44

44

SAE30 CD SAE10W CD SAE10W-30 CD Engine oil pan SAE15W-40 CD SAE5W-40 CD

Engine oil

SAE0W-30 CD Transmission case

SAE10W CD

Final drive case

SAE30 CD

Tandem drive case (each)

SAE10W CD SAE90

Circle reverse gear • Shear-pin type

Gear oil

• Slip-clutch type

SAE80 SAE75 SAE10W CD

Hydraulic system

Engine oil SAE5W-30 CD ASTM D975 No. 2

Fuel tank

Diesel fuel

Cooling system

Coolant

Add antifreeze ASTM D975 No. 1

GD555, 655, 675-3C

01-17 (4)

GENERAL

FUEL, COOLANT, AND LUBRICANT SELECTION

Remark •

When fuel sulphur content is less than 0.5%, change oil in the oil pan in accordance with the periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

• • • •

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

When starting the engine in atmospheric temperature of lower than 0ºC, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10ºC or more in the day time. Use API classification CD engine oil. If API classification CC is used, reduce the engine oil change interval in half. There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil, which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

01-18 (4)

GD555, 655, 675-3C

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCELERATOR CONTROL LINKAGE ............ 10-2 ACCELERATOR PEDAL................................... 10-3 FAN DRIVE ....................................................... 10-4 POWER TRAIN DIAGRAM ............................... 10-5 TRANSMISSION HYDRAULIC PIPING............ 10-6 TRANSMISSION HYDRAULIC PIPING............ 10-8 TORQUE CONVERTER ................................... 10-9 TORQUE CONVERTER LOCK-UP VALVE (ECMV) ...................................................... 10-14 TRANSMISSION............................................. 10-17 TRANSMISSION VALVE................................. 10-46 ECMV (ELECTRONIC CONTROL MODULATION VALVE).............................. 10-47 MAIN RELIEF VALVE ..................................... 10-52 TRANSMISSION PUMP ................................. 10-55 TRANSMISSION AND DIFFERENTIAL LOCK PUMP (WITH DIFFERENTIAL LOCK) ...... 10-56 FINAL DRIVE .................................................. 10-58 TANDEM DRIVE ............................................. 10-64 STEERING HYDRAULIC PIPING DRAWING 10-68 STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE).................................. 10-71 PRIORITY ACC GOVERNOR VALVE (Serial No. 50001 – 51000) ....................... 10-78 PRIORITY VALVE (Serial No. 51001 and up) ......................... 10-85 ACCUMULATOR PRESSURE GOVERNOR VALVE (Serial No. 51001 and up) ......................... 10-92 FRONT AXLE ................................................. 10-94 BRAKE HYDRAULIC PIPING ......................... 10-98 BRAKE VALVE.............................................. 10-102 WHEEL BRAKE ............................................ 10-106 SLACK ADJUSTER ...................................... 10-107 ACCUMULATOR............................................10-110 PARKING BRAKE .......................................... 10-111 PARKING BRAKE AND BANK CONTROL VALVE .........................10-112 WORK EQUIPMENT HYDRAULIC PIPING DRAWING ...................................10-114 HYDRAULIC PUMP (Serial No. 50001 – 51000) ..................... 10-124 HYDRAULIC PUMP (Serial No. 51001 and up) ....................... 10-146 MAIN CONTROL VALVE .............................. 10-169 CLSS............................................................. 10-188

GD555, 655, 675-3C

WORK EQUIPMENT CONTROL...................10-200 HYDRAULIC SYSTEM ..................................10-202 HYDRAULIC TANK........................................10-208 SWIVEL JOINT..............................................10-209 PILOT CHECK VALVE...................................10-212 BLADE ACCUMULATOR, FLOAT VALVE .....10-217 SHUT-OFF VALVE.........................................10-221 BLADE FLOAT DEVICE ................................10-222 CIRCLE ROTATION MOTOR ........................10-224 HYDRAULIC CYLINDER...............................10-226 CIRCLE, DRAWBAR .....................................10-232 LIFTER BRACKET LOCK PIN.......................10-234 BLADE ...........................................................10-236 CIRCLE ROTATION GEAR ...........................10-238 SCARIFIER....................................................10-242 RIPPER .........................................................10-244 MAIN FRAME ................................................10-247 AIR CONDITIONER (IF EQUIPPED) ............10-248 ENGINE STARTING CIRCUIT ......................10-252 ENGINE STOP CIRCUIT...............................10-256 PREHEAT CIRCUIT ......................................10-258 AUTOMATIC SHIFT CONTROL SYSTEM ....10-260 TRANSMISSION CONTROLLER..................10-261 MONITOR......................................................10-265 SENSORS .....................................................10-268

10-1 (8)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ACCELERATOR CONTROL LINKAGE

ACCELERATOR CONTROL LINKAGE

Outline • Operating the fuel control lever (1) pulls the spring rod (2), which moves the lever (3) and accelerator cable (9) to control the engine speed. • Depressing the accelerator pedal (5) moves the rod (4), lever (3), and accelerator cable (9) to control the engine speed. When this situation happens, the spring of the spring rod (2) moves in the direction of the compression. • Releasing the accelerator pedal (5) and depressing the decelerator pedal (rod) (6) cause the lever (3) to rotate, reducing engine speed.

10-2 (4)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Fuel control lever Spring rod Lever Rod. Accelerator pedal Decelerator pedal Fuel injection pump Fuel injection pump lever Accelerator cable

GD555, 655, 675-3C


ACCELERATOR PEDAL

ACCELERATOR PEDAL

1. 2. 3. 4.

Pedal Stopper bolt Cable Potentiometer

GD555, 655, 675-3C

10-3 (4)


FAN DRIVE

FAN DRIVE

1. 2. 3. 4. 5. 6.

Transmission Radiator Fan drive pulley V-belt Tension pulley Drive pulley

10-4 (4)

Outline • The fan drive is installed at the top of transmission (1). The fan is driven by V-belt (4) through drive pulley (6) at the front face of transmission (1). This drive pulley (6) is driven through a gear by the torque converter input shaft.

GD555, 655, 675-3C


POWER TRAIN DIAGRAM

POWER TRAIN DIAGRAM

• •

•

The power produced by diesel engine (5) goes to transmission (4) through torque converter with lock-up clutch (3). Transmission (4), with a multiple shaft mechanism and a hydraulic control unit combined, allows an easy selection of eight forward speeds and four reverse speeds. Through drive shaft (6), the power is transmitted from the transmission to the final drive (7). Here, final drive (7) directs the power to the right and left, and the power is transmitted to the left and right tandem drives (8) through shaft (11). Tandem drive (8) transmits the power to the wheel by a chain and the machine travels.

GD555, 655, 675-3C

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Cooling fan Hydraulic pump Torque converter Transmission Engine assembly Drive shaft Final drive Tandem drive Tire Wheel brake Shaft

10-5 (4)


TRANSMISSION HYDRAULIC PIPING

TRANSMISSION HYDRAULIC PIPING GD555-3C Serial No. 50001 – 51037 GD655-3C Serial No. 50001 – 51081 GD675-3C Serial No. 50001 – 51009

1. 2. 3. 4.

Engine assembly Transmission assembly Oil filter Hydraulic pump

10-6 (6)

GD555, 655, 675-3C


5. 6. 7. 8.


Hose-oil cooler inlet port Hose-oil cooler outlet port Oil filter Radiator and oil cooler

GD555, 655, 675-3C

10-7 (4)



TRANSMISSION HYDRAULIC PIPING GD555-3C Serial No. 51038 and up GD655-3C Serial No. 51082 and up GD675-3C Serial No. 51010 and up

1. 2. 3. 4. 5.

Engine assembly Transmission assembly Oil filter Return hose of oil in flywheel housing Hydraulic pump

10-7-1 (6)

GD555, 655, 675-3C




6. 7. 8. 9.

Hose-oil cooler inlet port Hose-oil cooler outlet port Oil filter Radiator and oil cooler

GD555, 655, 675-3C

10-7-2 (6)


TRANSMISSION CONTROL

TRANSMISSION CONTROL

1. Gearshift lever 2. Transmission controller

10-8 (4)

Gearshift lever positions Reverse Forward Parking Neutral 1 range (forward, reverse) 2 range (forward, reverse) 3 range (forward, reverse) 4 range (forward, reverse) 5 range (forward) 6 range (forward) 7 range (forward) 8 range (forward)

GD555, 655, 675-3C


TORQUE CONVERTER

TORQUE CONVERTER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Pump PTO drive gear (No. of teeth: 70) Outer race Output shaft (transmission input shaft) Stator shaft Lock-up clutch piston Lock-up clutch housing (No. of teeth: 72) Stator Pilot Freewheel Turbine Lock-up clutch disc Drive case

GD555, 655, 675-3C

Specifications: Name: TCA38-10A Type: 3 element, 1 stage, 2 phase Stall torque ratio: 2.17

10-9 (4)


10-10 (4)

TORQUE CONVERTER

GD555, 655, 675-3C


TORQUE CONVERTER

Unit: mm No.

Check item

Criteria

Remedy

Std. size

Tolerance

Repair limit

71.954

–0.010 –0.040

71.7

Pilot seal ring I.D.

35

+0.025 0

35.5

Clutch housing seal ring I.D.

340

+0.089 0

340.1 260.1

1

Pilot O.D.

2 3

Replace

4

Clutch piston seal ring I.D.

260

+0.081 0

5

PTO drive gear seal ring O.D.

125

+0.040 0

125.5

6

Clutch housing seal ring wear

Width

5

–0.01 –0.04

4.5

Thickness

6

±0.15

5.85

Width

3.95

0 –0.1

3.56

Thickness

4.8

±0.1

4.32

7

Stator shaft seal ring wear

8

One-way clutch outer race O.D.

88.882

+0.005 –0.008

88.912

9

Stator shaft one-way clutch O.D.

72.217

+0.008 –0.005

72.187

10

Bushing I.D.

72.32

+0.015 0

72.4

11

Bushing thickness

5

0 –0.1

4.9

12

Clutch disc thickness

5

±0.1

4.7

13

Stator shaft seal ring I.D.

55

+0.030 0

55.5

14

Backlash between PTO drive gear and idler gear

GD555, 655, 675-3C

Rebuild or replace

Rebuild or replace

Replace

0.160 to 0.407

10-11 (4)


TORQUE CONVERTER

LOCK-UP CLUTCH Lock-up clutch disengaged • When the lock-up clutch is disengaged, the drive case (13) and turbine (11) are separated, and the torque converter functions as normal. The power generated by the engine passes through the flywheel, is transmitted to lock-up clutch housing (7) and rotates drive case (13) and pump (1) as one unit. The power from the pump uses oil as a medium, rotates turbine (11), and is transmitted to output shaft (4), which forms one unit with the turbine.

Lock-up clutch engaged • When the lock-up clutch is engaged, the drive case (13) and turbine (11) are engaged, forming one unit. The stator (8) is rotated by the rotation of the pump (1) and turbine (11). Engine power is transmitted through the flywheel and through the lock-up clutch housing (7), rotating the drive case (13) and pump (1) as one unit. In addition, the drive case (13) and turbine (11) are engaged by the clutch. Thus, the power is transmitted directly to the turbine and output shaft (4), without using oil.

10-12 (4)

GD555, 655, 675-3C


TORQUE CONVERTER

OIL FLOW •

The oil supplied from the torque converter charging pump passes through the transmission valve and enters the inlet port (A). The oil then passes through the oil passage in the stator shaft (5) and PTO drive gear (2) and flows from between the pump (1) and stator (8) to the pump (1). The oil is given centrifugal force by the pump (1) and enters the turbine (11), transmiting the energy of the oil to the turbine. Because the turbine (11) is fixed to the output shaft (4), the power is transmitted to the output shaft. The oil from turbine (11) is sent to the stator (8), entering the pump again. However, part of the oil that returns from between the turbine (11) and stator (8) to the outlet port is routed to the oil cooler.

GD555, 655, 675-3C

10-13 (4)


TORQUE CONVERTER LOCK-UP VALVE (ECMV)


A P T Dr P1 P2

: : : : : :

To clutch From pump Drain Drain Clutch oil pressure detection port Pilot oil pressure detection port

10-14 (4)

1. 2. 3. 4. 5. 6. 7. 8.

Connector for proportional solenoid ECMV (for torque converter lock-up clutch) Seat Connector for fill switch Fill switch Oil pressure detection valve Pressure control valve spool Proportional solenoid

GD555, 655, 675-3C



ECMV FOR LOCK-UP CLUTCH Outline • This valve acts to set the lock-up clutch oil pressure to the set pressure, and also to switch the lock-up clutch. It forms a modulation wave pattern, so the lockup clutch is engaged smoothly to reduce the shock when shifting gear. In addition, it prevents generation of peak torque in the power train. As a result, it provides a comfortable ride for the operator and greatly increases the durability of the power train.

GD555, 655, 675-3C

Operation During torque converter travel • When transmission is in torque converter travel, no current flows to the proportional solenoid (1). Pressure control valve (3) drains the oil at clutch port A through drain port Dr and cancels the lock-up clutch. When this happens, there is no oil pressure acting on oil pressure detection valve (4), so fill switch (6) is OFF.

10-15 (7)



During direct travel (torque converter travel o direct travel) 1. When filling When the transmission is in direct travel (lockup), if electric current is applied to proportional solenoid (1) by the electric signal, a hydraulic force balancing with the force of the solenoid acts on chamber B, and pressure control valve spool (3) moves to the left. As a result, the circuit between pump port P and clutch port A opens, and oil starts to fill the clutch. When the clutch is filled with oil, fill switch (6) is turned ON.

10-16 (4)

2. Adjusting pressure When the electric current flows to the proportional solenoid (1), the solenoid generates a propulsion force proportional to the current. The pressure is adjusted so that the total of this propulsion force of the solenoid, the propulsion force of the oil pressure at the clutch port, and the reaction force of pressure control valve spring (2) is balanced. To reduce the shock when shifting gear, the lock-up clutch oil pressure is temporarily lowered to 0 MPa {0 kg/cm 2 } when the gear is shifted.

GD555, 655, 675-3C


TRANSMISSION

TRANSMISSION Serial No.: 50001 – 51000

1. 2. 3. 4. 5. 6.

Transmission control valve Transmission case Strainer mounting port Dipstick tube mounting port Torque converter lock-up valve Main relief, torque converter relief valve

GD555, 655, 675-3C

10-17 (4)


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

TRANSMISSION

Torque converter Input shaft FL clutch Upper shaft FH clutch Lower shaft 3rd clutch Coupling 4th clutch Output shaft 2nd clutch 1st clutch R clutch Mounting coupling for fan pulley Shaft for hydraulic pump drive

10-18 (4)

GD555, 655, 675-3C


TRANSMISSION

1. Shaft for transmission charge pump 2. R idler gear (Number of teeth: 37) 3. Speedometer gear set Unit: mm No.

4

Check item

Clearance between idler gear and bearing

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

50

+0.018 +0.002

0 –0.012

–0.030 to –0.002

Std. size

5

Clearance between idler gear bearing and case

90

0 –0.015

+0.016 –0.006

–0.006 to 0.031

6

Clearance between pump drive shaft and bearing (F)

50

+0.020 +0.009

0 –0.012

–0.032 to –0.009

7

Clearance between pump drive shaft bearing and case (F)

90

0 –0.015

+0.030 0

0 to 0.045

8

Clearance between pump drive shaft and bearing (R)

70

+0.030 +0.011

0 –0.015

–0.045 to –0.011

9

Clearance between pump drive shaft bearing and case (R)

100

0 –0.015

+0.030 0

0 to 0.045

10

Clearance between idler shaft and bearing

70

+0.032 +0.002

0 –0.015

–0.047 to –0.002

11


125

0 –0.018

–0.025 –0.050

–0.050 to –0.007

GD555, 655, 675-3C

Clearance limit

Replace

10-19 (4)


10-20 (4)

TRANSMISSION

GD555, 655, 675-3C


TRANSMISSION

Unit: mm No.

1

Check item

Clearance between FL, R clutch bearing and case (F)

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

150

0 –0.018

+0.030 0

0 to 0.048

Std. size

2

Clearance between FL, R clutch bearing and case (R)

100

0 –0.015

+0.022 –0.013

–0.013 to 0.037

3

Clearance between FH, 1st clutch bearing and case (F)

100

0 –0.015

+0.030 0

0 to 0.045

4

Clearance between FH, 1st clutch bearing and case (R)

110

0 –0.015

+0.022 –0.013

–0.013 to 0.037

5

Clearance between 2nd, 3rd clutch bearing and case (F)

140

0 –0.018

+0.026 –0.014

–0.014 to 0.044

6

Clearance between 2nd, 3rd clutch bearing and case (R)

130

0 –0.018

+0.026 –0.014

–0.014 to 0.044

7

Clearance between 4th clutch bearing and case (F)

140

0 –0.018

+0.026 –0.014

–0.014 to 0.044

8

Clearance between 4th clutch bearing and case (R)

160

0 –0.025

+0.040 0

0 to 0.065

9


50

+0.018 +0.002

0 –0.012

–0.030 to –0.002

10


90

0 –0.015

+0.016 –0.006

–0.006 to 0.031

11

Clearance between fan drive shaft and bearing

35

+0.025 +0.009

0 –0.012

–0.037 to –0.009

12

Clearance between fan drive shaft bearing and case

80

0 –0.013

+0.030 0

0 to 0.043

13


50

+0.020 +0.009

0 –0.012

–0.032 to –0.009

14


90

0 –0.015

+0.030 0

0 to 0.045

15


70

+0.030 +0.011

0 –0.015

–0.045 to –0.011

16


110

0 –0.015

+0.030 0

0 to 0.045

Wear of input shaft seal ring

GD555, 655, 675-3C

Replace

Standard size

Tolerance

Repair limit

2.5

+0.018 +0.010

2.7

Width

2.4

±0.05

2.2

Thickness

1.7

0 –0.010

1.5

Width of input shaft seal ring groove 17

Clearance limit

10-21 (4)


No.

Check item Width of input shaft seal ring groove

18

19

TRANSMISSION

Criteria

Remedy

3.2

+0.076 0

3.5

Width

3.1

±0.05

2.8

Thickness

2.29

0 –0.010

2.1

Inside diameter of case seal ring sliding portion

50

+0.05 0

50.1

Width of input shaft seal ring groove

3.2

+0.076 0

3.5

Width

3.1

±0.05

2.8

Thickness

2.29

0 –0.010

2.1



Replace

20

Outside diameter of output coupling oil seal sliding portion

80

0 –0.074

79.8

21

Outside diameter of fan pulley coupling oil seal sliding portion

65

0 –0.074

64.8

10-22 (4)

GD555, 655, 675-3C


TRANSMISSION

Serial No.: 51001 and up

1. Transmission control valve 2. Transmission case 3. Strainer mounting port

GD555, 655, 675-3C

4. Dipstick tube mounting port 5. Torque converter lock-up valve 6. Main relief, torque converter relief valve

10-23 (4)


1. 2. 3. 4. 5. 6. 7. 8.

Torque converter Input shaft FL clutch Upper shaft FH clutch Lower shaft 3rd clutch Coupling

10-24 (4)

9. 10. 11. 12. 13. 14. 15.

TRANSMISSION

4th clutch Output shaft 2nd clutch 1st clutch R clutch Mounting coupling for fan pulley Shaft for hydraulic pump drive

GD555, 655, 675-3C


TRANSMISSION

1. Shaft for the transmission charge pump 2. R idler gear (Number of teeth: 37) 3. Speedometer gear set Unit: mm No.

4

Check Item


Criteria Tolerance

Remedy

Shaft

Hole

Standard Clearance

Clearance Limit

50

+0.018 +0.002

0 –0.012

–0.030 to –0.002

—

Std. Size

5


90

0 –0.015

+0.016 –0.006

–0.006 to 0.031

—

6


50

+0.020 +0.009

0 –0.012

–0.032 to –0.009

—

7


90

0 –0.015

+0.030 0

0 to 0.045

—

8


70

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

9


100

0 –0.015

+0.030 0

0 to 0.045

—

10

Clearance between idler shaft and bearing

70

+0.032 +0.002

0 –0.015

–0.047 to –0.002

—

11


100

0 –0.015

–0.038 –0.073

–0.073 to –0.023

—

GD555, 655, 675-3C

Replace

10-25 (4)


10-26 (4)

TRANSMISSION

GD555, 655, 675-3C


TRANSMISSION

Unit: mm No.

1

Check Item

Clearance between FL, R clutch bearing and case (F)

Criteria Tolerance

Remedy

Shaft

Hole

Standard Clearance

Clearance Limit

150

0 –0.018

+0.030 0

0 to 0.048

—

Std. Size

2

Clearance between FL, R clutch bearing and case (R)

100

0 –0.015

+0.022 –0.013

–0.013 to 0.037

—

3

Clearance between FH, 1st clutch bearing and case (F)

100

0 –0.015

+0.030 0

0 to 0.045

—

4

Clearance between FH, 1st clutch bearing and case (R)

110

0 –0.015

+0.022 –0.013

–0.013 to 0.037

—

5

Clearance between 2nd, 3rd clutch bearing and case (F)

140

0 –0.018

+0.026 –0.014

–0.014 to 0.044

—

6

Clearance between 2nd, 3rd clutch bearing and case (R)

130

0 –0.018

+0.026 –0.014

–0.014 to 0.044

—

7

Clearance between 4th clutch bearing and case (F)

140

0 –0.018

+0.026 –0.014

–0.014 to 0.044

—

8

Clearance between 4th clutch bearing and case (R)

160

0 –0.025

+0.040 0

0 to 0.065

—

9


50

+0.018 +0.002

0 –0.012

–0.030 to –0.002

—

10


90

0 –0.015

+0.016 –0.006

–0.006 to 0.031

—

11

Clearance between fan drive shaft and bearing

35

+0.025 +0.009

0 –0.012

–0.037 to –0.009

—

12

Clearance between fan drive shaft bearing and case

80

0 –0.013

+0.030 0

0 to 0.043

—

13


50

+0.020 +0.009

0 –0.012

–0.032 to –0.009

—

14


90

0 –0.015

+0.030 0

0 to 0.045

—

15


70

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

16


110

0 –0.015

+0.030 0

0 to 0.045

—

Standard Size

Tolerance

Repair Limit

2.5

+0.018 +0.010

2.7

Width

2.4

±0.05

2.2

Thickness

1.7

0 –0.010

1.5

Width of input shaft seal ring groove 17 Wear of input shaft seal ring

GD555, 655, 675-3C

Replace

10-27 (4)


No.

Check Item Width of input shaft seal ring groove

18

19

TRANSMISSION

Criteria

Remedy

3.2

+0.076 0

3.5

Width

3.1

±0.05

2.8

Thickness

2.29

0 –0.010

2.1

Inside diameter of case seal ring sliding portion

50

+0.05 0

50.1

Width of input shaft seal ring groove

3.2

+0.076 0

3.5

Width

3.1

±0.05

2.8

Thickness

2.29

0 –0.010

2.1



Replace

20

Outside diameter of output coupling oil seal sliding portion

80

0 –0.074

79.8

21

Outside diameter of fan pulley coupling oil seal sliding portion

65

0 –0.074

64.8

10-28 (4)

GD555, 655, 675-3C


OUTLINE •

Combination of clutches and reduction ratio

The transmission is installed at the rear of the torque converter. The power from the torque converter passes through the transmission input shaft and enters the transmission. The transmission shifts the gear to FORWARD 1 to 8 or REVERSE 1 to 4, according to the combination of the FL, FH, and R clutches and the 4speed.

•

TRANSMISSION

Speed range

Clutch used

Reduction ratio

F1

FL x 1st

9.950

F2

FH x 1st

6.865

F3

FL x 2nd

4.879

F4

FH x 2nd

3.367

F5

FL x 3rd

2.222

F6

FH x 3rd

1.533

F7

FL x 4th

1.118

F8

FH x 4th

0.772

R1

R x 1st

7.549

R2

R x 2nd

3.702

R3

R x 3rd

1.686

R4

R x 4th

0.848

CLUTCHES FL, R clutches

1. 2. 3. 4. 5. 6. 7.

R gear (number of teeth: 25) R clutch FL, R cylinder FL clutch FL gear (number of teeth: 28) Idler gear (number of teeth: 36) Input shaft

GD555, 655, 675-3C

A. B. C. D.

R clutch oil port FL clutch oil port Lubrication oil port Lock-up clutch oil port

10-29 (4)


TRANSMISSION

FH, 1st clutches

1. 2. 3. 4. 5. 6. 7.

Idler gear (No. of teeth: 42) 1st gear (No. of teeth: 26) 1st clutch FH, 1st cylinder, idler gear (No. of teeth: 62) FH clutch FH gear (No. of teeth: 55) Upper shaft

A : FH clutch oil port B : 1st clutch oil port C : Lubrication oil port

2nd and 3rd clutches

1. 2. 3. 4. 5. 6. 7.

Idler gear (No. of teeth: 29) 2nd gear (No. of teeth: 61) 2nd clutch 2nd, 3rd cylinder, idler gear (No. of teeth: 77) 3rd clutch 3rd gear (No. of teeth: 55, 41) Lower shaft

10-30 (4)

A. 2nd clutch oil port B. 3rd clutch oil port C. Lubrication oil port

GD555, 655, 675-3C


TRANSMISSION

4th clutches

1. 2. 3. 4.

Output gear (No. of teeth: 44) 4th clutch 4th cylinder, idler gear (No. of teeth: 42) Output shaft

GD555, 655, 675-3C

A. 4th clutch oil port B. Lubrication oil port C. Lubrication oil port

10-31 (4)


TRANSMISSION

FL - R clutches

Unit: mm No.

Check item

Criteria

Shaft

Hole

Standard clearance

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

140

–0.300 –0.350

+0.130 0

0.300 to 0.480

0.53

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

140

–0.300 –0.350

+0.130 0

0.300 to 0.480

0.53

Std. size 1

Clearance between the piston and shaft (FL)

2 3 4

Inside Outside

Clearance between the piston and shaft (R)

Inside Outside

Tolerance

Remedy Clearance limit

5

Clearance between the FL, R shaft and bearing (F)

60

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

6

Clearance between the FL, R shaft and bearing (R)

55

+0.034 +0.021

0 –0.015

–0.049 to –0.021

—

7

Separator plate

Standard size

Tolerance

Repair limit

Thickness

1.7

±0. 05

1.6

Distortion

—

0.1

0.15

Thickness

2.2

±0.08

1.9

Distortion

—

0.1

0.25

1,010 N {103 kg}

±101 N {±10.3 kg}

859 N {87.6 kg}

8

Friction plate

9

Load of wave spring (height: 2.2 mm)

10

FL clutch thrust washer thickness

3

±0.1

2.7

11

R clutch thrust washer thickness

3

±0.1

2.7

12

FL gear end play

0.30 to 0.76

13

R gear end play

0.29 to 0.69

10-32 (4)

Replace

GD555, 655, 675-3C


TRANSMISSION

FH and 1st clutches

Unit: mm No.

Check item

Criteria

Shaft

Hole

Standard clearance

Clearance limit

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

145

–0.300 –0.350

+0.130 0

0.300 to 0.480

0.53

Inside

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

Outside

164.93

–0.200 –0.250

+0.130 0

0.200 to 0.380

0.42

Std. size 1

Clearance between piston and shaft (FH)

2 3 4

Inside Outside

Clearance between piston and shaft (1st)

Tolerance

Remedy

5

Clearance between the FH, 1st shaft and bearing (F)

55

+0.034 +0.021

0 –0.015

–0.049 to –0.021

—

6

Clearance between the FH, 1st shaft and bearing (R)

60

+0.034 +0.021

0 –0.015

–0.049 to –0.021

—

7

Separator plate

Standard size

Tolerance

Repair limit

Thickness

1.7

±0. 05

1.6

Distortion

—

0.1

0.15

Thickness

2.2

±0.08

1.9

Distortion

—

0.1

0.25

1,010 N {103 kg}

±101 N {±10.3 kg}

859 N {87.6 kg}

8

Friction plate

9


10

FH clutch thrust washer thickness

3

±0.1

2.7

11

1st clutch thrust washer thickness

3

±0.1

2.7

12

FH gear end play

0.39 to 0.79

13

1st gear end play

0.26 to 0.74

GD555, 655, 675-3C

Replace

10-33 (4)


TRANSMISSION

2nd and 3rd clutches

Unit: mm No.

Check item

Criteria Std. size

1

Clearance between piston and shaft (3rd)

2 3 4

Clearance between piston and shaft (2nd)

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Inside

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

Outside

164.93

–0.200 –0.250

+0.130 0

0.200 to 0.380

0.42

Inside

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

Outside

164.93

–0.200 –0.250

+0.130 0

0.200 to 0.380

0.42

5

Clearance between 2nd, 3rd shaft and bearing (F)

65

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

6

Clearance between 2nd, 3rd shaft and bearing (R)

60

+0.054 +0.044

0 –0.015

–0.069 to –0.044

—

7

Separator plate

Standard size

Tolerance

Repair limit

Thickness

1.7

±0. 05

1.6

Distortion

—

0.1

0.15

Thickness

2.2

±0.08

1.9

Distortion

—

0.1

0.25

1,010 N {103 kg}

±101 N {±10.3 kg}

859 N {87.6 kg}

8

Friction plate

9


10

3rd clutch thrust washer thickness

3

±0.1

2.7

11

2nd clutch thrust washer thickness

3

±0.1

2.7

12

3rd gear end play

0.38 to 0.82

13

2nd gear end play

0.35 to 0.85

10-34 (4)

Replace

GD555, 655, 675-3C


TRANSMISSION

4th clutches

Unit: mm No.

Check item

Criteria Std. size

1

Clearance between piston and cylinder (4th)

2

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Inside

96.73

0 –0.050

+0.180 +0.050

0.050 to 0.230

0.25

Outside

164.93

–0.200 –0.250

+0.130 0

0.200 to 0.380

0.42

3

Clearance between 4th shaft and bearing (F)

65

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

4

Clearance between 4th shaft and bearing (R)

75

+0.030 +0.011

0 –0.015

–0.045 to –0.011

—

5

Separator plate

Standard size

Tolerance

Repair limit

Thickness

1.7

±0.05

1.6

Distortion

—

0.01

0.15

Thickness

2.2

±0.08

1.9

Distortion

—

0.1

0.25

1010 N {103 kg}

±101 N {±10.3 kg}

859 N {87.6 kg}

6

Friction plate

7


8

Thickness of 4th clutch thrust washer

3

±0.1

2.7

Inside diameter of cylinder seal ring sliding portion

70

+0.030 0

70.1

4th shaft seal ring groove width

3.2

+0.076 0

3.5

Width

3.1

±0.05

2.8

Thickness

2.29

0 –0.10

2.1

9

4th shaft seal ring wear 10

4th cylinder idler gear end play

GD555, 655, 675-3C

Replace

0.30 to 0.70 mm

10-35 (4)


TRANSMISSION

CLUTCH OPERATION When operated: • The oil from the transmission valve passes through the oil passage inside the shaft (1) and goes to the rear face of the piston (6) to actuate the piston. • Actuating the piston (6) causes the separator plate (2) to press the clutch disc (3) and combines the shaft (1) and clutch gear (4) as one unit to transmit the motive force. • Oil is drained from the oil drain hole (5) at this time, but does not affect the clutch operation because less oil is drained than supplied. The oil drain hole (5) is only in the 2nd, 3rd, and 4th clutches. When not actuated: • If the oil from the transmission valve is turned off, the pressure acting on the rear face of the piston (6) drops. The piston then returns to its original position by the wave spring (7). Thus, the shaft (1) and clutch gear (4) disengage or separate. When the clutch is disengaged, the oil at the rear face of the piston is drained by centrifugal force through the oil drain hole (5). This situation prevents the clutch from remaining partially engaged.

10-36 (4)

GD555, 655, 675-3C


TRANSMISSION

POWER FLOW Forward 1st

Operation • In FORWARD 1st, the FL clutch (2) and 1st clutch (10) are engaged. The FL clutch (2) and 1st clutch (10) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) through the FL clutch (2) to the FL gear (4). The power is then transmitted to FH, 1st cylinder gear (11).

GD555, 655, 675-3C

•

The 1st clutch (10) is engaged, so the power transmitted to FH, 1st cylinder gear (11) passes through the 1st clutch (10). From the 1st clutch the power goes from 1st gear (13) to 2nd, 3rd cylinder gear (19). The power flow continues through the lower shaft (20), idler gear (21), output gear (24), and finally to the output shaft (25).

10-37 (4)


TRANSMISSION

Forward 2nd

Operation • In FORWARD 2nd, the FH clutch (9) and 1st clutch (10) are engaged. The FH clutch (9) and 1st clutch (10) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) to the idler gear (6). The power continues to the FH gear (8) and passes through the FH clutch (9), and is then transmitted to the FH, 1st cylinder gear (11).

10-38 (4)

•

With the 1st clutch (10) engaged, the power transmitted to the FH, 1st cylinder gear (11) passes through the 1st clutch (10). Power is then transmitted from the 1st gear (13) to 2nd, 3rd cylinder gear (19). Power then goes through the lower shaft (20), idler gear (21), output gear (24), and finally the output shaft (25).

GD555, 655, 675-3C


TRANSMISSION

Forward 3rd

Operation • In FORWARD 3rd, the FL clutch (2) and 2nd clutch (17) are engaged. The FL clutch (2) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) through the FL clutch (2) and then to the FL gear (4). Power is then transmitted through the FH, 1st cylinder gear (11), upper shaft (12), and idler gear (14), and goes to the 2nd gear (15).

GD555, 655, 675-3C

•

With the 2nd clutch (17) engaged, the power transmitted to 2nd gear (15) passes through the 2nd clutch (17). Power continues to the 2nd, 3rd cylinder gear (19) and lower shaft (20), and then passes through the idler gear (21), output gear (24), and to the output shaft (25).

10-39 (4)


TRANSMISSION

Forward 4th

Operation • In FORWARD 4th, the FH clutch (9) and 2nd clutch (17) are engaged. The FH clutch (9) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) to the idler gear (6) and the FH gear (8) and then passes through the FH clutch (9). Power is then transmitted through the FH, 1st cylinder gear (11), upper shaft (12), idler gear (14), and then to the 2nd gear (15).

10-40 (4)

•

With the 2nd clutch (17) engaged, the power transmitted to the 2nd gear (15) passes through the 2nd clutch (17), and to the 2nd, 3rd cylinder gear (19) and lower shaft (20). Power is then transmitted through the idler gear (21), output gear (24), and finally to the output shaft (25).

GD555, 655, 675-3C


TRANSMISSION

Forward 5th

Operation • In FORWARD 5th, the FL clutch (2) and 3rd clutch (18) are engaged. The FL clutch (2) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) through the FL clutch (2) and then to the FL gear (4). Power is then transmitted through the FH, 1st cylinder gear (11) to the 3rd gear (16).

GD555, 655, 675-3C

•

With the 3rd clutch (18) engaged, the power transmitted to the 3rd gear (16) passes through the 3rd clutch (18) and then goes to the 2nd, 3rd cylinder gear (19) and lower shaft (20). Power then is transmitted through the idler gear (21), output gear (24), and finally to the output shaft (25).

10-41 (4)


TRANSMISSION

Forward 6th

Operation • In FORWARD 6th, the FH clutch (9) and 3rd clutch (18) are engaged. The FH clutch (9) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) and then to the idler gear (6) and FH gear (8). Power then passes through the FH clutch (9) to the FH, 1st cylinder gear (11) and then to the 3rd gear (16). • With the 3rd clutch (18) engaged, the power transmitted to the 3rd gear (16) passes through the 3rd clutch (18) and then to the 2nd, 3rd cylinder gear (19) and lower shaft (20). Power is then transmitted through the idler gear (21), output gear (24), and finally to the output shaft (25).

10-42 (4)

GD555, 655, 675-3C


TRANSMISSION

Forward 7th

Operation • In FORWARD 7th, the FL clutch (2) and 4th clutch (23) are engaged. The FL clutch (2) and 4th clutch (23) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) through the FL clutch (2) and then to the FL gear (4). Power is then transmitted through the FH, 1st cylinder gear (11) and 3rd gear (16) to the 4th cylinder gear (22). • With the 4th clutch (23) engaged, the power transmitted to the 4th cylinder gear (22) goes through the 4th clutch (23), and then to the output shaft (25).

GD555, 655, 675-3C

10-43 (4)


TRANSMISSION

Forward 8th

Operation • In FORWARD 8th, the FH clutch (9) and 4th clutch (23) are engaged. The FH clutch (9) and 4th clutch (23) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) to the idler gear (6) and FH gear (8). Power then passes through the FH clutch (9) and FH, 1st cylinder gear (11) and 3rd gear (16) to the 4th cylinder gear (22). • With 4th clutch (23) engaged, the power transmitted to the 4th cylinder gear (22) passes through the 4th clutch (23), and finally to the output shaft (25).

10-44 (4)

GD555, 655, 675-3C


TRANSMISSION

Reverse 1st

Operation • In REVERSE 1st, the R clutch (3) and 1st clutch (10) are engaged. The R clutch (3) and 1st clutch (10) hold each clutch disc in position with the oil pressure applied to the piston. • The power from the torque converter is transmitted from the input shaft (1) through the R clutch (3). Power to the R gear (5) is rotated in the opposite direction by the R idler gear (7). The power is then transmitted through the idler gear (14) and upper shaft (12) to the FH, 1st cylinder gear (11).

GD555, 655, 675-3C

•

With the 1st clutch (10) engaged, the power transmitted to the FH, 1st cylinder gear (11) passes through the 1st clutch (10), and goes from 1st gear (13) to 2nd, 3rd cylinder gear (19). The power is then transmitted through the lower shaft (20), idler gear (21), output gear (24), and fianlly to the output shaft (25).

10-45 (4)


TRANSMISSION VALVE

TRANSMISSION VALVE

ECMV clutch actuation table A B C D E F G

: FL clutch oil pressure detection port : R clutch oil pressure detection port : FH clutch oil pressure detection port : 1st clutch oil pressure detection port : 2nd clutch oil pressure detection port : 3rd clutch oil pressure detection port : 4th clutch oil pressure detection port

1. 2. 3. 4. 5. 6. 7. 8. 9.

ECMV (for FL clutch) ECMV (for R clutch) ECMV (for FH clutch) ECMV (for 1st clutch) ECMV (for 2nd clutch) ECMV (for 3rd clutch) ECMV (for 4th clutch) Seat Last chance filter

ECMV Speed range

FL

F1

Q

F8

2

3

4

Q Q Q Q

Q

Q

Q Q

F6 F7

1

Q

F4 F5

R

Q

F2 F3

FH

Q

Q

Q Q

Q

R1

Q

R2

Q

R3

Q

R4

Q

Q Q Q Q

N

10-46 (4)

GD555, 655, 675-3C


ECMV (ELECTRONIC CONTROL MODULATION VALVE)


A P T Dr P1 P2

: To clutch : From pump : Drain : Drain : Clutch oil pressure detection port : Pilot oil pressure detection port

GD555, 655, 675-3C

1. 2. 3. 4. 5. 6.

Connector for fill switch Connector for proportional solenoid Oil pressure detection valve Fill switch Proportional solenoid Pressure control valve spool

10-47 (4)



ECMV FOR SPEED CLUTCH Outline of ECMV • The ECMV (Electronic Control Modulation Valve) consists of two components: the pressure control valve and the fill switch. Pressure control valve • The proportional solenoid receives the flow of electricity sent from the transmission controller, and the pressure control valve converts this into hydraulic pressure. Fill switch • This detects when oil has filled the clutch. It has the following functions. 1) When the clutch is filled with oil, it sends a signal (fill signal) to the controller to inform the controller that the filling is completed. 2) While oil pressure is applied to the clutch, it outputs a signal (fill signal) to the controller to inform the controller of the existence of the oil pressure. A range: Before gear shifting (drained) B range: Filling starts (trigger issued) C range: Filling completed D range: Regulation E range: Filling

ECMV and proportional solenoid • There is one proportional solenoid installed to each ECMV. It generates propulsion as shown in the diagram on the right according to the command current from the controller.

The propulsion generated by the proportional solenoid acts on the pressure control valve spool and generates oil pressure as shown in the diagram on the right. In this way, the command current is controlled and the propulsion force varies to actuate the pressure control valve and control the oil flow and oil pressure. ECMV and fill switch • There is one fill switch installed to each ECMV. When the filling of the clutch is completed, the fill switch is turned on by the clutch pressure. With this signal, the oil pressure starts to build up.

10-48 (4)

GD555, 655, 675-3C



OPERATION OF ECMV • The ECMV is controlled by the command current from the transmission controller to the proportional solenoid and the fill switch output signal. The relationship between the ECMV proportional solenoid command current and the clutch input pressure and fill switch output signal is as shown in the diagram on the right. A range: Before gear shifting (drained) B range: Filling starts (trigger issued) C range: Filling completed D range: Regulation E range: Filling

1. When gear shifting (during draining) (Range A in graph). When no current is flowing to proportional solenoid (1), pressure control valve spool (3) drains the oil at clutch port A through drain port Dr. When this happens, there is no hydraulic force acting on pressure detection valve (4), so fill switch (6) is turned OFF.

GD555, 655, 675-3C

10-49 (4)



2. When filling (when trigger command is input to pressure control valve) (Ranges B and C in graph) When there is no oil inside the clutch, if electric current is applied to proportional solenoid (1), a hydraulic force balancing the force of the solenoid acts on chamber B, and pressure control valve spool (3) moves to the left. As a result, the circuit between pump port P and clutch port A opens, and oil starts to fill the clutch. When the clutch is filled with oil, fill switch (6) is turned ON.

3. Adjusting pressure (Range D in graph) When electric current flows to proportional solenoid (1), the solenoid generates a propulsion force proportional to the current. The pressure is adjusted so that the total of this propulsion force of the solenoid, the propulsion force of the oil pressure at the clutch port, and the reaction force of pressure control valve spring (2) is balanced.

10-50 (4)

GD555, 655, 675-3C


MAIN RELIEF VALVE

MAIN RELIEF VALVE

1. 2. 3. 4. 5. 6. A B C D E P1 P2

Seat Body Piston Torque converter relief valve Piston Main relief valve : : : : : : :

Drain Port To torque converter Drain port Drain port From pump Main relief oil pressure detection port Torque converter oil pressure relief detection port

OUTLINE Main relief valve • The main relief valve (6) sets the pressure of the transmission main port pressure in front of ECMV set pressure. Torque converter relief valve • The torque converter relief valve (4) protects the torque converter from abnormally high pressure. It relieves the pressure when the pressure at the inlet port of the torque converter goes above the specified pressure. Specified pressure Serial No.

10-52 (4)

50001 – 51000

51001 and up

Main relief pressure

2.37 MPa {24.2 kg/cm2}

2.47 MPa {25.2 kg/cm2}

Torque converter inlet port pressure

0.91 MPa {9.31 kg/cm2}

0.91 MPa {9.31 kg/cm2}

GD555, 655, 675-3C


MAIN RELIEF VALVE

Unit: mm No.

7

8

Check item

Clearance between main relief valve and valve body

Clearance between torque converter relief valve and valve body

Criteria Tolerance Shaft

Hole

Standard clearance

Clearance limit

28

–0.035 –0.045

+0.013 0

0.035 to 0.058

0.08

22

–0.035 –0.045

+0.013 0

0.035 to 0.058

0.08

Std. size

Standard size 9

Main relief valve spring (Outer)

Remedy

Repair limit

Free length

Installed length

Installed load

Free length

Permissible load

108

82.5

226 N {23.1 kg}

104.8

224.6 N {22.9 kg}

10

Main relief valve spring (Inner)

108

82.5

290 N {29.6 kg}

104.8

287.3 N {29.3 kg}

11

Torque converter relief valve spring

50

42

153.0 N {15.6 kg}

48.5

145.1 N {14.8 kg}

GD555, 655, 675-3C

Replace

10-53 (4)


MAIN RELIEF VALVE

Main relief valve operation • The oil from the hydraulic pump passes through the filter and then enters port A of the main relief valve. The oil then passes through the orifice a and enters port B. When the oil from the pump fills the circuit, the oil pressure increases. • As the oil pressure increases within the circuit, the oil entering port B pushes the piston (4). The reaction compression compresses the spring and moves the main relief valve (6) to the left in the direction of the arrow. This action opens the passage between port A and port C. The oil from the pump is relieved from port A to port C and flows from port C into the torque converter. Oil pressure at port A: 2.37 MPa {24.2 kg/cm2} (Serial No.: 50001 – 51000) 2.47 MPa {25.2 kg/cm2} (Serial No.: 51001 and up) Torque converter operation • The oil relieved from the main relief valve flows from port C into the torque converter and simultaneously passes through orifice b and enters port D.

•

As oil fills the torque converter circuit, the oil pressure in the circuit increases. Thus, the oil entering port D pushes the piston (9). This action compresses the spring (3), moving the relief valve (2) to the right to open the passage between port C and port E. The oil from port C is now relieved to port E and merges with the transmission lubrication circuit. The oil pressure at port C is 0.91 MPa {9.31 kg/cm2}.

10-54 (4)

GD555, 655, 675-3C


TRANSMISSION PUMP

TRANSMISSION PUMP SAR(2)63

Unit: mm No.

Check item

1

Side clearance

2

Clearance between inside diameter of plain bearing and outside of diameter of gear shaft

3

Depth for knocking in pin

4

Rotating torque of spline shaft

—

Discharge amount Oil: EO10-CD Oil temperature: 45 – 55°C

GD555, 655, 675-3C

Criteria

Remedy

Standard clearance

Clearance limit

0.13 to 0.18

0.22

0.067 to 0.125

0.20 Replace

Standard size

Tolerance

12

0 –0.5 2.9 to 6.9 Nm {0.3 to 0.7 kgm}

Rotating speed

Delivery pressure

Standard delivery amount

Standard amount limit

2300 rpm

15.2 MPa {155 kg/cm2}

137 l/min

124 l/min

—

10-55 (4)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION AND DIFFERENTIAL LOCK

TRANSMISSION AND DIFFERENTIAL LOCK PUMP (WITH DIFFERENTIAL LOCK) SAR(2)63 + SBR(1)10

Unit: mm No.

1

2

3

4

—

Check item

Side clearance

Clearance between inside diameter of plain bearing and outside of diameter of gear shaft

Depth for knocking in pin

Criteria Model

Standard clearance

Clearance limit

SAR(2)63

0.13 to 0.18

0.22

SBR(1)10

0.10 to 0.15

0.19

SAR(2)63

0.067 to 0.125

0.20

SBR(1)10

0.064 to 0.119

0.20

Standard size

Tolerance

Repair limit

SAR(2)63

12

SBR(1)10

10

0 –0.5

—

4.9 to 11.8 Nm {0.5 to 1.2 kgm}

Model

SAR(2)63 SBR(1)10

10-56 (4)

Replace

Model

Rotating torque of spline shaft

Discharge amount Oil: EO10-CD Oil temperature: 45 – 55°C

Remedy

Rotating speed (rpm) 2300

Delivery pressure [MPa {kg/cm2}]

Standard delivery amount (l/min)

Delivery amount limit (l/min)

15.2 {155}

137

124

20.6 {210}

20

19

—

GD555, 655, 675-3C


FINAL DRIVE

FINAL DRIVE STANDARD FINAL DRIVE (NON-SPIN DIFFERENTIAL)

1. 2. 3. 4. 5.

Cage Non-spin differential Coupling Bevel pinion (12 teeth) Bevel gear (43 teeth)

10-58 (4)

6. 7. 8. 9. 10.

Shaft Sprocket (12 teeth) Breather Drain plug Oil filler tube

GD555, 655, 675-3C


FINAL DRIVE

Unit: mm No.

Check item

11

Preload of bevel pinion bearing

12

Preload of bevel gear bearing

13

Backlash between bevel pinion and bevel gear

GD555, 655, 675-3C

Criteria

Remedy

Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm} Starting rotation torque: (Item 11) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm} (after setting, measure at pinion bearing)

Adjust

Standard size 0.25 to 0.33

10-59 (4)


FINAL DRIVE

PLANETARY FINAL DRIVE (WITH DIFFERENTIAL LOCK)

1: For serial No. 51001 and up

1. 2. 3. 4. 5. 6. 7. 8. 9.

Shaft (Number of teeth: 24) Coupling Bevel pinion (Number of teeth: 12) Bevel gear (Number of teeth: 43) Shaft Sprocket (Number of teeth: 20) Plate Disc Piston

10-60 (4)

10. 11. 12. 13. 14. 15. 16. 17. 18.

Gear (Number of teeth: 10) Gear (Number of teeth: 20) Gear (Number of teeth: 66) Gear (Number of teeth: 20) Breather Drain plug Solenoid valve for differential lock-up Oil supply pipe Grease fitting (Serial No.: 51001 and up)

GD555, 655, 675-3C


FINAL DRIVE

Unit: mm No.

Check item

19

Preload of bevel pinion bearing

20

Preload of bevel gear bearing

21

Backlash between bevel pinion and bevel gear

GD555, 655, 675-3C

Criteria

Remedy

Starting rotation torque: 8.7 to 11.7 Nm {0.89 to 1.19 kgm} Starting rotation torque: ( Item 19) + 0.7 to 1.5 Nm {0.07 to 0.15 kgm}

Adjust

Standard size 0.25 to 0.33

10-61 (4)


FINAL DRIVE

Outline • When the motor grader works with its blade at a propulsion angle or its body inclined, its front part is pushed to the right or left by the reaction force. Since it must travel straight, resisting the reaction force, it is not equipped with a differential. • Since the motor grader is articulated, its rear wheels are slipped sideways rather frequently when it turns. To increase the durability of the rear wheels, an optional final drive having a differential can be installed. • The optional final drive has a differential lock-up mechanism, which can be controlled with the switch from the operator’s seat. Operation (with differential lock-up) • The power transmitted from the engine to the transmission passes through the meshing of bevel pinion (1) and bevel gear (2), and is then transmitted shaft (3) o (4) o sprocket (5). The differential is switched between ON and LOCK (OFF) by using hydraulic power to push together or separate disc (6) and plate (7). • Even when the differential lock is switched ON, if the machine is travelling at high speed (F6-F8), the controller acts to automatically cancel the differential lock.

10-62 (4)

GD555, 655, 675-3C


TANDEM DRIVE

TANDEM DRIVE FOR STANDARD FINAL DRIVE

1. 2. 3. 4.

Breather Hub shaft Sprocket (45 teeth) Disc

5. Plate 6. Oil level plug 7. Drain plug Unit: mm

No.

Check Item

8

Hub bearing preload

9

Extension of chain (10 links)

10-64 (4)

Criteria

Remedy

Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Size

Repair limit

317.5

322.26

Adjust Replace

GD555, 655, 675-3C


TANDEM DRIVE

FOR PLANETARY FINAL DRIVE

1. 2. 3. 4.

Breather Hub shaft Sprocket (20 teeth) Disc

5. Plate 6. Oil level plug 7. Drain plug Unit: mm

No.

Check Item

8

Hub bearing preload

9

Extension of chain (10 links)

GD555, 655, 675-3C

Criteria

Remedy

Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Size

Repair limit

508.0

515.62

Adjust Replace

10-65 (4)


TANDEM DRIVE

Outline Power from the final drive is transmitted to the front and back rear wheels by chain. The tandem cases can swing up and down 13° each. All four wheels are in contact with the ground even when the ground is rough restricting the upand-down movement of the blade to a minimum. Operation The movement of the blade of a motor grader when its rear wheel rides over an obstacle as follows: 1. When both left and right wheels ride over an object (height: H) at the same time, the center of the rear axle rises H/2 as right figure shows, and because the blade is situated about halfway between the front and rear axles, its movement further becomes H/4.

2. When only one left rear wheel rides over an object (height: H), the rise at the center of rear axle is H/2 at its left end as right figure shows and H/4 at the center line of machine and on the real axle. The movement of the center part of the blade is half of that, which is H/8.

10-66 (4)

GD555, 655, 675-3C


STEERING HYDRAULIC PIPING DRAWING

STEERING HYDRAULIC PIPING DRAWING Serial No.: 50001 – 51000

1. 2. 3. 4. 5.

Steering valve Steering wheel Priority valve Hydraulic tank Hydraulic pump

10-68 (4)

GD555, 655, 675-3C



1. 2. 3. 4.

Steering valve Steering wheel Priority valve Accumulator charge valve

GD555, 655, 675-3C

5. Hydraulic tank 6. Hydraulic pump 7. Steering cylinder

10-69 (4)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE (Q/AMP MANUAL ORBIT-

STEERING VALVE (Q/AMP MANUAL ORBIT-ROLL TYPE)

1. 2. 3. 4. 5. 6. 7.

Gland Valve body Check valve Gerotor Spacer Cover Spacer

GD555, 655, 675-3C

8. 9. 10. 11. 12.

Drive shaft Sleeve Spool Center pin Center spring

10-71 (6)


OUTLINE The Q/Amp manual Orbit-roll used on this machine has a flow amplification function. This function is provided by the structure of the Orbit-roll valve and orifice. With this, the steering pump speed range varies to change the steering discharge amount; in particular, at high speed it has the characteristic of providing an amplified flow above the metering amount of the Gerotor (Variable ratio steering function). The Gerotor used for this function has the following features. • Fine compensation of the steering is possible at high speed to ensure stable steering. • Quick turns are possible when the machine is traveling at low speed or when it is stationary. • Emergency steering is possible with the Orbit-roll control used independently.

10-72 (4)


1. Variable ratio steering function The amount of oil pushed out of the steering pump, in other words, the steering discharge amount, varies according to the steering wheel speed. When the steering wheel is turned at low speed, the steering discharge is small; and when the steering wheel is turned at high speed, the steering discharge is large. For this reason, when the machine is traveling at high speed, if the steering wheel is turned at low speed, the steering discharge is small. This makes fine compensation of the steering possible, and enables superior travel at high speed. When the machine is stationary or traveling at low speed, if the steering wheel is turned at high speed, a large steering discharge is easily ensured, so quick turns are possible.

GD555, 655, 675-3C



2. Flow amplification function • In addition to the metering by the Gerotor of the conventional Orbit-roll, there is a variable internal orifice with a bypass flow control function, so this makes it possible to send a large oil flow to the steering cylinder. In this way, even with a small Orbit-roll, a large amount of oil can be sent to the steering cylinder when traveling at high speed. 3. Q/Amp manual Orbit-roll • An Orbit-roll with an emergency steering function using a Q/Amp Orbit-roll is called a Q/Amp manual Orbit-roll. To achieve this function, the oil does not pass through the metering (Orbit-roll) but uses the characteristics of a bypass orifice (characteristics of flow amplification orifice AA) and closes the hole during emergency steering (valve at maximum flow position). • This type of Orbit-roll has great merits when it is used in the steering system of medium sized machines. • Normally, only an Orbit-roll with a small discharge volume can achieve actual emergency steering when the Orbit-roll is used independently. When selecting an Orbit-roll with a large discharge volume, it is necessary to provide an emergency source of pressure oil. With this Q/Amp manual Orbit-roll, the system is simplified, and as a result, the reliability is improved.

Steering lock-to-lock characteristics (Variable capacity steering system of Q/Amp steering speed)

GD555, 655, 675-3C

10-73 (4)



STRUCTURE • The shaft connected to the steering wheel meshes with the spline at the top of the spool and the spool (10) is fitted inside the sleeve (9). In addition, the spool and sleeve are connected by the center pin (7) (not touching the spool when the steering wheel is not being used).

•

•

The top of drive shaft (3) is engaged with center pin (7) and made one with sleeve (9). The bottom of drive shaft (3) is engaged with the spline of rotor (1) of the Gerotor set (combination of rotor (1) and stator (11)). Four ports in the valve body connect to the pump circuit, tank circuit, and circuits to the head and bottom ends of the steering cylinders. Also, a check valve isnide the body connects the port at the pump end and the port at the tank end. Thus, if the engine or pump fail, oil can be sucked in directly from the tank because of this check valve.

10-74 (6)

GD555, 655, 675-3C



CONNECTION BETWEEN HAND PUMP AND SLEEVE

•

•

•

•

•

•

The diagrams above show the connections with the sleeve ports connecting the suction and discharge ports of the Gerotor. When turning the wheel to the right, the vertical grooves in the spool connect ports a, c, e, g, i, and k to the pump side. Simultaneously, ports b, d, f, h, j, and i connect to the head end of the steering cylinder in the same way. In the diagram above left, ports 1, 2, 3 are the discharge ports and connect to ports l, b, and d. Thus, the oil is sent to the cylinder. Turning the steering wheel 90° changes the condition to that shown in the diagram above right. Ports 1, 2, and 3 are suction ports and connect to ports i, k, and a. Ports 5, 6, and 7 are discharge ports and connect to ports d, f, and h. In this way, the ports acting as the discharge ports of the hand pump connect to the ports going to the steering cylinder. And the ports acting as suction ports connect to the pump circuit. If the pump or engine fails, the suction and discharge of this hand pump is performed forcibly and oil is sent to the steering cylinder. Thus, it is still possible to steer the machine.

GD555, 655, 675-3C

10-75 (7)


•


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

DIFFERENCES BETWEEN TROCHOID PUMP AND STEERING PUMP HAND PUMP Trochoid pump

•

The trochoid pump is divided into an inlet port and an outlet port. When the shaft rotates as shown above, oil is sucked in from the inlet port and discharged from the outlet port as shown in stage 2 and 6.

Steering pump hand pump

•

With the hand pump, inlet and outlet ports exist at the bottom of the internal teeth of the stator. Rotating the shaft connects the steering pump and port as shown in stage 2 and 3 above. Also, oil is sucked in. Rotating the shaft further, the steering cylinder and port connect as shown in stage 5 and 6 above. The oil is delivered to the cylinder. This action is performed at each port.

10-76 (4)

GD555, 655, 675-3C



ROLE OF CENTERING SPRING •

The centering spring (4) consists of four Xshaped leaf springs and two flat leaf springs. It is assembled between the spool (10) and sleeve (9) as shown in the diagram on the right.

•

Turning the wheel, the spool compresses the spring. A difference (angle variation) is generated in the turning angle of the spool and sleeve. As a result, the spool port and sleeve connect and oil is directed to the cylinder. However, when the steering wheel is stopped, the hand pump rotation stops also. Thus, oil is no longer sent to the cylinder and the oil pressure increases. To prevent this situation, when the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the angle variation of the sleeve and spool. Thus, the steering wheel returns to the NEUTRAL position.

GD555, 655, 675-3C

10-77 (4)


PRIORITY ACC GOVERNOR VALVE

PRIORITY ACC GOVERNOR VALVE Serial No. 50001 – 51000

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Orifice Bypass compensator spool Orifice Flow fuse shuttle valve Relief valve Pilot unloader valve Shuttle valve Orifice Check valve Filter Check valve

10-78 (4)

T : To hydraulic tank S1 : (plugged) LSP1 (IN): From bank control B1 : (plugged) B2 : (plugged) EF2 : To right control valve A/P1 : To bank control A1 : To brake control A2 : To brake control CF6 : (plugged) EF1 : To left control valve

P1 : (plugged) P2 : From hydraulic pump CF : Orbit-roll valve LSP1 (OUT): (plugged) LSP2 : From hydraulic tank LSS : From Orbit-roll valve

GD555, 655, 675-3C


OUTLINE • If the hydraulic systems for both the work equipment and steering are covered by one pump, all the oil flow is consumed by the work equipment circuit. Thus, there is a lack of oil for the steering circuit. To prevent this dangerous situation, a valve is installed to ensure that priority is given to the oil flow to the steering circuit. •

If a large flow of oil is sent to the steering circuit even when the steering is at neutral, the oil flow


to the work equipment circuit will be reduced and poor efficiency results. To prevent this situation and to ensure a quick response when operating the steering, this valve keeps the steering circuit oil flow to a minimum (approx. 1 l/min) when the steering is at neutral. And to send the rest of the oil to the work equipment circuit. In addition, this valve is a load-sensing type that ensures the necessary flow even when operating the steering.

Valve circuit diagram

GD555, 655, 675-3C

10-79 (4)



OPERATION 1. When engine is stopped Spool (1) is pushed to the right by spring (2). In this condition, port CF is opened to the maximum and port EF is closed.

2. When engine is started (steering and main control valves at neutral) The oil from the pump flows from port A to port CF and the steering, but the steering valve is closed, so the pressure at port CF rises. The oil in chamber A from the pump passes through orifice a in spool (1), enters chamber B, and pushes spool (1) to the left. The steering valve is closed, so the oil at port CF flows to the brake accumulator line and charges the brake accumulator. The accumulator charge pressure passes through the LS and PLS lines and is transmitted to the servo valve of the pump. The pump then supplies the necessary oil flow and pressure. The accumulator charge oil flow is controlled by orifice e. When the accumulator pressure rises and the charging is completed, the governor valve is opened. When this flow from port CF passes through orifices e and b, a difference in pressure of approx. 0.98 MPa {10 kg/cm2} is formed on both sides of the orifices. The pressure in chamber B = pressure in chamber C + 0.98 MPa {10 kg/cm2}, so spool (1) is pushed to the left and tries to close portion d. If the area of the opening at portion d becomes smaller, the oil flow in the drain circuit passing through orifice b becomes smaller, so the differential pressure on both sides of orifice b becomes smaller. Spool (1) is pushed to the right by spring (2), and the opening at portion d again opens. When the oil flow becomes larger, the spool again moves to the left. This is repeated until a balance is reached. The forces acting on chamber B and chamber C are as follows: • Force in left direction (converted to hydraulic force): PB (=1.57 MPa {16 kg/cm2}) • Force in right direction: PC + 0.98 MPa {10 kg/cm2} (=1.57 MPa {16 kg/cm2}) • (0.98 MPa {10 kg/cm2} is the hydraulic force converted for spring (2))

10-80 (4)

GD555, 655, 675-3C



3. Steering operated (accumulator not charged, main control valve at neutral) When the steering wheel is turned, port CF and the steering cylinder are connected. When this happens, the pressure in chamber C becomes higher, and spool (1) is pushed to the right by spring (2). The area of the opening of portion d becomes larger, so the oil from the pump passes through port CF when the steering wheel is being turned, and the necessary oil flow goes from the steering valve to the steering cylinder. If the steering wheel is turned quickly, and the area of the variable throttle in the steering valve becomes larger, the difference in pressure on both sides of the variable throttle inside the steering valve becomes smaller, and the pressure in the LS circuit rises. (The pressure in chamber B drops.) At the same time, the oil pressure in chamber C also rises, so spool (1) is moved further to the right, and the area of the opening of portion d also becomes larger. This sends a large oil flow to the steering cylinder. On the other hand, if the steering wheel is turned slowly, the throttle of the variable orifice becomes smaller, so the differential pressure on both sides of the variable throttle inside the steering valve becomes larger. The pressure in chamber B then becomes larger than the pressure in chamber C, so spool (1) is pushed to the left, and the area of the opening of portion d becomes smaller to match the flow of oil needed for the steering valve. It becomes balanced in this position. In other words, spool (1) moves in accordance with the flow of oil needed for port CF to maintain the differential pressure between chamber C and chamber B at 0.98 MPa {10 kg/cm2}, and adjusts the opening of portion d. (In this way, all the oil not needed for the steering can be sent to port EF.) When the oil from port CF enters the steering cylinder and load is applied, the pressure in the circuit rises. This signal becomes PLS and is fed back to the pump servo valve. The angle of the swash plate in the pump is changed to increase the discharge amount, and to increase the pressure in the circuit. In this way, the PLS circuit acts to detect the hydraulic load on the steering and feeds back this information to the pump.

GD555, 655, 675-3C

10-81 (4)



4. Steering cylinder at end of stroke When the steering cylinder reaches the end of its stroke, and the operator continues to turn the steering wheel, the flow of oil to the cylinder is stopped regardless of the opening of the steering valve. There is no flow of oil, so the CF and LS pressures rise together with the pressure at pump port P, and at the same time, pressures chamber B and chamber C also rise, and spool (1) is moved to the right. If pressure chamber C goes above 15.21 MPa {155 kg/cm 2 }, steering relief valve opens and drains the oil in chamber C. Because of this flow of oil, a difference in pressure on both sides of orifices b and e is created, and pressure chamber C becomes lower than pressure chamber B. As a result, spool (1) moves to the left to a position where the oil flow inside the spool is 1 l/ min. Spool (1) stabilizes at a position where portion d of the spool is throttled, and this prevents the large loss of oil if the circuit is relieved. If spool (1) moves too far to the left, portion d is closed and the oil stops flowing. The flow of oil through orifice b stops, so pressure chamber C and pressure chamber B become the same, and spool (1) is moved again to the right by spring (2) to open portion d. Because of this repeated action, the pressure in the steering circuit is maintained at a maximum of 15.21 MPa {155 kg/cm2}. 5. Steering valve at neutral, work equipment control lever operated If the work equipment control lever is operated, pressure A changes to 1.96 – 24.5 MPa {20 – 250 kg/cm2}. However, the steering valve is at neutral, so the condition is the same as in Section 2. "When engine is started (steering and main control valves at neutral)", and the force acting on spool (1) is constant regardless of pressure A. If pressure A rises, the pressure at port CF also rises momentarily, and the amount of oil flowing through orifice b increases. A large difference in pressure is created, so spool (1) is pushed to the left, and the area of the opening of portion d becomes smaller. The oil flow is automatically adjusted so that only 1 l/min flows.

10-82 (4)

GD555, 655, 675-3C



6. Steering, work equipment operated simultaneously 1) When the load on steering circuit is higher than the load on the work equipment circuit, the actuation condition is the same as in Section 3, "Steering operated (accumulator not charged, main control valve at neutral)". 2) Port CF is at the same pressure as chamber A, and port EF is throttled by portion l until it balances at the same pressure as the pressure needed for the work equipment. In other words, the oil pressure in the main circuit for the pump is sent to the steering circuit.

3) When the load on steering circuit is less than the load on the work equipment circuit, circuit CF satisfies the demand for the amount of oil and oil pressure for the steering, but compared with port CF, when the pressure at port EF is higher, the flow of oil passing through portion d increases and the pressure in chamber B rises. As a result, spool (1) moves to the left, and the area of the opening at portion d becomes smaller. It balances so that the pressure and oil flow matches the needs of port CF. In other words, the pressure and oil flow needed for the steering circuit is supplied to the steering circuit by priority regardless of the pressure in the work equipment circuit.

GD555, 655, 675-3C

10-83 (4)



7. When brake accumulator is being charged When the brake is operated, the pressure inside the brake accumulator goes down. If the pressure goes down to 9.42 MPa {96 kg/cm 2 }, the governor valve for charging the brake accumulator closes, the flow of oil from orifice C to the steering valve stops, and the LS pressure rises. After this, the procedure is the same as when the engine is started, and the charging of oil pressure to the brake accumulator is completed. 8. Steering and brake accumulator charging actuated at same time 1) If the load in the steering circuit is higher than the load in the brake accumulator charge circuit, the load in the steering circuit for normal travel becomes lower than 5.89 MPa {60 kg/cm 2 }. Operating the steering when the machine is stationary may create such a situation, but after a few seconds, the accumulator charging will be completed, so in reality there is almost no effect. 2) When load in brake charge circuit is higher than load in steering circuit This pattern is normal when both circuits are operated at the same time. The steering valve discharges an amount of oil to match the operating angle of the steering, so when an oil flow matching the operating angle of the steering is sent to the steering cylinder. The steering valve then automatically closes and this gives an operating feeling that is the same as with normal operations.

10-84 (4)

GD555, 655, 675-3C


PRIORITY VALVE

PRIORITY VALVE Serial No. 51001 and up

1. 2. 3. 4. 5. 6. 7.

Relief valve Orifice Spring Spool Orifice Orifice Fitting face of accumulator pressure governor valve

P EF CF1 CF2 LS1 LS2 T

GD555, 655, 675-3C

: From pump : To accumulator pressure governor valve (To work equipment circuit) : To accumulator pressure governor valve (To brake circuit) : To steering valve : To accumulator pressure governor valve (To pilot circuit) : To accumulator pressure governor valve (To pilot circuit) : To accumulator pressure governor valve (To hydraulic tank)

10-85 (8)


PRIORITY VALVE

OUTLINE •

If the hydraulic systems for both the work equipment and steering and brake are covered by one pump, all the oil flow is consumed by the work equipment circuit. Thus, there is a lack of oil for the steering and brake circuit. To prevent this dangerous situation, a valve is installed to ensure that priority is given to the oil flow to the steering and brake circuit.

•

If a large flow of oil is sent to the steering circuit even when the steering is at neutral, the oil flow to the work equipment circuit will be reduced and poor efficiency results. To prevent this situation and to ensure a quick response when operating the steering, this valve keeps the steering circuit oil flow to a minimum (approx. 1 l/min) when the steering is at neutral. And to send the rest of the oil to the work equipment circuit. In addition, this valve is a load-sensing type that ensures the necessary flow even when operating the steering.

•

The built-in relief valve regulates the steering circuit pressure to prevent generation of abnormal pressure.

10-86 (8)

GD555, 655, 675-3C


PRIORITY VALVE

OPERATION 1. When engine is stopped Spool (1) is pushed to the right by spring (2). In this condition, port (CF) is opened to the maximum and port (EF) is closed.

2. When engine is started (steering and main control valves at neutral) The oil from the pump flows from port (A) to port (CF) and to the steering and brake line, but the steering valve is closed, so the pressure at port (CF) rises. The oil in chamber (A) from the pump passes through orifice (a) in spool (1), enters chamber (B), and pushes spool (1) to the left. The steering valve is closed, so the oil at port (CF) flows to the brake accumulator line and charges the brake accumulator. The accumulator charge pressure passes through the LS and PLS lines and is transmitted to the servo valve of the pump. The pump then supplies the necessary oil flow and pressure. The accumulator charge oil flow is controlled by orifice (e). When the accumulator pressure rises and the charging is completed, the governor valve is opened. The oil from orifice (b) flows in chamber (C) and is drained through orifice (c) and steering valve. The flow rate in the LS circuit is about 1 l/min. When this flow from port (CF) passes through orifices (e) and (b), a difference in pressure of approx. 0.98 MPa {10 kg/cm2} is formed on both sides of the orifices. The pressure in chamber (B) = pressure in chamber (C) + 0.98 MPa {10 kg/cm 2}, so spool (1) is pushed to the left and tries to close portion (d). If the area of the opening at portion (d) becomes smaller, the oil flow in the drain circuit passing through orifice (b) becomes smaller, so the differential pressure on both sides of orfice (b) becomes smaller. Spool (1) is pushed to the right by spring (2), and the opening at portion (d) again opens. When the oil flow becomes larger, the spool again moves to the left. This is repeated until a balance is reached. The forces acting on chamber (B) and chamber (C) are as follows: • Force in left direction (converted to hydraulic force): PB (=1.57 MPa {16 kg/cm2}) • Force in right direction: PC + 0.98 MPa {10 kg/cm2} (=1.57 MPa {16 kg/cm2}) (0.98 MPa {10 kg/cm2} is the hydraulic force converted for spring (2)) GD555, 655, 675-3C

10-87 (8)


PRIORITY VALVE

3. Steering operated (accumulator not charged, main control valve at neutral) When the steering wheel is turned, port (CF) and the steering cylinder are connected. When this happens, the pressure in chamber (C) becomes higher, and spool (1) is pushed to the right by spring (2). The area of the opening of portion (d) becomes larger, so the oil from the pump passes through port (CF) when the steering wheel is being turned, and the necessary oil flow goes from the steering valve to the steering cylinder. If the steering wheel is turned quickly, and the area of the variable throttle in the steering valve becomes larger, the difference in pressure on both sides of the variable throttle inside the steering valve becomes smaller, and the pressure in the LS circuit rises. (The pressure in chamber (B) drops.) At the same time, the oil pressure in chamber (C) also rises, so spool (1) is moved further to the right, and the area of the opening of portion (d) also becomes larger. This sends a large oil flow to the steering cylinder. On the other hand, if the steering wheel is turned slowly, the throttle of the variable orifice becomes smaller, so the differential pressure on both sides of the variable throttle inside the steering valve becomes larger. The pressure in chamber (B) then becomes larger than the pressure in chamber (C), so spool (1) is pushed to the left, and the area of the opening of portion (d) becomes smaller to match the flow of oil needed for the steering valve. It becomes balanced in this position. In other words, spool (1) moves in accordance with the flow of oil needed for port (CF) to maintain the differential pressure between chamber (C) and chamber (B) at 0.98 MPa {10 kg/cm2}, and adjusts the opening of portion (d). (In this way, all the oil not needed for the steering can be sent to port (EF).) When the oil from port (CF) enters the steering cylinder and load is applied, the pressure in the circuit rises. This signal becomes PLS and is fed back to the pump servo valve. The angle of the swash plate in the pump is changed to increase the discharge amount, and to increase the pressure in the circuit. In this way, the PLS circuit acts to detect the hydraulic load on the steering and feeds back this information to the pump.

10-88 (8)

GD555, 655, 675-3C


PRIORITY VALVE

4. Steering cylinder at end of stroke When the steering cylinder reaches the end of its stroke, and the operator continues to turn the steering wheel, the flow of oil to the cylinder is stopped regardless of the opening of the steering valve. There is no flow of oil, so the CF and LS pressure rise together with the pressure at pump port (P), and at the same time, pressure chamber (B) and chamber (C) also rise, and spool (1) is moved to the right. If pressure chamber (C) goes above 15.21 MPa {155 kg/cm 2 }, steering relief valve opens and drains the oil in chamber (C). Because of this flow of oil, a difference in pressure on both sides of orifices (b) and (e) is created, and pressure chamber (C) becomes lower than pressure chamber (B). As a result, spool (1) moves to the left to a poistion where the oil flow inside the spool is 1 l/ min. Spool (1) stabilizes at a position where portion (d) of the spool is throttled, and this prevents the large loss of oil if the circuit is relieved. If spool (1) moves too far to the left, portion (d) is closed and the oil stops flowing. The flow of oil through orifice (b) stops, so pressure chamber (C) and pressure chamber (B) become the same, and spool (1) is moved again to the right by spring (2) to open portion (d). Because of this repeated action, the pressure in the steering circuit is maintained at a maximum of 15.21 MPa {155 kg/cm2}. 5. Steering valve at neutral, work equipment control lever operated If the work equipment control lever is operated, pressure (PA) changes to 1.96 – 24.5 MPa {20 – 250 kg/cm2 }. However, the steering valve is at neutral, so the condition is the same as in Section 2. "When engine is started (steering and main control valves at neutral)", and the force acting on spool (1) is constant regardless of pressure (PA). If pressure (PA) rises, the pressure at port (CF) also rises momentarily, and the amount of oil flowing through orifice (b) increases. A large difference in pressure is created, so spool (1) is pushed to the left, and the area of the opening of portion (d) becomes smaller. The oil flow is automatically adjusted so that only 1 l/min. flows.

GD555, 655, 675-3C

10-89 (8)


PRIORITY VALVE

6. Steering, work equipment operated simultaneously 1) When the load on steering circuit is higher than the load on the work equipment circuit, the actuation condition is the same as in Section 3, "Steering operated (main control valve at neutral)". Port (CF) is at the same pressure as chamber (A), and port (EF) is throttled by portion (I) until it balances at the same pressure as the pressure needed for the work equipment. In other words, the oil pressure in the main circuit for the pump is sent to the steering circuit.

2) When the load on the steering circuit is less than the load on the work equipment circuit, circuit (CF) satisfies the demand for the amount of oil and oil pressure for the steering, but compared with port (CF), when the pressure at port (EF) is higher, the flow of oil passing through portion (d) increases and the pressure in chamber (B) rises. As a result, spool (1) moves to the left, and the area of the opening at portion (d) becomes smaller. It balances so that the pressure and oil flow matches the needs of port (CF). In other words, the pressure and oil flow needed for the steering circuit is supplied to the steering circuit by priority regardless of the pressure in the work equipment circuit.

10-90 (8)

GD555, 655, 675-3C


PRIORITY VALVE

7. When brake accumulator is being charged When the brake is operated, the pressure inside the brake accumulator goes down. If the pressure goes down to 9.42 MPa {96 kg/cm2 }, the brake accumulator pressure governor valve closes, the flow of oil from orifice (C) to the steering valve stops, and the LS pressure rises. After this, the procedure is the same as when the engine is started, and the charging of oil pressure to the brake accumulator is completed. 8. Steering and brake accumulator charging actuated at same time 1) If the load in the steering circuit is higher than the load in the brake accumulator charge circuit, the load in the steering circuit for normal travel becomes lower than 5.89 MPa {60 kg/cm 2 }. Operating the steering when the machine is stationary may create such a situation, but after a few seconds, the accumulator charging will be completed, so in reality there is almost no effect. 2) When load in brake charge circuit is higher than load in steering circuit This pattern is normal when both circuits are operated at the same time. The steering valve discharges an amount of oil to match the operating angle of the steering, so when an oil flow matching the operating angle of the steering is sent to the steering cylinder. The steering valve then automatically closes and this gives an operating feeling that is the same as with normal operations.

GD555, 655, 675-3C

10-91 (8)


ACCUMULATOR PRESSURE GOVERNOR VALVE

ACCUMULATOR PRESSURE GOVERNOR VALVE Serial No. 51001 and up

1. 2. 3. 4.

Pressure governor valve Solenoid (For releasing LS pressure) Accumulator shuttle valve Fitting face of priority valve

EF1 : To left main control valve EF2 : To right main control valve A1 : To brake control A2 : To brake control LSS : From steering valve LSP1:From parking and bank control valve LSP2:From LS pressure reducing valve T : To hydraulic tank EF CF1 LS1 LS2 T

10-92 (8)

: From priority valve : From priority valve : From priority valve : From priority valve : From priority valve GD555, 655, 675-3C


ACCUMULATOR PRESSURE GOVERNOR VALVE

Outline • The accumulator pressure governor valve is connected to the priority valve and used as a path for the oil from the priority valve to the main control valve and control the oil flow to the brake circuit. • The oil flowing in the brake circuit is distributed by the accumulator shuttle valve to the front and rear brake circuits to heighten the pressure in the brake accumulator. The accumulator charge pressure is transmitted by the pressure governor valve to the servo valve of the hydraulic pump. If it lowers to 9.36 MPa {95.4 kg/cm2}, it is raised. If it is raised to 13.38 MPa {14.1 kg/cm2}, it is stopped rising. • The LS pressure relief valve is installed to improve the startability of the engine (particularly in the cold season). While the starting motor is running, the solenoid operates to drain the oil sent by the hydraulic pump to the servo valve to reduce the load on the pump.

GD555, 655, 675-3C

10-93 (8)


FRONT AXLE

FRONT AXLE

1. 2. 3. 4. 5. 6.

Tie rod Steering cylinder Support axle Leaning rod Bracket Hub shaft

10-94 (4)

Specifications: Toe-in: –5 mm Camber: 0°

GD555, 655, 675-3C


FRONT AXLE

Unit: mm No.

Check item Standard size

7

8

9

Clearance between center pin and bushing

Clearance between king pin and bushing Clearance between axle end pin and bushing

Clearance limit

–0.030 –0.076

+0.197 +0.137

0.167 to 0.273

3.0

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

2.0

GD655 GD675

45

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

2.0

GD555

40

–0.025 –0.064

+0.161 +0.118

0.143 to 0.225

0.6

GD655 GD675

45

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

2.0

55

–0.060 –0.090

+0.020 +0.020

0.060 to 0.110

1.0

GD555

11

Preload of hub bearing

GD555, 655, 675-3C

Standard clearance

Hole

Clearance between ball joint and bushing

Hub nut tightening torque

Tolerance Shaft

10

12

Remedy

Criteria

55

GD555

Start to rotate: 147 to 196 Nm {15 to 20 kgm}

GD655 GD675

Start to rotate: 78.5 to 117.7 Nm {8 to 12 kgm}

GD555

314 to 608 Nm {32 to 62 kgm}

GD655 GD675

490 to 608 Nm {50 to 62 kgm}

Replace bushing

Adjust

10-95 (4)


FRONT AXLE

Function of front axle 1. Lessening blade angling and up-and-down movement • The front axle is fixed in the center with a center pin to the frame so that it can oscillate 16°. This, like the tandem system, restricts the up-and-down movement of the blade to a minimum when one front wheel rides over an object or falls into a hole. When the front wheel rides over an object (height-H), the center point of the front axle rises H/2, as shown in drawing. Because of possible rocking of front axle blade movement rises only H/4 while holding its horizontal posture. Unless the whole oscillating range (left, right 16°) of the front axle is used, the blade moves up-and-down holding its horizontal posture. 2. Prevention of side slipping of front wheels (leaning system) • The front wheels can be tilted to the left or right. This is called the leaning system, and is to prevent the front wheel from slipping sidewards and to reduce the turning radius. Operations with blade at propulsion angle are frequent among grader operations. In proportion to the propulsion angle a side slipping force acts on the blade to cause side slipping. •

10-96 (4)

Also, the distribution of weight on the front and rear wheels is about 3:7, and when the blade cuts into the ground, the load on the front wheels decreases and it is easier for the front wheels to slip sideward. To counteract this side slipping, the front wheels are leaned to make them more resistant, and this changes the center of the load on the front axle and the center of gravity of the machine and prevents side slipping.

GD555, 655, 675-3C


•

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

•

When backing, leaning should be reversed to the leaning for forward operation by turning a steering wheel in the same direction. Leaning angle is 16°

GD555, 655, 675-3C

FRONT AXLE

10-97 (4)


BRAKE HYDRAULIC PIPING

BRAKE HYDRAULIC PIPING Serial No.: 50001 – 51000

10-98 (4)

GD555, 655, 675-3C


1. 2. 3. 4. 5. 6. 7.


Priority ACC governor valve Air breather Slack adjuster Wheel brake Accumulator Stop lamp switch Brake valve

GD555, 655, 675-3C

10-99 (4)




1. 2. 3. 4.

Wheel brake (front) Wheel brake (rear) Accumulator (front) Accumulator (rear)

10-100 (8)

5. 6. 7. 8.

Stop lamp switch Brake valve Accumulator pressure governor valve Priority valve

GD555, 655, 675-3C



9. Slack adjuster (front) 10. Slack adjuster (rear)

GD555, 655, 675-3C

10-101 (4)


BRAKE VALVE

BRAKE VALVE

1. Piston 2. Spool 3. Spool A B PA PB T

: To rear slack adjuster : To front slack adjuster : To accumulator : To accumulator : To hydraulic tank

10-102 (4)

GD555, 655, 675-3C


BRAKE VALVE

Unit: mm No.

4

Check item

Clearance between pedal mounting hole and bracket

5

Clearance between roller and pin

6

Outside diameter of roller

Criteria Standard size

Tolerance Shaft

Hole

Standard clearance

—

–0.025 –0.075

+0.013 +0.013

0.175 to 0.025

0.25

—

–0.025 –0.075

+0.013 +0.013

0.175 to 0.025

0.25

Control spring

Clearance limit

Size

Tolerance

Repair limit

30

0 –0.5

29.2

Standard size 7

Remedy

Repair limit

Free length

Installed height

Installed load

Free length

Permissible load

54.5

49.7

80 N {8.1 kg}

33.4

—

8

Control spring

29.1

—

—

28.7

—

9

Return spring

86.2

58

60.8 N {6.2 kg}

78

—

10

Spring

17

16.5

17.7 N {1.8 kg}

16.2

—

11

Return spring

31.5

19.5

16.7 N {1.7 kg}

28

—

GD555, 655, 675-3C

Replace

10-103 (4)


BRAKE VALVE

OPERATION 1. Depressing the brake pedal. Depressing the brake pedal causes the piston (1) and spring (2) to make the spools (3, 4) move down. The port a (port b) close and oil now flows from port PA to port A and port PB and port B. Oil then flows from port A (port B) to the rear (front) slack adjuster and actuate the brakes. When this happens, the slack adjuster makes the flow of oil to the left and right brakes the same to ensure the same braking effect on both the left and right sides.

2. When the operation is in balance at the rear (front) brake. When the brake cylinder-fills with oil and the pressure between port PA (port PB) and port A (port B) increase, the oil entering port e (port f) from orifice c (orifice d) of spool (3) (spool 4) up against the spring (2), and port PA (port PB) and port A (port B) are shut off. When this situation happens, drain port a remains closed. Thus, the oil entering the rear (front) slack adjuster is held and the brake remains actuated.

10-104 (4)

GD555, 655, 675-3C


BRAKE VALVE

3. Releasing the brake. Removing the force from the pedal removes the force at the piston (1). This action causes back pressure from the brake cylinder and the force of the spool return spring to move the spools (3, 4) up. Drain port a (port b) now opens. The oil from the slack adjuster flows to the hydraulic tank return circuit and the brake released.

GD555, 655, 675-3C

10-105 (4)


WHEEL BRAKE

WHEEL BRAKE

1. Guide pin 2. Brake piston Unit: mm No.

Check item

Repair limit

3.8 ± 0.1

3.3 ± 0.1

Plate thickness

2.3 ± 0.08

—

Total thickness of disc and plate

26.7 ± 0.8

24.7 ± 0.8

Standard size

Repair limit

Disc thickness

4 5

Return spring

10-106 (4)

Remedy

Size

3

6

Criteria

Replace Free length

Installed height

Installed load

Installed load

76.5

60.5

75.0

654 N {66.7 kg}

GD555, 655, 675-3C


SLACK ADJUSTER

SLACK ADJUSTER

1. Bleeder 2. Check valve 3. Piston

Specifications: Piston actuation pressure: 0.01 ± 0.01 MPa {0.1 ± 0.1 kg/cm2}

A: Inlet port B: Outlet port

Check valve cracking pressure: 0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2} Check valve closing pressure: 0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}

Function: • The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. The slack adjuster provides a fixed time lag when applying the brakes.

•

It also fixes the quantity of oil fed by each application of the brake to prevent generation of peak pressure. Unit: mm

No.

4

Check item

Clearance between body and piston

Criteria Standard size —

Tolerance

Remedy

Shaft

Hole

Standard clearance

–0.030 –0.076

+0.074 +0.074

0.030 to 0.150

Standard size 5

6

Slack adjuster spring

Spring

GD555, 655, 675-3C

Clearance limit 0.25

Repair limit

Free length

Installed height

Installed load

Free length

Permissible load

198

38

43.2 N {4.4 kg}

—

—

38.8

33

66.7 N {6.8 kg}

—

—

Replace

10-107 (4)


SLACK ADJUSTER

OPERATION 1. Brake pedal depressed. • Before depressing the brake pedal, the piston is returned by the distance of stroke S (full stroke). Depressing the brake pedal discharges the oil from the brake valve and flows from port P of the slack adjuster. The oil is then divided to the left and right cylinders (2). The force of the oil moves the piston (4) by stroke S to the left and right.

•

Depressing the brake pedal moves the brake piston (7) a distance of stroke S. In this condition, the closer the clearance between the brake piston and the disc is to zero (0), the greater the braking force becomes.

•

Depressing the brake pedal further and the oil pressure discharged from the brake valve goes above the set pressure, the check valve opens (3) opens and the pressure applied to port C acts as the braking force. Thus, when the brake is applied, the time lag is a fixed value.

2. Brake pedal released. • Releasing the brake pedal causes the piston (4) to return by action of the brake return spring (8) by an amount equivalent to the oil for stroke S. Thus, the brake releases. In other words, the return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant, regardless of disc brake wear.

10-108 (4)

GD555, 655, 675-3C


ACCUMULATOR

ACCUMULATOR

1. 2. 3. 4.

Valve assembly Top cover Cylinder Piston

Specifications: Gas used: Nitrogen Amount of gas: 3000 cc Gas charging pressure (at 20 ± 5°C): 3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2}

Function: The accumulator is installed between the pressure governor valve and brake valve. Cylinder (3) is charged with nitrogen gas. Even after the engine stops, braking force is kept by the pressure of the nitrogen gas compressed by free piston (4). The compressibility of the nitrogen gas absorbs the pulsating pressure from the hydraulic pump.

10-110 (8)

GD555, 655, 675-3C


PARKING BRAKE

PARKING BRAKE

1. 2. 3. 4.

Piston Adjustment bolt Caliper Disc

Outline: • The parking brake is a disc type, and is installed to the final drive. • The parking brake is applied mechanically by the force of the spring inside the caliper, and is released by hydraulic force. • The parking brake caliper is secured to the final drive case. The disc is installed to the final drive coupling and rotates together with the coupling. Unit: mm

No. 5

6

Check item Disc thinkness

Pad thickness

GD555, 655, 675-3C

Criteria

Remedy

Standard size

Repair limit

10.4

9.4

12.5

9.5 (Remaining thickness when pad groove has disappeared)

Replace

10-111 (7)


PARKING BRAKE AND BANK CONTROL VALVE

PARKING BRAKE AND BANK CONTROL VALVE Serial No.: 50001 – 51000

DS1 DS2 B1 B2 T5 AP BR

: Solenoid valve for bank control : Solenoid valve for parking brake : To bank control cylinder : To bank control cylinder : From mine control valve : From hydraulic control valve : To parking brake

10-112 (8)

Outline The parking brake control valve has the solenoid valves for parking brake and bank control. If the solenoid for the parking brake is turned on, hydraulic oil is supplied to the parking brake to release the parking brake. If the solenoid for the bank control is turned on, hydraulic oil is supplied to the bank control cylinder to move the lock pin in the pulling out direction.

GD555, 655, 675-3C


PARKING BRAKE AND BANK CONTROL VALVE


1. Solenoid valve for bank control 2. Solenoid valve for parking brake AP B1 B2 QC ST BR T1 T2 T3 T4

: From accumulator : To bank control cylinder : To bank control cylinder : To parking brake : (Plugged) : (Plugged) : (Plugged) : To hydraulic tank : To accumulator pressure governor valve : (Plugged)

GD555, 655, 675-3C

Outline The parking brake control valve has the solenoid valves for parking brake and bank control. If the solenoid for the parking brake is turned on, hydraulic oil is supplied to the parking brake to release the parking brake. If the solenoid for the bank control is turned on, hydraulic oil is supplied to the bank control cylinder to move the lock pin in the pulling out direction.

10-113 (8)


WORK EQUIPMENT HYDRAULIC PIPING DRAWING

WORK EQUIPMENT HYDRAULIC PIPING DRAWING MAIN PIPING (1/2) Serial No.: 50001 – 51000

1. Priority ACC governer valve

10-114 (4)

GD555, 655, 675-3C



MAIN PIPING (2/2)

1. Shut-off valve 2. Hydraulic tank 3. Hydraulic pump

GD555, 655, 675-3C

10-115 (4)



MAIN PIPING (1/2) Serial No.: 51001 and up

1. 2. 3. 4.

Main control valve (left) Main control valve (right) Hydraulic tank Hydraulic pump

10-116 (8)

5. LS pressure reducing valve 6. Priority valve 7. Accumulator pressure governor valve

GD555, 655, 675-3C



MAIN PIPING (2/2)

GD555, 655, 675-3C

10-117 (8)



HIGH PRESSURE PIPING (1/3) Left side

10-118 (8)

GD555, 655, 675-3C



HIGH PRESSURE PIPING (2/3) Right side 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

GD555, 655, 675-3C

Pilot check valve – drawbar shift Pilot check valve – leaning Pilot check valve – articulate Pilot check valve – right blade lift Main control valve – right Articulate cylinder Main control valve Pilot check valve – left blade lift Pilot check valve – blade tip Blade lift cylinder

10-119 (8)



HIGH PRESSURE PIPING (3/3)

1. Swivel joint 2. Drawbar side-shift cylinder 3. Blade tilt cylinder

10-120 (8)

GD555, 655, 675-3C



LIFTER LOCK PIPING Serial No.: 50001 – 51000

1. Parking and bank control valve

GD555, 655, 675-3C

10-121 (8)




1. Parking and bank control valve 2. Bank pin 3. Lifter bracket

10-122 (8)

Function The lifter bracket (3) is fixed by the bank pin (2). When setting in the bank cutting position, operate control lever. This uses hydraulic oil to push piston. The pin can be removed and the bracket can be rotated.

GD555, 655, 675-3C



BANK PIN

1. Pin 2. Piston 3. Cover

GD555, 655, 675-3C

4. Shaft 5. Case 6. Bushing

10-123 (8)


HYDRAULIC PUMP

HYDRAULIC PUMP Serial No. 50001 – 51000

PA PA1 PA2 PA3 PDA PD1 PD2 PEN PLS PM PS

: : : : : : : : : : :

Pump discharge Pump pressure detection port LS pump pressure input Drain port Pump air bleed Pump drain Pump drain Control pressure detection port LS pressure input Drain port Pump suction

10-124 (4)

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The main pump consists of one unit formed by the pump, servo piston, PC valve, and LS valve. The explanation of structure and function is divided into two parts: the pump and PC valve + LS valve.

GD555, 655, 675-3C


1. 2. 3. 4. 5.

Shaft Cradle Case Rocker cam Shoe

GD555, 655, 675-3C

6. 7. 8. 9. 10.

HYDRAULIC PUMP

Piston Cylinder block Valve plate Spring Servo piston

10-125 (4)


HYDRAULIC PUMP

FUNCTION • The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. • It is possible to change the discharge amount by changing the swash plate angle.

STRUCTURE • Cylinder block (7) is supported to shaft (1) by spline a, and shaft (1) is supported by the front and rear bearings. • The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. • Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case and forms a static pressure bearing when it slides.

10-126 (4)

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Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

GD555, 655, 675-3C


HYDRAULIC PUMP

OPERATION 1. Operation of pump i) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle between center line X of rocker cam (4) and the axial direction of cylider block (7) changes. Angle is called the swash plate angle.

ii)

Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volume E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F – E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. At the same time, the volume of chamber F b e c o m e s l a r g e r, a n d a s t h e v o l u m e becomes larger, oil is sucked in. (The diagram shows chamber F at the end of the suction process and chamber E at the end of the discharge process.)

iii) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.) iv) In other words, there is a proportional relationship between swash plate angle and the pump discharge amount.

GD555, 655, 675-3C

10-127 (4)


HYDRAULIC PUMP

2. Control of discharge amount • If swash plate angle becomes larger, the difference in volumes E and F becomes larger and discharge amount Q increases. Swash plate angle is changed by servo piston (10). • Servo piston (10) moves in a reciprocal movement ( ) according to the command from the PC and LS valve. • This straight line movement is transmitted to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), moves in a rotating motion on the cylindrical surface in the ( ) direction. • With servo piston (10), the area receiving the pressure is different at the top and bottom, so main pump discharge pressure (self pressure) PP is always connected to the pressure chamber at the small diameter piston end (top). Output pressure Pen of the LS vale is brought to the pressure chamber at the large diameter piston end (bottom). The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter piston end, and the ratio between the pressure-receiving area at the small diameter piston end and the large diameter piston end controls the movement of servo piston (10).

10-128 (4)

GD555, 655, 675-3C


HYDRAULIC PUMP

PC VALVE, LS VALVE, SERVO PISTON

PA2 PA3 PLS PM PP

: LS pump pressure inlet port : Drain port : LS pressure inlet port : Drain port : Pump discharge port

Servo piston 1. Servo piston 2. Lever 3. Spring

GD555, 655, 675-3C

PC valve 4. Piston 5. Spring

LS valve 12. Plug 13. Sleeve

6. 7. 8. 9. 10. 11.

14. Spring 15. Piston

Seat Spring Piston Sleeve Piston Plug

10-129 (4)


HYDRAULIC PUMP

LS VALVE Function • The LS valve controls the pump discharge amount according to the amount of movement of the control lever, that is the oil flow demanded by the actuator. • The LS valve detects the oil flow demanded by the actuator from the differential pressure EPLS between input pressure Pa2 of the control valve (downstream pressure of self-pressure reducing valve) and control valve outlet pressure PLS, and controls main pump discharge amount Q. (Pa2 is called the LS pump pressure, PLS is called the LS pressure, and EPLS is called the LS differential presure.) • In other words, the pressure loss (= LS differential pressure EPLS) generated by the flow of oil from the pump passing through opening area of the control valve spool is detected. By controlling pump discharge amount Q so that this pressure loss remains constant, a pump discharge amount is supplied in accordance with the demands of the control valve by controlling pump discharge amount Q. • Main pump discharge pressure PP, LS pump pressure Pa2, and LS pressure PLS are brought to the LS valve. The relationship between pump discharge amount Q and LS differential pressure EPLS changes as shown in the diagram on the right.

10-130 (4)

GD555, 655, 675-3C


HYDRAULIC PUMP

Operation 1. When control valve is at HOLD position

10-132 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

The LS pressure PLS is brought from the control valve outlet port to spring chamber a of the LS valve. LS pump pressure Pa2 at the control valve inlet port is brought to the chamber b at the tip of the sleeve on the opposite side. The position of piston (15) is determined by the size of pump pressure Pa2 and the combined force of LS pressure PLS + force of spring (14). Before the engine is started, servo piston (1) is pushed down (direction of minimum swash plate angle) by spring (3). After the engine is started, if all the control valves are at the neutral position, no pressure oil flows to the control valve outlet port, so LS pressure PLS is 0 MPa {0 kg/cm2}. (Spring chamber a is connected to the drain circuit through the control valve spool.) At the same time, LS pump pressure Pa2 is held at the unload pressure of approx. 2.8 MPa {29 kg/cm2}. For this reason, piston (15) is pushed to the right ( ), port c and port d are interconnected, and pump pressure PP is brought from port d to chamber X at the large diameter end of servo piston (1). Pump pressure PP is always supplied to chamber Y at the small diameter end of servo piston (1), but the force applied to the large diameter end of servo piston (1) is greater because of the difference in area at both ends of the piston, so servo piston (1) moves up in the direction of the minimum swash plate angle ( ).

GD555, 655, 675-3C

10-133 (4)


HYDRAULIC PUMP

2. When opening area of control valve is maximum (lever operated fully)

10-134 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

When the control lever is operated fully, that is, when the area of opening of the control valve becomes larger, the difference between LS pump pressure Pa2 and LS pressure PLS (LS differential pressure PLS) becomes smaller. LS pressure PLS brought to spring chamber a of the LS valve becomes close to LS pump pressure Pa2, and piston (15) is pushed to the left ( ) by the combined force of LS pressure PLS + force of spring (14). This closes port c and interconnects port d and port e. As a result, the pressurized oil acting on chamber X at the large diameter end of servo piston (1) flows from port d to port e and is connected to port f of the PC valve. At this point, port f of the PC valve is drained inside the pump case through the inside of the piston, so the pressure in chamber X at the large diameter end of servo piston (1) also becomes the drain pressure. Because of this, servo piston (1) is moved down in the direction of the maximum swash plate angle ( ) by pump pressure PP acting on chamber Y at the small diameter end of the piston.

GD555, 655, 675-3C

10-135 (4)


HYDRAULIC PUMP

3. When opening area of control valve is small (small movement of lever)

10-136 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

When the control lever is operated in small movements, or when it is operated to the HOLD position (in other words, when the area of opening of the control valve becomes smaller), the difference between LS pump pressure Pa2 and LS pressure PLS (in other words, LS pressure EPLS) becomes larger. When this happens, the movement is the same as for [1. When control valve is at HOLD position]: LS pump pressure Pa2 pushes piston (14) to the right ( ), so servo piston (1) is moved up in the direction of the minimum swash plate angle ( ). In other words, the basic LS set differential pressure of the LS valve is taken as 2.35 MPa {24 kg/cm2}. In the range from the neutral position of the control valve to the small area of opening of the control valve (fine control), in the area where the LS differential pressure EPLS is more than 2.35 MPa {24 kg/cm 2 }, the pump swash plate angle moves in the minimum direction. If the area of opening of the control valve is further increased, and LS differential pressure EPLS goes below 2.35 MPa {24 kg/cm2 }, the pump swash plate angle is moved in the maximum direction.

GD555, 655, 675-3C

10-137 (4)


HYDRAULIC PUMP

4. When pump flow is amount demanded by control valve

10-138 (4)

GD555, 655, 675-3C


HYDRAULIC PUMP

PC VALVE •

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Let us take the area receiving the pressure at the large diameter end of servo piston as A1, the area receiving the pressure at the small diameter end as A2, the pressure acting on the large piston diameter end as Pen, and the pressure acting on the small piston diameter end as PP. When the flow of oil from the pump reaches the flow demanded by the control valve, LS pump pressure Pa2 acting on port b of the LS valve and the combined force of LS pressure PLS + force of spring (14) acting on spring chamber a are balanced, so piston (15) stops at almost the central position. As a result, port c, port d, and port e open approximately the same amount, so the pump pressure flows from port c to port d. Part flows from port e to the tank case and is drained, so the pressure is reduced by approx. 1/2 and flows to chamber X at the large diameter end of servo piston (1). At this point, the relationship between the area receiving the pressure at both ends of piston (1) is A2 : A1 = 1 : 2, so the pressure applied to both ends of servo piston (1) becomes PP : Pen = 2 : 1. This makes the force acting on both ends of servo piston (1) 1 : 1, so servo piston (1) stops in that position and the pump discharge amount is balanced with the oil flow demanded by the control valve. The force of the spring is adjusted so that Pa2 – PLS = EPLS = 2.35 MPa {24 kg/cm2} at the point E where piston (15) is balanced. In other words, when the area of opening of control valve is 1/2, the pump swash plate angle is also 1/2, and when the area of opening of control valve is 1/4, the pump swash plate angle is also 1/4. LS differential pressure EPLS is always held at 1.96 MPa {20kg/cm2}, so the pump discharge amount is in accordance with the area of opening of the control valve. For example, after balancing at an area of opening 1/4 of the control valve, LS differential pressure EPLS will drop momentarily. As a result, the LS valve is actuated and the pump discharge amount is increased, but when the pump swash plate angle rises to 3/4, the LS differential pressure EPLS rises to 2.35 MPa {24 kg/cm2}, so it is balanced in this position.

GD555, 655, 675-3C

Function • When discharge pressure PP becomes higher, the area of opening of the control valve becomes larger, and even if the LS valve tries to increase pump discharge amount Q, the PC valve carries out control to prevent any increase above fixed discharge amount Q to match discharge pressure PP. It carries out approximate horsepower control to prevent the hydraulic horsepower absorbed by the pump from exceeding the engine horsepower. • In other words, if the load during operations becomes larger and pump discharge pressure PP rises, pump discharge amount Q is reduced; and if pump discharge pressure PP goes down, pump discharge amount Q is increased. • The relationship between pump discharge pressure PP and pump discharge amount Q is as shown in the diagram below.

10-139 (4)


HYDRAULIC PUMP

Operation 1. When actuator load is large (pump discharge pressure PP is high)

10-140 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

When the load on the actuator becomes high and pump discharge pressure PP rises, piston (8) is pushed to the left ( ) because of the relationship between the cross-sectional area of piston portions S1 and S2 (S1 > S2). As a result, port f and port g are interconnected, pump pressure PP flows from port g to port f, and at the same time, port f and the drain circuit are shut off. If the LS valve takes action to increase the pump discharge amount, spool (15) of the LS valve is moved to the left ( ) and port d and port e are interconnected. As a result, pump pressure PP from port f of the PC valve flows from port e of the LS valve to port d, enters chamber X at the large diameter end of servo piston (1), and stops the movement of servo piston (1). If pump discharge pressure PP rises further, piston (8) moves to the left ( ) and servo piston (1) moves up in the direction of the minimum swash plate angle ( ) because of the pressure in chamber X at the large diameter end. When servo piston (1) moves up ( ), piston (4) is moved to the right ( ) through lever (2). As a result, springs (5) and (7) are moved in the direction of compression and piston (8) is pushed back to the right. When piston (8) is pushed back to the right and port f and port g are shut off, servo piston (1) stops moving ( ). The position where servo piston (1) stops is higher (closer to the minimum swash plate angle) than when the pump discharge pressure is low.

GD555, 655, 675-3C

10-141 (4)


HYDRAULIC PUMP

2. When actuator load becomes smaller (pump discharge pressure PP drops)

10-142 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

When the load on the actuator becomes smaller and pump discharge pressure PP drops, piston (8) is pushed to the right ( ) by the force of springs (5) and (7). As a result, port g and port f are shut off, and at the same time, port f is connected to the drain circuit. When this happens, if the LS valve is acting to increase the pump discharge pressure, the limit of the PC valve disappears, so the pressurized oil in chamber X at the large diameter end of servo piston (1) passes from port d of LS valve to port e, and flows from port f of the PC valve to the drain circuit as explained in the section on the LS valve. For this reason, servo piston (1) is moved down in the direction of the maximum swash plate angle ( ) by the pressure in chamber Y at the small diameter end.

GD555, 655, 675-3C

10-143 (4)


HYDRAULIC PUMP

3. Action of spring

10-144 (4)

GD555, 655, 675-3C


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HYDRAULIC PUMP

The spring load of springs (5) and (7) in the PC valve is changed by the swash plate angle. When servo piston (1) moves, lever (2) moves, and piston (5) moves to the right or left according to the direction of rotation of lever (2). If piston (4) moves to the right ( ), spring (5) and spring (7) are compressed. If it moves further to the right ( ), spring (5) contacts seat (6), so only spring (7) functions as a spring. In other words, the spring load is changed by piston (5) extending or contracting springs (5) and (7). The pump absorption torque curve, which shows the relationship between pump discharge pressure PP and discharge amount Q, is a bent curve as shown in the diagram on the right because springs (5) and (7) have different spring loads. In other words, if pump discharge pressure PP increases, pump discharge amount Q is reduced; and if pump discharge pressure PP goes down, pump discharge amount Q is increased.

GD555, 655, 675-3C

10-145 (4)


HYDRAULIC PUMP

HYDRAULIC PUMP Serial No. 51001 and up

PA PA1 PA2 PA3 PDA PD1 PD2 PEN PLS PS

: Pump discharge : Pump pressure detection port : LS pump pressure port : Drain port : Pump air bleed : Pump drain : Pump drain : Control pressure detection port : LS pressure input : Pump suction

10-146 (8)

a The main pump consists of one unit formed by the pump, servo piston, PC valve, and LS valve. The explanation in STRUCTURE, FUNCTION AND MAINTENANCE STANDARD is divided into two parts: the pump and the PC valve + LS valve.

GD555, 655, 675-3C


1. 2. 3. 4. 5.

Shaft Cradle Case Rocker cam Shoe

GD555, 655, 675-3C

6. 7. 8. 9. 10.

HYDRAULIC PUMP

Piston Cylinder block Valve plate Spring Servo piston

10-147 (8)


HYDRAULIC PUMP

PUMP Function • The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. • It is possible to change the discharge amount by changing the swash plate angle.

Structure • Cylinder block (7) is supported to shaft (1) by spline a, and shaft (1) is supported by the front and rear bearings. • The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. • Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case and forms a static pressure bearing when it slides.

10-148 (8)

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Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

GD555, 655, 675-3C


HYDRAULIC PUMP

Operation 1. Operation of pump i) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle is called the swash plate angle.)

ii)

Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F – E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. At the same time the volume of chamber F b e c o m e s l a r g e r, a n d a s t h e v o l u m e becomes bigger, the oil is sucked in. (The diagram shows chamber F at the end of the suction process and chamber E at the end of the discharge process.)

iii) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.) iv) In other words, there is a proportional relationship between swash plate angle and the pump discharge amount.

GD555, 655, 675-3C

10-149 (8)


HYDRAULIC PUMP

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

10-150 (8)

GD555, 655, 675-3C


HYDRAULIC PUMP

PC VALVE, LS VALVE, SERVO PISTON

PA PA2 PA3 PLS

: Pump discharge pressure : LS pump pressure inlet : Drain : LS pressure inlet

Servo piston 1. Servo piston 2. Lever 3. Spring

10-152 (8)

PC valve 4. Piston 5. Spring 6. Seat 7. Spring 8. Spool 9. Sleeve 10. Plug

LS valve 11. Plug 12. Sleeve 13. Spring 14. Spool

GD555, 655, 675-3C


HYDRAULIC PUMP

LS VALVE Function • The LS valve controls the pump discharge amount according to the amount of movement of the control lever, that is the oil flow demanded by the actuator. • The LS valve detects the oil flow demanded by the actuator from the differential pressure EPLS between inlet pressure PA2 of the control valve and control valve outlet pressure PLS and controls main pump discharge amount Q. (PA2 is called the LS pump pressure, PLS is called the LS pressure, and EPLS is called the LS differential pressure.) • In other words, the pressure loss (= LS differential pressure EPLS) generated by the oil flowing from the pump through the open area of the control valve spool is detected. Pump discharge amount Q is so controlled that this pressure loss will remain constant to supply oil from the pump according to the demand of the actuator. • Main pump discharge pressure PA, LS pump pressure PA2, and LS pressure PLS are led in the LS valve. The relationship between LS differential pressure EPLS and pump discharge amount Q changes as shown in the figure on the right.

GD555, 655, 675-3C

10-153 (8)


HYDRAULIC PUMP

Operation 1. When control valve is at HOLD position

10-154 (8)

GD555, 655, 675-3C


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HYDRAULIC PUMP

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

GD555, 655, 675-3C

10-155 (4)


HYDRAULIC PUMP

2. When opening area of control valve is maximum (lever operated fully)

10-156 (8)

GD555, 655, 675-3C


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HYDRAULIC PUMP

If the control lever is moved to the stroke end and the open area of the control valve is increased, LS differential pressure EPLS between LS pump pressure PA2 and LS pressure PLS is reduced. LS pressure PLS led in spring chamber a of the LS valve becomes near LS pump pressure PA2 and spool (14) is pushed to the left by the resultant of "LS pressure PLS and force of spring (13)". As a result, port c is closed and ports d and e are connected. Accordingly, the oil applied to chamber X on the large diameter side of servo piston (1) flows through ports d and e to port f of the PC valve. Since the oil in port f of the PC valve is drained through the piston into the pump case at this time, the drain pressure is also applied to chamber X on the large diameter side of servo piston (1). Consequently, servo piston (1) is moved toward the maximum swash plate angle side (lower side) by pump pressure PA applied to chamber Y on the small diameter side.

GD555, 655, 675-3C

10-157 (4)


HYDRAULIC PUMP

3. When opening area of control valve is small (small movement of lever)

10-158 (8)

GD555, 655, 675-3C


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HYDRAULIC PUMP

When the control lever is operated finely or set in the HOLD position and the open area of the control valve is reduced, LS differential pressure EPLS between LS pump pressure PA2 and LS pressure PLS is increased. At this time, the mechanism operates as described in "1. When control valve is at HOLD position". LS pump pressure PA2 pushes spool (14) to the right and servo piston (1) moves toward the minimum swash plate angle side (upper side). In other words, on the basis of the LS set differential pressure of 2.35 MPa {24 kg/cm2} for the LS valve and in the range from the HOLD position of the control valve to the minimum open area of the control valve (in the fine control operation), when LS differential pressure EPLS is higher than 2.35 MPa {24 kg/cm2 }, the swash plate angle reduces. When the open area of the control valve increases and LS differential pressure EPLS lowers below 2.35 MPa {24 kg/cm2}, the swash plate angle increases.

GD555, 655, 675-3C

10-159 (4)


HYDRAULIC PUMP

4. When pump flow is amount demanded by control valve

10-160 (8)

GD555, 655, 675-3C


HYDRAULIC PUMP

PC VALVE •

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Let the pressure receiving area on the large diameter side of servo piston (1) be A1, the pressure receiving area on the small diameter side be A2, the pressure applied on the large diameter side be PEN, and the pressure applied on the small diameter side be PA. When the oil flow from the pump reaches the flow rate demanded by the control valve, LS pump pressure PA2 applied to port b of the LS valve is balanced with the resultant of "LS pressure PLS and the force of spring (13)" applied to spring chamber a and spool (14) is stopped at an almost intermediate point. As a result, ports c, d, and e are opened almost equally. Then, some of the pump oil from port c flows in port d and the other is drained through port e into the tank case. Accordingly, the pressure of this oil is reduced to about 1/2 and applied to chamber X on the large diameter side of servo piston (1). At this time, since the relationship of the pressure receiving areas of servo piston (1) is as A2 : A1 = 1 : 2, the ratio of pressure PA to pressure PEN applied to both ends of servo piston (1) is 2 : 1. Accordingly, the same force is applied to both ends of servo piston (1), and then servo piston (1) is stopped at the current position and the oil flow demanded by the control valve is balanced with the pump discharge. The spring force is so adjusted that PA2 – PLS will be EPLS and will approximately equal 2.35 MPa {24 kg/cm 2 } to determine the balancing point of spool (14). In other words, when the open area of the control valve is 1/2, the swash plate angle is also 1/2, and when the open area of the control valve is 1/ 4, the swash plate angle is also 1/4. The pump discharge is changed according to the open area of the control valve by keeping LS differential pressure EPLS at 2.35 MPa {24 kg/cm2}. For example, if the spool is balanced at 1/4 of the open area of the control valve and then the open area of the control valve is increased to 3/4, LS differential pressure EPLS lowers temporarily. Accordingly, the LS valve operates to increase the pump discharge. After the swash plate angle increases to 3/4, however, LS differential pressure EPLS rises to 2.35 MPa {24 kg/cm2} and the spool is balanced at this point.

GD555, 655, 675-3C

Function • When discharge pressure PA rises and the open area of the control valve is wide, the LS valve increases pump discharge amount Q. At this time, the PC valve controls discharge amount Q so that it will not exceed a certain level according to discharge pressure PA. That is, the PC valve performs approximate equal horsepower control so that the pump absorption horsepower will not exceed the engine horsepower. • In other words, when the load increases and pump discharge pressure PA rises during work, pump discharge amount Q is reduced. When pump discharge pressure PA lowers, pump discharge amount is increased. • The relationship between pump discharge pressure PA and pump discharge amount Q is shown below.

10-161 (8)


HYDRAULIC PUMP

Operation 1. When actuator load is large (pump discharge pressure PA is high)

10-162 (8)

GD555, 655, 675-3C


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• •

HYDRAULIC PUMP

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

GD555, 655, 675-3C

10-163 (4)


HYDRAULIC PUMP

2. When actuator load becomes smaller (pump discharge pressure PA drops)

10-164 (8)

GD555, 655, 675-3C


•

• •

•

HYDRAULIC PUMP

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

GD555, 655, 675-3C

10-165 (4)


HYDRAULIC PUMP

3. Action of spring

10-166 (8)

GD555, 655, 675-3C


• • •

•

•

HYDRAULIC PUMP

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

GD555, 655, 675-3C

10-167 (8)


MAIN CONTROL VALVE

MAIN CONTROL VALVE LEFT 4-SPOOL VALVE (1/3)

P PP LS T TS A1 B1

: Pump port (from main pump) : PP port (to main pump) : LS port (to main pump) : Tank port (to tank) : Seal drain port (to tank) : To left blade lift cylinder bottom : To left blade lift cylinder head

GD555, 655, 675-3C

A2 B2 A3 B3 A4 B4

: To blade shift cylinder bottom : To blade shift cylinder head : To circle motor : To circle motor : To blade tilt cylinder bottom : To blade tilt cylinder head

10-169 (4)


MAIN CONTROL VALVE

LEFT 4-SPOOL VALVE (2/3)

10-170 (4)

GD555, 655, 675-3C


MAIN CONTROL VALVE

LEFT 4-SPOOL VALVE (3/3)

1. 2. 3. 4. 5. 6. 7. 8.

Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (Left blade lift) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle) Pressure compensation valve F (blade tilt)

9. 10. 11. 12. 13. 14. 15.

Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) LS bypass plug Unload valve Safety-suction valve

Unit: mm No.

Check item

Remedy


16

Spool return spring

Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

56.27 x 20.1

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

87.7 x 19.7

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

17

Spool return spring (circle)

18

Pressure compensation valve spring (R)

23 x 8.4

15

6.9 N {0.7 kg}

—

5.52 N {0.56 kg}

19

Pressure compensation valve spring (F)

15.4 x 6

8

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

20

Unload valve spring

35.25 x 19

20.5

137 N {14 kg}

—

110 N {11.2 kg}

GD555, 655, 675-3C

Replace spring if damaged or deformed

10-171 (4)


MAIN CONTROL VALVE

RIGHT 4-SPOOL VALVE (1/3)

P PP LS T TS A1 B1

: Pump port (from main pump) : PP port (to main pump) : LS port (to main pump) : Tank port (to tank) : Seal drain port (to tank) : To right blade lift cylinder bottom : To left blade lift cylinder head

GD555, 655, 675-3C

A2 B2 A3 B3 A4 B4

: To leaning cylinder head : To leaning cylinder bottom : To articulating cylinder head : To articulating cylinder bottom : To drawbar shift cylinder head : To drawbar shift cylinder bottom

10-173 (7)


MAIN CONTROL VALVE


10-174 (4)

GD555, 655, 675-3C


MAIN CONTROL VALVE


1. 2. 3. 4. 5. 6. 7. 8.

Spool (right blade lift) Spool (leaning) Spool (articulating) Spool (drawbar shift) Pressure compensation valve F (right blade lift) Pressure compensation valve F (leaning) Pressure compensation valve F (articulating) Pressure compensation valve F (drawbar shift)

9. 10. 11. 12. 13. 14.

Pressure compensation valve R (drawbar shift) Pressure compensation valve R (articulating) Pressure compensation valve R (leaning) Pressure compensation valve R (right blade lift) LS relief valve Main relief valve

Unit: mm No.

Check item

Remedy


15

Spool return spring

Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

56.27 x 20.1

25.4

34.8 N {3.55 kg}

—

27.8 N {2.84 kg}

16


23 x 8.4

15

6.9 N {0.7 kg}

—

5.52 N {0.56 kg}

17


15.4 x 6

8

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

GD555, 655, 675-3C


10-175 (4)


MAIN CONTROL VALVE

LEFT 5-SPOOL VALVE (SCARIFIER SPECIFICATION) (1/3)

P PP LS T TS A1 B1

: Pump port (from main pump) : PP port (to main pump) : LS port (to right valve LS port) : Tank port (to tank) : Seal drain port (to tank) : To scarifier cylinder bottom : To scarifier cylinder head

GD555, 655, 675-3C

A2 B2 A3 B3 A4 B4 A5 B5

: To left blade lift cylinder bottom : To left blade lift cylinder head : To blade shift cylinder bottom : To blade shift cylinder head : To circle motor : To circle motor : To blade tilt cylinder bottom : To blade tilt cylinder head

10-177 (4)


MAIN CONTROL VALVE


10-178 (4)

GD555, 655, 675-3C


MAIN CONTROL VALVE


1. 2. 3. 4. 5. 6. 7. 8. 9.

Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (left blade lift) Spool (scarifier) Pressure compensation valve F (scarifier) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle)

10. 11. 12. 13. 14. 15. 16. 17. 18.

Pressure compensation valve F (blade tilt) Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) Pressure compensation valve (scarifier) LS bypass plug Unload valve Safety-suction valve Unit: mm

No.

Check item

Remedy


19

Spool return spring

Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

56.27 x 20.1

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

87.7 x 19.7

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

20


21


23 x 8.4

15

6.9 N {0.7 kg}

—

5.52 N {0.56 kg}

22


15.4 x 6

8

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

23

Unload valve spring

35.25 x 19

20.5

137 N {14 kg}

—

110 N {11.2 kg}

GD555, 655, 675-3C


10-179 (4)


MAIN CONTROL VALVE

LEFT 5-SPOOL VALVE (RIPPER SPECIFICATION) (1/3) GD555-3C

P PP LS T TS A1 B1

: Pump port (from main pump) : PP port (to main pump) : LS port (to right valve LS port) : Tank port (to tank) : Seal drain port (to tank) : To ripper cylinder bottom : To ripper cylinder head

GD555, 655, 675-3C

A2 B2 A3 B3 A4 B4 A5 B5


10-181 (4)


MAIN CONTROL VALVE


10-182 (4)

GD555, 655, 675-3C


MAIN CONTROL VALVE


1. 2. 3. 4. 5. 6. 7. 8. 9.

Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (left blade lift) Spool (ripper) Pressure compensation valve F (ripper) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle)

10. 11. 12. 13. 14. 15. 16. 17. 18.

Pressure compensation valve F (blade tilt) Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) Pressure compensation valve (ripper) LS bypass plug Unload valve Safety-suction valve Unit: mm

No.

Check item

Remedy


19

Spool return spring

Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

56.27 x 20.1

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

87.7 x 19.7

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

20


21


23 x 8.4

15

6.9 N {0.7 kg}

—

5.52 N {0.56 kg}

22


15.4 x 6

8

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

23

Unload valve spring

35.25 x 19

20.5

137 N {14 kg}

—

110 N {11.2 kg}

GD555, 655, 675-3C


10-183 (4)


MAIN CONTROL VALVE

LEFT 5-SPOOL VALVE (RIPPER SPECIFICATION) (1/3) GD655, GD675-3C

P PP LS T TS A1 B1

: Pump port (from main pump) : PP port (to main pump) : LS port (to main pump) : Tank port (to tank) : Seal drain port (to tank) : To ripper cylinder bottom : To ripper cylinder head

GD555, 655, 675-3C

A2 B2 A3 B3 A4 B4 A5 B5


10-185 (4)


MAIN CONTROL VALVE


10-186 (4)

GD555, 655, 675-3C


MAIN CONTROL VALVE


1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Spool (blade tilt) Spool (circle) Spool (blade shift) Spool (left blade lift) Spool (ripper) Pressure compensation valve F (ripper) Pressure compensation valve F (left blade lift) Pressure compensation valve F (blade shift) Pressure compensation valve F (circle) Pressure compensation valve F (blade tilt)

11. 12. 13. 14. 15. 16. 17. 18. 19.

Pressure compensation valve R (blade tilt) Pressure compensation valve R (circle) Pressure compensation valve R (blade shift) Pressure compensation valve R (left blade lift) Pressure compensation valve (ripper) LS bypass plug Unload valve Safety-suction valve Safety-suction valve Unit: mm

No.

Check item Standard size

20

Spool return spring

Remedy

Criteria Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

56.27 x 20.1

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

87.7 x 19.7

25.4

34.8 N {3.55 kg}

—

27.9 N {2.84 kg}

21

Spool return spring

22


23 x 8.4

15

6.9 N {0.7 kg}

—

5.52 N {0.56 kg}

23


15.4 x 6

8

7.45 N {0.76 kg}

—

5.98 N {0.61 kg}

24

Unload valve spring

35.25 x 19

20.5

137 N {14 kg}

—

110 N {11.2 kg}

GD555, 655, 675-3C


10-187 (4)


CLSS

CLSS 1. OUTLINE OF CLSS Features CLSS stands for Closed center Load Sensing System, and has the following features. 1) Fine control not influenced by load. 2) Control enabling digging even with fine control. 3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. 4) Energy saving using variable pump control.

10-188 (8)

Structure • The CLSS consists of a variable capacity single piston pump, control valve, and actuators. • The pump body consists of the main pump, the PC valve and LS valve.

GD555, 655, 675-3C


CLSS

2. BASIC PRINCIPLE 1) Control of pump swash plate angle • The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure (EPLS) (the difference between pump pressure (PP) and control valve outlet port LS pressure (PLS)) (load pressure of actuator) is constant. (LS pressure (EPLS) = Pump discharge pressure (PP) – LS pressure (PLS)) • If LS differential pressure (EPLS) becomes lower than the set pressure of the LS valve, the pump swash plate becomes larger; if it becomes higher than the set pressure of the LS valve, the pump swash plate becomes smaller. a For details of the operation, see HYDRAULIC PUMP.

GD555, 655, 675-3C

10-189 (8)


CLSS

2) Pressure compensation control • Valves (pressure compensation valves) are installed on the inlet side of the control valves to balance the load. When the actuators are operated simultaneously, pressure difference (∆P) between the upstream (inlet) of the spool of each valve and downstream (outlet) is kept constant by the pressure compensation valves, regardless of the load (pressure). Accordingly, the oil flow from the pump is distributed (compensated) in proportion to the open areas (S1) and (S2) of the operated valves.

10-190 (8)

GD555, 655, 675-3C


CLSS

3. FUNCTIONS AND OPERATION OF EACH VALVE HYDRAULIC CIRCUITS AND NAMES OF VALVES

1. 2. 3. 4.

Unload valve LS relief valve Main relief valve Pressure compensation valve

GD555, 655, 675-3C

5. Safety-suction valve 6. LS pressure reducing valve

10-191 (8)


CLSS

UNLOAD VALVE 1) When control valve is at HOLD Function • When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. When this happens, pump discharge pressure PP is set to 2.9 MPa {30 kg/cm2} by spring (2) inside the valve. LS pressure PLS: 0 MPa {0 kg/cm2}.

Operation • At the left end of the spool (1), pump pressure PP is acting on area S1, and at the right end of spool (1), pump pressure PP is acting on area S2, and LS pressure PLS is acting on area S3. • When the control valve is at HOLD, LS pressure PLS is not generated, so only pump discharge pressure PP has any effect, and PP is set by the load of spring (2). • As pump discharge pressure PP rises and becomes PP x S1 = PP x S2 + spring force of spring (2), spool (1) is moved to the right. Pump circuit PP is then connected to tank circuit T through the drill hole. • In this way, pump discharge pressure PP is set to 2.9 MPa {30 kg/cm2}.

10-192 (8)

PP PLS T A B

: Pump circuit : LS circuit : Tank circuit : To valves : To pump LS valve

GD555, 655, 675-3C


CLSS

2) During fine control of control valve operation Function • During the fine control of the control valve, when the demand flow for the actuator is within the amount discharged by the minimum swash plate angle of the pump, pump discharge pressure PP is set to LS pressure PLS + 2.9 MPa {30 kg/cm2}. When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2) (2.9 MPa {30 kg/ cm2}), the unload valve opens, so LS differential pressure EPLS becomes 2.9 MPa {30 kg/cm2}.

Operation • When fine control is carried out on the control valve, LS pressure PLS is generated and acts on area S3 at the right end of spool (1). When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS pressure PLS and pump discharge pressure PP. • When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2), spool (1) moves to the right, and pump circuit PP and tank circuit T are connected. • In other words, pump discharge pressure PP is set to a pressure equal to the force of spring (2) (2.9 MPa {30 kg/cm2}) + LS pressure PLS, and LS differential pressure EPLS becomes 2.9 MPa {30 kg/cm2}.

GD555, 655, 675-3C

PP PLS T A B


10-193 (8)


CLSS

3) When control valve is operated Function • When the control valve is being operated and the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is shut off, and all the pump discharge amount Q flows to the actuator circuit.

Operation • When the control valve is operated to a larger stroke, LS pressure PLS is generated and acts on area S3 at the right end of spool (1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure PLS and pump discharge pressure PP is small. • For this reason, the difference in pressure between pump discharge pressure PP and LS pressure PLS does not reach the load of spring (2) (2.9 MPa {30 kg/cm2}), so spool (1) is pushed to the left by spring (2). • As a result, pump circuit PP and tank circuit T are shut off, and all the pump discharge amount Q flows to the actuator circuit.

10-194 (8)

PP PLS T A B


GD555, 655, 675-3C


CLSS

INTRODUCTION OF LS PRESSURE to the same pressure as actuation circuit pressure A, and sends it to the LS circuit PLS.

Function • The LS pressure is the actuator load pressure at the outlet port end of the control valve. • It actually reduces pump pressure PP at reducing valve (3) of the pressure compensation valve

Operation • When spool (1) is operated, pump pressure PP flows from flow control valve (2) and notch a in a spool (1) through bridge passage b to actuator circuit A. • At the same time, reducing valve (3) also moves to the right, so pump pressure PP has its pressure reduced by the pressure loss at notch C. It is introduced to LS circuit PLS, and then goes to spring chamber PLS1. • When it happens, LS circuit PLS is connected to tank circuit T from LS bypass plug (4) (see the section on the LS bypass plug).

GD555, 655, 675-3C

• •

Actuator circuit pressure PA (=A) acts on the left end of reducing valve (3); the reduced pump pressure PP acts on the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pressure of spring chamber PLS1 are the same. Pump pressure PP reduced at notch C becomes actuator circuit pressure A and is taken to LS circuit pressure PLS.

10-195 (8)


CLSS

PRESSURE COMPENSATION VALVE Function • During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase, compensation is received. (When this happens, the other actuator being used for compound operation (right side) is at a higher load than the actuator on this side (left side).)

Operation • If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator circuit A on this side (left side) tries to increase. • If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and flow control valve (2) are pushed to the left (i). • Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure loss is generated between PP and PPA. • Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PLS and PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control valve (2) are the same.

10-196 (8)

•

In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools used during compound operations is the same, so the pump flow is divided in proportions to the area of opening of notch a of each spool.

GD555, 655, 675-3C


CLSS

LS BYPASS PLUG Function • It releases the residual pressure of LS pressure PLS. • It makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discarded throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.

Operation • The pressurized oil for LS circuit PLS passes from clearance filter a (formed by the clearance between LS bypass plug (1) and the valve body) through orifice b and flows to the bank circuit T.

GD555, 655, 675-3C

PP PLS T A B


10-197 (8)


CLSS

LS RELIEF VALVE

A : L.H. control valve (unload section) B : R.H. control valve (LS relief section) Function • Even if the LS orifice functions, if another actuator is relieved in compound operation, the actuator speed is lower than in single operation. • When another actuator is relieved, if the speed lowers remarkably, the working performance is lowered. To prevent this, the LS relief valve is employed. • A small pilot relief valve installed to the LS circuit controls the maximum pressure. • The unload valve works as a relief valve installed to the main control valve and relieves the oil. • In addition, since the LS differential pressure equivalent to the set pressure of the unload valve is secured, the actuator speed does not lower even if another actuator is relieved.

10-198 (8)

Operation • If the LS circuit pressure PLS goes up and reaches the set pressure of LS relief valve (1), PLS is kept constant. • When this happens, the pump circuit PP is set to PLS + the spring force of unload valve (2). • The relief amount of pump circuit PP flows from unload valve (2) to circuit T. (Pump minimum swash plate flow). • Relief valve (3) is a backup for the LS relief valve and has the function of a surge absorption valve.

GD555, 655, 675-3C


CLSS

LS REDUCING VALVE

A B C D E

: To main control valve : To pump LS port : From steering valve LS port : From steering valve P port : To pump PP port

Function • The LS differential pressure (EPLS) of the main control valve and the steering valve are set to different values; the value for the main control valve is higher. • If the steering is operated with this circuit, the pump discharges the maximum flow. The excess oil is relieved by the unload valve of the main control valve, so there is a large energy loss. To prevent this, the steering LS pressure is reduced and is set to the same value as the LS differential pressure of the main control valve. This reduces the loss.

GD555, 655, 675-3C

Operation • Pump pressure PCF and LS pressure PLS (st) are brought in from the steering valve. • The PCF pressure is taken as the base pressure, and LS pressure PLS (v) reduced from PLS (st) by the load of spring (1) is taken to the main control valve. • Check valve (2) is installed to prevent the PP pressure when the work equipment is operated from entering the steering valve.

10-199 (8)


WORK EQUIPMENT CONTROL


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Steering adjustment knob R.H. blade lift lever Leaning lever Articulation lever Drawbar shift lever Blade rotation lever Blade tilt lever Blade shift lever Ripper, scarifier lever L.H. blade lift lever Steering control tilt pedal

Outline Steering tilt mechanism: Rotate the steering adjustment knob (1) to release the lock. Set steering to a suitable position, and then tighten the lever. Console box tilt mechanism: Depress the console box tilt pedal (11) and adjust the console box. The tilt angle can be adjusted steplessly to a maximum of 24°. In this way, it is possible for the operator to set the steering and control levers to the optimum position.

10-200 (4)

GD555, 655, 675-3C


GD555, 655, 675-3C


10-201 (4)


HYDRAULIC SYSTEM

HYDRAULIC SYSTEM Serial No.: 50001 – 51000 STRUCTURE OF SYSTEM

OUTLINE OF SYSTEM 1. Hydraulic pump 1) The hydraulic oil inside the hydraulic tank passes through the hydraulic pump and is sent to the priority ACC governor valve. 2) The hydraulic pump is the source of hydraulic power for the steering brake, work equipment, parking brake, and bank control lock pin. When there is a demand from the equipment, it generates an oil flow of the necessary amount and pressure to match the demands of the equipment. (= LS pressure + control pressure 2.35 MPa {24 kg/cm2} At neutral, the steering LS pressure 0.80 – 1.1 MPa {8 – 11 kg/cm2} + 2.35 MPa {24 kg/cm2} + pressure loss in piping = 3.24 – 3.63 MPa {33 – 37 kg/cm2}.

10-202 (4)

3) The pressure loss caused by flow resistance in the piping varies according to the temperature. At low temperature, the necessary control pressure may be lacking, and the necessary flow may not be provided. But to prevent this, pressure PP which is close to each piece of equipment is brought to the hydraulic pump, and the pressure generated by the hydraulic pump is controlled so that the differential pressure between PP and LS is 2.35 MPa {24 kg/cm2}. 4) In addition, it checks the pressure and discharge amount of the hydraulic pump, and ensures the resilience of the engine when there is compound operation or when there is excessive load caused by the PQ control when controlling at PQ = constant value. GD555, 655, 675-3C


5) When there are no demands for oil from the steering or work equipment (the system is at neutral), the swash plate in the hydraulic pump is held at a position where a fixed minimum flow is discharged so that the hydraulic pump can respond swiftly to any rapid operation of the steering or work equipment. 2. Steering circuit 1) The priority ACC governor valve is provided to ensure the necessary oil flow and to give priority to the oil flow in the steering brake system, which is closely related to safety, rather than to the work equipment. 2) The steering valve is an energy-saving, closed center type which lets the hydraulic oil flow only when necessary. When the steering is not being operated, it stops the flow of oil. When the steering wheel is operated, the pressure (LS pressure) passes through the priority ACC governor valve o LS pressure regulator valve, and goes to the servo valve of the hydraulic pump to ensure the necessary flow. It also generates pressure so that Pb = LS pressure + 2.35 MPa {24 kg/cm2} + pressure loss in piping. At the same time, the LS pressure is transmitted to the priority ACC governor valve. Priority is given to the steering circuit by keeping the spool at a position where it can provide the necessary oil flow to the steering circuit, regardless of whether there is any demand for oil from the work equipment. 3) The steering valve is a Q-Amp type that provides good control at high speed and engine should stall or if any problem should occur in the variable pump. 4) The maximum pressure in the steering circuit is determined by the relief valve inside the priority ACC governor valve. It is different from the hydraulic pressure for the work equipment.

GD555, 655, 675-3C

HYDRAULIC SYSTEM

3. Brake circuit 1) The oil that is given priority and ensured for the circuit has its pressure raised to the necessary pressure by the priority ACC governor valve and is charged in the brake accumulators inside the piping of the two systems. 2) If the brake is used and the pressure goes down to 9.32 MPa {96 kg/cm2}, the priority ACC governor valve is actuated and the brake accumulator is charged to the specified pressure of 13.4 MPa {137 kg/cm2}. 3) Even after the engine is stopped, braking is possible for a limited time using the pressure inside the brake accumulator. 4) When the brake accumulator pressure goes down, the force releasing the parking brake is reduced and the parking brake is automatically applied by the force of the spring. If the machine is stopped for a certain time, the parking brake is automatically applied, and it can only be released by starting the engine. 5) In postures such as the bank cut posture or shoulder reach posture, when changing the posture of the work equipment, the lifter lock pin is removed and installed. When doing this, the accumulator is also used as the source of hydraulic power. 6) The brakes are the most important devices for ensuring safety, so charging always starts immediately the engine is started. But particularly when starting in cold weather, if the accumulator is charged during the starting operation, there will be an excessive load on the hydraulic pump, and this will make it difficult to start the engine. To prevent this, an electromagnetic LS pressure release valve is installed. This cancels the charging of the accumulator when the starting motor is cranking and makes it easier to start the engine.

10-203 (4)


4. LS pressure regulator valve 1) To improve the response when the steering is operated suddenly and to ensure a quick response for the work equipment, a specified minimum flow of oil is discharged from the hydraulic pump, so an unload valve is installed to the control valve. 2) When the steering is operated, the steering LS pressure rises and the pump discharge is increased. For this reason, the steering Pb pressure also rises, but the function of the priority ACC governor valve sends the excess oil used for the steering to the control valve. When this happens, if the control valve is open, this excess oil flow is relieved by the unload valve and returns to the tank. This causes an energy loss, so when the steering brake is charged and the oil is not being used for the work equipment, a signal is sent to the unload valve. The control valve is set to on-load and shuts off the flow of oil back to the hydraulic tank to prevent loss of energy. 3) The internal shuttle valve transmits the higher of the steering brake charge LS pressure and the work equipment LS pressure to the pump to make is possible to carry out simultaneous operations. 4) The excess oil flow for the steering brake is sent to the control valve.

10-204 (4)

HYDRAULIC SYSTEM

5. Control valve 1) The control valve is a closed center type, so at neutral when the work equipment is not being used, the hydraulic oil returns from the unload valve to the hydraulic tank. The unload pressure is 3.1 MPa {32 kg/cm 2 } when the engine is at low idling and 3.5 MPa {35 kg/cm2} when it is at full throttle. 2) When the work equipment control valve lever is operated, the pressure at the valve inlet side is transmitted to the hydraulic pump as Pb. At the same time, the maximum pressure for the work equipment load passes through the LS line and is transmitted to the hydraulic pump, so the necessary oil flow is sent from the hydraulic pump. 3) At hydraulic relief, the upper limit for the LS pressure is determined by the LS relief valve. The control valve is a closed center load sensing valve, and has a proportional flow and proportional dividing pressure compensation function. It also has a built-in unload valve, LS relief valve, and surge absorption valve. This gives it the following features. • The operating effort is light and the lever travel is short. • It is possible to adjust each work equipment to the optimum cylinder set speed. • The raise and lower speeds (cylinder extending and retracting speeds) are the same, so the height can be adjusted. • There is a wide fine control range. • A constant movement position can be obtained, regardless of the load. • The work equipment can be operated with small movements of the lever and fine control is easy. • Operations are certain even during simultaneous operations. • Simultaneous operations are possible even when there is a lack of oil. • Other work equipment moves even when there is hydraulic relief. • When used in combination with the CLSS hydraulic pump, it has the following features. • The work equipment speed is fixed, regardless of the engine speed. • The neutral loss is reduced. • The relief loss is reduced. • There is little problem of the engine stalling even during compound operations or when there is a large load.

GD555, 655, 675-3C


HYDRAULIC SYSTEM

Serial No.: 51001 and up STRUCTURE OF SYSTEM

OUTLINE OF SYSTEM 1. Hydraulic pump 1) The hydraulic oil inside the hydraulic tank passes through the hydraulic pump and is sent to the priority valve. 2) The hydraulic pump is the source of hydraulic power for the steering brake, work equipment, parking brake, and bank control lock pin. When there is a demand from the equipment, it generates an oil flow of the necessary amount and pressure to match the demands of the equipment. =LS pressure + control pressure 2.35 MPa {24 kg/cm2} At neutral, the steering LS pressure 0.8 to 1.1 MPa {8 to 11 kg/cm2} + 2.35 MPa {24 kg/cm2} + pressure loss in piping = 3.24 to 3.63 MPa (33 to 37 kg/cm2}.

GD555, 655, 675-3C

3) The pressure loss caused by flow resistance in the piping varies according to the temperature. At low temperature, the necessary control pressure may be lacking, and the necessary flow may not be provided. But to prevent this, pressure PP which is close to each piece of equipment is brought to the hydraulic pump, and the pressure generated by the hydraulic pump is controlled so that the differential pressure between PP and LS is 2.35 MPa {24 kg/cm2}. 4) In addition, it checks the pressure and discharge amount of the hydraulic pump, and ensures the resilience of the engine when there is compound operation or when there is excessive load caused by PQ control when controlling at PQ = constant value.

10-205 (8)


5) When there are no demands for oil from the steering or work equipment (the system is at neutral), the swash plate in the hydraulic pump is held at a position where a fixed minimum flow is discharged so that the hydraulic pump can respond swiftly to any rapid operation of the steering wheel or work equipment. 2. Steering circuit 1) The priority valve is provided to ensure the necessary oil flow and to give priority to the oil flow in the steering brake system, which is closely related to safety, rather than to the work equipment. 2) The steering valve is an energy saving closed center type which lets the hydraulic oil flow only when necessary. When the steering is not being operated, it stops the flow of oil. When the steering wheel is operated, the pressure (LS pressure) passes through the accumulator pressure governor valve o LS pressure regulator valve, and goes to the servo valve of the hydraulic pump to ensure the necessary flow. It also generates pressure so that Pb = LS pressure + 2.35 MPa {24 kg/cm2} + pressure loss in piping. At the same time, the LS pressure is transmitted to the priority valve through the accumulator pressure governor valve. Priority is given to the steering circuit by keeping the spool at a position where it can provide the necessary oil flow to the steering circuit, regardless of whether there is any demand for oil from the work equipment. 3) The steering valve is a Q-Amp type that provides good control at high speed and can also ensure the steering ability if the engine should stall or if any problem should occur in the variable pump. 4) The maximum pressure in the steering circuit is determined by the relief valve inside the priority valve. It is different from the hydraulic pressure for the work equipment.

10-206 (8)

HYDRAULIC SYSTEM

3. Brake circuit 1) The oil that is given priority and ensured for the circuit has its pressure raised to the necessary pressure by the priority valve and is charged in the brake accumulators inside the piping of the two systems. 2) If the brake is used and the pressure goes down to 9.36 MPa {95 kg/cm2} the accumulator pressure governor valve is actuated and the brake accumulator is charged to the specified pressure of 13.4 MPa {137 kg/ cm2}. 3) Even after the engine is stopped, braking is possible for a limited time using the pressure inside the brake accumulator. 4) When the brake accumulator pressure goes down, the force releasing the parking brake is reduced and the parking brake is automatically applied by the force of the spring. If the machine is stopped for a certain time, the parking brake is automatically applied, and it can only be released by starting the engine. 5) In postures such as the bank cut posture or shoulder reach posture, when changing the posture of the work equipment, the lifter lock pin is removed and installed. When doing this, the accumulator is also used as the source of hydraulic power. 6) The brakes are the most important devices for ensuring safety, so charging always starts immediately after the engine is started. But particularly when starting in cold weather, if the accumulator is charged during the starting operation, there will be an excessive load on the hydraulic pump, and this will make it difficult to start the engine. To prevent this, an electromagnetic LS pressure release valve is installed in the accumulator pressure governor valve. This cancels the charging of the accumulator when the starting motor is cranking and makes it easier to start the engine.

GD555, 655, 675-3C


4. LS pressure regulator valve 1) To improve the response when the steering is operated suddenly and to ensure a quick response for the work equipment, a specified minimum flow of oil is discharged from the hydraulic pump, so an unload valve is installed to the control valve. 2) When the steering is operated, the steering LS pressure rises and the pump discharge pressure is increased. For this reason, the steering Pb pressure also rises, but the function of the priority valve sends the excess oil used for the steering to the control valve. When this happens, if the control valve is open, this excess oil flow is relieved by the unload valve and returns to the tank. This causes an energy loss, so when the steering brake is charged and the oil is not being used for the work equipment, a signal is sent to the unload valve. The control valve is set to on-load and shuts off the flow of oil back to the hydraulic tank to prevent loss of energy. 3) The internal shuttle valve transmits the higher of the steering brake charge LS pressure and the work equipment LS pressure to the pump to make it possible to carry out simultaneous operations. 4) The excess oil flow for the steering brake is sent to the control valve.

GD555, 655, 675-3C

HYDRAULIC SYSTEM

5. Control valve 1) The control valve is closed center type, so at neutral when the work equipment is not being used, the hydraulic oil returns from the unload valve to the hydraulic tank. The unload pressure 3.1 MPa {32 kg/cm2} when the engine is at low idle and 3.5 MPa {35 kg/ cm2} when it is at full throttle. 2) When the work equipment control valve lever is operated, the pressure at the valve inlet side is transmitted to the hydraulic pump as Pb. At the same time, the maximum pressure for the work equipment load passes through the LS line and is transmitted to the hydraulic pump, so the necessary oil flow is sent from the hydraulic pump. 3) At the hydraulic relief, the upper limit for the LS pressure is determined by the LS relief valve. The control valve is a closed center load sensing valve, and has a proportional flow and proportional dividing pressure compensation function. It also has a built-in unload valve, LS relief valve, a surge absorption valve. This gives it the following features. • The operating effort is light and the lever travel is short. • It is possible to adjust each work equipment to the optimum cylinder set speed. • The raise and lower speeds (cylinder extending and retracting speeds) are the same, so the height can be adjusted. • There is a wide fine control range. • A constant movement position can be obtained, regardless of the load. • The work equipment can be operated with small movements of the lever and fine control is easy. • Operations are certain even during simultaneous operations. • Simultaneous operations are possible even when there is lack of oil. • Other work equipment moves even when there is hydraulic relief. When used in combination with the CLSS hydraulic pump, it has the following features. • The work equipment speed is fixed, regardless of the engine speed. • The neutral loss is reduced. • The relief loss is reduced. • There is little problem of the engine stalling even during compound operations or when there is a large load.

10-207 (8)


HYDRAULIC TANK

HYDRAULIC TANK

1. 2. 3. 4. 5.

Filter Filter by-pass Oil filler Oil filler strainer Strainer

10-208 (4)

GD555, 655, 675-3C


SWIVEL JOINT

SWIVEL JOINT Serial No.: 50001 – 51000

1. 2. 3. 4. 5.

Plug Plate Cover Shaft Roter

GD555, 655, 675-3C

a. b. c. d.

Blade tilt cylinder head Blade tilt cylinder bottom Blade shift cylinder head Blade shift cylinder bottom

10-209 (4)


SWIVEL JOINT


1. 2. 3. 4. 5.

Plug Plate Cover Shaft Rotor

10-210 (4)

a. b. c. d.

Blade tilt cylinder head Blade tilt cylinder bottom Blade shift cylinder head Blade shift cylinder bottom

GD555, 655, 675-3C


PILOT CHECK VALVE

PILOT CHECK VALVE For blade lift (right), leaning, articulating, drawbar shift

1. 2. 3. 4. 5. A: B: C: D:

Piston Check valve Body Piston Check valve

From control valve From control valve To cylinder head To cylinder bottom

Operation When the hydraulic cylinder is extended, the control valve is operated and oil from the pump enters port A, opens check valve (5), and flows to port D. When pressure is generated, the oil from orifice a pushes up piston (1), then opens check valve (2), connects port C and port B, and flows to the drain port. Hunting occurs when check valve (2) opens and closes to compensate for changes in the pressure at the bottom end and head end, but even if the pressure at port A goes down, orifice a is provided, so there is a damper effect to prevent check valve (2) from closing immediately.

10-212 (4)

GD555, 655, 675-3C


PILOT CHECK VALVE

For blade lift (left) 1. 2. 3. 4. 5.

Check valve Plug Body Piston Relief valve

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

GD555, 655, 675-3C

10-213 (4)


PILOT CHECK VALVE

For ripper (GD555-3C) 1. Piston 2. Check valve

Operation When the control valve is operated to lower the ripper, pressure is generated at the bottom end of the ripper cylinder. This pressure passes through a throttle valve and pushes piston (1). This opens pilot check valve (2), and the oil in chamber C at the cylinder head returns to the tank. The ripper hold pressure is acting on the head end of the ripper cylinder. When it pushes open check valve (2), the oil in chamber C suddenly escapes to chamber A, and the pressure at the bottom drops. When this happens, if there is no throttle at the pilot valve, the check valve will always open and close according to the changes in the pressure at the bottom and head ends. This will cause ripper chattering. To prevent this, a throttle is installed at E which acts as a damper, so even if the pressure at the bottom end drops, the check valve will not close immediately.

10-214 (4)

GD555, 655, 675-3C


PILOT CHECK VALVE

For blade tilt, ripper (GD655, 675-3C) 1. 2. 3. 4. 5.

Check valve Piston Body Check valve Relief valve

The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. Operation When the lever is operated to extend the cylinder, oil from the pump enters chamber A1 and pushes piston (2) and check valve (4). It then passes through chamber B1 and flows to the chamber at the bottom end of the cylinder. The oil at the cylinder head flows back through chamber B2 and chamber A2 and returns to the tank. When the lever is operated to retract the cylinder, the oil from the pump enters chamber A2. As the pressure in chamber A2 rises, check valve (1) is pushed. This pushes open check valve (1), and the oil flows to the cylinder head form chamber B2. If shock causes abnormal pressure of over For blade tilt: 24.5 MPa {250 kg/cm2}, For ripper: 21.5 MPa {219 kg/cm2} in chamber B2, it pushes open relief valve (5) and oil flows to chamber B1 to relieve the shock.

GD555, 655, 675-3C

10-215 (4)


PILOT CHECK VALVE

For scarifier 1. 2. 3. 4. 5.

Check valve Piston Body Check valve Relief valve

A1:From control valve A2:From control valve B1:To cylinder head B2:To cylinder bottom

The check valve with safety valve prevents hydraulic drift of the cylinder and also protects the cylinder from abnormal pressure caused by external force. Operation Operating the lever to retract the cylinder, oil from the pump enters chamber A1 and pushes check valve (1). Oil then passes through chamber B1 and flows to the chamber at the head of the cylinder to push the cylinder piston. The oil at the bottom of the cylinder flows back through chamber B2 and chamber A2 and returns to the tank. Operating the lever to extend the cylinder, oil from the pump enters chamber A2 and flows through chamber B2 to the bottom of the cylinder. As pressure increases in chambers A2 and B2, pressure pushes the piston (4) and opens the check valve (1). The oil at the cylinder head flows from chamber B1 through the throttle of check valve (1). It then flows from chamber A1 back to the tank. If there is any shock to the work equipment during operations, and the pressure in chamber B1 rises to an abnormal pressure of 24.5 MPa {250 kg/cm2} or more, relief valve (5) is pushed open and the oil flows to chamber B2. This raises the work equipment and relieves the shock.

10-216 (4)

GD555, 655, 675-3C


BLADE ACCUMULATOR, FLOAT VALVE

BLADE ACCUMULATOR, FLOAT VALVE OUTLINE •

•

The blade accumulator prevents excessive load and pushing up by the blade in propulsion work on roads where there are many buried rocks. In this way, it improves the durability of the work equipment and blade, and reduces operator fatigue. The blade accumulator can also be used effectively in snow-clearing operations on compacted snow. It is possible to carry out operations following the ups and downs on the road surface, so the snow can be cleared smoothly.

The blade float can be used in clearing fresh snow. It allows only the weight of the work equipment to push against the snow, making it possible to carry out operations following the ups and downs on the road surface, allowing fresh snow to be cleared effectively at high speed, while increasing the safety of the operation.

FOR BLADE LIFT (LEFT)

1. 2. 3. 4. 5.

Body Piston Check valve Check valve Piston

GD555, 655, 675-3C

A B C D

: From main control valve : From main control valve : To cylinder head : To cylinder bottom

10-217 (4)



FOR BLADE LIFT (RIGHT)

1. 2. 3. 4. 5.

Body Check valve Piston Piston Check valve

10-218 (4)

A B C D

: From main control valve : From main control valve : To cylinder head : To cylinder bottom

GD555, 655, 675-3C



ACCUMLATOR For blade float 1. 2. 3. 4.

Valve assembly Top cover Cylinder Cylinder

Specifications Gas used: Nitrogen gas Amount of gas: 1,000 cc Gas charging pressure: 2.0 ± 0.1 MPa {20 ± 1.0 kg/cm2} (at 20 ± 5°C)

Function When oil pressure is applied to the blade cylinder, the pressure oil flows to the accumulator through the solenoid valve and the oil flows into cylinder (4). Thereby, nitrogen gas is compressed and piston mov es upper side. Cons equently, the shock imposed on the blade cylinder is reduced by the compressible amount of the nitrogen gas. When the oil pressure in the blade cylinder drops, the piston moves to lower side by the gas pressure in cylinder (3), and the oil in cylinder (4) sends to the blade cylinder until the oil pressure in the cylinder balances to that in blade cylinder circuit. The flow of oil in the accumulator hydraulic circuit is repeated smoothly to reduce the shock imposed on the blade.

GD555, 655, 675-3C

10-219 (4)


SHUT-OFF VALVE

SHUT-OFF VALVE Serial No.: 50001 – 51000

1. 2. 3. 4. 5.

Connector Filter Spring Spool Solenoid

Function When the engine is started, this valve temporarily stops the charging of the accumulator in the brake circuit. This reduces the load on the engine and makes it easier to start the engine. Specifications Max. pressure A: 20.6 MPa {210 kg/cm2} B: 15.7 MPa {160 kg/cm2} Max. flow: 20 l/min

GD555, 655, 675-3C

10-221 (4)


BLADE FLOAT DEVICE

BLADE FLOAT DEVICE

10-222 (4)

GD555, 655, 675-3C


1. 2. 3. 4. 5. 6.

BLADE FLOAT DEVICE

Blade float and accumulator switch Blade accumulator, float valve Blade lift cylinder Proximity switch Blade lift control valve Pilot check valve

Outline • When the lift lever is at N position, and the blade float and accumulator switch (1) is pushed to FLOAT position, blade accumulator, float valve (2) is actuated, and the bottom and head ends of the blade lift cylinder (3) are connected to the drain circuit. This sets the blade in a float condition. • When the blade float and accumulator switch (1) is pushed to FLOAT position, and the blade lift lever is operated to the RAISE or LOWER position, proximity switch (4) turns the blade float and accumulator switch (1), and the blade returns to normal RAISE or LOWER condition, and this condition maintained. If the blade lift lever is returned to the N position, the blade is placed in floating condition. a If the blade and accumulator switch (1) is pushed to FLOAT position with the blade raised, the blade will suddenly drop.

GD555, 655, 675-3C

10-223 (4)


CIRCLE ROTATION MOTOR


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Output shaft Flange Shaft seal Taper roller bearing for heavy loads Main drive O-ring Giroller Valve drive Wear compensation mechanism valve PF1/2 rolling port Check valve Valve plate

10-224 (4)

GD555, 655, 675-3C



Outline The circle rotation motor is a small, compact lowspeed torque motor and the giroller carries out planetary motion. Therefore, it can provide the same torque as other types of hydraulic motors using a mechanical reduction gear when the reduction ratio is 1:6. A hydraulic balance type disc valve is used for the valve mechanism. A high-precision giroller is used, so leakage is small. The valve parts are assembled independently from the power transmission mechanism, so accurate valve timing can always be obtained, providing stable performance over long periods. A taper roller bearing for heavy loads is assembled to the output shaft, so it can withstand high radial loads and high thrust loads. Operation The high-pressure oil flowing into the motor passes through disc valve (1), enters giroller (2), and the star of giroller (2) moves in a planetary motion. Of this planetary motion, only the rotation is taken off by main drive (3) to rotate output shaft (4). When this happens, disc valve (1) is driven by valve drive (4). The relationship between the positions of the 12 ports of disc valve (1) and the 7 ports (5) of the valve plate changes, and the position of the hydraulic oil flowing to giroller (2) changes in turn.

GD555, 655, 675-3C

10-225 (4)


HYDRAULIC CYLINDER

HYDRAULIC CYLINDER GD555-3C

Unit: mm No.

Check item


1

Clearance between piston rod and bushing

10-226 (4)

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Steering

35

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Blade lift

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Blade side shift

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Drawbar shift

45

–0.025 –0.087

+0.152 +0.007

0.032 to 0.239

0.539

Leaning

35

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Articulate

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Blade tilt

40

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Scarifier

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Ripper

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Replace bushing

GD555, 655, 675-3C


HYDRAULIC CYLINDER

Unit: mm No.

Check item


2

3

Clearance between piston rod support and bushing

Clearance between cylinder bottom (yoke, support ball joint, support) and bushing

GD555, 655, 675-3C

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Steering

55

–0.06 –0.09

+0.02 +0.02

0.06 to 0.11

1.0

Blade lift

80

–0.05 –0.15

+0.1 +0.1

0.05 to 0.25

1.0

Blade side shift

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Drawbar shift

80

–0.05 –0.15

+0.1 +0.1

0.05 to 0.25

1.0

Leaning

45

–0.025 –0.064

+0.142 +0.080

0.104 to 0.206

1.0

Articulate

50

–0.025 –0.064

+0.142 +0.080

0.104 to 0.206

1.0

Blade tilt

40

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Scarifier

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Ripper

55

–0.030 –0.076

+0.174 +0.100

0.13 to 0.25

1.0

Steering

35

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Blade lift

45

–0.080 –0.142

+0.062 +0.062

0.080 to 0.204

1.0

Blade side shift

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Drawbar shift

80

–0.05 –0.15

+0.10 +0.10

0.05 to 0.25

1.0

Leaning

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Articulate

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Blade tilt

40

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Scarifier

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Ripper

60

–0.100 –0.174

+0.174 +0.100

0.200 to 0.348

1.0

Replace bushing

10-227 (4)


HYDRAULIC CYLINDER

Unit: mm No.

4

5

Check item

Piston nut tightening torque

Cylinder head tightening torque

10-228 (4)

Criteria

Steering

245 ± 24.5 Nm {25 ± 2.5 kgm} (width across flats: 30)

Blade lift


Blade side shift


Drawbar shift


Leaning


Remedy

Articulate

1420 ± 142 Nm {145 ± 14.5 kgm} (width across flats: 55)

Blade tilt


Scarifier


Ripper

1080 ± 108 Nm {110 ± 11 kgm} (width across flats: 50)

Steering

392 ± 39.2 Nm {40 ± 4 kgm}

Blade lift

588 ± 58.8 Nm {60 ± 6 kgm}

Blade side shift

588 ± 58.8 Nm {60 ± 6 kgm}

Drawbar shift

588 ± 58.8 Nm {60 ± 6 kgm}

Leaning

539 ± 53.9 Nm {55 ± 5.5 kgm}

Articulate

677 ± 67.7 Nm {69 ± 6.9 kgm}

Blade tilt

588 ± 58.8 Nm {60 ± 6 kgm}

Scarifier

588 ± 58.8 Nm {60 ± 6 kgm}

Ripper

785 ± 78.5 Nm {80 ± 8 kgm}

Retighten

GD555, 655, 675-3C


HYDRAULIC CYLINDER

GD655, 675-3C

Unit: mm No.

Check item


1

Clearance between piston rod and bushing

GD555, 655, 675-3C

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Steering

35

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Blade lift

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Blade side shift

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Drawbar shift

45

–0.025 –0.087

+0.152 +0.007

0.032 to 0.239

0.539

Leaning

40

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Articulate

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Blade tilt

40

–0.025 –0.087

+0.132 +0.006

0.031 to 0.219

0.519

Scarifier

50

–0.025 –0.087

+0.164 +0.007

0.032 to 0.251

0.551

Ripper

55

–0.030 –0.104

+0.163 +0.006

0.036 to 0.267

0.567

Replace bushing

10-229 (4)


HYDRAULIC CYLINDER

Unit: mm No.

Check item


2

3

Clearance between piston rod support and bushing

Clearance between cylinder bottom (yoke, support ball joint, support) and bushing

10-230 (4)

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

Steering

55

–0.06 –0.09

+0.02 +0.02

0.06 to 0.11

1.0

Blade lift

80

–0.05 –0.15

+0.1 +0.1

0.05 to 0.25

1.0

Blade side shift

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Drawbar shift

80

–0.05 –0.15

+0.1 +0.1

0.05 to 0.25

1.0

Leaning

50

–0.025 –0.064

+0.142 +0.080

0.104 to 0.206

1.0

Articulate

50

–0.025 –0.064

+0.142 +0.080

0.104 to 0.206

1.0

Blade tilt

40

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Scarifier

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Ripper

60

–0.030 –0.076

+0.174 +0.100

0.13 to 0.25

1.0

Steering

35

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Blade lift

45

–0.080 –0.142

+0.062 +0.062

0.080 to 0.204

1.0

Blade side shift

40

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Drawbar shift

80

–0.05 –0.15

+0.10 +0.10

0.05 to 0.25

1.0

Leaning

45

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Articulate

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Blade tilt

40

–0.025 –0.064

–0.012 –0.012

0.013 to 0.064

1.0

Scarifier

50

–0.025 –0.064

+0.142 +0.080

0.105 to 0.206

1.0

Ripper

60

–0.100 –0.174

+0.174 +0.100

0.200 to 0.348

1.0

Replace bushing

GD555, 655, 675-3C


HYDRAULIC CYLINDER

Unit: mm No.

4

Check item

Piston nut tightening torque

Steering


Blade lift


Blade side shift


Drawbar shift


Leaning


Articulate

1420 ± 142 Nm {145 ± 14.5 kgm} (width across flats: 55)

Blade tilt


Scarifier

785 ± 78.5 Nm {80 ± 8 kgm} (width across flats: 46)

Ripper

5

Cylinder head tightening torque

GD555, 655, 675-3C

Criteria

1770 ± 77 Nm {180 ± 18 kgm} (width across flats: 60)

Steering

392 ± 39.2 Nm {40 ± 4 kgm}

Blade lift

588 ± 58.8 Nm {60 ± 6 kgm}

Blade side shift

588 ± 58.8 Nm {60 ± 6 kgm}

Drawbar shift

588 ± 58.8 Nm {60 ± 6 kgm}

Leaning

588 ± 58.8 Nm {60 ± 6 kgm}

Articulate

677 ± 67.7 Nm {69 ± 6.9 kgm}

Blade tilt

588 ± 58.8 Nm {60 ± 6 kgm}

Scarifier

677 ± 67.7 Nm {69 ± 6.9 kgm}

Ripper

981 ± 98.1 Nm {100 ± 10 kgm}

Remedy

Retighten

10-231 (4)


CIRCLE, DRAWBAR

CIRCLE, DRAWBAR

10-232 (4)

GD555, 655, 675-3C


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Circle Drawbar Blade lift cylinder Drawbar side shift cylinder Shim Ball joint Lifter bracket (Upper) Shim Lifter bracket (Lower) Yoke Pin Bushing Adjustment bolt Shim Guide Bolt Shim Guide Shim Guide

CIRCLE, DRAWBAR

Outline • The drawbar is an important piece of equipment which supports the circle and blade. If ball joint (6) is worn, use shim (5) to adjust the clearance at the joint so that there is no excessive play. • When adjusting the clearance at the contact portions of guides (15), (18), and (20), adjust with shims (14), (17), and (19), and adjustment bolt (13). • There are two cylinders installed in the lifter for moving the blade device. Brackets (7) and (9) are installed by the guide, which is welded to the main frame. They can be revolved by revolving the guide by extracting a pin (11) controlled from the operator's seat. There are four insertion holes altogether for the pin stopping revolution. Holes b, c and d, e are used for the blade to make a bank cut to left or right. At other times, holes a are used. • These a get used much more than other holes and bushing (12) is used in it to make the clearance between the pin and the hole at a minimum. (This clearance amplifies the up and down movement of the blade.) Also, the clearance between the bracket and the guide welded to the frame can be adjusted with shims (8). Unit: mm

No.

21

22

Check item

Wear of drawbar ball joint end

Clearance between yoke and bushing

GD555 GD655 GD675

23

Axial clearance of yoke

24

Clearance between circle and drawbar

GD555, 655, 675-3C


Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

150

–0.050 –0.100

+0.100 +0.100

0.050 to 0.200

—

75

–0.030 –0.076

+0.174 +0.100

0.130 to 0.250

0.6

75

–0.030 –0.076

+0.220 +0.160

0.190 to 0.296

0.6

Standard clearance

Clearance limit

0.8 to 1.3

2.0

0 to 3.0

1.0 to 2.0

Adjust or replace

Replace bushing Replace yoke or bushing Adjust or replace

10-233 (4)


LIFTER BRACKET LOCK PIN

LIFTER BRACKET LOCK PIN

The lifter bracket is fixed by bank pin (3). When setting in the bank cutting position, operate control lever. This uses hydraulic oil to push piston (4). The pin can be removed and the bracket can then be rotated.

10-234 (4)

1. 2. 3. 4. 5. 6.

Parking, bank control valve Lifter Bank pin Piston Bushing Case

GD555, 655, 675-3C


BLADE

BLADE

1. Adjuster 2. Blade tilt cylinder

10-236 (4)

3. Drawbar side-shift cylinder 4. Blade side-shift cylinder GD555, 655, 675-3C


BLADE

Function • Side edge installed to the blade is designed so that it can be used twice by turning it upside down and moving it to the other (left or right) side. • A power tilt device is installed to adjust the cutting angle of the blade. Adjustment can be made freely between 32° and 81° using a single lever. The guide acts as a bushing for the sliding parts when shifting the blade to the side. If the clearance from the sliding parts is too large and the finishing accuracy cannot be obtained, adjust the shims or replace the guide.

Unit: mm No.

Check item

Repair limit

From blade holder: 32




Height

368

364

Thickness

25

21

Height

8

5

Width of groove

25

33

Wear of cutting edge

6

Wear of side edge

7a

Wear of blade rail

8a 8b

Wear of blade rail guide

GD555, 655, 675-3C

Remedy

Standard size

5

7b

Criteria

Replace

10-237 (4)


CIRCLE ROTATION GEAR


1. 2. 3. 4. 5. 6.

Drain plug Worm wheel Oil filler plug Joint Shear pin Worm gear

10-238 (4)

GD555, 655, 675-3C



Unit: mm No.

7

Check item

Clearance between worm wheel shaft and bushing

8

Clearance between worm wheel shaft and bushing

9

Backlash between worm and worm wheel

10

Cleaarance between pinion gear and wear plate

11

Pinion gear wear

12

Wormshaft bearing preload

GD555, 655, 675-3C

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

75

+0.291 +0.077

+0.057 +0.010

0.281 to 0.02

0.4

75

+0.035 +0.005

+0.057 +0.010

0.052 to 0.025

0.4

Std. Size

Standard clearance

Clearance limit

0.3 to 0.4

2.0

0.1 to 0.5

0.6

Standard size

Repair limit

25

20

Starting torque: 2.9 to 7.8 Nm (0.3 to 0.8 kgm) when worm wheel is not meshed

Replace bushing

Replace Adjust Replace Adjust

10-239 (4)



With slip clutch

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Floating seal Shaft Case Worm wheel Plate Disc Spring Cover Shim Pinion gear Drain plug Worm gear shaft Oil motor

10-240 (4)

Outline • The circle rotation gear is driven by an oil motor connected to worm gear shaft (12). • Pinion gear shaft (2) has a clutch mechanism, and if an abnormal rotating force is transmitted from the blade, disc (6) slips to prevent breakage of the blade. • The clutch pressure of this clutch mechanism is adjusted by the thickness of shim (9).

GD555, 655, 675-3C


SCARIFIER

SCARIFIER

10-242 (4)

GD555, 655, 675-3C


1. 2. 3. 4.

SCARIFIER

Lift arm Scarifier cylinder Scarifier body Wedge Unit: mm

No.

Check item

5

Tooth wear

6

Point tooth wear

GD555, 655, 675-3C

Criteria

Remedy

Standard size

Repair limit

450

330

450

407

Replace tooth Replace point

10-243 (4)


RIPPER

RIPPER GD555-3C

1. Bracket 2. Ripper cylinder 3. Shank

Outline • Ripper lifting height and digging depth can be controlled with ripper cylinder (2). Since the point tips cut into the ground under the load of the ripper’s heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier. Unit: mm

No.

4

Check item

Clearance between pin and bushing

Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

50

–0.025 –0.050

+0.142 +0.080

0.105 to 0.192

0.5

Std. size

5


60

–0.025 –0.055

+0.046 +0.046

0.025 to 0.101

0.5

6

Clearance between trunnion and bushing

60

–0.100 –0.174

+0.174 +0.100

0.200 to 0.348

0.5

7

Point wear

10-244 (4)

Standard size

Repair limit

198

123

Replace

GD555, 655, 675-3C


RIPPER

GD655-3C, GD675-3C

1. 2. 3. 4.

Bracket Rod Shank Ripper cylinder

Outline • Ripper lifting height and digging depth can be controlled with ripper cylinder (4). Since the point tips cut into the ground under the load of the ripper’s heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier. Unit: mm

No.

4

Check item


Criteria Tolerance

Remedy

Shaft

Hole

Standard clearance

50

–0.025 –0.050

+0.142 +0.080

0.105 to 0.292

0.5

Std. size

Clearance limit

5


60

–0.030 –0.076

+0.054 +0.054

0.03 to 0.13

0.5

6

Clearance between trunnion and bushing

60

–0.100 –0.174

+0.174 +0.100

0.200 to 0.348

0.5

7

Point wear

GD555, 655, 675-3C

Standard size

Repair limit

290

150

Replace

10-245 (4)


MAIN FRAME

MAIN FRAME

1. 2. 3. 4. 5.

Articulate cylinder Front frame Rear frame Upper center pin Lower center pin

GD555, 655, 675-3C

10-247 (4)


AIR CONDITIONER (IF EQUIPPED)

AIR CONDITIONER (IF EQUIPPED) AIR CONDITIONER PIPING Serial No.: 50001 – 51000

1. Condenser 2. Air conditioner compressor 3. Receiver-dryer

10-248 (4)

GD555, 655, 675-3C



4. Air conditioner unit 4a. Hot water heater 4b. Evaporator 4c. Blower unit

GD555, 655, 675-3C

10-249 (4)




1. Condenser 2. Air conditioner compressor 3. Receiver-dryer

10-250 (4)

GD555, 655, 675-3C



4. Air conditioner unit 4a. Hot water heater 4b. Evaporator 4c. Blower unit

GD555, 655, 675-3C

10-251 (4)


ENGINE STARTING CIRCUIT

ENGINE STARTING CIRCUIT Serial No.: 50001 – 51000

Function • To ensure safety while starting the engine, a neutral safety circuit is used. This circuit makes it impossible to start the engine, if the gearshift lever is not at the P (PARK) position. • After starting the engine, pressurized oil is stored in the brake circuit accumulator. However, this process is temporarily canceled while starting the engine to reduce the load on the engine, making it easier to start the engine.

10-252 (4)

Operation • When the starting switch is turned to the ON position, electricity flows from the switch BR terminal to the battery relay. The battery relay points now close. In addition, electricity flows from the ACC terminal of the switch to the holding coil of the fuel shut-off solenoid to supply fuel. • When the gearshift lever is at the P (PARK) position, electricity flows from gearshift lever terminal 6 to the coil of the neutral relay. Electricity now flows through contacts 3 and 5 of the neutral relay. • If the gearshift lever is not in the P (PARK) position, the flow of electricity from the gearshift lever terminal 6 is stopped. Thus, no electricity flows to the neutral relay and the engine starting circuit is not energized.

GD555, 655, 675-3C


•

•

•


When the starting switch is turned to the START position, electricity flows from terminal C at the switch to terminals 3 and 5 of the starter relay and then to ground, completing the circuit. The engine now starts. Electrical current also flows from terminal C of the switch to the starter solenoid. The storage of pressurized oil in the accumulator is temporarily canceled. After the engine starts, electricity flows from the neutral relay to the fuel shut-off relay and closes the fuel shut-off relay contact. Electrical current now flows to the pull-in coil of the fuel shut-off solenoid. The system is now set to the maximum fuel supply condition. When the starting switch is returned to the ON position, the flow of electric current from terminal C of the switch is stopped, the starting motor relay points open, and the flow of electric current to the starting motor is blocked. At the same time, the fuel shut-off relay contacts open and the fuel shut-off solenoid returns to the normal fuel supply condition. In addition, the power supply is shut off from the starter solenoid. Thus, the system returns to the normal condition and the hydraulic pump starts and pressure is stored in the accumulator.

GD555, 655, 675-3C

10-253 (4)




Function • The neutral safety circuit is employed to secure safety when the engine is started. This circuit allows the engine to start only when the gearshift lever is in the P (Parking) position. • When the engine is started, storing pressure in the accumulator of the brake circuit is canceled temporarily to reduce the load of the hydraulic pump on the engine for the ease of starting of the engine. In addition, the engine start auxiliary switch is installed to reduce the load on the engine and stabilize the engine rotation when the engine is started at low temperature.

10-254 (4)

Operation • If the starting switch is turned from the OFF position to the START position, a current flows from starting switch terminal BR to the battery relay to "close" the contacts of the battery relay. • The current flows in the holding coil of the solenoid to supply fuel. It also flows in the fuel shutoff timer to "close" the contacts of the fuel shutoff relay for about 3 seconds. Then, the current also flows in the pull-in coil of the fuel shut-off solenoid to supply the fuel at the maximum rate so that the engine will be started easily. • If the gearshift lever is in the P (Parking) position, a current flows from gearshift lever terminal 6 to the neutral relay coil to connect contacts 1 and 2 of the neutral relay. While the gearshift lever is not in the P (Parking) position, the current does not flow from gearshift lever terminal 6. Accordingly, any current does not flow in the neutral relay coil and the starting circuit is not formed. • A current flows from starting switch terminal C through neutral relay terminals 1 and 2 to the starting motor to start the engine. • At this time, another current flows from starting switch terminal C to the engine startup solenoid to temporarily cancel storing pressure in the brake accumulator so that the load on the engine will be reduced and the engine will be started easily. GD555, 655, 675-3C


•

•

•


After the engine is started, if the starting switch is turned to the ON position, the current flowing from starting switch terminal C is turned OFF, and the current flowing through neutral relay terminals 1 and 2 to the starting motor is turned off consequently. The current flowing in the engine startup solenoid is turned OFF, the solenoid is returned to the normal state, and the hydraulic pump starts storing pressure in the accumulator. A current keeps flowing from starting switch terminal ACC to the holding coil of the fuel shut-off solenoid. The fuel shut-off timer turns OFF the current flowing in the fuel shut-off relay coil, and then any current does not flow in the pull-in coil of the fuel shut-off solenoid. Accordingly, the fuel supplied normally. If the engine start auxiliary switch is held even after the engine is started in when the temperature is low, a current flows from neutral relay terminal 3 through terminal 4 to the engine startup solenoid to reduce the load of the hydraulic pump on the engine while the switch is held.

GD555, 655, 675-3C

10-255 (4)


ENGINE STOP CIRCUIT

ENGINE STOP CIRCUIT Serial No.: 50001 – 51000

Function • Turning the starting switch to the OFF position stops the current flow from terminal ACC of the switch to the fuel shut-off solenoid. The fuel shutoff solenoid now stops the fuel flow to the engine, stopping the engine.

10-256 (4)

GD555, 655, 675-3C


ENGINE STOP CIRCUIT


Function • Turning the starting switch to the OFF position stops the current flow from terminal ACC of the switch to the fuel shut-off solenoid. The fuel shutoff solenoid now stops the fuel flow to the engine, stopping the engine.

GD555, 655, 675-3C

10-257 (4)


PREHEAT CIRCUIT

PREHEAT CIRCUIT Serial No.: 50001 – 51000

Operation • Turning the starting switch to the PREHEAT position, electricity flows from switch terminal BR to the battery relay to ground. The battery relay contacts close. In addition, current now flows from terminal R1 of the switch to the heater relay to ground, closing the heater relay contacts. As a result, current flows from the battery to the battery relay to the heater relay to the preheater to ground. The circuit is complete and the engine is heated. • Simultaneously, current now flows from terminal R1 of the switch to terminal 3 of the timer. The timer is now actuated. Current now flows from terminal 1 of the timer to the preheating pilot lamp to ground for a fixed period of time. The circuit is now complete and the preheating pilot lamp lights up.

10-258 (4)

GD555, 655, 675-3C


PREHEAT CIRCUIT


Operation • If the starting switch is set in the PREHEAT position, a current flows from starting switch terminal BR through the battery relay to the ground, and the battery relay contacts are "closed". At this time, a current flows from starting switch terminal R1 through the heater relay to the ground, and the heater relay contacts are "closed". As a result, the circuit from the battery through the battery relay, heater relay, and preheater to the ground is formed, and the engine is preheated. • At this time, another current flows from starting switch terminal R1 to timer terminal 3 to turn the timer ON. Then, a current flows through the fuse, preheater pilot lamp, and timer to the ground and the pilot lamp lights up for a certain period (about 20 seconds).

GD555, 655, 675-3C

10-259 (4)


AUTOMATIC SHIFT CONTROL SYSTEM

AUTOMATIC SHIFT CONTROL SYSTEM SYSTEM DIAGRAM

Outline • The automatic shift control system receives the shift position signal from the gearshift lever, the transmission speed signal, and signals from other switches and sensors. The transmission controller automatically shifts the transmission to the most suitable speed range. In addition to shift control the transmission controller also drives and controls the torque converter lock-up solenoid.

10-260 (4)

GD555, 655, 675-3C


TRANSMISSION CONTROLLER


Outline • This transmission controller controls the system using a built-in computer, which has the following functions: • Upshifts and downshifts in relation to the pedal angle. • Drives and controls the torque converter lock-up solenoid. • Installed separately from the gearshift lever.

ECMV Speed range F1

Clutches used Low

F8

3rd

4th

Q Q

Q

Q

Q Q

Q

Q

Q Q

Q

R1

Q

R2

Q

R3

Q

R4

Q

GD555, 655, 675-3C

2nd

Q

Q

F6 F7

1st Q

Q

F4 F5

R

Q

F2 F3

High

Q Q Q Q

10-261 (4)



GEARSHIFT LEVER POSITION Gearshift lever position and automatic gearshifting range • The gearshifting range for each gearshift lever position is as shown in the chart below. • As the transmission mode selector switch is operated, the gearshift pattern and lock-up/torque converter pattern changes. • When the transmission mode switch is in in “MODE 1”, the gear is shifted manually at each lever position. • When the transmission mode switch is in in “MODE 2”, the gear is shifted manually at the lever positions of F1 – F4 and R1 – R4 but shifted automatically at the lever positions of F5 – F8 according to the travel speed. (Automatic gearshifting) MODE 1 Speed Range

LEVER POSITION

N

N

A

F1

F1

F2

F3

F4

F5

F6

F7

F8

R1

R2

R3

R4

B

F2

B

F3

B

F4

B

F5

B

F6

B

F7

B

F8

B

R1

B

R2

B

R3

A

R4

A

MODE 2 Speed Range

LEVER POSITION

N

N

A

F1

F1

F2

F3

F4

F5

F6

F7

F8

R1

R2

R3

R4

A

F2 F3

A A

F4

A

F5

A

C

F6

A

C

C

F7

A

C

C

C

F8

A

C

C

C

R1 R2 R3 R4

C A A A A

A = Does not lockup B = Locks up C = Locks up automatically

10-262 (4)

GD555, 655, 675-3C



Gearshifting diagram • Gearshifting range • As the transmission mode selector switch is operated, the gearshift pattern changes.

GD555, 655, 675-3C

10-263 (4)



OVERRUN PREVENTION FUNCTION Automatic gearshift wiring diagram • Transmission mode switch: Mode 2 • Lever position: F5 – F8

•

When shifting gears suddenly, the transmission may enter a speed range that does not match the position of the lever. This action prevents the engine from overrunning. When this situation occurs, a short warning sound is given to warn the operator. Reducing the machine’s travel speed automatically shifts the transmission to the position selected by the lever.

Ultra low-speed travel control • When the gearshift lever is at F1, the transmission is in the torque converter mode, the accelerator pedal is not depressed, and if the travel speed is less than 1.8 km/h (1.1 mph), the transmission enters the ultra low-speed travel control mode and maintains the travel speed at 1 km/h. VHP specification machine • With the VHP specification machine, switching between the standard output and high output of the engine is possible, as shown in the diagram below, by turning the lock-up switch ON/OFF. Lock-up switch OFF F1 F2

Standard output

ON

Standard output

F3 F4 F5 F6

High output

High output

F7 F8

10-264 (4)

GD555, 655, 675-3C


MONITOR

MONITOR MONITOR PANEL

1. 2. 3. 4. 5. 6. 7. 8. 9.

Engine water temperature gauge Turn signal pilot lamp Speedometer Turn signal pilot lamp Fuel gauge Message center Engine oil pressure caution lamp Battery charge caution lamp Electric circuit monitor of transmission system caution lamp 10. Brake oil pressure caution lamp 11. Torque converter oil temperature caution lamp 12. Lift arm lock pilot lamp

GD555, 655, 675-3C

13. Differential oil temperature caution lamp (if equipped) 14. Differential control pilot lamp (if equipped) 15. AWD pilot lamp (if equipped) 16. Working pilot lamp (if equipped) 17. Blade accumulator pilot lamp (if equipped) 18. Preheating pilot lamp 19. Blade float pilot lamp (if equipped) 20. Head lamp beam pilot lamp 21. Parking brake pilot lamp 22. Torque converter oil temperature gauge (if equipped) 23. Articulate meter

10-265 (4)


MONITOR

MONITOR ITEMS DISPLAY Category

Symbol

Item indicated

Indicated range

Differential oil temperature

More than 120° C

Torque converter oil temperature

More than 110° C

Brake oil pressure

Max. 4.17 MPa {42.5 kg/cm2} Off when normal, lights up when problem detected

Caution

Pilot

10-266 (4)

Description

Monitor transmission electrical circuit

Off when normal, lights up when problem detected

Battery charge

When charge is defective

Engine oil pressure

Max. 82 kPa {0.837 kg/cm2}

Turn signal indicator

When operated

Parking brake

When operated

Head lamp beam

When operated

Blade float

When operated

Lights up when blade accumulator/float switch is at FLOAT

Engine preheating

When electricity flows in the preheating circuit

While starting, lights up for approx. 20 seconds when the switch is at HEAT

Lights up when operated

GD555, 655, 675-3C


Category

Symbol

Pilot

Item indicated

MONITOR

Indicated range

Blade accumulator

When operated

Working lamp

When operated

AWD

When operated

Differential control

When operated

Lift arm lock

When cancelled

Description Lights up when blade accumulator/float switch is at ACCUMULATOR

Lights up when operated

Lights up when not locked

—

Engine water temperature

• Displays while starting switch is ON • Indicator shows engine water temperature

—

Articulate

• Displays while starting switch is ON • Indicator shows angle

—

Fuel

• Displays while starting switch is ON

Torque converter oil temperature

• Displays while starting switch is ON • Indicator shows torque converter oil temperature

Gauges

—

Speedometer

—

Speedometer

• Displays while starting switch is ON • Indicator shows vehicle speed

Message center

—

Message center

Digital display: displays speed range, error code, travel speed

GD555, 655, 675-3C

10-267 (4)


SENSORS

SENSORS Engine water temperature sensor Torque converter oil temperature sensor (for monitor panel)

Serial No.: 50001 – 51000

1. Connector 2. Sensor Temperature (°C)

50 ± 0.2

60 ± 0.2

80 ± 0.2

100 ± 0.3

106 ± 0.3

120 ± 0.3

Resistance (z)

80 ± 10

56.3 ± 5

29.5 ± 2.5

16.5 ± 0.9

14.3 ± 0.5

10 ± 0.3

Function • The engine water temperature sensor is installed to the engine cylinder block. As the engine temperature changes, so does the sensor’s resistance. The gauge on the monitor panel moves to indicate the engine temperature. • The torque converter oil temperature sensor is installed to the torque converter hydraulic piping. The sensor sends a signal to the monitor panel. If the value is above the set value, the warning lamp lights.

10-268 (4)

GD555, 655, 675-3C


SENSORS


1. Connector 2. Plug 3. Thermistor Temperature (°C)

50 ± 0.2

60 ± 0.2

80 ± 0.2

100 ± 0.3

106 ± 0.3

120 ± 0.3

Resistance (z)

80 ± 10

56.3 ± 5

29.5 ± 2.5

16.5 ± 0.9

14.3 ± 0.5

10 ± 0.3

Function • The engine water temperature sensor is installed to the engine cylinder block. As the engine temperature changes, so does the sensor’s resistance. The gauge on the monitor panel moves to indicate the engine temperature. • The torque converter oil temperature sensor is installed to the torque converter outlet port on the transmission. If it senses the torque converter outlet oil temperature, its resistance changes. The resistance is converted into temperature and displayed on the monitor panel. Brake oil pressure switch

1. Pressure sensor 2. Cable 3. Connector

Function • This electronic switch uses a semiconductor. When the brake oil pressure (accumulator pressure) drops below a specified value, the switch turns ON. This action causes the brake oil pressure lamp to light up and warn of a problem.

GD555, 655, 675-3C

10-269 (4)


SENSORS

Transmission speed sensor

1. 2. 3. 4.

Sensor Locknut Wiring harness Connector

Function • Two transmission-speed sensors are screwed into the transmission case: one sensor detects transmission input shaft speed and the other sensor detects output shaft speed. • Gears are installed to the transmission input shaft and output shaft. When the tip of a gear tooth passes the sensor, an electrical pulse is generated, which is detected by the sensor. The speed is calculated by the transmission controller. This information controls the transmission.

Differential oil temperature sensor

1. Sensor 2. Wiring harness 3. Connector

10-270 (4)

Function • The differential oil temperature sensor is a bimetal type. It detects the temperature of the oil in the differential case. If the oil temperature exceeds 120°C, the switch turns ON. This signal is sent to the transmission controller and is also used to control the transmission.

GD555, 655, 675-3C


SENSORS

Hydraulic oil temperature sensor Transmission oil temperature sensor Torque converter oil temperature sensor (for transmission controller)

1. 2. 3. 4.

Thermistor Plug Wiring harness Connector

Function • The hydraulic oil sensor, transmission oil temperature sensor, and torque converter oil temperature sensor are installed at the hydraulic tank. These sensors use a thermistor to detect the temperature. The sensors connect to the transmission controller and used to control the transmission.

Articulation sensor

1. Lever

GD555, 655, 675-3C

Function • The articulation sensor is installed to the center of the frame. This sensor uses a variable resistor. The resistor’s resistance varies according to lever movement. The amount of resistance determines the angle displayed on the gauge, which is located on the monitor panel.

10-271 (4)


SENSORS

Fuel level gauge sensor

Serial No.: 50001 – 51000

1. 2. 3. 4.

Connector Variable resistor Gear Float

10-272 (4)

Function • The fuel gauge is installed on the side of the fuel tank. The float moves up and down, according to the fuel level. Float movement is sent through a gear and adjusts a variable resistor’s resistance. The voltage signal is adjusted according to the resistance and then transmitted to the fuel level display. Thus, the display reflects the fuel level within the fuel tank.

GD555, 655, 675-3C


SENSORS


Float Arm Variable resistor Connector

Function • The fuel gauge sensor is installed to the rear side of the fuel tank and its float moves up and down according to the fuel level in the tank. The float moves the variable resistor and changes its resistance through the arm. The change of the resistance is converted into a change of voltage is transmitted to the fuel level gauge, then the fuel level gauge pointer indicates the fuel level in the fuel tank.

GD555, 655, 675-3C

10-273

1. 2. 3. 4.

(4)


SENSORS

ACCELERATOR PEDAL POTENTIOMETER

1. 2. 3. 4. 5. 6. 7.

Connector Case Shaft Element Bearing Contact Mold

10-274 (4)

Function • This sensor is installed to the accelerator pedal. The sensor detects the pedal angle when depressing the pedal. • Inside the potentiometer, the pedal angle is converted into a voltage signal. A variable resistor adjusts the 5 volt source signal as the pedal angle changes. The adjusted voltage signal is now sent to the transmission controller.

GD555, 655, 675-3C

20 TESTING AND ADJUSTING STANDARD VALUE TABLE ............................................................................................................................ 20-2 STANDARD VALUE TABLE FOR ENGINE.............................................................................................. 20-2 STANDARD VALUE TABLE FOR CHASSIS............................................................................................ 20-6 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................... 20-13 TESTING AND ADJUSTING ...................................................................................................................... 20-101 TROUBLESHOOTING ................................................................................................................................ 20-201

a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims.

k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving.

k When working with other workers, always use signals and do not let unauthorized people near the machine. k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. k Be careful not to get caught in the fan, fan belt or other rotating parts.

GD555, 655, 675-3C

20-1 (4)

TESTING AND ADJUSTING

STANDARD VALUE TABLE

STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE Machine model

GD555-3C

Serial No.

50001 – 51000

Engine Item

Measurement condition

Engine speed

High idle Low idle Rated speed

Exhaust temperature (turbine inlet temp.)

All speed (intake air temp. 20° C)

Intake resistance

At rated output

Exhaust gas color

Sudden acceleration High idle

Valve clearance (cold)

Intake valve Exhaust valve

Blowby pressure (SAE 15W-40 oil)

Unit

Standard machine

VHP specification machine

SA6D102E-1

SA6D102E-1

Standard value

Permissible value

Standard value

Permissible value

rpm

2,200 ± 50 800 ± 50 2,000

2,200 ± 50 800 ± 50 2,000

2,200 ± 50 800 ± 50 2,000

2,200 ± 50 800 ± 50 2,000

°C

—

—

385 to 485

—

kPa {mm Hg}

—

—

130 to 150 {975 to 1,125}

—

Bosch index

— —

— —

Max. 5.5 Max. 1.0

Max. 6.5 Max. 2.0

mm

0.25 0.51

— —

0.25 0.51

— —

kPa {mmH2O}

0.65 {66}

3.3 {337}

0.65 {66}

3.3 {337}

MPa {kg/cm2}

0.4 {4.1}

Max. 0.27 {2.8}

0.4 {4.1}

Max. 0.27 {2.8}

0.19 {1.9}

Max. 0.07 {0.7}

0.19 {1.9}

Max. 0.07 {0.7}

Max. 127

Max. 127

Max. 127

Max. 127

—

—

12.5 to 14.5

—

12 to 13

Max. 11 or Min. 14

12 to 13

Max. 11 or Min.14

14 to 16

Max. 13 or Min. 17

14 to 16

Max. 13 or Min. 17

At rated output Coolant temperature: Operating range Coolant temperature: Operating range

Oil pressure (SAE 15W-40 oil)

At rated output At low idle

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

Before T.D.C.

New belt Deflection when pressed Fan belt with finger force of tension When adjusting approx. 59 N {6 kg}. belt tension

20-2 (4)

degrees

mm

GD555, 655, 675-3C



GD555-3C

GD655-3C

51001 and up

50001 – 51000

51001 and up


Standard machine



SAA6D102E-2

S6D114E-1

SA6D114E-1

SAA6D114E-2

Standard value

Permissible value

Standard value

Permissible value

Standard value

Permissible value

Standard value

Permissible value

2,200 ± 50 850 ± 50 2,000

2,200 ± 50 850 ± 50 2,000

2,200 ± 50 850 ± 50 1,900

2,200 ± 50 850 ± 50 1,900

2,200 ± 50 850 ± 50 1,900

2,200 ± 50 850 ± 50 1,900

2,200 ± 50 800 ± 100 1,900

2,200 ± 50 800 ± 100 1,900

550 to 650

—

—

—

375 to 475

—

450 to 550

—

Max. 3.7 {380}

Max. 6.2 {635}

—

—

140 to 160 {1,050 to 1,200}

—

Max. 3.7 {380}

Max. 6.2 {635}

Max. 4.5 Max. 1.0

Max. 5.5 Max. 2.0

— —

— —

Max. 4.5 Max. 1.0

Max. 5.5 Max. 2.0

Max. 6.5 Max. 1.0

Max. 8.5 Max. 2.0

0.25 0.51

— —

0.3 0.61

— —

0.3 0.61

— —

0.30 0.56

— —

0.49 {50}

2.0 {200}

0.9 {92}

4.5 {460}

0.9 {92}

4.5 {460}

1.0 {100}

2.0 {200}

0.39 to 0.64 {4.0 to 6.5}

Min. 0.25 {2.6}

0.4 {4.1}

Max. 0.27 {2.8}

0.4 {4.1}

Max. 0.27 {2.8}

0.29 to 0.49 {3.0 to 5.0}

Min. 0.21 {2.1}

Min. 0.15 {1.5}

Min. 0.09 {0.9}

0.19 {1.97}

Max. 0.07 {0.7}

0.16 {1.6}

Max. 0.07 {0.7}

Min. 0.12 {1.2}

Min. 0.07 {0.7}

80 to 110

Max. 120

Max. 127

Max. 127

Max. 127

Max. 127

80 to 110

Max. 120

9.5 to 10.5

—

—

—

13 to 15

—

7.5 to 9.5

—

12 to 13

Max. 11 or Min. 14

12 to 13

Max. 11 or Min. 14

12 to 13

Max. 11 or Min. 14

12 to 13

Max. 11 or Min. 14

14 to 16

Max. 13 or Min. 17

14 to 16

Max. 13 or Min. 17

14 to 16

Max. 13 or Min. 17

14 to 16

Max. 13 or Min. 17

GD555, 655, 675-3C

20-3 (4)



Machine model

GD675-3C

Serial No.

50001 – 51000

Engine Item


Engine speed

High idle Low idle Rated speed

Exhaust temperature (turbine inlet temp.)

All speed (intake air temp. 20° C)

Intake resistance

At rated output

Exhaust gas color

Sudden acceleration High idle

Valve clearance (cold)

Intake valve Exhaust valve

Blowby pressure (SAE 15W-40 oil)

Standard machine


S6D114E-1

SA6D114E-1

Unit

Standard value

Permissible value

Standard value

Permissible value

rpm

2,200 ± 50 800 ± 50 1,900

2,200 ± 50 800 ± 50 1,900

2,200 ± 50 800 ± 50 1,900

2,200 ± 50 800 ± 50 1,900

°C

—

—

365 to 465

—

kPa {mm Hg}

—

—

160 to 180 {1,200 to 1,350}

—

Bosch index

— —

— —

Max. 4.5 Max. 1.0

Max. 5.5 Max. 2.0

mm

0.3 0.61

— —

0.3 0.61

— —

kPa {mmH2O}

2.0 {204}

4.5 {460}

2.0 {204}

4.5 {460}

MPa {kg/cm2}

0.4 {4.1}

Max. 0.27 {2.8}

0.4 {4.1}

Max. 0.27 {2.8}

0.16 {1.6}

Max. 0.07 {0.7}

0.16 {1.6}

Max. 0.07 {0.7}

Max. 127

Max. 127

Max. 127

Max. 127

—

—

13 to 15

—

12 to 13

Max. 11 or Min. 14

12 to 13

Max. 11 or Min. 14

14 to 16

Max. 13 or Min. 17

14 to 16

Max. 13 or Min. 17

At rated output Coolant temperature: Operating range Coolant temperature: Operating range

Oil pressure (SAE 15W-40 oil)

At rated output At low idle

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

Before T.D.C.

New belt Deflection when pressed Fan belt with finger force of tension When adjusting approx. 59 N {6 kg}. belt tension

20-4 (4)

degrees

mm

GD555, 655, 675-3C



GD675-3C 51001 and up VHP specification machine SAA6D114E-2 Standard value

Permissible value

2,200 ± 50 800 ± 100 1,900

2,200 ± 50 800 ± 100 1,900

490 to 550

—

Max. 3.7 {380}

Max. 6.2 {635}

Max. 6.5 Max. 1.0

Max. 8.5 Max. 2.0

0.30 0.56

— —

1.0 {100}

2.0 {200}

0.29 to 0.49 {3.0 to 5.0}

Min. 0.21 {2.1}

Min. 0.12 {1.2}

Min. 0.07 {0.7}

80 to 110

Max. 120

7.5 to 9.5

—

12 to 13

Max. 11 or Min. 14

14 to 16

Max. 13 or Min. 17

GD555, 655, 675-3C

20-5 (4)



STANDARD VALUE TABLE FOR CHASSIS Category

Item

Unit

216 ± 10

Accelerator pedal

Amount of up-down movement at tip of pedal

60 ± 10

Inching pedal

Amount of up-down movement at tip of pedal

44 ± 10

NoP

Engine speed stopped, travel at tip of lever

35 ± 5

N o F1


30 ± 5

1o2


30 ± 5

2o3


30 ± 5

3o4


4o5


30 ± 5

5o6


30 ± 5

6o7


30 ± 5

7o8


30 ± 5

N o R1


30 ± 5

1o2


30 ± 5

2o3


30 ± 5

3o4


30 ± 5

Travel

Amount of movement at center of lever knob when moved from LOW

mm

Max. value at tip of lever to just before end of travel

Max. 30 {Max. 3}

Accelerator pedal

Operating effort at a position 150 mm from center of pedal rotation. Max. value just before end of travel.

Max. 90 {Max. 9}

Inching pedal

Operating effort at a position 150 mm from center of pedal rotation. Max. value just before end of travel.

Brake pedal

Operating effort at a position 150 mm from center of pedal rotation. Measure with wheels fully locked.

275 ± 28 {28.1 ± 2.8}

Gearshift lever (including parking brake lever)

Measure at center of lever grip. Max. value just before end of travel.

Max. 45 {Max. 4.5}

Others

Inching pedal height (when operated)

N {kg}

60 to 90 {6 to 9}

188 ±5 Height from floor surface to tip of pedal.

mm

Inching pedal play

Transmission slippage

(4)

30 ± 5

Fuel control lever

Inching pedal height (when not operated)

20-6

Standard value

Fuel control lever

Gearshift lever

Operating effort

Measurement conditions

104 ± 5 0

GD555 Run engine at full throttle, set to R4, depress the brake pedal, release the inching pedal. Measure GD655 time taken for engine speed to enter specified range. GD675

STD VHP STD VHP STD VHP

1,505 ± 100 1,580 ± 100 rpm

1,615 ± 100 1,700 ± 100 1,660 ± 100 1,730 ± 100

GD555, 655, 675-3C


Standard value

Category

Travel speed

Unit

Permissible value

GD555-3C

GD655-3C GD675-3C

—

1st

3.3 ± 0.2

3.3 ± 0.2

—

2nd

4.8 ± 0.3

4.7 ± 0.3

—

3rd

6.8 ± 0.4

6.7 ± 0.4

—

4th

9.8 ± 0.5

9.7 ± 0.5

—

5th

14.9 ± 0.8

14.6 ± 0.7

—

21.6 ± 1.1

21.2 ± 1.1

—

29.6 ± 1.5

29.1 ± 1.5

—

42.9 ± 2.1

42.1 ± 2.1

—

4.4 ± 0.2

4.3 ± 0.2

—

2nd

( 1) 8.9 ± 0.5 ( 2) 9.0 ± 0.5

8.8 ± 0.5

—

3rd

( 1) 18.7 ± 1.0 ( 1) 18.1 ± 1.0 ( 2) 19.7 ± 1.0 ( 2) 19.1 ± 1.0

—

4th

( 1) 36.1 ± 2.0 ( 1) 35.1 ± 2.0 ( 2) 39.1 ± 2.0 ( 2) 38.4 ± 2.0

—

Flat, dry road surface: 6th • Oil temperature and pressure within operating range 7th • Engine at the rated speed 8th • Work equipment unloaded 1st • Tires inflated to the specified pressure

Engine stopped: Leaning • Measure at the tip of the lever. control lever • Measure travel from neutral to end of travel.

mm

22 ± 5

—

Engine stopped: Leaning • Measure at center of lever control lever grip. • Max. value to end of travel

N {kg}

Max. 24.5 {2.5}

—

Brake pedal performance

Travel

km/h

Operating effort

Reverse

Controls


Item

Forward

Brake


Play

Engine stopped: • Pedal movement in direction of operation

mm

Max. 5

Max. 5

Travel

Engine stopped: • Measure at the tip of the pedal

mm

66 ± 4

66 ± 10

Brake oil pressure

Hydraulic oil temperature: 45 to 50°C

MPa {kg/cm2}

+1 3.9 +0.1 –0.31 {40 –3 }

+1 3.9 +0.1 –0.31 {40 –3 }

Stopping distance

When braking from a speed of 32 km/h (20 mph)

m

Max. 11

Max. 13 (SAE standard = Max. 15.1 m)

1. For serial No. 50001 – 51000 2. For serial No. 51001 and up

GD555, 655, 675-3C

20-7 (4)


Steering

Category

20-8 (4)


Standard value

Permissible value


Unit

Steering wheel play

Raise front tires 50 to 100 mm from ground. • Turn the steering wheel and then measure the distance to the point where the wheels start to turn to side.

mm

0 to 10

—

Lock-to-lock

Raise front tires 50 to 100 mm from ground. Check the point where the steering wheel starts to turn, then turn steering wheel fully and measure the distance to the point where the steering wheel stops turning. • Turn the steering wheel at 120 rpm • Check distance to both left and right

—

5 to 9.5

—

Steering wheel operating effort

Engine at low idle when travelling in F1.

N {kg}

Max. 49 {5}

—

Item

GD555-3C

GD655-3C GD675-3C

—

GD555, 655, 675-3C


Item

Wheel

Steering

Category



Unit

Standard value

Permissible value

mm

Max. 7

—

kPa {kg/cm2}

275 {2.75} 250 {2.50} 275 {2.75}

—

degree

0

—

mm

-5 ± 1

—

degree

21.7

—

Blade lift lever (right, left)

22 ± 5

—

Blade side shift lever

22 ± 5

—

22 ± 5

—

22 ± 5

—

22 ± 5

—

22 ± 5

—

Scarifier lever

22 ± 5

—

Ripper lever

22 ± 5

—

Blade lift lever (left, right)

Max. 24.5 {2.5}

—

Blade side shift lever

Max. 24.5 {2.5}

—

Drawbar shift lever

Max. 24.5 {2.5}

—

Max. 24.5 {2.5}

—

Max. 24.5 {2.5}

—

Articulation lever

Max. 24.5 {2.5}

—

Scarifier lever

Max. 24.5 {2.5}

—

Ripper lever

Max. 24.5 {2.5}

—

9.4 + 1.0 {93.6 + 10}

9.4 ± 1 {93.6 ± 10}

13.4 + 0.5 {136.5 + 5}

13.4 ± 1 {136.5 ± 10}

Tire runout

Put dial gauge in contact with sidewall of both front and rear

Tire inflation pressure

GD555-3C: 13.00-24-10 PR GD655-3C: 14.00-24-10 PR GD675-3C: 14.00-24-12 PR

Camber Toe-in

Flat, paved road surface • Angle of knuckle bracket

Leaning angle

Travel

Drawbar shift lever Circle rotation lever Power tilt lever

Accumulator

Operating effort

Controls

Articulation lever

Circle rotation lever Power tilt lever

Charge cut-in pressure Charge cut-out pressure

GD555, 655, 675-3C

Engine stopped: • Measure at tip of lever • Measure travel from Neutral to end of travel

Engine stopped: • Measure at center of lever grip • Max. value to end of travel

Engine at low idle: • Hydraulic oil temperature: 40 to 55°C

mm

N {kg}

MPa {kg/cm2}

20-9 (4)



GD655-3C GD675-3C

GD555-3C

Category

Item

Hydraulic drift

Work equipment

Work equipment speed

Blade lifting speed

Blade sideshift speed with circle movement (drawbar) Blade sideshift speed compared to circle (blade shift)


Engine full throttle: Raise Oil temp. 40 ± 5°C Independent op. Make a mark on the cylinLower der rod and operate it 350 mm. Left Right Left Right

Unit

Left Right Left Right

Engine full throttle: Oil temp. 40 ± 5°C. Set height of bottom edge of blade to 100 mm with blade at center as standard condition Engine full throttle: Oil temp. 40 ± 5°C Set height of bottom edge of blade to 100 mm with blade at center as standard condition

Blade rotation speed

Engine full throttle: Oil temp. 40 ± 5°C Time taken to turn 90°

Scarifier lifting speed

Engine full throttle: Raise Oil temp. 40 ± 5°C Make a mark on the cylinder rod and operate it the distance shown below: GD555: 200 mm GD655: 180 mm Lower GD675: 180 mm

Seconds

Std. value

Permis. value

Std. value

Permis. value

2.7 ± 0.4

4

2.7 ± 0.4

4

2.7 ± 0.4

4

2.7 ± 0.4

4

6.9 ± 0.8

9

6.9 ± 0.8

9

7.5 ± 0.8

10

7.5 ± 0.8

10

9.1 ± 1.0

11

9.1 ± 1.0

11

9.1 ± 1.0

11

9.1 ± 1.0

11

8.8 ± 1.3

12

8.8 ± 1.3

12

( 1) 1.8 ± 0.3

3

( 2) 1.1 ± 0.2

2

( 1) 1.8 ± 0.3

3

( 2) 1.5 ± 0.3

3

1.6 ± 0.3

1.6 ± 0.3

3

3

Blade drift

Engine stopped: Oil temp. 40 ± 5°C Downward movement of cylinder when blade is suspended at right angle

10

20

10

20

Scarifier drift

Engine stopped: Oil temp. 40 ± 5°C Downward movement of cylinder when scarifier is suspended

10

20

10

20

Chassis drift when pushed up with blade

Engine stopped: Oil temp. 40 ± 5°C Downward movement of cylinder after blade is lowered to ground and used to raise front wheels from ground

20

35

20

35

Chassis drift when pushed up with scarifier

Engine stopped: Oil temp. 40 ± 5°C Downward movement of cylinder after scarifier is lowered to ground and used to raise front wheels from ground

20

35

20

35

mm/ 10 min.


20-10 (4)

GD555, 655, 675-3C


GD555-3C

Category

Hydraulic pressure

Item

Main control valve

Work equipment


Work equipment hydraulic pressure

Hydraulic pump discharge amount


Work Engine full throttle: equip. Oil temperature: 45 to 50°C Steer- Operate blade lift cylinder to raise ing Engine at low idle (800 rpm) Work Oil temperature: 45 to 50°C equip. Rotate circle

GD555, 655, 675-3C

Std. value

Permis. value

Std. value

Permis. value

20.6 ± 1 {210 ± 10}

—

20.6 ± 1 {210 ± 10}

—

—

15.1 ± 0.4 {154 ± 4}

—

76

—

76

—

130

—

130

—

mm

Circle: 5 Others: 6

—

Circle: 5 Others: 6

—

N {kg}

Circle: max. 109.8 {11.2} Others: Max. 73.5 {7.5}

—

Circle: max. 109.8 {11.2} Others: Max. 73.5 {7.5}

—

MPa {kg/cm2} 15.1 ± 0.4 {154 ± 4}

l/min.

Engine full throttle Trans. Oil temperature: 45 to 50°C

Spool travel (one side)

Spool operating effort

Unit

Engine stopped

GD655-3C GD675-3C

20-11 (4)


Category Main control valve

Item



Unit

GD555-3C

GD655-3C, GD675-3C

mm

Circle: 5 Others: 6

Circle: 5 Others: 6

N {kg}

Circle: Max. 109.8 {11.2} Others: Max. 73.5 {7.5}

Circle: Max. 109.8 {11.2} Others: Max. 73.5 {7.5}

2.8 +0.98 {29 + 10}

2.8 + 0.98 {29 + 10}

0.74 ± 0.15 {7.5 ± 1.5}

0.74 ± 0.15 {7.5 ± 1.5}

0.59 ± 0.1 {6 ± 1.0}

0.59 ± 0.1 {6 ± 1.0}

2.01 ± 0.15 {20.5 ± 1.5}

2.01 ± 0.15 {20.5 ± 1.5}

2.24 ± 0.1 {22.9 ± 1.0}

2.24 ± 0.1 {22.9 ± 1.0}

2.37 ± 0.1 {24.2 ± 1.0}

2.37 ± 0.1 {24.2 ± 1.0}

FL

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

R

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

2nd

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

3rd

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

4th

2.25 ± 0.2 {23 ± 2.0}

2.25 ± 0.2 {23 ± 2.0}

Spool travel (one side) Spool operating effort

Unload pressure

Engine stopped

Hydraulic oil temperature: 45 to 50°C

Outlet oil pressure

Oil temperature: 60 to 80°C

Main relief pressure

Lock-up pressure

Control valve set pressure

Torque converter Transmission

Hydraulic pressure

Inlet oil pressure

Low idle High idle

Oil temperature: 60 to 80°C Engine full throttle

MPa {kg/cm2}

FH 1st

Oil temperature: 60 to 80°C Engine at full throttle

( 1) STD: 1,505 ± 100

Engine speed

Oil temperature: 60 to 80°C

Engine speed at torque converter stall

Engine coolant temperature: operating range Run engine at full throttle, set to R4, depress the brake pedal and then release the inching pedal. Measure engine speed when engine stalls.

rpm

( 1) GD655-3C STD: 1,615 ± 100 VHP: Base power 1,610 ± 100 High power 1,700 ± 100

VHP: Base power 1,470 ± 100 GD675-3C High power 1,580 ± 100 STD: 1,660 ± 100 VHP: Base power 1,665 ± 100 High power 1,730 ± 100 ( 2) GD655-3C VHP: Base power 1,559 ± 100 High power 1,665 ± 100

( 2) VHP: Base power 1,378 ± 100 High power 1,552 ± 100 GD675-3C VHP: Base power 1,593 ± 100 High power 1,698 ± 100


20-12 (4)

GD555, 655, 675-3C



STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM System

Component

Connec- Inspection tor No. method


Judgement table If the condition is as shown in the table below, the condition is normal.

Switch power source

T1 T2

Measure voltage

Between T1 (7), (13) - chassis Between T2 (1), (12) - chassis Between T1 (7), (13) - (6), (12)

20 to 30V

1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON

Between T1 (7), (12) - (11), (21)

Measure voltage

VHP select switch

T3B

Measure voltage

Between (4), (12) - chassis

AWD select switch

Measure voltage

VHP spec.

Max. 1V 20 to 30V

AWD spec.

Between (3) and chassis

Max. 1V 20 to 30V

If the condition is as shown in the table below, the condition is normal.

Inching select switch

Measure voltage

Differential lock select switch

Inching pedal spec. Without inching pedal spec.

T3A

GD555, 655, 675-3C



Without AWD spec.

Type select switch (spare)

4 to 8V


Without VHP spec. Controller

Transmission control related

S-NET



Max. 1V 20 to 30V

If the condition is as shown in the table below, the condition is normal. Measure voltage

Differential spec. Without differential spec.

Between(10) and chassis

Max. 1V 20 to 30V

If the condition is as shown in the table below, the condition is normal. T5

Measure voltage

Standard spec. Without standard spec.


Max. 1V 20 to 30V

1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON

20-13 (4)


System

Component





Forward switch

Measure voltage

Gearshift lever at any position except above.

T5

Reverse switch

Gearshift lever at (F1) thru (F8)


20 to 30V

Max. 1V


Gearshift lever at (R1) thru (R4) Gearshift lever at any position except above.


20 to 30V

Max. 1V

Neutral signal

Controller




T3A

Drive lever (A)

Gearshift lever at Neutral or Park

20 to 30V Between (8) and chassis

Max. 1V


Gearshift lever at any position except Neutral or Park Gearshift lever at Neutral or Park


20 to 30V

1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON




Max. 1V

If the condition is as shown in the table below, the condition is normal. Drive lever (B)

Measure voltage


T5

Drive lever (C)

Gearshift lever at (F1), (F5) thru (F7) and (R1) thru (R3)

(4)

Between (7) and chassis Max. 1V


Gearshift lever at (F1) thru (F5) and (R1) Gearshift lever at any position except above.

20-14

20 to 30V



20 to 30V


Max. 1V

GD555, 655, 675-3C


System

Component





Drive lever (D)

Measure voltage

Gearshift lever at (F1) thru (F3) Gearshift lever at any position except above.

20 to 30V Between (8) and chassis

Max. 1V


If the condition is as shown in the table below, the condition is normal. T5 Drive lever (E)

Measure voltage

Gearshift lever at (F3) thru (F6) and (R1), (R2) Gearshift lever at any position except above.

20 to 30V

Max. 1V


Reset switch

Measure resistance Reset switch ON

Reset switch OFF


Max. 1 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. Controller



Memory reset switch

Measure resistance

Initialize switch (memory reset) Initialize switch (Initialize learning function or OFF)

T3A

Min. 1 z

Initialize switch (memory reset or OFF)


Max. 1 z

Measure voltage

T/C lock-up switch ON T/C lock-up switch OFF

T5

Differential switch


20 to 30V Max. 1V


Differential switch ON Differential switch OFF

GD555, 655, 675-3C




Min. 1 z

If the condition is as shown in the table below, the condition is normal. Lockup switch


If the condition is as shown in the table below, the condition is normal. Initialize switch Measure (Initialize learning resistance function)

Initialize switch

Max. 1 z Between (11) and chassis


20 to 30V Max. 1V



20-15 (4)


System

Component





Hi set switch

T3B

Measure Potentiometer set resistance switch HI Potentiometer set switch LOW


Max. 1 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. Low set switch

T5

Measure Potentiometer set resistance switch HI or OFF Potentiometer set switch LOW or OFF


Max. 1 z Min. 1 z



Controller



Accelerator potentiometer signal

Measure voltage

T3A

Between (7) and (16)

4.75 to 5.25V


0.5 to 4.75V

Between (3) and (16) at low idle

1.0 to 2.0V

Between (3) and (16) at high idle

2.4 to 4.3V

1. Turn starting switch OFF 2. Insert the T-adapter The above table shows the specified value for the 3. Turn starting switch voltage for a potentiometer that allows the controlON ler to recognize the dial range correctly. When adjusting the potentiometer, allow a margin for the error judgement range. At low idle, adjust within the range of 1.0 to 2.0V. The error judgement range is potentiometer <0.5V or potentiometer voltage > 4.5V. If the condition is as shown in the table below, the condition is normal.

Inching potentiometer signal

Measure voltage


4.75 to 5.25V


0.5 to 4.75V 1. Turn starting switch OFF 0.8 to 1.6V 2. Insert the T-adapter 3. Turn starting switch ON 3.2 to 4.0V

Between (13) and (16), inching pedal not depressed (min. travel) Between (13) and (16), inching pedal depressed (max. travel)

At minimum travel, adjust within the range of 0.8 to 1.6V. The error judgement range is potentiometer <0.5V or potentiometer voltage > 4.5V.

20-16 (4)

GD555, 655, 675-3C


System

Component Transmission input shaft speed sensor Transmission output shaft speed sensor



T5

T4 T5

Measure voltage

Measure voltage


Judgement table If the condition is as shown in the table below, the condition is normal. Measure with AC range. Between (2) and (1)

0.5V

If the condition is as shown in the table below, the condition is normal. Measure with AC range. Between T4 (1) and T5 (1)

0.5V

If the condition is as shown in the table below, the condition is normal. FL clutch fill switch

T36

At (F1), (F3), (F5), Measure and (F7) resistance


Min. 1 z

If the condition is as shown in the table below, the condition is normal. FH clutch fill switch

T37

At (F2), (F4), (F6), Measure and (F8) resistance

Controller


At any position except above

Max. 1 z

At any position except above


Min. 1 z

If the condition is as shown in the table below, the condition is normal. R clutch fill switch

T38

Measure resistance

Max. 1 z

At (R1) thru (R4) At any position except above


Min. 1 z

If the condition is as shown in the table below, the condition is normal. 1st clutch fill switch

T39

At (F1), (F2), and Measure (R1) resistance At any position except above


Min. 1 z

If the condition is as shown in the table below, the condition is normal. 2nd clutch fill switch

T40

At (F3), (F4), and Measure (R2) resistance At any position except above

GD555, 655, 675-3C


Min. 1 z

1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Turn starting switch ON

20-17 (4)


SysComponent tem





3rd clutch fill switch

T41

Measure At (F5), (F6), and resistance (R3) At any position except above


Max. 1 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. 4th clutch fill switch

T42

Measure At (F7), (F8), and resistance (R2) At any position except above


Max. 1 z Min. 1 z


If the condition is as shown in the table below, the condition is normal. Lock-up clutch fill switch

T43

At F1 to F4, (R1) to Measure (R2) resistance T/C lock-up switch ON


T/C lock-up switch OFF

Max. 1 z

Min. 1 z

If the condition is as shown in the table below, the condition is normal. FL solenoid

T24

Measure Between (1) and (2) resistance Between (1) and chassis

5 to15 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. FH solenoid

T25


5 to15 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. R solenoid

T26


5 to15 z Min. 1 z

If the condition is as shown in the table below, the condition is normal. 1st solenoid

T27


20-18 (4)

5 to15 z Min. 1 z

1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Start engine 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Start engine 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 4. Manual mode 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter

GD555, 655, 675-3C


SysComponent tem





2nd solenoid

T28

Measure Between (1) and (2) resistance

5 to15 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. 3rd solenoid

T29


5 to15 z


Min. 1 z



4th solenoid

T30


5 to15 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. Lock-up solenoid

T31


5 to15 z


T/C output hydraulic temp. sensor

Min. 1 z

1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter

If the condition is as shown in the table below, the condition is normal. T34

Measure 25°C normal temp. resistance 100°C

Between (1) and (2)

1. Turn starting switch OFF 2. Disconnect the con3.5 to 4.0 kz nector 38.5 to 47.0 3. Connect the T-adapter kz

If the condition is as shown in the table below, the condition is normal. T/M hydraulic temp. sensor

T35


Between (1) and (2)


If the condition is as shown in the table below, the condition is normal. Hydraulic temp. sensor

E5


GD555, 655, 675-3C

Between (1) and (2)


20-19 (4)


SysComponent tem

Transmission input shaft speed sensor



If the condition is as shown in the table below, the condition is normal. Measure with AC range. T32

Measure resistance Between (1) and (2) Between (1), (2), and chassis


Transmission input shaft speed sensor

Transmission output shaft speed sensor

—

Adjust

1. Turn starting switch OFF 2. Disconnect the con500 to 1,000 nector z 3. Connect the T-adapter Min. 1 z

1. Screw the transmission input shaft speed sensor in until it contacts the ring gear, then turn back 1/ 2 to 1 turn. 2. Works normally after above adjustment.

T33

Measure resistance Between (1) and (2)

—

Adjust


1. Screw the transmission input shaft speed sensor in until it contacts the ring gear, then turn back 1/ 2 to 1 turn. 2. Works normally after above adjustment.

—

If the condition is as shown in the table below, the condition is normal. Engine speed sensor

T46

Measure resistance Between (1) and (2) Between (1), (2), and chassis

Engine speed sensor

—

Adjust


1. Screw the transmission input shaft speed sensor in until it contacts the ring gear, then turn back 1/ 2 to 1 turn. 2. Works normally after above adjustment. If the condition is as shown in the table below, the condition is normal.

Engine start solenoid

B20

Measure Between (1) and (2) resistance Between (1), (2), and chassis

20-20 (4)

—

If the condition is as shown in the table below, the condition is normal. Measure with AC range.

Between (1), (2), and chassis Transmission output shaft speed sensor


Judgement table

0.5 to 1.0 z Min. 1 z

—

1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter

GD555, 655, 675-3C


SysComponent tem

Lifter lock solenoid





FL7

Measure resistance Between (1) and (2)

40 to 60 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. Parking brake solenoid

FL8


40 to 60 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. Accumulator solenoid (left)

FL9


20 to 30 z



Min. 1 z

If the condition is as shown in the table below, the condition is normal. Accumulator solenoid (right)

FL10


20 to 30 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. Float solenoid (right)

FL11 FL12


20 to 30 z


Min. 1 z

If the condition is as shown in the table below, the condition is normal. Float solenoid (left)

FL13 FL14


20 to 30 z


Min. 1 z

1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter 1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter

If the condition is as shown in the table below, the condition is normal. Articulator sensor

FL6

Measure resistance Articulate angle: Left 23° Articulate angle: Right 23°

GD555, 655, 675-3C

1. Turn starting switch OFF 2. Disconnect the connector 180 to 200 z 3. Connect the T-adapter 5 to 15 z 80 to 100 z

Articulate angle: 0° Between (1) and (2)

20-21 (4)

TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................... 20-102 MEASURING EXHAUST COLOR .............................................................................................................. 20-103 MEASURING BLOWBY PRESSURE ......................................................................................................... 20-104 MEASURING ENGINE OIL PRESSURE .................................................................................................... 20-105 MEASURING ENGINE SPEED .................................................................................................................. 20-105 TESTING FAN BELT TENSION.................................................................................................................. 20-106 TESTING AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................. 20-107 MEASURING TORQUE CONVERTER STALL SPEED.............................................................................. 20-107 CHECKING CLUTCH OIL PRESSURE ...................................................................................................... 20-108 CHECKING TORQUE CONVERTER OIL PRESSURE.............................................................................. 20-109 ADJUSTING SPEED SENSOR .................................................................................................................. 20- 110 FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT ............................................................. 20- 112 ADJUSTING ACCELERATOR CONTROL LINKAGE................................................................................. 20- 113 TESTING BRAKE DISC.............................................................................................................................. 20- 114 TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE ......................................................... 20- 115 TESTING ACCUMULATOR CHARGE PRESSURE ................................................................................... 20- 116 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE ........................................................ 20- 116 TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE.................................................................. 20- 117 ADJUSTING PC VALVE.............................................................................................................................. 20- 119 BLEEDING AIR FROM HYDRAULIC CIRCUIT .......................................................................................... 20- 119 MEASURING INTERNAL CYLINDER LEAKAGE....................................................................................... 20-120 MEASURING STEERING, BRAKE OIL PRESSURE ................................................................................. 20-122 BLEEDING AIR FROM BRAKE PIPING ..................................................................................................... 20-123 CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR .............................. 20-124 TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE ..................................................................... 20-125 TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE...................................................... 20-127 MEMORIZING IDLE AND FULL POSITION PROCEDURE ....................................................................... 20-129 INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER ..................................................... 20-130 DIODE CHECKING PROCEDURE............................................................................................................. 20-132 MOVING MACHINE WHEN TRANSMISSION VALVE FAILS..................................................................... 20-133 ADJUSTING CAB STOPPER BOLT ........................................................................................................... 20-135

GD555, 655, 675-3C

20-101 (4)


TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING Check or measurement item Engine speed

Symbol

A

Coolant and oil temperature

Part No.

Part Name

Remarks

1

799-203-8001

Multi-tachometer

2

795-790-2500

Adapter

Digital display L: 60 to 2,000 rpm H: 60 to 19,999 rpm

799-101-1502

Digital temperature gauge

–99.9 to 1,299°C

799-101-5002

Hydraulic tester

Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

799-261-1203

Digital hydraulic tester

58.8 MPa {600 kg/cm2}

799-401-2320

Hydraulic gauge

1.0 MPa {10 kg/cm2}

B

1

2 3 Oil pressure

C

799-101-5160 799-101-5220

Nipple

799-401-2701

Differential pressure gauge

DC 12 V

5

790-261-1231

Elbow

M10 x 1.25 (RC 1/8)

6

Both male and female 14 x 1.5 (R.C. 1/8)

790-261-1321

Adapter

Both male and female 14 x 1.5 (R.C. 1/8) Both male and female 14 x 1.5 (R.C. 1/8)

790-261-1331

Blowby pressure

M10 x 1.25

4

790-261-1311

Exhaust color

RC 1/8

1

799-201-9000

Handy smoke checker

Discoloration 0 to 70 percent (with standard color)

2

Commercially available

Smoke meter

Discoloration % x 1/10 = Bosch index

1

799-201-1504

Blowby checker

0 to 4,900 Pa {0 to 500 mm H2O}

D

799-201-1511

E 2

Nozzle 795-790-1950 79A-264-0021

Orifice diameter: 5.613 mm (102 engine) 0 to 294 N {0 to 30 kg}

Operating effort

F

Stroke

G

Troubleshooting of wiring harnesses and sensors

H

Measuring voltage and resistance values

I

Commercially available

Tester

—

Charging accumulator

J

792-610-1700

Charging tool

—

Procedure for moving machine when transmission valve fails

K

794-423-1190

Plug

—

20-102 (4)

79A-261-0091 Commercially available 799-601-2500 799-601-9200

Push-pull scale

Orifice diameter: 7.67 mm (114 engine)

Scale T-adapter assembly

0 to 490 N {0 to 50 kg} — — For DT series

GD555, 655, 675-3C


MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR •

When measuring in the field where is no air or electric power supply, use tool D1; when recording formal data, use tool D2. a Increase the coolant temperature to the operating temperature range before measuring.

Measuring with D1

2. Connect the air hose of the probe hose accelerator switch to the tool D2. a Keep the air pressure supply below 1.47 MPa {15 kg/cm2}. 3. Connect the power cord to the AC 100V socket. a When connecting the cord, check that the power switch of tool D2 is OFF.

1. Install the filter paper to tool D1. 2. Insert the exhaust gas suction port into the exhaust pipe. 3. Accelerate the engine suddenly while simultaneously operating the handle of tool D1. 4. Remove the filter paper and compare it with the scale supplied to judge the condition.

4. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that exhaust gas cannot leak. 5. Turn the power switch of tool D2 ON. 6. Accelerate the engine suddenly while simultaneously depressing the accelerator pedal of tool D2 to collect the exhaust gas color on the filter.

Measuring with D2 1. Insert the probe into the outlet port of the exhaust pipe (1) and tighten the clip to secure the probe to the exhaust pipe.

GD555, 655, 675-3C

7. Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder. 8. Read the value shown.

20-103 (7)


MEASURING BLOWBY PRESSURE

MEASURING BLOWBY PRESSURE Before measuring the blowby pressure, heighten the coolant temperature to the operating range. 1. Connect the nozzle E2 of the blowby checker E1 to the end of the engine breather hose (1).

•

If it is impossible to run the engine at the rated output or perform a stall operation, measure while the engine is running at high idle. The value obtained in this case is about 80 percent of the blowby pressure at the rated output. a The blowby pressure may vary largely with the engine condition. If the measured value is judged abnormal, check for oil consumption increase, bad exhaust gas color, oil deterioration, high speed of oil deterioration, etc., which are related to the abnormal blowby pressure.

2. Connect the nozzle E2 to the blowby checker E1.

3. Run the engine at the rated output and measure the blowby pressure. k Take care not to touch the hot or rotating parts during measurement.

a The regular blowby pressure is measured while the engine is running at the rated output. • In the field, perform a stall operation for an approximate value.

20-104 (4)

GD555, 655, 675-3C


MEASURING ENGINE OIL PRESSURE a Increase the coolant temperature to the operating temperature range before measuring. 1. Remove the pressure measurement sensor (1) then install the oil pressure gauge C2 (0.98 MPa {10kg/cm2}).

MEASURING ENGINE OIL PRESSURE MEASURING ENGINE SPEED

MEASURING ENGINE SPEED k Do not to touch any hot parts when handling the measuring tools. a Measure the engine speed per listed conditions: a. Coolant temperature: operating range. b. Power train oil temperature: 60 to 80°C. c. Hydraulic temperature: 45 to 55°C

GD555-3C 1. Remove the cap of the speed pickup port. 2. Install the adapter assembly A2 to the speed pickup port, then install the tachometer sensor and connect to the body A1.

GD655-3C, GD675-3C

2. Start the engine and measure the oil pressure at low idle and the rated speed.

GD555, 655, 675-3C

20-105 (4)


TESTING FAN BELT TENSION

TESTING FAN BELT TENSION 3. Start the engine and measure the engine speed at high and low idle.

k When measuring the engine speed, be careful not to touch the rotating or hot parts.

1. Testing belt tension Measure the deflection A of the belt when the belt is pressed with a force of approx. 98N {10 kg} at a point midway between the fan pulley and tension pulley.

a When measuring items other than above (torque converter stall), see the measurement procedure for each item.

(Unit: mm) MODEL

GD555

GD655, 675

Belt

Deflection A

Deflection A

New belt

12.2 to 13.3

11.8 to 12.8

After adjusting tension

14.7 to 16.0

14.0 to 15.6

2. Adjusting the belt tension 1) Loosen the nut (1). 2) Loosen the locknut (2), then turn the adjustment nut (3) to adjust the belt tension. 3) After adjusting the belt tension, tighten the nut (1) and then the locknut (2).

20-106 (4)

GD555, 655, 675-3C

TESTING AIR CONDITIONER COMPRESSOR BELT TENSION MEASURING TORQUE CONVERTER STALL SPEED


TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 1. Testing belt tension Measure the deflection a of the belt when the belt is pressed with a force of approx. 98N {10 kg} at a point midway between the fan pulley and tension pulley.

MEASURING TORQUE CONVERTER STALL SPEED k Do not touch the hot parts when measuring. And ensure that no one is near the machine during the procedure. a Measure the torque converter stall speed under the following conditions: • Coolant temperature: within operating range • Power train oil temperature: 60 to 80°C • Hydraulic oil temperature: 45 to 55°C 1. Remove the cap from the engine speed pick-up port, install the adapter assembly A2 and multitachometer sensor , then connect to the main body A1.

BELT

DEFLECTION a (mm)

New belt

15 to 16

After adjusting

17 to 19

2. Adjusting the belt tension 1) Loosen the locknut (1), then turn the adjustment bolt (2) and move the compressor (4) with the shaft (3) at the center to adjust the belt tension. 2) After adjusting the belt tension, tighten the locknut (1).

2. Start the engine and run at low idle. 3. Depress the brake pedal. Stop the engine and move the gear lever to TOP reverse speed (R4). 4. Measure the speed when the accelerator pedal or the regulator lever is set to the full throttle position. a Measure when the engine speed is stable.

GD555, 655, 675-3C

20-107 (7)


CHECKING CLUTCH OIL PRESSURE

CHECKING CLUTCH OIL PRESSURE k Set the front frame and rear frame facing straight to the front, then secure in position with the lock pin. k Raise the tandem drive with a hydraulic jack and raise the 4 rear wheels off the ground.

k Set the blade at right angles to the chassis and lower the blade completely to the ground. k The oil is hot, so be careful not to burn yourself.

k Stop the engine before removing or installing the plug or pressure gauge. a Oil temperature when measuring: 60 to 80°C 1. Checking transmission modulating oil pressure (Clutch circuit oil pressure) 1) Measure the main relief oil pressure and check that it is normal. 2) Remove the plugs (1) thru (7) from the places to be measured, then install tool C1. All gauges: 5.88 MPa {60 kg/cm2} Plug No.

Oil pressure circuit

Plug No.

Oil pressure circuit

1

FL clutch

5

R clutch

2

FH clutch

6

3rd clutch

3

1st clutch

7

4th clutch

4

2nd clutch

—

—

Plug size: Rc1/8 or 1/4 3) Run the engine at low idle and shift the gearshift lever to the speed range (oil pressure circuit) to be measured. 4) Run the engine at full throttle and measure the clutch pressure of that circuit.

ECMV clutch actuation table ECMV FL

Speed Range

FH

R

1st

2nd

3rd

4th

F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 N

20-108 (7)

GD555, 655, 675-3C


CHECKING TORQUE CONVERTER OIL PRESSURE

CHECKING TORQUE CONVERTER OIL PRESSURE k Set the front frame and rear frame facing straight to the front, then secure in position with the lock pin. k Raise the tandem drive with a hydraulic jack and raise the 4 rear wheels off the ground.

k Set the blade at right angles to the chassis and lower the blade completely to the ground.

k The oil is at high temperature, so be careful not to burn yourself.

3. Torque converter outlet port pressure 1) Measurement port: 3 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle. 4. Torque converter lock-up port pressure 1) Measurement port: 4 (Rc 1/4) 2) Start the engine and measure the pressure at high and low idle.

k Stop the engine before removing or installing the plug or pressure gauge. a Oil temperature: 60 to 80°C

1. Main relief pressure 1) Measurement port: 1 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle. 2. Torque converter inlet port pressure 1) Measurement port: 2 (Rc 1/8) 2) Start the engine and measure the pressure at low idle and high idle.

GD555, 655, 675-3C

20-109 (4)


ADJUSTING SPEED SENSOR

ADJUSTING SPEED SENSOR 1. Engine speed sensor 1) Screw the sensor (1) in by hand until the sensor tip contacts the gear (2). a When positioning the sensor tip in contact with the gear, tighten lightly by hand and check that the sensor in contact. Never use a wrench or any other tool when tightening.

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

2) When the sensor (1) tip contacts the gear (2), screw the sensor out 1/2 to 1 turn. Standard clearance a: 0.68 to 1.13 mm 3) Tighten the locknut (3) from 49.0 to 68.6 Nm {5 to 7 kgm} a Tighten the sensor carefully to prevent excessive force being applied to the sensor wiring. a Be careful not to scratch the sensor tip or let any iron filings or powder stick to the tip.

20-110 (4)

GD555, 655, 675-3C


ADJUSTING SPEED SENSOR

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

2) When the sensor (5) contacts the gear (2), turn the sensor out 1/2 to 1 turn. Standard clearance a: 0.68 to 1.13 mm 3) Tighten the locknut (3) from 49.0 to 68.6 Nm {5 to 7 kgm} a Tighten carefully and take action to prevent any excessive force from being applied to the sensor wiring. a Be careful not to scratch the sensor tip or let any iron filings or powder stick to the tip.

GD555, 655, 675-3C

20-111 (4)


FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT

FLUSHING TORQUE CONVERTER, TRANSMISSION CIRCUIT a Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the torque converter and transmission life, and will cause internal damage. To prevent this situation, flush the system to remove the dirt in the hydraulic circuit. 1. Flush the circuit, if the following conditions apply. 1) If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are circulating in the hydraulic circuit. 2) When the torque converter and transmission have been overhauled or repaired. 2. Cleaning the filter 1) After removing the filter, remove the drain plug (1) and drain the system.

2) Travel or perform the actual operations for at least 20 minutes. a Use all the speed ranges (FORWARD, REVERSE, and 1st – 8th). 3) Repeat the procedure in Step 4.1 and run the engine at low idle for approx. 20 minutes. 5. Replace the flushing element. 1) Using the procedure in Step 2.1, replace the flushing element with the standard element (714-07-28711). 2) Add oil and check the level again. 6. Replace the transmission fail-safe filter. 1) Remove the mounting bolt (3) of the filter assembly (2), then remove the filter assembly. 2) Remove the element (4) and replace it with a new element. a If there is any dirt inside the filter case (5), wash the case. 3) Install a new O-ring (6) to the outside circumference of the case (5). a Coat the outside circumference of the Oring with a small amount of grease. 4) Install the case (5). 3 Case bolts: 34.3 to 44.1 Nm {3.5 to 4.5 kgm} 5) Install the filter assembly (2).

2) Remove the transmission oil filter, clean the inside, then reinstall the element for a second flushing. 3. Fill the transmission case with oil. Add fresh oil through the oil filler port to the specified level, and run the engine to circulate the oil through the system. Then check the level again. 5 Transmission case: 45 l

4. Perform the flushing as follows. 1) After starting the engine, run the engine for approx. 20 minutes at low idle, without operating the gearshift lever. a From time to time, increase the engine speed to approx. 1,500 rpm. a If the ambient temperature is low and the engine water temperature gauge does not enter the green range, continue the warming-up operation longer.

20-112 (4)

GD555, 655, 675-3C


ADJUSTING ACCELERATOR CONTROL LINKAGE

ADJUSTING ACCELERATOR CONTROL LINKAGE

1. Procedure for adjusting the accelerator pedal: • Remove the floor mat to adjust. 1) Set the installed height of the stopper bolt (1) to dimension A. a Dimension A: 75 mm 2) Set the installed length of pedal (2) to dimension B. a Dimension B: 193 mm 3) Set the installed length of cable (3) to dimensions C and D. Unit: mm GD555-3C

Serial No.

GD655, 675-3C

50001 – 51000

51001 and up

50001 – 51000

51001 and up

Dimension C

289

290

289

290

Dimension D

322.5

280

331.5

332

4) Adjust the rod length (4) so that the idle speed is 800 to 850 rpm. a Dimension E of rod (4) (standard length): 459 mm 5) Depress the pedal (2) until it contacts the stopper bolt (1), and adjust the rod length (4) so that the engine governor lever (5) is at the end of its stroke (engine high idle: 2,200 ± 50 rpm). a Dimension E of rod (4) (standard length): 459 mm 6) Turn back the stopper bolt (1) one-half turn and lock in position.

GD555, 655, 675-3C

20-113 (4)


TESTING BRAKE DISC

TESTING BRAKE DISC 2. Procedure for adjusting the regulator lever a Adjust the accelerator pedal before adjusting the regulator lever. 1) Set the installed length of the spring unit (6) to dimension F. a Dimension F: 290 mm 2) Adjust with the stopper bolt (8) so that the speed changes from idle speed to 2,200 ± 50 rpm when operating the regulator lever (7).

k Stop the machine on flat ground and put blocks under the front wheels. 1. Remove the rear wheel assembly. For details, see REMOVAL OF REAR WHEEL ASSEMBLY. 2. Apply the brake, remove the cap (1), then push in the pin (2). 3. Measure the height of the pin tip (2) and the guide end face (3). Height (new part): 1.8 to 2.0 mm 4. If the pin tip (2) and the guide end face (3) are level, replace the disc.

20-114 (4)

GD555, 655, 675-3C


TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE

TESTING AND ADJUSTING PARKING BRAKE PAD CLEARANCE k Stop the machine on flat ground and put blocks under the front wheels.

1. Checking the parking brake pad clearance 1) Start the engine, charge the accumulator with hydraulic oil, then stop the engine. 2) Turn the engine starting switch to the ON position and set the gearshift lever to the N position. 3) Measure the front and rear clearances (a and b) between the parking brake pad (1) and disc (2). 4) If the total clearance (a + b) is more than 2.5 mm, follow the procedure for adjusting the parking brake pad clearance below to adjust the clearance. a Total clearance for new part (a + b): 0.5 to 0.8 mm

2. Adjusting the parking brake pad clearance 1) Start the engine, charge the accumulator with hydraulic oil, then stop the engine. 2) Turn the engine start switch ON and set the gearshift lever to the N position. 3) Measure parking brake pad (1) thickness. • If thickness is 3 mm or more: Use again • If thickness is less than 3 mm: Replace 4) Remove the plug (3); loosen the locknut (4). 5) Loosen the double nut (5), then loosen the bolt (6) five turns. 6) After loosening the nut (7), loosen the bolt (8) three turns. 7) Tighten the bolt (9) so that the front and rear pads (1) contact disc (2).

GD555, 655, 675-3C

8) Tighten the bolt (8) until it contacts the urethane spring (10), then tighten the bolt an additional 1/2 turn. 9) Tighten nut (7) from 242 to 302 Nm {24.7 to 30.8 kgm}. Target: 272 Nm {27.7 kgm} 10) Loosen the adjustment bolt (9) to adjust so that the total clearance (a + b) between the disc and pads is from 0.5 to 0.8 mm.

11) Position the bolt tip (6) in contact with the bracket (11). Turn the bolt and adjust so that the clearance (a and b) between the disc (2) and pads (1) is uniform. Torque the double nut (5) from 24.1 to 30.1 Nm {2.46 to 3.07 kgm} Target: 27.1 Nm {2.76 kgm} 12) Secure the adjustment bolt (9) with the locknut (4) torqued from 102.8 to 128.2 Nm {10.5 to 13.1 kgm}. Target: 115.5 Nm {11.8 kgm}. 13) Check the clearance between the disc (2) and pads (1) again. 14) Install the plug (3). 15) Set the gearshift lever to the P position and check that the clearance between the pads (1) and disc (2) is removed.

k If the adjustment procedure for steps 3) thru 15) takes longer than 15 minutes, perform the adjustment procedure continuously after completing the proce-dure in steps 1) and 2). 16) Turn the engine start switch OFF.

20-115 (4)


TESTING ACCUMULATOR CHARGE PRESSURE a Hydraulic oil temperature: 45 to 55°C

k Stop the engine and depress the brake pedal slowly at least 30 times to release the pressure inside the accumulator circuit. 1. Remove the accumulator inlet port pressure switch (1) (Rc 1/4), then install tool C1 (39.2 MPa {400 kg/cm2}). 2. Measure the accumulator charge cut-out pressure. Start the engine, run the engine at low idling, and measure the rise in pressure. The point where the pressure stops rising is the cutout pressure. 3. Measure the accumulator charge cut-in pressure. Start the engine, run the engine at low idle, wait for the accumulator charge cut-out, then depress and release the brake repeatedly to lower the pressure. The point where the pressure starts to rise again is the cut-in pressure.

TESTING ACCUMULATOR CHARGE PRESSURE TESTING AND ADJUSTING WORK EQUIPMENT OIL

TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

k Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Oil temperature when measuring: 45 to 55°C 1. Measuring unload oil pressure 1) Remove the pressure measurement plug (1) (M10 x 1.25). 2) Fit the nipple C3, then install the oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Run the engine at full throttle and measure the oil pressure with all levers at HOLD. 2. Measuring work equipment pressure (relief pressure) 1) Remove the pressure measurement plug (1) (M10 x 1.25). 2) Fit the nipple C3, then install the oil pressure gauge C1 (39.2 MPa {400 kg/cm2}). 3) Run the engine at full throttle and measure the relief pressure; operate the blade lift lever to the RAISE position.

4. After stopping the engine, press and release the brake pedal slowly at least 20 times repeatedly, then run the engine at low idling. The initial pressure at this time is the accumulator gas charge pressure, which is 3.4 ± 0.1 MPa {35 ± 1.0 kg/ cm2}. 5. Charge fully (to the cut-out pressure) with the engine at full throttle, then stop the engine. Turn the starting switch to the ON position and press and release the brake pedal repeatedly. At this time, if the low brake oil pressure caution buzzer sounds before the brake pedal is pressed 10 times, check the accumulator gas pressure. • For the method of checking the accumulator gas pressure, see Procedure for Charging Accumulator for Brake and Work Equipment with Nitrogen Gas.

20-116 (4)

GD555, 655, 675-3C


TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE

TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE Adjusting 1. Adjusting the LS relief valve a If the work equipment oil pressure is not normal, adjust the LS relief valve (2) as follows. 1) Loosen the locknut (3) and turn the adjustment screw (4) as follows. • To INCREASE the pressure, turn CLOCKWISE. • To DECREASE the pressure, turn COUNTER-CLOCKWISE.

1. Measuring LS differential pressure with the main relief differential pressure gauge 1) Remove the high-pressure (1) and low-pressure (2) measurement plugs.

2) Fit the elbow C5 and nipple C3.

a One turn of the adjustment screw equals 15.1 MPa {154 kg/cm2} 2) After adjusting, tighten the locknut (3) from 68.6 to 78.5 Nm {7 to 8 kgm} a After completing the adjustment, use the measurement procedure above to check the oil pressure again. 3) Connect the differential pressure gauge C4.

a Connect the LS pump pressure (1) to the highpressure side of the differential pressure gauge and LS pressure (2) to the low-pressure side.

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20-117 (4)


TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE

4) Set to the conditions in Table 1, and measure the LS differential pressure. Table 1 Accelerator

Operation

Differential pressure MPa {kg/cm2}

Full

Levers at neutral

2.84 to 3.9 {29 to 40}

Full

Blade lever (operate fully to raise)

2.35 ± 0.1 {24 ± 1}

2. Measuring with an oil pressure gauge a Measure with the same gauge. 1) Remove the high-pressure (1) and low-pressure (2) oil measurement plugs.

4) Set to the conditions in Table 1, and measure the LS pump pressure. a Read the gauge indicator while standing directly in front of it. 5) Set to the conditions in Table 1, and measure the LS pressure. a Read the gauge indicator while standing directly in front of it. LS differential pressure = (LS pump pressure) – (LS pressure)

Adjusting the LS valve When measuring the differential pressure under the above conditions and the pressure is not within the standard value, adjust as follows. 1. To adjust the differential pressure, loosen the locknut (2) and turn the screw (3) • CLOCKWISE to increase pressure • COUNTERCLOCKWISE to decrease pressure One turn of the adjustment screw equals 1.3 MPa {13.3 kg/cm2} 2. After adjusting, tighten the locknut (2) to 49 ± 63.7 Nm {5 ± 6.5 kgm} a Always measure the differential pressure while adjusting.

2) Fit the elbow C5 and nipple C3.

3) Connect the differential pressure gauge C1 (39.2 MPa {400 kg/cm2}). a Use a gauge with a scale in units of 1.0 MPa {10 kg/cm2}.

20-118 (4)

GD555, 655, 675-3C


ADJUSTING PC VALVE BLEEDING AIR FROM HYDRAULIC CIRCUIT

ADJUSTING PC VALVE

BLEEDING AIR FROM HYDRAULIC CIRCUIT

a If the load becomes high and the engine speed drops, or the engine speed remains normal and the work equipment becomes slower, but the pump discharge pressure and the LS differential pressure are normal, adjust the PC valves as follows.

1. Bleeding air from the pump 1) Loosen the air bleed plug (1), and bleed the air from the pump. a When air no longer is discharged with the oil, the air bleeding operation is completed. 2) Tighten the plug (1) from 14.7 to 19.6 Nm {1.5 to 2.0 kgm} a Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idle for 10 minutes.

1. Loosen the locknut (1) and turn the sleeve (2) to adjust as follows. • If the work equipment speed is slow, turn CLOCKWISE. • If the engine speed drops, turn COUNTERCLOCKWISE a Turning the sleeve clockwise increases the pump absorption torque. a Turn the adjustment sleeve within a range of 180° to the left or right. 2. After adjusting, tighten the locknut (1) from 88 to 113 Nm {9 to 11.5 kgm}. Serial No. 50001 – 51000

2. Bleeding air from the pump circuit 1) Start the engine, remove the plugs (1) and (2), and bleed the air. a When air no longer is discharged with the oil, the air bleeding operation is completed. 2) Tighten the plugs (1) and (2).

Serial No. 51001 and up

GD555, 655, 675-3C

20-119 (4)


MEASURING INTERNAL CYLINDER LEAKAGE

MEASURING INTERNAL CYLINDER LEAKAGE 3. Bleeding air from the hydraulic cylinder 1) Start the engine and run at idle for approx. 5 minutes. 2) Run the engine at low idle, and raise and lower the boom 4 to 5 times in succession. a Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from all the cylinders.

a If the hydraulic drift of the work equipment is not within the standard value, measure the amount of leakage inside the cylinder as follows to judge if cause of the hydraulic drift is in the cylinder or in the control valve. • If the amount of leakage is within the standard value, the problem is with the control valve. • If the amount of leakage is not within the standard value, the problem is with the cylinder. a Oil temperature when measuring: 45 to 55°C. 1. Fully extend the cylinder rod to be measured, then stop the engine. a When measuring the blade lift and the scarifier cylinders, lower the work equipment to the ground, remove the joint at the rod end from the work equipment, then extend the cylinder. 2. Disconnect the piping at the head end, and block the piping (1) at the chassis end with a blind plug.

k Be careful not to disconnect the piping at the bottom end. 3. Start the engine, then run the engine at high idle and apply the relief pressure to the bottom end of the cylinder. 4. Wait 30 seconds, then measure the amount of oil that leaks during the next minute. a Minimum leakage: 10 cc BLADE LIFT CYLINDER L.H. R.H.

20-120 (4)

GD555, 655, 675-3C


MEASURING INTERNAL CYLINDER LEAKAGE

BLADE SHIFT CYLINDER

LEANING CYLINDER

POWER TILT CYLINDER

ARTICULATION CYLINDER R.H. L.H.

DRAWBAR SHIFT CYLINDER RIPPER CYLINDER

GD555, 655, 675-3C

20-121 (4)


MEASURING STEERING, BRAKE OIL PRESSURE

MEASURING STEERING, BRAKE OIL PRESSURE k Stop the machine on flat ground, apply the parking brake, and lower the blade completely to the ground. k Stop the engine, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2) Fit the nipple C3, then install the oil pressure gauge C1 (5.88 MPa {60 kg/cm2}).

1. Measuring the steering circuit pressure 1) Remove the oil pressure measurement plug, 10 x 1.25, (1) at the front of the pump. 2) Fit the nipple C3, then install the oil pressure gauge C1 (39.2 MPa {400 kg/cm2}). 3) Run the engine at full throttle, and measure the oil pressure after relieving the left or right steering circuits (operate to end of the stroke). 3) Measure the oil pressure after depressing the brake pedal. a After measuring the oil pressure, install the plug and bleed the air from the system.

2. Measuring the brake circuit pressure a After charging the brake accumulator fully with oil pressure, stop the engine. 1) Remove the air bleed plug (2) (Rc 1/4).

20-122 (4)

GD555, 655, 675-3C


BLEEDING AIR FROM BRAKE PIPING

BLEEDING AIR FROM BRAKE PIPING k Stop the machine on flat ground and put blocks under the front wheels. a Start the engine and charge the accumulator.

2. Bleeding the air between the slack adjuster and the brake 1) Install the vinyl tube (4) to the tip of the air bleed valve (3).

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

2) Depress the brake pedal and loosen the air bleed valve (1) 3/4 turns, then close the valve and release the pedal. 3) Continue this procedure until no more bubbles exit with the oil discharged from the air bleed valve (1). 4) Bleed the air from the slack adjuster air bleed valves at 2 places on the left and right.

GD555, 655, 675-3C

2) Depress the brake pedal and loosen the air bleed valve (3) 3/4 turns, then close the valve and release the pedal. 3) Continue this procedure until no more bubbles exit with the oil discharged from the air bleed valve (3). 4) Bleed the air from the brake air bleed valves at four places on the left and right.

20-123 (4)


CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR

CHARGING NITROGEN GAS FOR BRAKE, WORK EQUIPMENT ACCUMULATOR 1. Before charging with gas, check that the oil pressure is completely released. a If the oil pressure is not released, it is impossible to charge with the nitrogen gas. 2. Turn the charging assembly handle (1) counterclockwise and raise it to the point where it stops. 3. 3. Turn the bleed plug handle (2) counterclockwise to open it.

4. Remove the cap from the gas valve (1), then assemble the charging assembly to the gas valve (2).

8. Open the valve of the nitrogen cylinder slowly and charge the cylinder (bladder) with nitrogen gas. a While doing this step, close the nitrogen cylinder valve from time to time, wait for the charging assembly pressure gauge to become stable, and check the displayed pressure. 9. When the gas is charged to the specified pressure, close the valve of the nitrogen cylinder securely. a If the pressure in the cylinder is too high, turn the handle (2) counterclockwise gradually to release the excessive pressure. 1) Accumulator (721-32-10240, capacity: 3 l): • Specified pressure at 20 ± 5°C: 3.4 ± 0.1 MPa {35 ± 1.0 kg/cm2} • The relationship between the temperature and pressure of the charged gas at the time of charging is as follows. • Px = 35 (kg/cm2) x {273 + t (°C)} / {273 +20(°C)} Px: Pressure of charged gas t: Gas temperature when charging (nearly ambient temperature) 35: Specified gas pressure 2) Accumulator (721-32-10250, capacity: 1 l): • Specified pressure at 20 ± 5°C: 2.0 ± 0.1 MPa {20 ±1.0 kg/cm2} • The relationship between the temperature and pressure of the charged gas at the time of charging is as follows. • Px = 20 (kg/cm2) x {273 + t (°C)} / {273 + 20 (°C)} Px: Pressure of charged gas t: Gas temperature when charging (nearly ambient temperature) 20: Specified gas pressure

5. Connect the nitrogen cylinder and charging assembly with hose assembly (3). 6. Open the nitrogen cylinder valve slightly, take care that the gas does not discharge quickly, and let the gas flow at a pressure from 0.20 to 0.29 MPa {2 to 3 kg/cm2}. When the gas starts to exit from the handle (2), turn the handle (2) clockwise to stop the gas from escaping.

10. Turn the handle (1) counterclockwise. Return the gas valve piston to its original position. Then, turn the handle (2) counterclockwise to release the gas remaining inside the hose and charging assembly. 11. Remove the charging assembly from the accumulator.

7. Turn the handle (1) slowly clockwise to push the piston of the gas valve (1).

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GD555, 655, 675-3C


TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE

TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE 12. Use water or soapy water to check that the gas is not leaking from the gas valve (1). Install the cap and valve guard. a After charging with nitrogen gas, check the charge pressure about a week later to verify pressure is maintaining. After that, check once every month or once every six months, according to the conditions of use. Note that when the check is performed, the pressure will go down. Thus, add a slight charge to replace the pressure that is lost.

k If the following conditions occur during adjustment, replace the circle guide. • When clearance R between the circle and circle guide is lost. • When the clearance between the tip (or root) of the teeth of the circle gear and the root (or tip) of the teeth of the pinion gear of the circle rotation gear becomes zero (0). Testing 1. Testing clearance in top-to-bottom direction Let the blade hang and measure clearance P between the top face of the circle and the bottom face of the drawbar as shown in the diagram. Standard clearance P: 1.5 ± 0.5 mm 2. Checking clearance in front-to-rear direction Leave the blade hanging down, apply force to the rear, then measure clearance Q between the circle and circle guide as shown in the figure. Standard clearance QF (front): 0 mm QC (center): 0.7 mm ([*1]) QR (rear): 1.5 mm or QF = QR = 1 mm (*1: Except GD555-3) Adjusting 1. Adjusting clearance in top-to-bottom direction Raise the blade, remove the bolts (1), (5), and (9), and circle guides (2), (6), and (10). Adjust with shims. a Standard shim thickness: 5.5 mm (Shim thickness: 1 mm, 0.5 mm)

GD555, 655, 675-3C

20-125 (4)


TESTING AND ADJUSTING CIRCLE GUIDE CLEARANCE

2) Adjust clearance D between the end face of the flange at the bottom of the circle rotation gear and the sliding surface on the inside diameter of the circle. Standard clearance at D: 15 to 17 mm (shear pin type) 20 to 22 mm (slip clutch type)

3) When QF=0, tighten locknut (4), then tighten bolt (1) from 490.3 to 608 Nm {50 to 62 kgm}

2. Adjusting clearance in front-to-rear direction 1) Bring the blade lightly into contact with the ground. Loosen the bolt (1) and locknut (4). Extend the bolt (3). Push the circle guide (2) open to make QF=0. a Push open the left and right circle guides (2) uniformly.

20-126 (4)

3. Adjusting clearance in left-to-right direction 1) Loosen the bolt (9) and locknut (12), extend bolt (11), and push the circle guide (10) open to make QR=0. a Push open the left and right circle guides (10) uniformly. 2) Loosen the bolt (5) and locknut (8). Extend the bolt (7), and push the circle guide (6) open to make QC=0. (*: Except GD555-3) a Push open left and right circle guides (6) uniformly. 3) When QR=0, turn the bolt (11) back 1/4 turn, and tighten the locknut (12). Turn back the circle guide (10) until it contacts the bolt (11). Then tighten the bolt (9) from 490.3 to 608 Nm {50 to 62 kgm} 4) The standard clearance between the tip of the teeth of the circle gear and the root of the teeth of the pinion gear of the rotation gear is from 1.5 to 3.0 mm. 5) When QC=0, turn the bolt (7) back 1/2 turn and tighten locknut (8). Turn back the circle guide (6) until it contacts the bolt (7). Tighten the bolt (5) from 490.3 to 608 Nm {50 to 62 kgm}. (*: Except GD555-3) 6) Check that the circle guide rotates even when the work equipment is set to the 90° high bank position on the left and right.

GD555, 655, 675-3C


TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE

TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE Testing 1. Remove bolts (1) and cover (2). 2. Check that you can see the internal teeth of worm wheel (3) through the hole at P.

3. Press the blade against the ground and raise the front wheel to lock the circle or fix the blade end. • How to raise the front wheel 1) Lower the blade to the ground and extend the blade lift cylinder until the front wheels are raised. 2) Apply the parking brake.

4. Run the engine at full throttle and operate the circle rotation lever slowly to see if the clutch slips. • Check by rotation of worm wheel (3). • If worm wheel (3) rotates and the blade does not rotated, the clutch is slipping. Adjusting 1. When clutch does not slip 1) Remove bolts (4) and holder (5) and add 1 shim 0.2 mm thick (6). 2) Install holder (5) and tighten bolts (4).

3 Bolt (4): 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}

3) Check the clutch for slipping according to the "testing" procedure. 4) Repeat steps 1) - 3) until the clutch slips and set the clutch to the critical slipping point. 5) If the clutch comes to slip, remove 1 shim 0.2 mm thick (6). a After the shim is adjusted, the clutch must not slip.

GD555, 655, 675-3C

20-127 (4)


TESTING AND ADJUSTING SLIP CLUTCH-TYPE ROTARY DEVICE

2. When clutch slips 1) Remove bolts (4) and holder (5), and then remove 1 shim 0.2 mm thick (6). 2) Install holder (5) and tighten bolts (4). 3 Bolt (4): 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm}

3) Check the clutch for slipping according to the "testing" procedure. 4) Repeat steps 1) - 3) until the clutch does not slip and set the clutch to the critical slipping point. 5) At the critical slipping point, remove 1 shim 0.2 mm thick (6). a After the shim is adjusted, the clutch must not slip.

3. Installation of cover 1) Install cover (2) and tighten bolts (1).

3 Bolt (1): 65.7 ± 6.8 Nm {6.7 ± 0.7 kgm}

Running in clutch • After the clutch disc is replaced with new one, run in the clutch according to the following procedure. a When installing the disc, apply oil GO #90 to its both sides. 1) Set the clutch to the critical slipping point according to adjusting steps 1 and 2. 2) Add 1 shim 0.2 mm thick so that the clutch will slip. 3) Slip the clutch for 3.5 - 4.0 seconds. • Run the engine at full throttle. • The clutch rotates 1 turn while it is slipping for 3.5 - 4.0 seconds. 4) Repeat step 2) by 20 - 25 times at intervals of 3 minutes.

k If the clutch housing temperature exceeds 50 °C, stop the work until it lowers to the normal temperature. k If the clutch stops slipping during the work, add 1 shim 0.2 mm thick.

5) Wait until the clutch is cooled to the normal temperature. 6) Set the clutch to the critical slipping point again (according to steps 1 and 2). 7) Remove 1 shim 0.2 mm thick so that the clutch will not slip.

20-128 (4)

GD555, 655, 675-3C


MEMORIZING IDLE AND FULL POSITION PROCEDURE

MEMORIZING IDLE AND FULL POSITION PROCEDURE Accelerator, inching potentiometer a If the accelerator pedal assembly, accelerator linkage and inching pedal assembly have been removed or replaced, perform the operation to memorize the idle position and full position after installing. a For the accelerator, perform the operation after adjusting the accelerator control linkage. 1. Memorizing the idle position 1) Release the accelerator pedal and inching pedal, and leave the pedal free. 2) Set the regulator lever to the idling position. 3) Turn the start switch to the ON position. 4) Push the potentiometer set switch (1) down for at least 1 second. a If the buzzer sounds continuously for 2 seconds, the value for the accelerator and inching potentiometer idling position has been stored cor-rectly. a If the buzzer sounds three times in a cycle of 1 second on, 1 second off, the setting has not been stored in memory.

2. Memorizing the full position 1) Depress the accelerator pedal and inching pedal fully. 2) Turn the start switch to the ON position. 3) Push the potentiometer set switch (1) up for at least 1 second. a If the buzzer sounds continuously for 2 seconds, the value for the accelerator and inching potentiometer full position has been stored correctly. a If the buzzer sounds three times in a cycle of 1 second ON, 1 second OFF, the setting has not been stored in memory. Measuring voltage Pedal

Connector

Potentiometer voltage

Accelerator

T9 C to B

2.42 to 4.3

Inching

T8 C to B

3.2 to 4.0

Measuring voltage Pedal

Connector

Potentiometer voltage

Accelerator

T9 C to B

1 to 2

Inching

T8 C to B

0.8 to 1.6

GD555, 655, 675-3C

20-129 (4)


INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER

INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER •

•

•

The transmission controller is equipped with a self-compensating learning function that corrects to a fixed level the differences in operating feeling caused by the individual differences in the hydr aulic val ves and maintains a constant gearshifting feeling by compensating for the changes in the transmission clutches caused by wear. If the transmission is overhauled or replaced, or the hydraulic valves are replaced, the transmission controller still has the control command values learned to match the previous transmission. For this reason, transmission shock, abnormal noise, or defective operating feeling may occur. After operating the machine for a short time, the controller will learn the condition of the new transmission and will gradually return to the optimum condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to carry out resetting of the learned data, learning of correction of individual valve differences, and initial learning of stabilized transmission feeling as follows.

1. Preparation of machine for learning of correction for individual differences in valves and initial learning of transmission feeling stabilization • It is necessary to carry out the learning operation at the specified oil temperature, so do as follows to raise the oil temperature. 1) Depress the brake pedal fully, set the gearshift lever to R4, stall the torque converter, and raise the transmission oil temperature. During the stall operation, keep the gearshift lever at R4 and do not shift to any other speed range. (If the stall operation is carried out in any speed range other than R4, there is danger that the machine may pitch or the clutch may be damaged.) 2) Raise the machine and set it on a stand to keep the rear wheels off the ground 3) Operate the gearshift lever as follows to circulate the oil fully through the transmission valves and the whole of the case. P o N o F1 o F2 o F3 o F4 o N o R1 o R2 o R3 o R4 o N 4) Use the above operation to raise the oil temperature to 50 – 60°C. 5) Set to N, run the engine at idling for 3 minutes, check again that the oil is at the specified level, then turn the engine starting switch OFF.

20-130 (4)

2. Resetting learned data a Do as follows to return all the previously learned control data in the controller to the default values. 1) Check that the starting switch is at the OFF position. 2) Turn the starting switch ON. (Do not start the engine.) 3) Push memory set/learning function initializing switch (1) down for at least 1 second, then turn the starting switch OFF. 3. Method for learning correction for individual differences in valves • When correcting the individual differences in the valves, do as follows. The correction operation is for three types of clutch: FL, FH, and R. 1) Start the engine and run it at low idling. (Depress the accelerator pedal, then let it back fully.) 2) Push memory set/learning function initializing switch (1) up, then within 0.8 seconds, push the reset switch. Hold it in this condition for at least 1 second, then release the switch.

3) The learning of the correction for individual differences in the valves will start and [FWL1] - [REV3] will be displayed on message center (3).

GD555, 655, 675-3C


•

INITIAL LEARNING METHOD FOR TRANSMISSION CONTROLLER

Item

Display

Item

Display

Item

Display

1st time for FL

FWL1

1st time for FH

FWH1

1st time for R

REV1

2nd time for FL

FWL2

2nd time for FH

FWH2

2nd time for R

REV2

3rd time for FL

FWL3

3rd time for FH

FWH3

3rd time for R

REV3

The transmission oil temperature is displayed on the controller LED during the correction of the individual differences in the valves. 4) The corrected values are saved in the controller memory and the correction learning function is automatically completed. 5) When the correction learning is completed, the message center returns to the normal display. 6) Turn the start switch OFF.

4. Initial learning method for stabilized transmission feeling • To adjust the controller learning control data for each clutch from the default settings to the optimum values, always carry out resetting of the learned data and learning of the correction for individual differences in the valves, then do as follows. 1) Start the engine and run at low idling. 2) Set the transmission mode switch to [Mode 1]. 3) Operate the gearshift lever as follows three times in succession: P o N o F1 o F2 o F3 o F5 o F3 o F2 o F1 o N o R1 o R2 o R3 o R4 o R3 o R2 o R1 o N a When doing this, hold each speed range for at least 3 seconds, then shift to the next speed range.

GD555, 655, 675-3C

20-131 (4)


DIODE CHECKING PROCEDURE

DIODE CHECKING PROCEDURE • •

Use the following procedure to check the diode as an individual part and the wiring harness, including the diode. Use a digital tester with a range for measuring diodes.

1. Put the red (+) test pin in contact with the diode’s anode (P), and the black (–) test pin in contact with the cathode (N). a A mark exists on the diode surface that shows the direction of continuity. 2. If a normal tester is switched to the diode range, the internal battery voltage is displayed. The value indicates the following. • No change: No continuity • Changes: Continuity exists (normal) (Note) • The value is 0 or near 0: Short circuit inside the diode. NOTE: With silicon diodes, a value between 0.450 and 0.600 is displayed.

20-132 (4)

GD555, 655, 675-3C


MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

MOVING MACHINE WHEN TRANSMISSION VALVE FAILS a If the machine cannot be moved because of a failure in any part of the transmission valve system (electrical system, solenoid valves, spools, etc.), it is possible to move the machine by installing Plug K.

k Plug K is only for emergency use when the machine cannot be moved by any other means because of a failure in the transmission control valve system. Do not install plate N to the ECMV except when there has been a failure and it is necessary to move the machine from a dangerous working area to a safe place for repairs. k When carrying out this operation, keep strictly to the procedure and pay careful attention to safety when moving the machine.

3. Depending on the direction for moving the machine (forward or reverse), remove the following 2 ECMV sooenoids (3) and install Plug K. • FORWARD: F L solenoid and 2nd solenoid • REVERSE: R solenoid and 2nd solenoid a If there is any mistake in the selection of the solenoid to remove, there is danger that the transmission may be damaged. a Install Plug K with the protruding surface facing the ECMV. Check also that there is an Oring installed to the mating surface. a Be careful not to let any dirt or mud get inside the removed solenoid or valve.

k To prevent the machine from moving, lower the work equipment completely to the ground, apply the parking brake, and put blocks under the tires. k Carry out operation with the engine stopped.

k Be careful not to burn yourself if the oil is hot. 1. Remove valve cover (1) at front of transmission. a Clean around the ECMV and remove all dirt and dust.

2. Disconnect wiring connectors (2). (14 places)

GD555, 655, 675-3C

20-133 (4)


MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

4. Depress the brake pedal securely. 5. Start the engine, release the parking brake, then release the brake pedal gradually to allow the machine to start, then move the machine. k Remove the blocks under the tires.

k When the engine is started, the transmission is also engaged to start the machine. To ensure safety when starting the engine, check carefully that the direction of travel and area around the machine are safe. Always keep the brake pedal depressed when starting. k After moving the machine, stop the engine, apply the parking brake, and put blocks under the tires.

20-134 (4)

GD555, 655, 675-3C


ADJUSTING CAB STOPPER BOLT

ADJUSTING CAB STOPPER BOLT 1. Remove 4 stopper bolts (1). (Top, bottom, left, right)

5. Check clearance a between door handle (5) and cab (surface of glass). • Clearance a = 8 mm

6. If clearance a is 8 mm, door striker (3) is not angled to the left or right, and the center of door striker (3) is aligned, the adjustment of door striker (3) is correct. a If the adjustment of the striker is correct, go on to Step 10. 7. If the striker is angled to the left or right, install door striker (3) so that installation height b from the surface of door glass (6) is uniform. • Installation height b: 67 ± 1 mm (standard)

2. Check that door striker (3) is properly set and is not angled to the left or right. 3. Fit door striker (3) to lock (4) on the cab. 4. Check that the centers of door striker (3) and lock (4) on cab are aligned.

8. If clearance a is less than 8 mm, move the mounting of door striker (3) out from the surface of door glass (6) by an amount equal to clearance a - 8 mm. Fit the door to the cab again and check that clearance a is 8 mm. 9. If the center of door striker (3) is not aligned, remove door link cover (2) and move door striker (3) up or down to set it in the center. 10. Install 4 stopper bolts (1). (Top, bottom, left, right) 11. Screw stopper bolts (1) fully into the cab, then fit door striker (3) to lock (4) on the cab. 12. If there is a clearance at portion C of door glass (6) and the rubber tip of stopper bolt (1), the condition is correct. a If there is a clearance at portion C, go to Step 15.

GD555, 655, 675-3C

20-135 (4)


ADJUSTING CAB STOPPER BOLT

13. If there is no clearance at portion C of door glass (6) and the rubber tip of stopper bolt (1) (when the rubber tip is pushed against the glass surface), replace stopper bolt (1).

a Remove 20Y-54-11611 (length below head: 42 mm) and install 23A-952-1430 (length below head: 32 mm) 14. Fit door striker (3) to lock (4) on the cab, and check again that there is a clearance at portion C of door glass (6) and the rubber tip. 15. Turn the stopper bolt and put it in contact with the surface of door glass (6). (Clearance at portion C = 0) 16. With the clearance of stopper bolt (1) = 0, turn the bolt 3 turn to the left (to move it out from the surface of the glass).

20-136 (4)

GD555, 655, 675-3C

TROUBLESHOOTING TROUBLESHOOTING POINTS TO REMEMBER...................................................................................... 20-202 TROUBLESHOOTING SEQUENCE........................................................................................................... 20-203 POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE .......................................................... 20-204 CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212 CONNECTOR TYPES AND MOUNTING LOCATIONS ............................................................................. 20-213 CONNECTOR ARRANGEMENT DIAGRAM .............................................................................................. 20-222 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-230 MESSAGE CENTER DISPLAY AND TABLE ERROR CODES .................................................................. 20-251 USING THE TROUBLESHOOTING CHARTS............................................................................................ 20-255

GD555, 655, 675-3C

20-201 (4)

TROUBLESHOOTING

TROUBLESHOOTING POINTS TO REMEMBER

TROUBLESHOOTING POINTS TO REMEMBER

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.

k When removing the plug or cap from a location which is under pressure from oil, water or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after a failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask the user or operator. 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting. 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment.

20-202 (4)

3) Check the travel of the control levers. 4) Check the stroke of the control valve spool. 5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming the failure. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

GD555, 655, 675-3C

TROUBLESHOOTING

TROUBLESHOOTING SEQUENCE

TROUBLESHOOTING SEQUENCE

GD555, 655, 675-3C

20-203 (4)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE

POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil). 1. Precautions when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protector or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness 1) Faulty contact of connectors (faulty contact between male and female). Problems with faulty contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidation of the contact surfaces.

2) Defective compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper connection or breakage.

20-204 (4)

GD555, 655, 675-3C

TROUBLESHOOTING


3) Disconnections in wiring If the wiring is held and tugged and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping compression of the connectors to the wire may be loosened, or the soldering may be damaged, or the wiring may be broken.

4) High pressure water entering a connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. The connector is designed to prevent water from entering, but if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

5) Oil, grease or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, and this will cause a defective contact. If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is water or oil present, it will increase the contamination of the points, so clean with air until all water and oil has been removed.

GD555, 655, 675-3C

20-205 (4)

TROUBLESHOOTING


2) Removing, installing, and drying connectors and wiring harnesses • Disconnecting connectors 1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never try to pull apart with one hand. 2) When removing the connectors from the clips, pull the connector in a parallel direction to the clip. a If the connector is twisted to the left and right or up and down, the housing may break.

3) Action to take after removing connectors. After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

•


Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, faulty contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has gotten inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. Since the DT 8-pole and 12-pole heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. a 1: Male connector, 2: Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c

2) Assemble the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with a lock stopper: Push in the connector until the stopper clicks into position. 3) Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with properly filtered air. 4) When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp.

GD555, 655, 675-3C

20-207 (4)

TROUBLESHOOTING

•


Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows: 1) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with air, there is the risk that oil in the air may cause a faulty contact, so avoid blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, spray it with contact restorer and reassemble.

20-208 (4)

GD555, 655, 675-3C

TROUBLESHOOTING


3) Handling control box 1) The control box contains a microcomputer and electronic control circuits. This controls all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2) Do not open the cover of the control box unless necessary.

3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) Do not leave the control box in a place where it is exposed to rain.

6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) 7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in the circuit.

GD555, 655, 675-3C

20-209 (4)

TROUBLESHOOTING


3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust proof workshop, and the performance should be confirmed with special test equipment.

3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tape, or vinyl bags to prevent any dirt or dust from entering. Never leave any openings opened or blocked with a rag, this could cause particles or dirt to get into the system. Drain all oil into a container and not unto the ground and be sure to follow the proper environmental regulation for any disposal of oil.

4) Do not let any dirt, or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-210 (4)

GD555, 655, 675-3C

TROUBLESHOOTING


5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

GD555, 655, 675-3C

20-211 (4)

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING Action

Check fuel level, type of fuel

—

Add fuel

2.

Check for impurities in fuel

—

Clean, drain

3.

Check hydraulic oil level

—

Add oil

4.

Check hydraulic oil strainer

—

Clean, drain

5.

Check the transmission oil level strainer

—

Add oil

6.

Check the final drive oil level

—

Add oil

7.

Check the tandem drive oil level

—

Add oil

8.

Check the circle reverse gear oil level

—

Add oil

9.

Check the engine oil level (Oil pan oil level), oil type

—

Add oil

10. Check the coolant level

—

Add coolant

11. Check the dust indicator for clogging

—

Clean or replace

12. Check the hydraulic filter

—

Replace

1.

Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

2.

Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

3.

Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

1.

Check for abnormal noise, smell

—

Repair

2.

Check for oil leakage

—

Repair

3.

Carry out air bleeding

—

Bleed air

1.

Check battery voltage (Engine stopped)

20 – 30 V

Replace

2.

Check battery electrolyte level

—

Add or replace

3.

Check for discolored, burnt, exposed wiring

—

Replace

4.

Check for missing wiring clamps, hanging wire

—

Repair

5.

Check for water leaking on wiring (Pay particular attention to water leaking on connectors or terminals)

—

Disconnect connector and dry

6.

Check for blown, corroded fuses

—

Replace

7.

Check alternator voltage (Engine running at 1/2 throttle or above)

After running for several minutes: 27.5 – 29.5 V

Replace

8.

Sound of actuation of battery relay (When starting switch is turned ON, OFF)

—

Replace

Electrics, electrical equipment

Lubricating oil, coolant

1.

Electrical equipment

Judgement Value

Hydraulic, mechanical equipment

Item

20-212 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING LOCATIONS


12 14 16 16 20 7 12 12 12 8 8 2 8 12 8 8

B11

L

2

B12

L

2

B13 B14

DT2 DT2

2 2

B15

KES

2

B16

KES

2

B17 B18 B19 B20

KES DT2 DT2 DT2

2 3 3 2

B21

DT2

2

B22 B23 B24 B25 BR1 BR2 BR3 BR4 BR5 BR6 BR7 BR8

DT1 L DT2 (B) DT2 (B) DT2 DT2 DT2 Relay Relay Relay Relay Relay

4 1 8 12 2 2 2 5 5 5 5 5

BR9

Relay

5

BR10 BR11

Relay Relay

5 5

GD555, 655, 675-3C

Air-con unit Air-con unit Air-con unit Air-con control unit Air-con control unit Air-con intake duct Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector (battery relay) Intermediate connector (starter motor) Brake lamp switch Brake lamp switch Window washer (Front upper) Window washer (Front lower) Window washer (Rear) Float cancel switch (R.H.) Float cancel switch (L.H.) Engine start solenoid Diode (Engine start up solenoid) Intermediate connector Fuse box Intermediate connector Intermediate connector Diode (Battery relay) Diode (Battery relay) Diode (Buzzer) Alternator relay Charge lamp relay Back-up alarm relay Differential relay VHP relay Accumulator hydraulic pressure relay Brake pump relay Parking brake relay

G-9 X-3 W-2 U-7 U-8 W-2 D-8 C-8 C-8 A-8 C-9 D-8 C-9 B-9 B-9 B-9 B-8 B-8 D-7 D-7 G-3 G-3 G-3 D-6 E-4 G-9

BR12 BR13

Relay Relay

5 6

Neutral relay Front work lamp relay

BR14

Relay

5

Rear work lamp relay

BR15 BR16 BR18 BR19 BR20 BR21 BR22 BR23

Relay Relay KES KES KES DT2 M DT2

5 5 4 6 4 2 2 2

BR24

DT2

2

BR25

DT2

2

BR26 BR27 BR28 BT30 BT31 BT32 BT33 BT34 BT35 BT36 BT37 BT38

8 8 3 1 1 1 1 1 1 1 1 1

O-5 P-5 N-4 D-7 P-5 P-5 P-5 P-5 P-5 M-3 N-3 N-3

1

Switch panel lamp

P-5

1

Cigar lighter

Q-5

1

Cigar lighter

Q-5

1

Accumulator float switch

—

1


—

1


—

C1 C2

VCH VCH DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector 1-pin connector 1-pin connector 1-pin connector DT2 (G) DT2 (Gr)

Float cancel relay (R.H.) Float cancel relay (L.H.) Front wiper switch Preheat timer relay Flasher Buzzer (B) Buzzer (A) Lifter lock switch Work lamp switch (If equipped) Fog lamp switch (If equipped) Hazard lamp switch Head lamp switch Accumulator float switch GND Starter switch (B) Starter switch (Br) Starter switch (R1) Starter switch (C) Starter switch (ACC) Horm relay Horm relay Horm relay

8 8

G-4 H-4

C3

DT2

6

C4 C5 C6 C7 C8

DT1 — KES KES KES

3 9 2 2 6

Intermediate connector Intermediate connector Intermediate connector (Wiper) Heater (If equipped) Radio (If equipped) Speaker (R.H.) Speaker (L.H.) Rear wiper switch

BT41

H-9

BT42

B-8 K-6 L-6 L-6 M-5 M-5 N-4 Q-1 Q-1 R-3 R-2 R-2

BT43

R-2 R-3 P-5

BT44 BT45 BT46

Mounting location

Address

SWP SWP SWP — — — DT2 (G) DT2 (Gr) DT2 (Br) DT2 (B) DT2 (G) L DT2 (Br) DT2 (B) DT2 (Gr) DT2 (G)

Type

No. of pins

No. of pins

AC1 AC3 AC4 AC5 AC6 AC8 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Mounting location

Connector No.

Type

Address

Connector No.

Serial No. 50001 – 51000

Q-5 R-3 P-4 R-3 R-4 R-3 N-4 R-4 R-4 P-1 Q-1 Q-5 O-4 O-5

H-4 H-4 U-8 V-8 X-7 X-4

20-213 (4)

6 2 2 2 2 2 4 4

C17

KES

4

C18

KES

4

C19

Relay

5

C20

M

2

C21

Relay

5

C22

KES

3

C23 C24 C25 C26

M M M M

2 2 2 2

C27

M

3

C28

M

3

C29 C30

M KES

2 2

C31

M

2

C32

M

2

C33

M

3

C34

M

3

1-pin connector CT41 TERMINAL E1 DT2 CT35

2

E9 E10 E11

(PKD) DT2 DT2

3 3 2

E12

DT2

3

E13

DT2

3

E14

DT2

3

E15 E16

DT2 DT2

6 4

E17

DT2

2

V-2

E18

DT2

2

X-6

E95

T-7 S-6 S-6 S-5

ET39

1

Beacon

S-5

1 2

Gnd Alternator Thermostat sensor (GD655, 675) Thermostat sensor (GD555) Intermediate connector Hydraulic thermo sensor for T/C (If equipped) Hydraulic thermo sensor for AWD (If equipped) Diode (Starter relay) Diode (Grid heater relay)

X-3 H-9

X

2

E2

X

2

E3

DT2

2

E4

X

2

E5

DT2

2

E6 E7

DT2 DT2

2 2

(4)

DT2

X-3 T-7 X-4 X-5 U-2 X-6 S-4 W-7

E2

20-214

E8

Front lower wiper switch Room lamp switch Fan switch (front) Fan switch (rear) Defroster fan (front) Defroster fan (rear) Front wiper motor Rear wiper motor Front lower wiper motor (R.H.) Front lower wiper motor (L.H.) Front lower wiper motor relay (R.H.) Beacon switch Work lamp relay (If equipped) Work lamp switch (If equipped) Work lamp (If equipped) Work lamp (If equipped) Work lamp (If equipped) Work lamp (If equipped) Head lamp (R.H.) (If equipped) Head lamp (L.H.) (If equipped) Power (24V) (Spare) Spot lamp (If equipped) Intermediate connector (Defroster fan, front) Intermediate connector (Defroster fan, rear) Combination lamp (R.H.) (If equipped) Combination lamp (L.H.) (If equipped)

T-2 U-2 V-2 X-5

S-3 S-5 X-6 V-8 U-2 X-6 T-3 S-6

H-9 I-9 J-8 J-7 J-7 J-4 I-3

ET40 ET41 ET42 ET43 ET44 ET45 ET46 ET47 ET48 ET49 ET50 ET51 ET52 ET53 ET54 ET55 ET56 ET58 ET59 ET60 ET62 ET63 ET64 ET65 ET66 ET67 ET68 ET69 ET70 ET71 ET72

1-pin connector 1-pin connector TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

1

Mounting location Diode (Fuel shut-off relay) Fuel shut-off solenoid VHP valve Diode (VHP valve) Engine oil pressure switch Accumulator hydraulic pressure switch (R.H.) Accumulator hydraulic pressure switch (L.H.) Joint connector Intermediate connector Diff. thermostat sensor (If equipped) Diff. lock solenoid (If equipped) Hydraulic thermo sensor for T/C

Address

KES KES M M M M KES KES

Type

No. of pins

No. of pins

C9 C10 C11 C12 C13 C14 C15 C16

Mounting location

Connector No.

Type


Address

Connector No.

TROUBLESHOOTING

J-6 J-7 J-7 J-7 J-6 H-4 H-4 J-5 I-4 H-4 I-4 —

1

Fuel sensor

J-8

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Gnd Battery (-) Battery (+) Battery (-) Battery (+) Battery relay Battery relay Slow blow fuse Slow blow fuse Battery relay Starter motor Starter motor (Gnd) Gnd Starter motor (B) Grid heater relay Grid heater relay Grid heater Battery relay Slow blow fuse Slow blow fuse Battery relay Slow blow fuse Battery relay Alternator (B) Alternator (I terminal) Alternator (E) Slow blow fuse Slow blow fuse Fuel shut-off relay Fuel shut-off relay Starter relay

J-6 J-6 J-6 G-9 G-9 K-3 K-2 I-2 J-2 K-2 H-9 I-9 J-7 H-9 J-2 I-3 J-7 K-3 I-2 I-2 K-3 H-9 L-3 M-8 M-8 M-8 I-2 I-2 J-5 I-5 K-2

GD555, 655, 675-3C

DT2

2

FL10

DT2

2

FL11 FL12 FL13 FL14 FL15 FL16 FL17 FL18

DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2

FL19

1 1 1 1 1 1 1 1 1

Starter relay Starter motor (C) Battery relay (+) Battery relay (–) Gnd Starter relay Starter relay Grid heater relay Grid heater relay

J-4 H-9 J-4 K-4 I-5 K-2 J-4 I-4 J-2

1

Aircon compressor

J-7

1 1 1 1 1 1 3 3 3 8 12 8 2 2 2

J-6 I-5 I-5 J-6 J-5 I-4 — B-5 A-2 A-4 D-6 D-6 E-5 F-4 F-4

2 2 2 2 2 2 2 2

Battery (–) Fuel shut-off relay Fuel shut-off relay Gnd (Engine) Gnd (Engine) Gnd (Alternator) Intermediate connector Head lamp (R.H.) Head lamp (L.H.) Intermediate connector Intermediate connector Intermediate connector Articulate sensor Lifter lock solenoid Parking brake solenoid Accumulator solenoid (R.H.) Accumulator solenoid (L.H.) Float solenoid (R.H.) Float solenoid (R.H.) Float solenoid (L.H.) Float solenoid (L.H.) Diode (solenoid) Diode (solenoid) Diode (solenoid) Diode (solenoid)

DT2

2

Diode (solenoid)

FL20

DT2

2

Diode (solenoid)

FL21 FL22 FL23 FL24 FL25

DT2 M M M M

4 3 3 2 2

FL26

M

2

FL27

M

2

Intermediate connector Combination lamp (R.H.) Combination lamp (L.H.) Fog (If equipped) Fog (If equipped) Front work lamp (R.H.) (If equipped) Front work lamp (L.H.) (If equipped)

ET88

GD555, 655, 675-3C

C-6 E-2 B-5 C-6 D-2 C-6 C-1 F-3 D-1 D-1 E20 E20 C-6 A-5 A-2 A-4 A-3 E-5 F-4

FL28

M

2

FL29

M

2

FP1 FP2 FP3 FP6 FP7 FP8 FP9 FP10 FP11 FP12

DT2 (Gr) DT2 (B) DT2 (Br) DT2 (B) DT2 (Gr) DT2 (Br) KES DT2 DT2 DT2

12 12 12 12 8 12 1 4 3 3

FP13

DT2

2

FP14

DT2

2

FP15

DT2

2

FP16

DT2

6

FP17

DT2

3

FP18

DT2 1-pin connector 1-pin connector TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector 1-pin connector 1-pin connector TERMINAL TERMINAL TERMINAL

3

Front work lamp (spare) (R.H.) Front work lamp (spare) (L.H.) Meter assembly Warning module (L.H.) Warning module (R.H.) Intermediate connector Intermediate connector Intermediate connector Service meter Message center Turn signal switch Dimmer switch Differential switch (If equipped) AWD on/off switch (If equipped) AWD auto/manual switch (If equipped) AWD auto/manual switch Front wheel rev. tuning potentiometer Intermediate connector

1

Horn (L.H.)

F-4

1

Horn (R.H.)

E-5

1 1 1 1 1 1

Floor (Floor) Gnd (front frame) Gnd (front frame) Gnd (rear frame) Articulate sensor (–) Articulate sensor (G) Speed meter (If equipped)

E-5 F-4 D-7 J-5 — —

FT6 FT7 FT10 FT11 FT12 FT13 FT16 FT17 FT18 FT19 FT20 FT21 FT22 FT23 FT24 FT25

1

Mounting location

Address

Type

No. of pins

FL9

Mounting location

Connector No.

ET89 ET90 ET91 ET92 ET93 ET94 FB18 FL1 FL2 FL3 FL4 FL5 FL6 FL7 FL8

TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL DT2 M M DT2 (B) DT2 (B) DT2 (Br) DT2 (PKD) (PKD)

ET73 ET74 ET75 ET76 ET77 ET80 ET81 ET82 ET83


Address

Type

No. of pins

Connector No.

TROUBLESHOOTING

B-5 B-1 D-8 D-8 E-9 B-7 B-8 A-8 D-7 E-9 D-8 D-8 D-8 D-8 D-8 E-9 E-9 E-9

D-9

1

T/C HYD temp. gauge

1

Water temperature gauge D-9

1

Fuel gauge

D-9

1

Articulate gauge

D-9

1 1 1

T/C HYD temp. gauge (B) T/C HYD temp. gauge (T) T/C HYD temp. gauge (E) Water temperature gauge (B) Water temperature gauge (T) Water temperature gauge (E)

D-9 D-9 D-9

FT26 TERMINAL

1

FT27 TERMINAL

1

FT28 TERMINAL

1

—

D-9 D-9 D-9

20-215 (4)

Fuel gauge (B) Fuel gauge (T) Fuel gauge (E) Articulate gauge (E)

D-9 D-9 D-9 D-9

T20 T21 T22

DT2 (B) DT2 DT2 (Gr)

1

Articulate gauge (B)

D-9

1

Articulate gauge (T)

D-9

1

Articulate gauge

D-9

1

Horn switch

F-9

2 1 1 8 6 6

F-9 F-9 F-9 J-8 I-9 J-8

RL4

M

2

RL5

M

2

Heater If equipped If equipped Intermediate connector Combination lamp (R.H.) Combination lamp (L.H.) Rear work lamp (If equipped) Rear work lamp (If equipped) License lamp Back-up alarm Back-up alarm Rear work lamp (If equipped) Rear work lamp (If equipped) T/M controller T/M controller T/M controller T/M controller T/M controller T/M controller Connector for flash ROM writer Connector for specification selection Inching potentiometer Accelerator potentiometer For floor harness Intermediate connector Intermediate connector Shift lever T/C lockup switch Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector

FT33 FT34 FT35 FT37

RT1 M RT2 TERMINAL RT3 TERMINAL 1-pin RT4 connector 1-pin RT5 connector T1 MIC T2 MIC T3A 040 T3B 040 T4 040 T5 MIC

1 1 1 1 1 13 21 20 16 12 17

T6

DT2

4

T7

DT2

6

T8

DT2

3

T9

DT2

3

T10 T11 T12 T13 T14 T15 T16 T17 T18 T19

DT2 (G) DT2 (Gr) DT2 DRC DT2 DT2 DT2 (Br) DT2 (B) DT2 DT2 (Gr)

12 8 6 24 2 2 12 8 6 12

20-216 (4)

12 6 12

T23

DT2

3

T24 T25 T26 T27 T28 T29 T30 T31

DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2

2 2 2 2 2 2 2 2

T32

DT2

2

T33

DT2

2

T34

DT2

2

T35

DT2

2

T36 T37 T38 T39 T40 T41 T42 T43 T44 T46 T47 T48 T49 T50 TT1 TT2 TT3 TT4 TT5 TT6 TT7 TT8 TT9

DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

2 2 2 2 2 2 2 2 6 2 6 6 6 6 1 1 1 1 1 1 1 1 1

I-9 J-8 J-8 J-8 I-9 — — N-3 N-4 N-2 N-3 N-3 Q-5 D-7 O-1 P-1 O-1 A-7 A-8 C-8 N-3 N-4 N-4 A-9 A-9 A-8 A-9

Mounting location Intermediate connector Intermediate connector Intermediate connector Intermediate connector (for MF controller) FL solenoid FH solenoid R solenoid 1st solenoid 2nd solenoid 3rd solenoid 4th solenoid Lockup solenoid Transmission input shaft speed sensor Transmission output shaft speed sensor T/C hydraulic temp. sensor T/M hydraulic temp. sensor FL clutch fill switch FH clutch fill switch R clutch fill switch 1st clutch fill switch 2nd clutch fill switch 3rd clutch fill switch 4th clutch fill switch Lockup clutch fill switch Intermediate connector Engine riv. sensor Joint connector Joint connector Joint connector Joint connector Potentiometer set switch Potentiometer set switch Potentiometer set switch Intialize switch Intialize switch Intialize switch Reset switch Reset switch Gnd (Floor)

Address

Connector No.

1 1 1 1

H1 OP1 OP2 RL1 RL2 RL3

TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector 1-pin connector M M M DT2 (Br) M M

FT29 FT30 FT31 FT32

Mounting location

No. of pins

Address


Type

Type

No. of pins

Connector No.

TROUBLESHOOTING

Q-9 Q-9 Q-9

R-8 R-8 R-8 R-7 R-7 R-7 R-6 N-9 R-9 Q-6 R-8 R-6 R-8 R-7 R-8 R-7 R-7 R-6 R-6 N-8 A-8 Q-9 P-9 P-9 Q-9 Q-9 R-4 R-4 R-4 R-5 R-5 R-5 Q-5 R-5 D-8

GD555, 655, 675-3C

TROUBLESHOOTING


12 14 16

AC5

—

16

AC6

—

20

AC8

—

7

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

DT2 (G) DT2 (Gr) DT2 (Br) DT2 (B) DT2 (G) L DT2 (Br) DT2 (B) DT2 (Gr) DT2 (G)

12 12 12 8 8 2 8 12 8 8

B11

L

2

B12

L

2

B13

DT2

2

B15

KES

2

B16

KES

2

B17

KES

2

B18 B19 B20

DT2 DT2 DT2

3 3 2

B21

DT2

2

B22 B23 B24 B25 B26 B27 BR1 BR2 BR3 BR4 BR5 BR6 BR7 BR8

DT1 L DT2 (B) DT2 (B) DT2 DT2 DT2 DT2 DT2 Relay Relay Relay Relay Relay

4 1 8 12 2 2 2 2 2 5 5 5 5 5

BR9

Relay

5

GD555, 655, 675-3C

Air-con unit (If equipped) Air-con unit (If equipped) Air-con unit (If equipped) Air-con control unit (If equipped) Air-con control unit (If equipped) Air-con intake duct (If equipped) Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector (Battery relay) Intermediate connector (Battery relay) Brake lamp switch Window washer (Front upper) (If equipped) Window washer (Front lower) (If equipped) Window washer (Rear) (If equipped) Float cancel switch (R.H.) Float cancel switch (L.H.) Engine start solenoid Diode (Engine start up solenoid) Intermediate connector Fuse box Intermediate connector Intermediate connector Diode Diode Diode (Battery relay) Diode (Battery relay) Diode (Buzzer) Alternator relay Charge lamp relay Buck-up alarm relay Differential relay VHP relay Accumulator hydraulic pressure relay

G-9 X-3 W-2

BR10 BR11 BR12 BR13

Relay Relay Relay Relay

5 5 6 6

Brake pump relay Parking brake relay Neutral relay Front work lamp relay

BR14

Relay

5

Rear work lamp relay

BR15 BR16 BR18 BR19 BR20 BR21 BR22 BR23

Relay Relay KES KES KES DT2 M DT2

5 5 4 6 4 2 2 2

BR24

DT2

2 2 8 8 3 1 1 1 1 1 1 1 1 1

Float cancel relay (R.H.) Float cancel relay (L.H.) Front wiper switch Preheat timer relay Flasher Buzzer (B) Buzzer (A) Lift lock switch Work lamp switch (If equipped) Fog lamp (If equipped) Hazard lamp switch Head lamp switch Accumulator float switch GND Starter switch (B) Starter switch (BR) Starter switch (R1) Starter switch (C) Starter switch (ACC) Horn relay Horn relay Horn relay

O-5 O-5 P-5 N-4 D-7 P-5 P-5 P-5 P-5 P-5 M-3 N-3 N-3

1

Switch panel lamp

P-5

1

Cigar lighter

O-5

1

Cigar lighter

O-5

8 8

Intermediate connector Intermediate connector Intermediate connector (Wiper) Glass heater (If equipped) Radio (If equipped) Speaker (R.H.) (If equipped) Speaker (L.H.) (If equipped) Rear wiper switch (If equipped) Front lower wiper switch (If equipped)

G-4 G-4

U-7 U-8 W-2 D-8 C-8 C-8 A-8 C-9 D-8 D-9 B-9 B-9 B-9 B-8 B-8 D-7 G-3 G-3 G-3 D-6 E-5 G-9 H-9 B-8 K-7 L-6 L-6 — — M-5 M-5 N-4 Q-1 Q-1 R-3 R-2 —

BR25 BR26 BR27 BR28 BT30 BT31 BT32 BT33 BT34 BT35 BT36 BT37 BT38

DT2 (VCH) (VCH) DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL 1-pin BT41 connector 1-pin BT42 connector 1-pin BT43 connector C1 DT2 (G) C2 DT2 (Gr) C3

DT2

6

C4

DT1

3

C5

—

9

C6

KES

2

C7

KES

2

C8

KES

6

C9

KES

6

Mounting location

Address

SWP SWP SWP

Type

No. of pins

No. of pins

AC1 AC3 AC4

Mounting location

Connector No.

Type

Address

Connector No.


R-3 P-5 Q-5 R-3 P-5 R-3 R-4 R-3 N-4 R-4 R-4 P-1 Q-1 Q-5 O-4

H-4 H-4 U-8 V-8 X-7 X-4 X-3

R-2

20-217 (4)

2

C11

M

2

C12

M

2

C13

M

2

C14

M

2

C15

KES

4

C16

KES

4

C17

KES

4

C18

KES

4

C19

Relay

5

C20

M

2

C21

Relay

5

C22

KES

3

C23 C24 C25 C26

M M M M

2 2 2 2

C27

M

3

C28

M

3

C29 C30

M KES

2 2

C31

M

2

C32

M

2

C33

M

3

C34

M

3

1-pin connector CT41 TERMINAL E1 DT2 CT35

E4

X

2

X-4

E5

DT2

2

X-5

E6

DT2

2

U-2

E6

DT2

2

E7

DT2

2

E8

DT2

2

E9

DT

3

E10 E11

DT2 DT2

3 2

E12

(PKD)

3

E13

DT2

3

E14

DT2

3

E15 E16

DT2 DT2

6 4

E17

DT2

2

E18

DT2

2

E20 E21 ET39 ET40 ET41 ET42 ET43 ET44 ET45 ET46 ET47 ET48 ET49 ET50 ET51 ET52 ET53 ET54 ET55 ET56 ET58 ET59 ET60 ET62 ET63

DT DT DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

4 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

X-6 S-4 W-7 T-2 U-2 V-2 X-5 V-2 X-6 T-7 S-6 S-6 S-5 S-3 S-5 X-6 V-8 U-2 X-6 T-3 S-6

Beacon (If equipped)

S-5

1 2

GND Alternator Thermostat sensor (GD555) Thermostat sensor (GD655, 675) Intermediate connector

X-3 H-9

X

2

E2

X

2

E3

DT2

2

(4)

T-7

1

E2

20-218

Room lamp switch (If equipped) Fan switch (Front) (If equipped) Fan switch (Rear) (If equipped) Defroster fan (Front) (If equipped) Defroster fan (Rear) (If equipped) Front wiper motor (If equipped) Rear wiper motor (If equipped) Front lower wiper motor (L.H.) (If equipped) Front lower wiper motor (R.H.) (If equipped) Front lower wiper motor relay (R.H.) (If equipped) Beacon switch (If equipped) Work lamp relay (If equipped) Work lamp switch (If equipped) Work lamp (If equipped) Work lamp (If equipped) Work lamp (If equipped) Work lamp (If equipped) Head lamp (R.H.) (If equipped) Head lamp (L.H.) (If equipped) Power (24V) (Spare) Spot lamp (If equipped) Intermediate connector (Defroster fan, front) Intermediate connector (Defroster fan, rear) Combination lamp (R.H.) (If equipped) Combination lamp (L.H.) (If equipped)

I-9 H-9 J-8

Mounting location Hydraulic thermostat sensor for T/C (If equipped) Hydraulic thermostat sensor for AWD (If equipped) Diode (Starter safety relay) (GD555) Starter motor (GD655, 675) Diode (Grid heater relay) Diode (Fuel shut-off solenoid) Fuel shut-off solenoid (GD655, 675) VHM valve Diode (VHP valve) Engine oil pressure switch Accumulator hydraulic pressure switch (R.H.) Accumulator hydraulic pressure switch (L.H.) Joint connector Intermediate connector Differential thermostat sensor (If equipped) Differential lock solenoid (If equipped) Fuel shut-off timer Fuel shut-off relay Fuse sensor GND Battery (–) Battery (+) Battery (–) Battery (+) Battery relay Battery relay Slow blow fuse Slow blow fuse Battery relay Starter motor Starter motor (GND) GND Starter motor (B) Grid heater relay Grid heater relay Grid heater Battery relay Slow blow fuse Slow blow fuse Battery relay Slow blow fuse

Address

KES

Type

No. of pins

No. of pins

C10

Mounting location

Connector No.

Type


Address

Connector No.

TROUBLESHOOTING

J-7 J-7 J-4 X-3 I-3 J-6 J-7 — J-7 J-7 H-4 H-4 J-5 I-4 H-4 H-4 J-5 I-5 J-8 J-6 J-6 J-5 G-9 G-9 K-3 K-2 I-2 J-2 K-3 H-9 I-9 I-9 H-9 J-2 I-3 J-7 K-3 I-2 I-2 K-3 H-9

GD555, 655, 675-3C

1 1 1 1 1 1 1

ET72 TERMINAL

1

ET73 TERMINAL

1

TERMINAL TERMINAL TERMINAL TERMINAL

1 1 1 1

ET81 TERMINAL

1

TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

1 1 1 1 1 1 1

ET97 TERMINAL

1

ET98 TERMINAL

1

ET99 TERMINAL

1

ET74 ET75 ET76 ET77

ET82 ET83 ET88 ET89 ET92 ET93 ET94

FL1 FL2 FL3 FL4 FL5 FL6 FL7 FL8

M M DT2(B) DT2(B) DT2(Br) DT2 DT2 DT2

3 3 8 12 8 2 2 2

FL9

DT2

2

FL10

DT2

2

FL11 FL12 FL13 FL14 FL15 FL16 FL17 FL18 FL19 FL20

DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2

2 2 2 2 2 2 2 2 2 2

GD555, 655, 675-3C

Battery relay Alternator (B) Alternator (I terminal) Alternator (E) Slow blow fuse Fuel shut-off relay Fuel shut-off relay Starter safety relay (B) (GD555) Starter safety relay (C) (GD555) Starter motor (C) Battery relay (+) Battery relay (–) GND Starter safety relay (E) (GD555-3A) Grid heater relay Grid heater relay Aircon compressor Battery (–) GND (Engine) GND (Engine) GND (Alternator) Fuel shut-off solenoid (GND) (GD555) Fuel shut-off solenoid (PULL) (GD555) Fuel shut-off solenoid (COMM) (GD555) Head lamp (R.H.) Head lamp (L.H.) Intermediate connector Intermediate connector Intermediate connector Articulate sensor Lifter lock solenoid Parking brake solenoid Accumulator solenoid (R.H.) Accumulator solenoid (L.H.) Float solenoid (R.H.) Float solenoid (R.H.) Float solenoid (L.H.) Float solenoid (L.H.) Diode (Solenoid) Diode (Solenoid) Diode (Solenoid) Diode (Solenoid) Diode (Solenoid) Diode (Solenoid)

L-3 M-8 M-8 M-8 I-2 J-5 I-5

FL21 FL22 FL23

DT2 M M

4 3 3

FL26

M

2

FL27

M

2

K-2

FL28

M

2

J-4

FL29

M

2

H-9 J-4 K-4 I-5

FP1 FP2 FP3 FP6 FP7 FP8 FP9 FP10 FP11 FP12

DT2 (Gr) DT2 (B) DT2 (Br) DT2 (B) DT2 (Gr) DT2 (Br) KES DT2 DT2 DT2

12 12 12 12 8 12 2 4 3 3

FP13

DT2

2

FP19

DT2 1-pin connector 1-pin connector TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector 1-pin connector

J-4 I-4 J-2 J-7 J-6 J-6 J-5 I-4 J-7

FT6

J-7

FT7

J-7 B-5 A-2 A-4 D-6 C-6 D-6 F-4 F-4 B-6 E-2 B-5 C-6 D-2 C-6 C-1 F-3 D-1 D-1 E-2 E-2

FT10 FT11 FT12 FT13 FT16 FT17 FT18 FT19 FT20 FT21

Mounting location

Address

TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

Type

No. of pins

No. of pins

ET64 ET65 ET66 ET67 ET68 ET70 ET71

Mounting location

Connector No.

Type


Address

Connector No.

TROUBLESHOOTING

C-6 A-5 A-2

2

Intermediate connector Combination lamp (R.H.) Combination lamp (L.H.) Front work lamp (R.H.) (If equipped) Front work lamp (L.H.) (If equipped) Front work lamp (Spare) (R.H.) Front work lamp (Spare) (L.H.) Meter assembly Warning module (L.H.) Warning module (R.H.) Intermediate connector Intermediate connector Intermediate connector Service meter Message center Turn signal switch Dimmer switch Differential switch (If equipped) Engine start up switch

1

Horn (L.H.)

F-4

1

Horn (R.H.)

E-5

1 1 1 1 1 1

GND (Floor) GND (Front frame) GND (Front frame) GND (Rear frame) Articulate sensor (-) Articulate sensor (G) Speed meter (If equipped) T/C Hydraulic temperature gauge

E-5 F-4 D-7 J-5 — —

1 1

E-5 F-4 B-5 B-1 D-8 D-8 E-9 B-7 B-8 A-8 D-7 E-9 D-8 D-8 D-8 E-9

D-9 —

1

Water temperature gauge D-9

1

Fuel gauge

FT23 TERMINAL

1

FT24 TERMINAL

1

FT25 TERMINAL

1

FT26 TERMINAL

1

FT27 TERMINAL

1

D-9

T/C Hydraulic temperature gauge (B) T/C Hydraulic temperature gauge (T) T/C Hydraulic temperature gauge (E) Water temperature gauge (B) Water temperature gauge (T)

D-9 D-9 D-9 D-9 D-9

20-219 (4)

1

Articulate gauge (B)

D-9

1

Articulate gauge (T)

D-9

1

Horn switch

E-9

1 1 1 8 6 6

Heater If equipped If equipped Intermediate connector Combination lamp (R.H.) Combination lamp (L.H.) Rear work lamp (If equipped) Rear work lamp (If equipped) Intermediate connector (license lamp) License lamp Intermediate connector (license lamp) Back-up alarm Back-up alarm T/M controller T/M controller T/M controller T/M controller T/M controller T/M controller Connector for flash ROM writer Converter for specified selection Inching potentiometer Accelerator potentiometer Intermediate connector Intermediate connector Intermediate connector Shift lever T/C switch Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector

F-9 F-9 F-9 J-8 I-9 J-8

H1 OP1 OP2 RL1 RL2 RL3

TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector M M M DT2 (Br) M M

RL4

M

2

RL5

M

2

RL6

M

2

RL7

X

2

RT1

M

2

FT37

RT2 TERMINAL RT3 TERMINAL T1 MIC T2 MIC T3A 040 T3B 040 T4 040 T5 MIC

1 1 13 21 20 16 12 17

T6

DT2

4

T7

DT2

6

T8

DT2

3

T9

DT2

3

T10 T11 T12 T13 T14 T15 T16 T17 T18 T19

DT2 (G) DT2 (Gr) DT2 DRC DT2 DT2 DT2 (Br) DT2 (B) DT2 DT2 (Gr)

12 8 6 24 2 2 12 8 6 12

20-220 (4)

I-9 J-8 J-8 — J-8 J-8 I-9 N-3 N-4 N-2 N-3 N-3 Q-5 D-7 O-1 P-1 O-1 A-7 A-8 C-8 N-3 N-4 N-4 A-9 A-9 A-8 A-9

T20 T21 T22 T24 T25 T26 T27 T28 T29 T30 T31

DT2(B) DT2 DT2(Gr) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2

12 6 12 2 2 2 2 2 2 2 2

T32

DT2

2

T33

DT2

2

T34

DT2

2

T35

DT2

2

T36 T37 T38 T39 T40 T41 T42 T43 T44 T46 T47 T48 T49 T50 TT1 TT2 TT3 TT4 TT5 TT6 TT7 TT8 TT9

DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

2 2 2 2 2 2 2 2 6 2 6 6 6 6 1 1 1 1 1 1 1 1 1

Mounting location Intermediate connector Intermediate connector Intermediate connector FL solenoid FH solenoid R solenoid 1st solenoid 2nd solenoid 3rd solenoid 4th solenoid Lockup solenoid Transmission input shaft speed sensor Transmission output shaft speed sensor T/C hydraulic temperature sensor T/M hydraulic temperature sensor FL clutch fill switch FH clutch fill switch R clutch fill switch 1st clutch fill switch 2nd clutch fill switch 3rd clutch fill switch 4th clutch fill switch Lockup clutch fill switch Intermediate connector Engine riv. sensor Joint connector Joint connector Joint connector Joint connector Potentiometer set switch Potentiometer set switch Potentiometer set switch Initialize switch Initialize switch Initialize switch Reset switch Reset switch GND (Floor)

Address

Type

No. of pins

D-9 D-9 D-9 D-9

FT29 FT30 FT31 FT32

D-9

Connector No.

1 1 1 1

1

FT34

Mounting location Water temperature gauge (E) Fuel gauge (B) Fuel gauge (T) Fuel gauge (E) Articulate gauge (E)

FT28 TERMINAL

FT33


Address

Type

No. of pins

Connector No.

TROUBLESHOOTING

Q-9 Q-9 Q-9 R-8 R-8 R-8 R-7 R-7 R-7 R-6 N-9 R-9 Q-6 R-8 R-6 R-8 R-7 R-8 R-7 R-7 R-6 R-6 N-8 A-8 R-9 P-9 P-9 Q-9 R-9 R-4 R-4 R-4 R-5 R-5 R-5 Q-5 R-5 D-8

GD555, 655, 675-3C

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

CONNECTOR ARRANGEMENT DIAGRAM Serial No. 50001 – 51000

20-222 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-223 (4)

TROUBLESHOOTING

20-224 (4)


GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-225 (4)

TROUBLESHOOTING



20-226 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-227 (4)

TROUBLESHOOTING

20-228 (4)


GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-229 (4)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins while the terms male housing and female housing refer to the mating portion of the housing. X-Type Connector

Number of Pins

Male (Female Housing)

Female (Male Housing)

T-adapter Part Number

1

Part Number: 08055-00181


799-601-7010

BWP04702

2



3

799-601-7030


4

799-601-7020


BWP04705

799-601-7040



—

Terminal part number: 79A-222-3370 • Wire size: 0.85 • Grommet: black • Quantity: 20 pieces

Terminal part number: 79A-222-3390 • Wire size: 0.85 • Grommet: black • Quantity: 20 pieces

—

—

Terminal part number: 79A-222-3380 • Wire size: 2.0 • Grommet: red • Quantity: 20 pieces

Terminal part number: 79A-222-3410 • Wire size: 2.0 • Grommet: red • Quantity: 20 pieces

—

20-230 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

Number of Pins


SWP-Type Connector Male (Female Housing)

BWP04707

6


8

BWP04709


BWP04711

12


BWP04713

14


GD555, 655, 675-3C



BWP04708

799-601-7050


BWP04710

799-601-7060


BWP04712

799-601-7310


BWP04714

799-601-7070


20-231 (4)

TROUBLESHOOTING

Number of Pins

16


SWP-Type Connector Male (Female Housing)

BWP04715



BWP04716


799-601-7320


—

Terminal part number: • Wire size: 0.85 • Grommet: black • Quantity: 20 pieces

Terminal part number: • Wire size: 0.85 • Grommet: black • Quantity: 20 pieces

—

—

Terminal part number: • Wire size: 1.25 • Grommet: red • Quantity: 20 pieces

Terminal part number: • Wire size: 1.25 • Grommet: red • Quantity: 20 pieces

—

20-232 (4)

GD555, 655, 675-3C

TROUBLESHOOTING


M-Type Connector

Number of Pins

Male (Female Housing)



1



799-601-7080

2

BWP04717


3

BWP04719


4

BWP04721


6

BWP04723


BWP04718

799-601-7090


BWP04720

799-601-7110


BWP04722

799-601-7120


BWP04724

799-601-7130


799-601-7340

8

BWP04725


GD555, 655, 675-3C

BWP04726


20-233 (4)

TROUBLESHOOTING

Number of Pins

8


S-Type Connector Male (Female Housing)

BWP04727


10 (White)

BWP04729


12 (White)

BWP04731


16 (White)

BWP04733


20-234 (4)


BWP04728


799-601-7140


BWP04730

799-601-7150


BWP04732

799-601-7350


BWP04734

799-601-7330


GD555, 655, 675-3C

TROUBLESHOOTING

Number of Pins


S-Type Connector Male (Female Housing)

10 (Blue)

BWP04735

—

12 (Blue)

BWP04737


16 (Blue)

BWP04739


GD555, 655, 675-3C


BWP04736


—

—

BWP04738

799-601-7160


BWP04740

799-601-7170


20-235 (4)

TROUBLESHOOTING

Number of Pins


MIC-Type Connector Male (Female Housing)



7

Body Part Number: 79A-222-2640 (Quantity: 5 pieces)


—

11



—

5

BWP04741


9

BWP04743


13

BWP04745


20-236 (4)

BWP04742

799-601-2710


BWP04744

799-601-2950


BWP04746

799-601-2720


GD555, 655, 675-3C

TROUBLESHOOTING

Number of Pins


MIC-Type Connector Male (Female Housing)

BWP04747

17


BWP04749

21


BWP04748

799-601-2730


BWP04750





GD555, 655, 675-3C


799-601-2740

—

20-237 (4)

TROUBLESHOOTING

Number of Pins

8


AMP040-Type Connector Male (Female Housing)

BWP04751

—

12

16

799-601-7190

BWP047544

Housing Part Number: 79A-222-3440

799-601-7210

BWP04756


BWP04757

—

799-601-7180


BWP04755

—

20

BWP04752

BWP04753

—



799-601-7220

BWP04758


a Terminal Part Number: 79A-222-3470 (For all numbers of pins).

20-238 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

Number of Pins


AMP070-Type Connector Male (Female Housing)

10

BWP04759

—

12

BWP04761

—

14

BWP04763

—

18

BWP04765

—

20

BWP04767

—

GD555, 655, 675-3C


BWP04760


799-601-7510


BWP04762

799-601-7520


BWP04764

799-601-7530


BWP04766

799-601-7540


BWP04768

799-601-7550


20-239 (4)

TROUBLESHOOTING

Number of Pins


L-Type Connector Male (Female Housing)


2

—

—

Number of Pins

—

PA-Type Connector Male (Female Housing)


9

—

BENDIX MS-Type Connector Male (Female Housing)


10

(4)


799-601-3460

—

20-240


—

—

Number of Pins


—

GD555, 655, 675-3C

TROUBLESHOOTING

Number of Pins


KES1 Automobile-Type Connector Male (Female Housing)


2


—

Part Number: 08027-10210 (Natural color) 08027-10220 (Black)


3

—



4

—



6

—


GD555, 655, 675-3C


20-241 (4)

TROUBLESHOOTING

Number of Pins


KES1 Automobile-Type Connector Male (Female Housing)



8

—


Number of Pins


Socket-Type Connector for Relay Male (Female Housing)


5

799-601-7360

—

—

6

799-601-7370

—

Number of Pins

—

F-Type Connector Male (Female Housing)


4

(4)


—

—

20-242


—

GD555, 655, 675-3C

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9210

18-8 (1)

Part No.:08191-11201, 08191-11202, 08191-11205, 08191-11206

Part No.:08191-14101, 08191-14102, 08191-14105, 08191-14106

Pin (female terminal)

Pin (male termial)

799-601-9210

Part No.:08191-12201, 08191-12202, 08191-12205, 08191-12206

Part No.:08191-13101, 08191-13102, 08191-13105, 08191-13106

Pin (male terminal)


799-601-9220

18-14 (2)

Part No.:08191-21201, 08191-12202, 08191-21205, 08191-12206

Part No.:08191-24101, 08191-24102, 08191-24105, 08191-24106


Pin (male termial)

799-601-9220

Part No.:08191-22201, 08191-22202, 08191-22205, 08191-22206

GD555, 655, 675-3C

Part No.:08191-23101, 08191-23102, 08191-23105, 08191-23106

20-243 (4)

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)


T-adapter Part No.

799-601-9230

18-20 (3)

Part No.:08191-31201, 08191-31202

Part No.:08191-34101, 08191-34102


Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202

Part No.:08191-33101, 08191-33102

Pin (male terminal)


799-601-9240

18-21 (4)

Part No.:08191-41201, 08191-42202

Part No.:08191-44101, 08191-44102


Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

20-244 (4)

Part No.:08191-43101, 08191-43102

GD555, 655, 675-3C

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)


T-adapter Part No.

799-601-9250

24-9 (5)

Part No.:08191-51201, 08191-51202

Part No.:08191-54101, 08191-54102


Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202

Part No.:08191-53101, 08191-53102

Pin (male terminal)


799-601-9260

24-16 (6)

Part No.:08191-61201, 08191-62202, 08191-61205, 08191-62206

Part No.:08191-64101, 08191-64102, 08191-64105, 08191-64106


Pin (male termial)

799-601-9260

Part No.:08191-62201, 08191-62202, 08191-62205, 08191-62206

GD555, 655, 675-3C

Part No.:08191-63101, 08191-63102, 08191-63105, 08191-63106

20-245 (4)

TROUBLESHOOTING




Body (receptacle)

Pin (male terminal)


T-adapter Part No.

799-601-9270

24-21 (7)

Part No.:08191-71201, 08191-71202, 08191-71205, 08191-71206

Part No.:08191-74101, 08191-74102, 08191-74105, 08191-74106


Pin (male termial)

799-601-9270

Part No.:08191-72201, 08191-72202, 08191-72205, 08191-72206

Part No.:08191-73101, 08191-73102, 08191-73105, 08191-73106

Pin (male terminal)


799-601-9280

24-22 (8)

Part No.:08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206

Part No.:08191-84101, 08191-84102 08191-84103, 08191-84104 08191-84105, 08191-84106


Pin (male termial)

799-601-9280

Part No.:08191-82201, 08191-82202 08191-82203, 08191-82204 08191-82205, 08191-82206

20-246 (4)

Part No.:08191-83101, 08191-83102 08191-83103, 08191-83104 08191-83105, 08191-83106

GD555, 655, 675-3C

TROUBLESHOOTING




Body (receptacle)

Pin (male termial)


T-adapter Part No.

799-601-9290

24-31 (9)

Part No.:08191-91203, 08191-91204, 08191-91205, 08191-91206

Part No.:08191-94103, 08191-94104, 08191-94105, 08191-94106


Pin (male termial)

799-601-9290

Part No.:08191-92203, 08191-92204, 08191-92205, 08191-92206

GD555, 655, 675-3C

Part No.:08191-93103, 08191-93104, 08191-93105, 08191-93106

20-247 (4)

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins

DT Series connector Body (plug)

Body (receptacle)

2

799-601-9020

Part No.:08192-12200 (normal type) 08192-22200 (fine wire type)


3

799-601-9030



4

799-601-9040



6

799-601-9050


20-248 (4)

T-adapter Part No.


GD555, 655, 675-3C

TROUBLESHOOTING


[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

8GR:799-601-9060 8B:799-601-9070 8G:799-601-9080 8BR:799-601-9090

8



12GR:799-601-9110 12B:799-601-9120 12G:799-601-9130 12BR:799-601-9140

12


GD555, 655, 675-3C


20-249 (4)

TROUBLESHOOTING



DTM Series connector Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9010

2

Part No.: 08192-02200

Part No.: 08192-02100


DTHD Series connector Body (plug)

T-adapter Part No.

Body (receptacle)

2

—

Part No.:08192-31200 (Contact size#12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

20-250 (4)

Part No.:08192-31100 (Contact size#12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)

GD555, 655, 675-3C

TROUBLESHOOTING

MESSAGE CENTER DISPLAY AND TABLE ERROR CODES


1. Display function of the message center (1) 1) Content of mode display (8 modes displayed with 4 digits) [1] Auto

[5] Lum. (monitor illumination brightness)

[2] Rpm (engine speed)

[6] Ver.T (version of software)

[3] Gear (speed range)

[7] M7TT (display in miles)

[4] Err (error code)

[8] M8TT (display in kilometers)

2) When pressing the mode button (2), the mode display changes in the following sequence: [1] o [2] o [3] o [4] o [5] o [6] o [7] o [8] 3) Starting switch ON display • It remembers the content (mode) of the display when the starting switch is OFF. • Turning the start switch ON starts with the mode saved in memory when the switch was OFF. i) ii) iii) iv) v) vi)

Displays [V1.4]: The display goes out immediately and changes to the mode display. Displays [RpmT]: Displays this mode for 3 seconds, then changes to the engine speed display. ( [RpmT] is an example, the mode is the mode when the start switch is turned off) Displays the engine speed in [TTT] and maintains this mode until the mode button is pressed. Press the mode button. Displays [Gear]: Displays this mode for 3 seconds, then changes to the engine speed display. Displays the speed range in [TTT] and maintains this mode until the mode button is pressed.

GD555, 655, 675-3C

20-251 (4)

TROUBLESHOOTING


4) Display time and display 1) Mode display [Auto] i) Displays [Auto] for 3 seconds, then changes to the engine speed display. ii) Displays the engine speed in [TTTT] for 3 seconds, then changes to engine speed display. iii) Displays [RpmT] for 2 seconds, then changes to the engine speed display. iv) Continues to display the engine speed in [TTT]. • When the speed range changes The speed range is displayed for 3 seconds, then the display changes to the engine speed display and continues to display the engine speed. • When the speed range changes during the speed range display Even if the previous speed range display is shown for less than 3 seconds, the display shows the next speed range. • If the error occurs (priority given to error display) Even if the speed range or engine speed is being displayed, the display changes to the error code display and continues to display it. If multiple errors occur at the same time, the error codes are displayed in sequence for 2 seconds each. • When the error is removed Display returns to the speed range display. 2) Mode display [RpmT] i) Displays [RpmT] for 3 seconds, then changes to the engine speed display. ii) Displays the engine speed in [TTTT] and maintains this mode until the mode button is pressed. • The display is shown with four digits: If the speed is 1794 rpm, the value is rounded and displayed as [1790]; if the speed is 878 rpm, it is displayed as [T880]. (The T indicates a blank.) 3) Mode display [Gear] i) Displays [Gear] for 3 seconds, then changes to the engine speed display. ii) Displays the engine speed in [TTTT] and maintains this mode until the mode button is pressed. Speed range

Display

Speed range

Display

Speed range

Display

P

[T - P - 1]

F4

[TTF4]

R1

[TTR1]

N

[T - N -]

F5

[TTF5]

R2

[TTR2]

F1

[TTF1]

F6

[TTF6]

R3

[TTR3]

F2

[TTF2]

F7

[TTF7]

R4

[TTR4]

F3

[TTF3]

F8

[TTF8]

4) Mode display [ErrT] i) Displays [ErrT] for 3 seconds, then changes to the error display. ii) Displays the error code in [TTTT] and maintains this mode until the mode button is pressed. • If there is no error, the display shows [ETT]. • If there is an error, the display shows [ETEE]. If there are multiple errors, the display shows the error for 2 seconds, then displays the next error, and continues to display each error for 2 seconds each. (EE indicates the error code.) iii) A maximum of 32 error codes can be displayed in the order of occurrence (the display at the present point of operation). (The error code for the transmission controller is also displayed at the same time with the LED.) iv) When the error code is displayed, the electric circuit monitor for the transmission system on the monitor panel also lights up at the same time.

20-252 (4)

GD555, 655, 675-3C

TROUBLESHOOTING


5) Mode display [Lum.] i) Displays [Lum.] for 3 seconds, then changes to the engine speed display. ii) Displays the brightness in [TTTT] and maintains this mode until the mode button is pressed. • Each time the scroll button (3) is pressed, the display changes • [100%] o [ 50%] o [ 25%] o [100%] • The brightness data is not stored in memory; when the starting switch is turned ON, it always starts from 100%. 6) Mode display [Ver T] i) Displays [Ver T] for 3 seconds, then changes to the program No. display. ii) Displays the program No. in [PEEE] and maintains this mode until the mode button is pressed. (EEE shows the program No. For example: P5R2) 7) Mode display [M7TT] i) Displays [M7TT] for 3 seconds, then changes to the travel speed (miles) display. ii) Displays [MPHT] for 3 seconds, then changes to the travel speed display. iii) Displays the travel speed (miles) in two digits in [EEM.], and maintains this mode until the mode button is pressed. 8) Mode display [M8TT] i) Displays [M8TT] for 3 seconds, then changes to the travel speed (km/h) display. ii) Displays [kmPHT] for 3 seconds, then changes to the travel speed display. iii) Displays the travel speed (kilometers) in two digits in [EEkm], and maintains this mode until the mode button is pressed. 5) The error codes can be displayed on the message center only for the [Auto] and [Err T] modes.

GD555, 655, 675-3C

20-253 (4)

TROUBLESHOOTING


2. Table of error codes A1 Short circuit in the FL solenoid system

E2

Short circuit with power source, or the neutral signal system disconnected

E3

Short circuit with power source, or the parking signal system disconnected

E4

Short circuit with power source, or the logic A signal system disconnected

E5

Short circuit with power source, or the logic B signal system disconnected

E6

Short circuit with power source, or the logic C signal system disconnected

E7

Short circuit with power source, or the logic D signal system disconnected

E8

Short circuit with power source, or the logic E signal system disconnected

F1

Short circuit with ground in the FL clutch pressure switch signal system

F2

Short circuit with ground in the FH clutch pressure switch signal system

F3

Short circuit with ground in the R clutch pressure switch signal system

A2 Short circuit in the FH solenoid system A3 Short circuit in the R solenoid system A4 Short circuit in the 1st, 3rd solenoid system A5 Short circuit in the 2nd, 4th solenoid system A8 Short circuit in the lock-up solenoid system b1 FL solenoid system disconnected b2 FH solenoid system disconnected b3 R solenoid system disconnected b4 1st solenoid system disconnected b5 2nd solenoid system disconnected b6 3rd solenoid system disconnected b7 4th solenoid system disconnected b8 Lock-up solenoid system disconnected C0 Drop in power supply voltage C1 Engine speed sensor system disconnected C3

Short circuit with power source, or accelerator potentiometer system disconnected

F4

C4

Short circuit with power source, or inching potentiometer system disconnected.

Short circuit with ground in the 1st clutch pressure switch signal system

F5

C5

Short circuit with power source, or transmission oil temperature sensor system disconnected

Short circuit with ground in the 2nd clutch pressure switch signal system

F6

C6

Short circuit with power source, or torque converter outlet oil temperature sensor system disconnected

Short circuit with ground in the 3rd clutch pressure switch signal system

F7

C7

Short or open circuit of power source in the hydraulic oil temperature sensor system

Short circuit with ground in the 4th clutch pressure switch signal system

F8

C8

Transmission input speed sensor system disconnected

Short circuit with ground in the lock-up clutch pressure switch signal system

91

C9

Transmission output speed sensor system disconnected

FL clutch pressure switch signal system disconnected

92

d1

Short circuit with power source, or differential oil temperature warning lamp system disconnected

FH clutch pressure switch signal system disconnected

93

Short circuit with power source, or transmission d2 (torque converter outlet) oil temperature warning lamp system disconnected

R clutch pressure switch signal system disconnected

94

1st clutch pressure switch signal system disconnected

d4

Short circuit with power source, or alarm buzzer system disconnected

95

2nd clutch pressure switch signal system disconnected

d5

Short circuit with power source, or warning lamp system disconnected

96

3rd clutch pressure switch signal system disconnected

d6

Short circuit with power source, or differential control relay system disconnected

97

4th clutch pressure switch signal system disconnected

d7

Short circuit with power source, or VHP relay system disconnected

98

Lock-up clutch pressure switch signal system disconnected

E1

Short circuit with power source, or F (Forward), R (Reverse) system disconnected

20-254 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

USING THE TROUBLESHOOTING CHARTS

USING THE TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting Code No.

Component

E-QQ

Troubleshooting of electrical system

T-QQ

Troubleshooting of transmission controller system

H-QQ

Troubleshooting of hydraulic, mechanical system

M-QQ

Troubleshooting of machine monitor system

2. Using the troubleshooting flow chart 1) Troubleshooting code number and problem The title at the top of the troubleshooting chart gives the troubleshooting code and problem with the machine. Example: Abnormal buzzer 2) General precautions When troubleshooting the problem, precautions that apply to all items are given at the top of the page under the title and marked with (a). The common precautions marked (a) at the page top are not given below each item, but must always be followed when performing the check. Example: a Before troubleshooting, check that all the related connectors are properly inserted. a Always connect any disconnected connectors before going on the next step. 3) Distinguishing the conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode is further divided into sections marked with small letters. For example, a) go to the appropriate troubleshooting section. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the flow chart. Example: a) Turning the start switch ON (3 sec.) and the buzzer does not sound b) Buzzer always sounds 4) Follow the troubleshooting chart • Check or measure the item described inside the box. Answer the question YES or NO. No Yes

• •

•

According to the answer, follow either the YES line or the NO line to the next box. NOTE: The number at the top right corner of the box is an index number; it does not indicate the order to follow.

Following the YES or NO lines, according to the check or measurement result, will lead to the Cause column. Check the cause and take the action given in the Remedy column on the right. To the left of the box is a another box formed with a gray line. The gray line box contains the methods for inspection or measurement, and the judgement values. If the judgement values to the left of the box are correct or the answer to the question inside the box is YES, follow the YES line; if the judgement value is incorrect, or the answer to the question is NO, follow the NO line. The data inside the gray line box gives the preparatory work needed for inspection, measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause an incorrect judgement or equipment damage. Therefore, before starting the inspection or measurement, always read the instructions carefully, and start the work in order from the first item.

5) Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number. When troubleshooting, see this chart for the location for the inspection and measurement of the wiring connector in the troubleshooting flow chart.

GD555, 655, 675-3C

20-255 (4)

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ELECTRICAL CIRCUIT DIAGRAM ............................................................................................................ 20-302 E-1 Engine does not start..................................................................................................................... 20-306 E-2 Engine does not stop ..................................................................................................................... 20-316 E-3 Engine preheating pilot lamp does not glow .................................................................................. 20-318 E-4 Electrical components do not work ................................................................................................ 20-320

GD555, 655, 675-3C

20-301 (4)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM For engine start, stop, preheat, charge Serial No. 50001 – 51000

20-302 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-303 (4)

TROUBLESHOOTING



20-304 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-305 (4)

TROUBLESHOOTING

E-1

E-1

Engine does not start

A) Starter mortor does not turn Serial No. 50001 – 51000

20-306 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-1

E-1 A) Related electrical circuit diagram

GD555, 655, 675-3C

20-307 (4)

TROUBLESHOOTING

E-1

A) Starter mortor does not turn Serial No. 51001 and up

20-308 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-1

E-1 A) Related electrical circuit diagram

GD555, 655, 675-3C

20-309 (4)

TROUBLESHOOTING

E-1

B) Engine starter solenoid does not work

E-1 B) Related electrical circuit diagram Serial No. 50001 – 51000

20-310 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-1


GD555, 655, 675-3C

20-311 (4)

TROUBLESHOOTING

E-1

C) Fuel shut-off solenoid does not work Serial No. 50001 – 51000 • Set the gearshift lever to the P position before starting the troubleshooting process.

20-312 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-1

E-1 C) Related electrical circuit diagram

GD555, 655, 675-3C

20-313 (4)

TROUBLESHOOTING

E-1

C) Fuel shut-off solenoid does not work Serial No. 51001 and up • Set the gearshift lever to the P position before starting the troubleshooting process.

20-314 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-1

E-1 C) Related electrical circuit diagram

GD555, 655, 675-3C

20-315 (4)

TROUBLESHOOTING

E-2

E-2

Engine does not stop

Serial No. 50001 – 51000

E-2 Related electrical circuit diagram

20-316 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-2


E-2 Related electrical circuit diagram

GD555, 655, 675-3C

20-317 (4)

TROUBLESHOOTING

E-3

E-3

Engine preheating pilot lamp does not glow

a Check that the pilot lamp is not defective.

20-318 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-3

E-3 Related electrical circuit diagram Serial No. 50001 – 51000


GD555, 655, 675-3C

20-319 (4)

TROUBLESHOOTING

E-4

E-4

Electrical components do not work

a Verify that normal battery voltage exists.

20-320 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

E-4

E-4 Related electrical circuit diagram Serial No. 50001 – 51000


GD555, 655, 675-3C

20-321 (4)

TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE) TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE............................................................ 20-354 CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE.......................................... 20-358 ELECTRICAL CIRCUIT DIAGRAM ............................................................................................................ 20-378 T-1 Failure code [A1]............................................................................................................................ 20-382 T-2 Failure code [A2]............................................................................................................................ 20-383 T-3 Failure code [A3]............................................................................................................................ 20-384 T-4 Failure code [A4]............................................................................................................................ 20-385 T-5 Failure code [A5]............................................................................................................................ 20-386 T-6 Failure code [A8]............................................................................................................................ 20-387 T-7 Failure code [b1] ............................................................................................................................ 20-388 T-8 Failure code [b2] ............................................................................................................................ 20-389 T-9 Failure code [b3] ............................................................................................................................ 20-390 T-10 Failure code [b4] .......................................................................................................................... 20-391 T-11 Failure code [b5] .......................................................................................................................... 20-392 T-12 Failure code [b6] .......................................................................................................................... 20-393 T-13 Failure code [b7] .......................................................................................................................... 20-394 T-14 Failure code [b8] .......................................................................................................................... 20-395 T-15 Failure code [C0].......................................................................................................................... 20-396 T-16 Failure code [C1].......................................................................................................................... 20-397 T-17 Failure code [C3].......................................................................................................................... 20-398 T-18 Failure code [C4].......................................................................................................................... 20-400 T-19 Failure code [C5].......................................................................................................................... 20-402 T-20 Failure code [C6].......................................................................................................................... 20-403 T-21 Failure code [C7].......................................................................................................................... 20-404 T-22 Failure code [C8].......................................................................................................................... 20-405 T-23 Failure code [C9].......................................................................................................................... 20-406 T-24 Failure code [d1] .......................................................................................................................... 20-407 T-25 Failure code [d2] .......................................................................................................................... 20-408 T-26 Failure code [d4] .......................................................................................................................... 20-409 T-27 Failure code [d5] .......................................................................................................................... 20-410 T-28 Failure code [d6] .......................................................................................................................... 20- 411 T-29 Failure code [d7] .......................................................................................................................... 20-412 T-30 Failure code [E1].......................................................................................................................... 20-413 T-31 Failure code [E2].......................................................................................................................... 20-414 T-32 Failure code [E3].......................................................................................................................... 20-415 T-33 Failure code [E4].......................................................................................................................... 20-417 T-34 Failure code [E5].......................................................................................................................... 20-417 T-35 Failure code [E6].......................................................................................................................... 20-418 T-36 Failure code [E7].......................................................................................................................... 20-419 T-37 Failure code [E8].......................................................................................................................... 20-419 T-38 Failure code [F1] .......................................................................................................................... 20-421

GD555, 655, 675-3C

20-351 (4)

TROUBLESHOOTING

T-39 Failure code [F2] .......................................................................................................................... 20-421 T-40 Failure code [F3] .......................................................................................................................... 20-422 T-41 Failure code [F4] .......................................................................................................................... 20-423 T-42 Failure code [F5] .......................................................................................................................... 20-423 T-43 Failure code [F6] .......................................................................................................................... 20-424 T-44 Failure code [F7] .......................................................................................................................... 20-424 T-45 Failure code [F8] .......................................................................................................................... 20-425 T-46 Failure code [91] .......................................................................................................................... 20-426 T-47 Failure code [92] .......................................................................................................................... 20-426 T-48 Failure code [93] .......................................................................................................................... 20-427 T-49 Failure code [94] .......................................................................................................................... 20-428 T-50 Failure code [95] .......................................................................................................................... 20-428 T-51 Failure code [96] .......................................................................................................................... 20-429 T-52 Failure code [97] .......................................................................................................................... 20-429 T-53 Failure code [98] .......................................................................................................................... 20-431

20-352 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE


Open circuit in the 2nd solenoid circuit

Open circuit in the 3rd solenoid circuit

Open circuit in the 4th solenoid circuit

b4

b5

b6

b7

Q

Q

Q

Q

Open circuit in the 1st solenoid circuit

Open circuit in the R solenoid circuit

Open circuit in the FH solenoid circuit

Open circuit in the FL solenoid circuit

Short circuit to the power source in the lock-up solenoid circuit

Short circuit to the power source in the 2nd, 4th solenoid circuit

Short circuit to power source in the R solenoid circuit

Failure mode

Short circuit to the power source in the FH solenoid circuit

Failure code

Short circuit to the power source in the FL solenoid circuit

Failure location

Short circuit to the power source in the 1st, 3rd solenoid circuit

Self-diagnostic display (problem displayed)

Transmission controller error A1 A2 A3 A4 A5 A8

b1

b2

Q

Q

Q

Q

Q

Q

Q

8. Inching does not function normally

Q

Q

Q

9. Modulation clutch control does not function

Q

Q

Troubleshooting code when an error code is displayed

T1

T2

b3

1. Travel is impossible 2. Autoshifting is not performed

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

T3

T4

T5

T6

T7

T8

T9

T10

T11

T12

T13

3. Downshifts, regardless of travel speed 4. Upshifts, regardless of travel speed 5. Excessive gearshift shock 6. Abnormal gearshifting speed when traveling in the automode 7. Engine speed not displayed on the message center

20-354 (4)

GD555, 655, 675-3C

T14

T15

T16

Q

T17

GD555, 655, 675-3C

Q

Q

T18

T19

T20

T21

Q

Q

T22

T23

b8 C0 C1 C3 C4 C5 C6 C7 C8 C9 d1

T24 d2

T25 d4

T26 d5

T27 d6

T28

Q

T29 E1 E2 E3 E4 E5 E6 E7 E8 —

Logic D signal system

Logic C signal system

Logic B signal system

Logic A signal system

Parking signal system

Neutral signal system

Stop lamp signal system

Transmission controller error Logic E signal system

d7

F (forward), R (reverse) signal system

VHP solenoid relay system (opt)

Differential control relay system

Warning lamp system

Alarm buzzer A system

Torque converter outlet oil temperature lamp system (opt)

Differential oil temperature lamp system (opt)

Transmission output speed sensor system

Transmission input speed sensor system

Hydraulic oil temperature sensor system (opt)

Torque converter outlet oil temperature system

Transmission oil temperature sensor system

Inching potentiometer system

Accelerator potentiometer system

Engine speed sensor system

Power supply voltage reduced

Open circuit in the lock-up solenoid circuit

TROUBLESHOOTING TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE


Q

Q

Q

Q Q

Q Q Q Q Q Q Q Q Q

T30

T31

T32

T33

T34

T35

T36

T37

20-355

(4)

TROUBLESHOOTING


Memory reset switch system

Learning function initialize switch system

Short circuit to ground in the FL clutch pressure switch signal system


—

—

F1

AWD selection switch system

VHP selection switch system

Reset switch system

High set switch system

Inching selection switch system

Differential selection switch system

Model selection switch system

Low set switch system

Failure mode

Lock-up switch system

Failure code

Differential selector switch system

Failure location

Transmission controller error — 1. Travel is impossible

—

—

—

—

—

—

—

—

—

Q

2. Autoshifting is not performed 3. Downshifts, regardless of travel speed 4. Upshifts, regardless of travel speed 5. Excessive gearshift shock 6. Abnormal gearshifting speed when traveling in the automode 7. Engine speed not displayed on the message center 8. Inching does not function normally

Q

9. Modulation clutch control does not function Troubleshooting code when an error code is displayed

20-356 (4)

T38

GD555, 655, 675-3C

91

Q

T46 F2

Q

Q

Q

T39 92

Q

Q

T47 F3

Q

Q

Q

T40 93

Q

T48

GD555, 655, 675-3C F4

Q

Q

T41 94

Q

T49 F5

Q

Q

T42 95

Q

T50 F6

Q

Q

T43 Q

T51

Open circuit in the lock-up clutch pressure switch signal system

F7 97 F8 98

Q

Q

Q

Q

Q

T44

T52

Q

Q

T45

T53

Troubleshooting code when no error code is displayed

Short circuit to ground in the lock-up clutch pressure switch signal system

96

Open circuit in the 4th clutch pressure switch signal system

Transmission controller error

Short circuit to ground in the 4th clutch pressure switch signal system

Open circuit in the 3rd clutch pressure switch signal system

Short circuit to ground in the 3rd clutch pressure switch signal system

Open circuit in the 2nd clutch pressure switch signal system

Short circuit to ground in the 2nd clutch pressure switch signal system

Open circuit in the 1st clutch pressure-switch signal system

Short circuit to ground in the 1st clutch pressure switch signal system

Open circuit in the R clutch pressure switch signal system

Short circuit to ground in the R clutch pressure switch signal system

Open circuit in the FH clutch pressure switch signal system

Short circuit to ground in the FH clutch pressure switch signal system

Open circuit in the FL clutch pressure switch signal system

TROUBLESHOOTING TRANSMISSION-CONTROLLER SYSTEM JUDGEMENT TABLE


H-11

Q

20-357

(4)

TROUBLESHOOTING

CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE

CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE No.

1

2

3

4

5

Failure code

A1

Nature of the problem

1. Defective FL solenoid 2. Short circuit to ground, short circuit to power source in the wiring harness between T2 (female) (7) and T24 (female) (1) Short circuit to 3. Short circuit to the power source in the wiring harness between T2 the power source (female) (17) and T24 (female) (2) in the FL solenoid 4. Short circuit in the wiring harness between T2 (female) (7) and T24 circuit (female) (1) and wiring harness between T2 (female) (17) and T24 (female) (2) 5. Defective transmission controller

Normal condition (volts, amps and ohms)

Resistance between T2 (female) (7) and (17): 5 to 15 z Voltage between T2 (17) and chassis at neutral: Less than 0.1 V

Short circuit to the power source in FH solenoid system

1. Defective FH solenoid. 2. Short circuit to ground, short circuit to power source in wiring harness between T2 (female) (8) and T25 (female) (1) 3. Short circuit to the power source in the wiring harness between T2 (female) (18) and T25 (female) (2) 4. Short circuit in wiring harness between T2 (female) (8) and T25 (female) (1); and between T2 (female) (18) and T25 (female) (2) 5. Defective transmission controller


Short circuit to the power source in the R solenoid system

1. Defective R solenoid 2. Short circuit to ground, short circuit to power source in wiring harness between T2 (female) (9) and T26 (female) (1) 3. Short circuit to power source in wiring harness between T2 (female) (19) and T26 (female) (2) 4. Short circuit in wiring harness between T2 (female) (9) and T26 (female) (1); and between T2 (female) (19) and T26 (female) (2) 5. Defective transmission controller


A4

Short circuit to power source in 1st, 3rd solenoid system

1. Defective 1st or 3rd solenoid 2. Short circuit to ground, short circuit to power source in wiring harness between T2 (female) (2) and T27 (female) (1) or T2 (female) (3) and T29 (female) (1) 3. Short circuit to the power source in the wiring harness between T2 (female) (13) and T27 (female) (2) or T2 (female) (14) and T29 (female) (2) 4. Short circuit in wiring harness between T2 (female) (2) and T27 (female) (1); and between T2 (female) (13) and T27 (female) (2) 5. Short circuit in the wiring harness between T2 (female) (3) and T29 (female) (1) and wiring harness between T2 (female) (14) and T29 (female) (2) 6. Defective transmission controller

Resistance between T2 (female) (2) and (13): 5 to 15 z Voltage between T2 (13) and chassis at neutral: Less than 0.1 V Resistance between T2 (female) (3) and (14): 5 to 15 z Voltage between T2 (14) and chassis at neutral: Less than 0.1 V

A5

1. Defective 2nd or 4th solenoid 2. Short circuit to ground, short circuit to power source in the wiring harness between T2 (female) (4) and T28 (female) (1) or T2 (female) (5) and T30 (female) (1) Short circuit to 3. Short circuit to power source in wiring harness between T2 (female) (15) power source in and T28 (female) (2) or T2 (female) (16) and T30 (female) (2) the 2nd, 4th sole4. Short circuit in wiring harness between T2 (female) (4) and T28 (female) noid system (1); and between T2 (female) (15) and T28 (female) (2) 5. Short circuit in wiring harness between T2 (female) (5) and T30 (female) (1); and between T2 (female) (16) and T30 (female) (2) 6. Defective transmission controller

Resistance between T2 (female) (4) and (15): 5 to 15 z Voltage between T2 (15) and chassis at neutral: Less than 0.1 V Resistance between T2 (female) (5) and (16): 5 to 15 z Voltage between T2 (16) and chassis at neutral: Less than 0.1 V

A2

A3

20-358 (4)

System problem

GD555, 655, 675-3C

TROUBLESHOOTING


Problem with the machine

Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory

Troubleshooting code

Turns FL, FH, R solenoid outputs OFF Lever command when at: N: 1st - 4th solenoids OFF F1, F2: F1 F3, F4: F3 F5, F6: F5 F7, F8: F7 R: 1st thru 4th solenoids OFF After alarm buzzes for 2 seconds, chimes sound continuously

Big transmission shock, but possible to travel in F1, F3, F5, F7

Q

Q

Q

Q

Q

T-1

Turns FL, FH, R solenoid outputs OFF Lever command when at: N, F1: S solenoid OFF F2, F3: F2 F4, F5: F4 F6, F7: F6 F8: F8 R: 1st thru 4th After alarm buzzes for 2 seconds, chimes sound continuously

Big transmission shock, but possible to travel in F2, F4, F6, F8

Q

Q

Q

Q

Q

T-2

Turns FL, FH, R solenoid outputs OFF Lever command when at: N, F1 - F8: 1st - 4th solenoids OFF R1: R1 R2: R2 R3: R3 R4: R4 After alarm buzzes for 2 seconds, chimes sound continuously

Big transmission shock, but possible to travel in R1, R2, R3, R4

Q

Q

Q

Q

Q

T-3

Turns 1st thru 4th solenoid outputs OFF After alarm buzzes for 2 seconds, chimes sound continuously

Big transmission shock, but possible to travel in F1, F2, F5, F6, R1, R3

Q

Q

Q

Q

Q

T-4

Turns 1st thru 4th solenoid outputs OFF After alarm buzzes for 2 seconds, chimes sound continuously

Big transmission shock, but possible to travel in F3, F4, F7, F8, R2, R4

Q

Q

Q

Q

Q

T-5

Controller action after detecting the problem

GD555, 655, 675-3C

20-359 (4)

TROUBLESHOOTING

No.

6

7

8

9

10

11

12

13

Failure code


System problem


Short circuit to the power source in the lock-up solenoid system

1. Defective lock-up solenoid 2. Short circuit to ground, short circuit to power source in the wiring harness between T2 (female) (10) and T31 (female) (1) 3. Short circuit to power source in the wiring harness between T2 (female) (20) and T31 (female) (2) 4. Short circuit in wiring harness between T2 (female) (10) and T31 (female) (1); and between T2 (female) (20) and T31 (female) (2) 5. Defective transmission controller


Open circuit in the FL solenoid circuit

1. Defective FL solenoid 2. Defective contact or open circuit in the wiring harness between T2 (female) (7) and T24 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (17) and T24 (female) (2) 4. Defective transmission controller


Open circuit in the FH solenoid circuit

1. Defective FH solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (8) and T25 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (18) and T25 (female) (2) 4. Defective transmission controller


b3

Open circuit in the R solenoid system

1. Defective R solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (9) and T26 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (19) and T26 (female) (2) 4. Defective transmission controller


b4

Open circuit in the 1st solenoid system

1. Defective 1st solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (2) and T27 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (13) and T27 (female) (2) 4. Defective transmission controller


Open circuit in the 2nd solenoid system

1. Defective 2nd solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (4) and T28 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (15) and T28 (female) (2) 4. Defective transmission controller


Open circuit in the 3rd solenoid system

1. Defective 3rd solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (3) and T29 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (14) and T29 (female) (2) 4. Defective transmission controller


b7

Open circuit in the 4th solenoid system

1. Defective 4th solenoid 2. Defective contact or open circuit in wiring harness between T2 (female) (5) and T30 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (16) and T30 (female) (2) 4. Defective transmission controller


b8

Open circuit in the lock-up solenoid system

A8

b1

b2

b5

b6

1. Defective lock-up solenoid 14

2. Defective contact or open circuit in wiring harness between T2 (female) (10) and T31 (female) (1) 3. Short circuit to ground in wiring harness between T2 (female) (20) and T31 (female) (2)


Voltage between T1 (7), (13) – chassis: 19 to 30V Voltage between T2 (1), (12) – chassis: 19 to 30 V

1. Defective contact or open circuit in wiring harness between T1 (female) (7), (13), T2 (1), (12) - T11 (male) (1) 15

C0

20-360 (4)

Power source voltage reduced

2. Defective contact or open circuit in wiring harness between T1 (female) (6), (12), T2 (11), (21) - chassis 3. Defective contact or open circuit in wiring harness between T11 (female) (11) and battery relay 4. Defective transmission controller

Resistance between T4 (female) (7) and T5 (female) (1): 500 to 1000 z

GD555, 655, 675-3C

TROUBLESHOOTING




Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


Turns lock-up solenoid output OFF After alarm buzzes for 2 seconds, chimes sound continuously

Lock-up is always applied

Q

Q

Q

Q

Q

T-6

No action

Does not travel in F1, F3, F5, F7 (coasts)

Q

Q

Q

Q

Q

T-7

No action

Cannot travel in F2, F4, F6, F8 (coasts)

Q

Q

Q

Q

Q

T-8

No action

Does not travel in reverse (coasts)

Q

Q

Q

Q

Q

T-9

No action

Cannot travel in F1, F2, R1

Q

Q

Q

Q

Q

T-10

No action


Q

Q

Q

Q

Q

T-11

No action

Does not travel in F5, F6, R3

Q

Q

Q

Q

Q

T-12

No action


Q

Q

Q

Q

Q

T-13

No action

Always torque converter drive (lock-up is not applied)

Q

Q

Q

Q

Q

T-14

All solenoid outputs OFF (sets to Neutral)

Stays in N

Q

Q

Q

—

Q

T-15

GD555, 655, 675-3C

20-361 (4)

TROUBLESHOOTING

No.

16

17

18

19

20

21

22

23

Failure code

System problem


C1

Open circuit in the engine speed sensor system

1. Defective engine speed sensor 2. Defective contact or open circuit in wiring harness between T4 (female) (7) and T46 (female) (1) 3. Defective contact or open circuit in wiring harness between T5 (female) (1) and T46 (female) (2) 4. Defective transmission controller

C3

Short circuit to the power source in the accelerator potentiometer system

1. Defective accelerator potentiometer 2. Short circuit to power source in wiring harness between T3A (female) (3) and T9 (female) (B) Voltage between T3A (13) 3. Defective contact, open circuit, short circuit, short circuit to ground, or and (16): 0.5 to 4.75 V short circuit to power source in wiring harness between T3A (female) (7) and T9 (female) (A) 4. Defective transmission controller

C3

Open circuit in the accelerator potentiometer system

1. Defective accelerator potentiometer 2. Defective contact or open circuit in the wiring harness between T3A (female) (16) and T9 (female) (3) 3. Contact of wiring harness between T3A (female) (3) and T9 (female) (B) with wiring harness between T3A (female) (7) and T9 (female) (A), or contact with power source wiring harness 4. Defective transmission controller

C4

1. Defective inching potentiometer 2. Short circuit to power source in wiring harness between T3A (female) Short circuit to (13) and T8 (female) (B) the power source in inching potenti- 3. Defective contact, open circuit, short circuit, short circuit to ground, or short circuit to the power source in the wiring harness between T3A ometer system (female) (7) and T8 (female) (A) (opt) 4. Defective transmission controller

Voltage between T3A (female) (11), T34 (female) (1) and chassis: Max. 4.75 Resistance between T34 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z

C4

1. Defective inching potentiometer 2. Defective contact or open circuit in the wiring harness between T3A Open circuit in (female) (16) and T8 (female) (C) the inching 3. Contact of wiring harness between T3A (female) (13) and T8 (female) potentiometer cir(B) with wiring harness between T3A (female) (7) and T8 (female) (A), cuit (opt) or contact with power source wiring harness 4. Defective transmission controller

Voltage between T3A (female) (1), T35 (female) (1) and chassis: Max. 4.75 V Resistance between T35 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z

Short circuit to 1. Defective transmission oil temperature sensor the power source 2. Short circuit to ground, short circuit, or short circuit to the power source in the transmisin wiring harness between T3A (female) (1) and T35 (female) (1) sion oil tempera3. Defective transmission controller ture sensor circuit


C5

1. Defective transmission oil temperature sensor 2. Defective contact or open circuit in the wiring harness between T3A (female) (1) and T35 (female) (1) 3. Defective contact or open circuit in the wiring harness between T35 (female) (2) and chassis 4. Defective transmission controller

C5

Open circuit in the transmission oil temperature sensor circuit

C6

Short circuit to the power source 1. Defective torque converter outlet oil temperature sensor in the torque con- 2. Short circuit to ground, short circuit, or short circuit to the power source verter outlet oil in the wiring harness between T3A (female) (11) and T34 (female) (1) temperature sen- 3. Defective transmission controller sor system

20-362 (4)



Voltage between T3A (13) and (16): 0.5 to 4.75 V


Voltage between T3A (female) (2), E5 (female) (1) and chassis: Max. 4.75 V Resistance between E5 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z Voltage between T3A (female) (2), E5 (female) (1) and chassis: Max. 4.75 V Resistance between E5 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z

GD555, 655, 675-3C

TROUBLESHOOTING




Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


Engine speed not displayed on message center

None in particular

Q

Q

—

—

Q

T-16

Calculates for the accelerator at low position

Reduced power

Q

Q

—

—

Q

T-17

Calculates for the accelerator at low position

Reduced power

Q

Q

—

—

Q

T-17

No inching output

Inching impossible

Q

Q

—

—

Q

T-18

No inching output

Inching impossible

Q

Q

—

—

Q

T-18

Outputs with oil temperature map for less than 20°C

Normal operation

Q

Q

—

—

Q

T-19

Outputs with oil temperature map for less than 20°C

Normal operation

Q

Q

—

—

Q

T-19

No action

Normal operation

Q

Q

—

—

Q

T-20

GD555, 655, 675-3C

20-363 (4)

TROUBLESHOOTING

No.

24

25

26

27

28

29

30

31

32

Failure code

System problem

C6

Open circuit in the torque converter outlet oil temperature sensor system



1. Defective torque converter outlet oil temperature sensor 2. Defective contact or open circuit in the wiring harness between T3A (female) (11) and T34 (female) (1) 3. Defective contact or open circuit in the wiring harness between T34 (female) (2) and chassis 4. Defective transmission controller


Short circuit to power source in hydraulic oil temperature sensor system (opt)

1. Defective hydraulic oil temperature sensor 2. Short circuit to ground, short circuit, or short circuit to the power source in the wiring harness between T3A (female) (2) and E5 (female) (1) 3. Defective transmission controller

Voltage between T3A (female) (2), E5 (female) (1) and chassis: Max. 4.75 V Resistance between E5 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z

C7

Open circuit in hydraulic oil temperature sensor system (opt)

1. Defective hydraulic oil temperature sensor 2. Defective contact or open circuit in wiring harness between T3A (female) (2) and E5 (female) (1) 3. Defective contact or open circuit in wiring harness between E5 (female) (2) and chassis 4. Defective transmission controller

Voltage between T3A (female) (2), E5 (female) (1) and chassis: Max. 4.75 V Resistance between E5 (male) (1) and (2): 25°C (normal temperature): 3.5 to 4.0 z 100°C: 38.5 to 47.0 z

C8

Open circuit in the transmission input speed sensor system

1. Defective transmission input shaft speed sensor 2. Defective contact or open circuit in wiring harness between T5 (female) (2) and T32 (female) (1) 3. Defective contact or open circuit in wiring harness between T5 (female) (1) and T32 (female) (2) 4. Defective transmission controller

Resistance between T5 (2) and (1): 500 to 1000 z

C9

Open circuit in the transmission output speed sensor system

1. Defective transmission output shaft speed sensor 2. Defective contact or open circuit in wiring harness between T4 (female) (2) and T33 (female) (1) 3. Defective contact or open circuit in wiring harness between T5 (female) (1) and T33 (female) (2) 4. Defective transmission controller

Resistance between T4 (1) and T5 (1): 500 to 1000 z

d1

Short circuit to power source in the differential oil temperature warning lamp system (opt)

1. Defective differential oil temperature warning lamp 2. Short circuit to power source in wiring harness between T1 (female) (1) and FP3 (female) (4) 3. Defective transmission controller

Voltage between T1 (1) and chassis: When output is OFF: Max. 1 V

d1

Open circuit in the differential oil temperature warning lamp system (opt)

1. Defective differential oil temperature warning lamp 2. Defective contact or open circuit in wiring harness between T1 (female) (1) and FP3 (female) (4) 3. Defective transmission controller

Voltage between T1 (1) and chassis: When output is ON: 17 to 30 V

d2

Short circuit to 1. Defective transmission (torque converter outlet) oil temperature warning power source in lamp transmission (torque converter 2. Short circuit to power source in wiring harness between T1 (female) (3) and FP3 (female) (6) outlet) oil temper3. Defective transmission controller ature warning lamp system


d2

Open circuit in 1. Defective transmission (torque converter outlet) oil temperature warning the transmission lamp (torque converter 2. Defective contact or open circuit in wiring harness between T1 (female) outlet) oil temper(3) and FP3 (female) (6) ature warning 3. Defective transmission controller lamp system


C7

20-364 (4)


GD555, 655, 675-3C

TROUBLESHOOTING



Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


No action

Normal operation

Q

Q

—

—

Q

T-20

No action

Normal operation

Q

Q

—

—

Q

T-21

No action

Normal operation

Q

Q

—

—

Q

T-21

No action

Normal operation

Q

Q

Q

Q

Q

T-22

When starting switch is ON and gearshift lever kept at N, possible up to 2nd; when traveling, taken as N until starting switch is turned OFF

Travel impossible after stopping the machine

Q

Q

Q

Q

Q

T-23

Differential oil temperature warning lamp output OFF

Differential oil temperature warning lamp stays on and does not go out

Q

Q

—

—

Q

T-24

Differential oil temperature warning lamp output OFF

Warning lamp does not light up when the differential oil temperature is abnormal

Q

Q

—

—

Q

T-24

Torque converter outlet port oil Torque converter outlet port oil temperature temperature warning lamp output OFF warning lamp stays on and does not go out

Q

Q

—

—

Q

T-25

Warning lamp does not light up when transmisTorque converter outlet port oil temperature sion oil temperawarning lamp output OFF ture problems exist (torque converter outlet port)

Q

Q

—

—

Q

T-25


GD555, 655, 675-3C

20-365 (4)

TROUBLESHOOTING


Failure code

System problem



d4

Short circuit to power source in alarm buzzer (alarm buzzer A) system

1. Defective alarm buzzer (alarm buzzer A) 2. Short circuit to power source in wiring harness between T1 (female) (9) and BR22 (female) (1) 3. Defective transmission controller


d4

Open circuit in the alarm buzzer (alarm buzzer A) system

1. Defective alarm buzzer (alarm buzzer A) 2. Defective contact or open circuit in wiring harness between T1 (female) (9) and BR22 (female) (1) 3. Defective contact or open circuit in wiring harness between BR22 (female) (2) and chassis 4. Defective transmission controller


d5

Short circuit to power source in the transmission control warning lamp system

1. Defective warning lamp 2. Short circuit to the power source in the wiring harness between T1 (female) (5) and FP3 (female) (7) 3. Defective transmission controller


d5

Open circuit in the transmission control warning lamp system

1. Defective warning lamp 2. Defective contact or open circuit in the wiring harness between T1 (female) (5) and FP3 (female) (7) 3. Defective transmission controller


d6

Short circuit to power source in the differential control relay system

1. Defective differential control relay 2. Short circuit to power source in the wiring harness between T1 (female) (11) and BR7 (female) (1) 3. Defective transmission controller


d6

Open circuit in the differential control relay system

1. Defective differential control relay 2. Defective contact or open circuit in the wiring harness between T1 (female) (11) and BR7 (female) (1) 3. Defective contact or open circuit in the wiring harness between BR7 (female) (2) and chassis 4. Defective transmission controller


d7

Short circuit to the power source in VHP solenoid relay system (opt)

1. Defective VHP solenoid relay 2. Short circuit to the power source in the wiring harness between T1 (female) (2) and BR8 (female) (1) 3. Defective transmission controller

Voltage between T1 (2) and chassis: When output is OFF (except for VHP specification): Max. 1 V

40

d7

Open circuit in the VHP solenoid relay system (opt)

1. Defective VHP solenoid relay 2. Defective contact or open circuit in the wiring harness between T1 (female) (2) and BR8 (female) (1) 3. Defective contact or open circuit in the wiring harness between BR8 (female) (2) and chassis 4. Defective transmission controller

Voltage between T1 (2) and chassis: When output is ON (VHP specification): 17 to 30 V

41

E1

1. Defective gearshift lever Short circuit to the power source 2. Short circuit to the power source in the wiring harness between T5 in the F (Forward) (female) (6) and T13 (female) (7) 3. Defective transmission controller signal circuit

Voltage between T5 (6) and chassis: Except when gearshift lever is at [F1] to [F8]: Max. 1 V

E1

Open circuit in the F (Forward) signal circuit

1. Defective gearshift lever 2. Defective contact or open circuit in the wiring harness between T5 (female) (6) and T13 (female) (7) 3. Defective transmission controller

Voltage between T5 (6) and chassis: When gearshift lever is at [F1] to [F8]: 20 to 30 V

E1

Short circuit to the power source in R (Reverse) signal system

1. Defective gearshift lever 2. Short circuit to power source in wiring harness between T5 (female) (14) and T13 (female) (13) 3. Defective transmission controller

Voltage between T5 (14) and chassis: Except when gearshift lever is in [R1] to [R4]: Max. 1 V

E1

Open circuit in the R (Reverse) signal system

1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T5 (female) (14) and T13 (female) (13) 3. Defective transmission controller

Voltage between T5 (14) and chassis: When gearshift lever is at [R1] to [R4]: 20 to 30 V

No.

33

34

35

36

37

38

39

42

43

44

20-366 (4)

GD555, 655, 675-3C

TROUBLESHOOTING




Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


Alarm buzzer output OFF

Alarm buzzer does not stop

Q

Q

—

Q

Q

T-26

Alarm buzzer output OFF

Alarm buzzer does not sound

Q

Q

—

Q

Q

T-26

Warning lamp output OFF

Warning lamp stays lit and does not go out

Q

—

—

Q

Q

T-27

Warning lamp output OFF

Warning lamp does not light up

Q

—

—

Q

Q

T-27

Differential control relay output OFF

Normal differential condition

Q

Q

—

Q

Q

T-28

Differential control relay output OFF

Normal differential lock condition

Q

Q

—

Q

Q

T-28

VHP solenoid relay output OFF

Normal VHP condition

Q

Q

—

Q

Q

T-29

VHP solenoid relay output OFF

Does not change to VHP

Q

Q

—

Q

Q

T-29

F and R signals input at same time o N

achine coasts, and then stops

Q

Q

Q

Q

Q

T-30

No action

Impossible to travel in FORWARD

Q

Q

Q

Q

Q

T-30

F and R signals input at same time o N

Machine coasts, and then stops

Q

Q

Q

Q

Q

T-30

No action

Impossible to travel in REVERSE

Q

Q

Q

Q

Q

T-30

GD555, 655, 675-3C

20-367 (4)

TROUBLESHOOTING


No.

Failure code

45

E2

Short circuit to 1. Defective gearshift lever the power source 2. Short circuit to power source in wiring harness between T3A (female) (8) in the neutral sigand T13 (female) (2) nal system 3. Defective transmission controller

E2

Open circuit in the neutral signal system

1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T3A (female) (8) and T13 (female) (2) 3. Defective transmission controller

Voltage between T3A (8) and chassis: When gearshift lever is in Neutral, Parking: 20 to 30 V

E3

Short circuit to power source in parking signal system

1. Defective parking brake relay 2. Short circuit to the power source in the wiring harness between T3A (female) (9) and BR11 (female) (6) 3. Short circuit to the power source in the wiring harness between T13 (female) (10) and BR11 (female) (1) 4. Defective transmission controller 5. Defective gearshift lever

Voltage between T3A (9) and chassis: Except when gearshift lever is in Park: Max. 1 V

48

E3

1. Defective parking brake relay 2. Defective contact or open circuit in the wiring harness between T3A (female) (9) and BR11 (female) (6) Open circuit in 3. Defective contact or open circuit in the wiring harness between T13 the parking signal (female) (10) and BR11 (female) (1) system 4. Defective contact or open circuit in the wiring harness between BR11 (female) (2) and chassischassis 5. Defective transmission controller 6. Defective gearshift lever

49

E4

Short circuit to power source in logic A system

1. Defective gearshift lever 2. Short circuit to power source in wiring harness between T3A (female) (18) and T13 (female) (4) 3. Defective transmission controller

Voltage between T3A (18) and chassis: When gearshift lever is in Park, Neutral: Max. 1 V

E4

Open circuit in logic A system

1. Defective gearshift lever 2. Defective contact or open circuit in the wiring harness between T3A (female) (18) and T13 (female) (4) 3. Defective transmission controller

Voltage between T3A (18) and chassis: Except when gearshift lever is in Park, Neutral: 20 to 30 V

E5

Short circuit to the power source in logic B system

1. Defective gearshift lever 2. Short circuit to the power source in the wiring harness between T5 (female) (7) and T13 (female) (5) 3. Defective transmission controller

Voltage between T5 (7) and chassis: Except when gearshift lever is in [F1], [F5] [F7], [R1] - [R3]: Max. 1 V

52

E5

Open circuit in logic B system


Voltage between T5 (7) and chassis: When gearshift lever is at [F1], [F5] - [F7], [R1] - [R3]: 20 to 30 V

53

E6

Short circuit to power source in logic C system


Voltage between T5 (15) and chassis: Except when gearshift lever is at [F1] [F5], [R1]: Max. 1 V

E6

Open circuit in the logic C system


Voltage between T5 (15) and chassis: When gearshift lever is at [F1] - [F5], [R1]: 20 to 30 V

E7

Short circuit to the power source in logic D system

1. Defective gearshift lever 2. Short circuit to power source in the wiring harness between T5 (female) (8) and T13 (female) (18) 3. Defective transmission controller

Voltage between T5 (8) and chassis: Except when gearshift lever is at [F1] - [F3]: Max. 1 V

E7

Open circuit in logic D system


Voltage between T5 (8) and chassis: When gearshift lever is at [F1] - [F3]: 20 to 30 V

46

47

50

51

54

55

56

20-368 (4)

System problem


Normal condition (volts, amps and ohms) Voltage between T3A (8) and chassis: Except when gearshift lever is in Neutral, Park: Max. 1 V

Voltage between T3A (9) and chassis: When gearshift lever is in Park: 20 to 30 V

GD555, 655, 675-3C

TROUBLESHOOTING


Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


Machine coasts, N, P, and other signals input at same time and then stops oN After stopping, N and other signals input at same time o N cannot travel

Q

Q

Q

Q

Q

T-31

No F, R, N signals o N

Cannot travel

Q

Q

Q

Q

Q

T-31

No action

Danger that machine will move when the lever is operated and the parking brake will seize

Q

Q

—

Q

Q

T-32

No action

When machine stops, it does not move when operating the lever. Shifts to Neutral during travel when accelerator pedal is being depressed

Q

Q

—

Q

Q

T-32

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-33

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-33

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-34

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-34

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-35

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-35

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-36

Set to Neutral

Cannot travel

Q

Q

—

Q

Q

T-36


GD555, 655, 675-3C


20-369 (4)

TROUBLESHOOTING


No.

Failure code

57

E8

Short circuit to power source in logic E system


Voltage between T5 (16) and chassis: Except when gearshift lever is at [F3] [F6], [R1], [R2]: Max. 1 V

E8

Open circuit in logic E system


Voltage between T5 (16) and chassis: When gearshift lever is at [F3] - [F6], [R1], [R2]: 20 to 30 V

—

Short circuit to power source in stop lamp signal system

1. Defective stop lamp or stop lamp relay 2. Short circuit to power source in wiring harness between T3A (female) (19) and BR10 (female) (5) or RL1 (female) (3) 3. Defective transmission controller

Voltage between T3A (19) and chassis: When output is OFF (brake pedal not being depressed): Max. 1 V

—

1. Defective stop lamp or stop lamp relay Open circuit in 2. Defective contact or open circuit in wiring harness between T3A the stop lamp sig(female) (19) and BR10 (female) (5) or RL1 (female) (3) nal system 3. Defective transmission controller

Voltage between T3A (19) and chassis: When output is ON (brake pedal being depressed): 17 to 30 V

—

Short circuit to ground in differential selector switch system

1. Defective differential switch 2. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T5 (female) (9) and FP13 (female) (2) 3. Defective transmission controller

Voltage between T1 (11) and chassis: When differential selector switch is ON: 20 to 30 V When differential selector switch is OFF: Max. 1 V

—

Open circuit in the differential selector switch system

1. Defective differential switch 2. Defective contact or open circuit in the wiring harness between T5 (female) (9) and FP13 (female) (2) 3. Defective transmission controller

Voltage between T1 (11) and chassis: When differential selector switch is ON: 20 to 30 V When differential selector switch is OFF: Max. 1 V

—

Short circuit to ground in lock-up switch system

1. Defective lock-up switch 2. Short circuit to the ground, short circuit, or short circuit to power source in wiring harness between T5 (female) (17) and T14 (female) (2) 3. Defective transmission controller

Voltage between T5 (17) and chassis: When lock-up switch is ON: 20 to 30 V When lock-up switch is OFF: Max. 1 V

—

Open circuit in the differential lock-up switch system

1. Defective lock-up switch 2. Defective contact or open circuit in the wiring harness between T5 (female) (17) and T14 (female) (2) 3. Defective transmission controller

Voltage between T5 (17) and chassis: When lock-up switch is ON: 20 to 30 V When lock-up switch is OFF: Max. 1 V

—

Short circuit to ground in low set switch system

1. Defective low set switch 2. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T5 (female) (12) and TT (terminal) (4) 3. Defective transmission controller

Resistance between T5 (12) and chassis: When potentiometer switch is at LOW: Max. 1 z When potentiometer switch is at HIGH OFF: Min. 1 Mz

—

1. Defective low set switch Open circuit in 2. 2. Defective contact or open circuit in wiring harness between T5 the low set switch (female) (12) and TT (terminal) (4) system 3. 3. Defective transmission controller

Resistance between T5 (12) and chassis: When potentiometer switch is at LOW: Max. 1 z When potentiometer switch is at HIGH OFF: Min. 1 Mz

—

Short circuit to ground in the model selection switch system

1. Short circuit to ground, short circuit, or short circuit to the power source in the wiring harness between T5 (female) (5) and T7 (female) (1)

Resistance between T5 (5) and chassis: STD specification: Max. 1 z Specification: Min. 1 MC

—

Open circuit in the model selection switch system

1. Defective contact or open circuit in the wiring harness between T5 (female) (5) and T7 (female) (1)

Resistance between T5 (5) and chassis: STD specification: Max. 1 z Specification: Min.1 Mz

58

59

60

61

62

63

64

65

66

67

68

20-370 (4)

System problem



GD555, 655, 675-3C

TROUBLESHOOTING




Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


Sets to neutral

Cannot travel

Q

Q

—

Q

Q

T-37

Sets to neutral

Cannot travel

Q

Q

—

Q

Q

T-37

Takes no action

Shock becomes greater when decelerating

—

—

—

—

—

—

Takes no action

None

—

—

—

—

—

—

No action

Differential lock may be applied

—

—

—

—

—

—

No action

Differential lock always applied

—

—

—

—

—

—

No action

Always enters the lock-up mode when in F1 - F4 or R1 - R4

—

—

—

—

—

—

No action

Always enters torque converter mode when in F1 - F4 or R1 - R4

—

—

—

—

—

—

If a short circuit exists when turning the start switch to ON, the setting does not work

Normal operation

—

—

—

—

—

—

No action

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 second), does not enter the selection mode Normal

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter selection mode

Normal operation

—

—

—

—

—

—

GD555, 655, 675-3C

20-371 (4)

TROUBLESHOOTING

No.

69

70

71

72

73

74

75

76

77

78

Failure code



1. Short circuit to ground, short circuit, or short circuit to the power source in wiring harness between T3A (female) (10) and T7 (female) (2).

Resistance between T5 (9) and chassis: When differential selection switch is ON: Max. 1 z When differential selection switch is OFF: Min. 1 Mz

1. Defective contact or open circuit in the wiring harness between T3A (female) (10) and T7 (female) (2).

Resistance between T5 (9) and chassis: When differential selection switch is ON: Max. 1 z When differential selection switch is OFF: Min. 1 Mz

1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3A (female) (20) and T7 (female) (4).

Resistance between T3A (20) and chassis: With inching specification: Max. 1 z Without inching specification: Min. 1 Mz

—

Short circuit to ground in differential selection switch system

—

Open circuit in the differential selection switch system

—

Short circuit to ground in inching selection switch system

—

Open circuit in the inching selec- 1. Defective contact or open circuit in the wiring harness between T3A (female) (20) and T7 (female) (4). tion switch system

Resistance between T3A (20) and chassis: With inching specification: Max. 1 z Without inching specification: Min. 1 Mz

—

Short circuit to 1. Short circuit to ground, short circuit, or short circuit to power source in ground in high set wiring harness between T3B (female) (1) and TT (terminal) (3). switch system

Resistance between T3B (1) and chassis: When potentiometer switch is at HIGH: Max. 1 z When potentiometer switch is at LOW OFF: Min. 1 Mz

—

Open circuit in the high set switch system

1. Defective contact or open circuit in the wiring harness between T3B (female) (1) and TT (terminal) (3).

Resistance between T3B (1) and chassis: When potentiometer switch is at HIGH: Max. 1 z When potentiometer switch is at LOW OFF: Min. 1 Mz

—

Short circuit to ground in the reset switch system

1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (9) and TT (terminal) (8).

Resistance between T3B (9) and chassis: When reset switch is ON: Max. 1 z When reset switch is OFF: Min. 1 Mz

1. Defective contact or open circuit in the wiring harness between T3B (female) (9) and TT (terminal) (8)

Resistance between T3B (9) and chassis: When reset switch is ON: Max. 1 z When reset switch is OFF: Min. 1 Mz

1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (2) and T7 (female) (3)

Resistance between T3B (2) and chassis: With VHP specification: Max. 1 z Without VHP specification: Min. 1 Mz

1. Defective contact or open circuit in wiring harness between T3B (female) (2) and T7 (female) (3)

Resistance between T3B (2) and chassis: With VHP specification: Max. 1 z Without VHP specification: Min. 1 Mz

—

Open circuit in the reset switch system

—

Short circuit to ground in VHP selection switch system

—

Open circuit in the VHP selection switch system

20-372 (4)

System problem


GD555, 655, 675-3C

TROUBLESHOOTING



Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


If the reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter differential mode

Normal operation

—

—

—

—

—

—

If the reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter differential mode

Normal operation

—

—

—

—

—

—

If the reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter inching mode

Normal operation

—

—

—

—

—

—

If the reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter inching mode

Normal operation

—

—

—

—

—

—

If potentiometer voltage is not ± 0.1V, the setting does not work. If there is a short cirNormal operation cuit when the start switch is turned ON, the setting does not work.

—

—

—

—

—

—

No action

Normal operation

—

—

—

—

—

—

No action

Normal operation

—

—

—

—

—

—

No action

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter VHP mode

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter VHP mode

Normal operation

—

—

—

—

—

—


GD555, 655, 675-3C

20-373 (4)

TROUBLESHOOTING

No.

79

80

81

82

83

84

85

86

87

88

89

Failure code

—

Short circuit to ground in AWD selection switch system

—

Open circuit in the AWD selection switch system

—

Short circuit to ground in memory reset switch system



1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (3) and T7 (female) (5)

Resistance between T3B (3) and chassis: AWD specification: Max. 1 z Except AWD specification: Min. 1 Mz

1. Defective contact or open circuit in the wiring harness between T3B (female) (3) and T7 (female) (5)

Resistance between T3B (3) and chassis: AWD specification: Max. 1 z Except AWD specification: Min. 1 Mz

1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (11) and TT (terminal) (6)

Resistance between T3B (11) and chassis: Initialize switch at [Memory set]: Max. 1 z Initialize switch at [Initialize learning function] or OFF: Min. 1 Mz

—

Open circuit in 1. Defective contact or open circuit in wiring harness between T3B the memory reset (female) (11) and TT (terminal) (6) switch system

Resistance between T3B (11) and chassis: Initialize switch at [Memory set]: Max. 1 z Initialize switch at [Initialize learning function] or OFF: Min. 1 Mz

—

Short circuit to ground in learning function initialize switch system

1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T5 (female) (13) and TT (terminal) (4)

Resistance between T3B (13) and chassis: Initialize switch at [Initialize learning function]: Max. 1 z Initialize switch at [Memory set] or OFF: Min. 1 Mz

—

Open circuit in learning function initialize switch system

1. Defective contact or open circuit in wiring harness between T5 (female) (13) and TT (terminal) (4)

Resistance between T3B (13) and chassis: Initialize switch at [Initialize learning function]: Max. 1 z Initialize switch at [Memory set] or OFF: Min. 1 Mz

F1

Short circuit to ground in FL clutch pressure switch system

1. Defective FL clutch pressure switch 2. Short circuit to ground in wiring harness between T3B (female) (5) and T36 (female) (1) 3. Defective transmission controller

Resistance between T3B (5) and chassis: At F1, F3, F5, F7: Max. 1 z Except F1, F3, F5, F7: Min. 1 Mz

91

Open circuit in the FL clutch pressure switch system

1. Defective FL clutch pressure switch 2. Defective contact or open circuit in wiring harness between T3B (female) (5) and T36 (female) (1) 3. Defective transmission controller


F2

Short circuit to ground in the FH clutch pressure switch system

1. Defective FH clutch pressure switch 2. Short circuit to ground in the wiring harness between T3B (female) (13) and T37 (female) (1) 3. Defective transmission controller


92

Open circuit in the FH clutch pressure switch system

1. Defective FH clutch pressure switch 2. Defective contact or open circuit in the wiring harness between T3B (female) (13) and T37 (female) (1) 3. Defective transmission controller


F3

Short circuit to ground in the R clutch pressure switch system

1. Defective R clutch pressure switch 2. Short circuit to ground in the wiring harness between T3B (female) (6) and T38 (female) (1) 3. 3. Defective transmission controller

Resistance between T3B (6) and chassis: At R1 - R4 : Max. 1 z Except R1 - R4: Min. 1 Mz

20-374 (4)

System problem


GD555, 655, 675-3C

TROUBLESHOOTING




Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory


If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter AWD mode

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), does not enter AWD mode

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), error code is not deleted

Normal operation

—

—

—

—

—

—

If reset switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), error code is not deleted

Normal operation

—

—

—

—

—

—

If learning function initialize switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), potentiometer set value, trigger time, learning value, model selection values cannot be deleted from memory

Normal operation

—

—

—

—

—

—

If learning function initialize switch is not turned OFF (at least 1 sec) o ON (at least 1 sec) o OFF (at least 1 sec), potentiometer set value, trigger time, learning value, model selection values cannot be deleted from memory

Normal operation

—

—

—

—

—

—

Sets to neutral

Sets to neutral

Q

Q

Q

Q

Q

T-38

Sets to rapid raise mode

Gearshift shock Gearshift timelag

Q

Q

—

—

Q

T-46

Sets to neutral

Sets to neutral

Q

Q

Q

Q

Q

T-39



Q

Q

—

—

Q

T-47

Sets to neutral

Sets to neutral

Q

Q

Q

Q

Q

T-40

GD555, 655, 675-3C

20-375 (4)

TROUBLESHOOTING


No.

Failure code

90

93

Open circuit in 1. Defective R clutch pressure switch the R clutch pres- 2. Defective contact or open circuit in the wiring harness between T3B sure switch sys(female) (6) and T38 (female) (1) tem 3. Defective transmission controller

Resistance between T3B (13) and chassis: At R1 - R4: Max. 1 z Except R1 - R4: Min. 1 Mz

F4

Short circuit to ground in 1st clutch pressure switch system

1. Defective 1st clutch pressure switch 2. Short circuit to ground in the wiring harness between T3B (female) (14) and T39 (female) (1) 3. Defective transmission controller

Resistance between T3B (14) and chassis: At F1, F2, R1: Max. 1 z Except F1, F2, R1: Min. 1 Mz

94

Open circuit in the 1st clutch pressure switch system

1. Defective 1st clutch pressure switch 2. Defective contact or open circuit in wiring harness between T3B (female) (14) and T39 (female) (1) 3. Defective transmission controller


F5

Short circuit to 1. Defective 2nd clutch pressure switch ground in the 2nd 2. Short circuit to ground in wiring harness between T3B (female) (7) and clutch pressure T40 (female) (1) switch system 3. Defective transmission controller


95

Open circuit in the 2nd clutch pressure switch system

1. Defective 2nd clutch pressure switch 2. Defective contact or open circuit in wiring harness between T3B (female) (7) and T40 (female) (1) 3. Defective transmission controller


F6

Short circuit to ground in 3rd clutch pressure switch system

1. Defective 3rd clutch pressure switch 2. Short circuit to ground in wiring harness between T3B (female) (15) and T41 (female) (1) 3. Defective transmission controller


96

Open circuit in the 3rd clutch pressure switch system

1. Defective 3rd clutch pressure switch 2. Defective contact or open circuit in the wiring harness between T3B (female) (15) and T41 (female) (1) 3. Defective transmission controller


F7

Short circuit to ground in the 4th clutch pressure switch system

1. Defective 4th clutch pressure switch 2. Short circuit to ground in wiring harness between T3B (female) (8) and T42 (female) (1) 3. Defective transmission controller


97

Open circuit in the 4th clutch pressure switch system

1. Defective 4th clutch pressure switch 2. Defective contact or open circuit in wiring harness between T3B (female) (8) and T42 (female) (1) 3. Defective transmission controller


F8

Short circuit to ground in the lock-up clutch pressure switch system

1. Defective lock-up clutch pressure switch 2. Short circuit to ground in wiring harness between T3B (female) (16) and T43 (female) (1) 3. Defective transmission controller

Resistance between T3B (16) and chassis: When lock-up switch is ON: Max. 1 z When lock-up switch is OFF: Min. 1 Mz

98

Open circuit in 1. Defective lock-up clutch pressure switch the lock-up clutch 2. Defective contact or open circuit in wiring harness between T3B pressure switch (female) (16) and T43 (female) (1) system 3. Defective transmission controller

91

92

93

94

95

96

97

98

99

100

20-376 (4)

System problem



Resistance between T3B (16) and chassis: When lock-up switch is ON: Max. 1 z When lock-up switch is OFF: Min. 1 Mz

GD555, 655, 675-3C

TROUBLESHOOTING



Code displayed

Warning lamp

Alarm buzzer

Warning chime

Memory




Q

Q

—

—

Q

T-48

Set to neutral

Set to neutral

Q

Q

Q

Q

Q

T-41



Q

Q

—

—

Q

T-49

Set to neutral

Set to neutral

Q

Q

Q

Q

Q

T-42



Q

Q

—

—

Q

T-50

Set to neutral

Set to neutral

Q

Q

Q

Q

Q

T-43



Q

Q

—

—

Q

T-51

Set to neutral

Set to neutral

Q

Q

Q

Q

Q

T-44



Q

Q

—

—

Q

T-52

Set to neutral

Set to neutral

Q

Q

Q

Q

Q

T-45



Q

Q

—

—

Q

T-53


GD555, 655, 675-3C

20-377 (4)

TROUBLESHOOTING


ELECTRICAL CIRCUIT DIAGRAM For the transmission control system Serial No. 50001 – 51000

20-378 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C

20-379 (4)

TROUBLESHOOTING


20-380 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C

20-381 (4)

TROUBLESHOOTING

T-1

T-1

Failure code [A1]

Short circuit with power source, ground, or FL solenoid system

T-1 Related electrical circuit diagram

20-382 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-2

T-2

Failure code [A2]

Short circuit with power source, ground, or FH solenoid circuit

T-2 Related electrical circuit

GD555, 655, 675-3C

20-383 (4)

TROUBLESHOOTING

T-3

T-3

Failure code [A3]

Short circuit with power source, R solenoid circuit, or ground


20-384 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-4

T-4

Failure code [A4]

Short circuit with power source, 1st or 3rd solenoid circuit, or ground


GD555, 655, 675-3C

20-385 (4)

TROUBLESHOOTING

T-5

T-5

Failure code [A5]

Short circuit with power source, 2nd or 4th solenoid system, or ground


20-386 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-6

T-6

Failure code [A8]

Short circuit with power source, lockup solenoid circuit, or ground


GD555, 655, 675-3C

20-387 (4)

TROUBLESHOOTING

T-7

T-7

Failure code [b1]

Open FL solenoid circuit


20-388 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-8

T-8

Failure code [b2]

Open FH solenoid circuit


GD555, 655, 675-3C

20-389 (4)

TROUBLESHOOTING

T-9

T-9

Failure code [b3]

Open R solenoid circuit


20-390 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-10

T-10 Failure code [b4] Open 1st solenoid circuit


GD555, 655, 675-3C

20-391 (4)

TROUBLESHOOTING

T-11

T-11 Failure code [b5] Open 2nd solenoid circuit


20-392 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-12

T-12 Failure code [b6] Open 3rd solenoid circuit


GD555, 655, 675-3C

20-393 (4)

TROUBLESHOOTING

T-13

T-13 Failure code [b7] Open 4th solenoid circuit


20-394 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-14

T-14 Failure code [b8] Open lock-up solenoid circuit


GD555, 655, 675-3C

20-395 (4)

TROUBLESHOOTING

T-15

T-15 Failure code [C0] Power supply voltage reduced a When fuse I-(7) is normal. If it is blown, check for a short circuit to ground in the wiring harness between the fuse and inside the controller. a When the battery is normal.


20-396 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-16

T-16 Failure code [C1] Open engine-speed sensor circuit


GD555, 655, 675-3C

20-397 (4)

TROUBLESHOOTING

T-17

T-17 Failure code [C3] Short circuit with power source or open accelerator potentiometer circuit

20-398 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-17

Table 1 T3A

T9

Voltage 0.5 to 4.75V


Between (B) and (C)

0.5 to 1.6 V (low idle) 2.1 V at low idle to 4.75 V at high idle


Between (A) and (C)

4.75 to 5.25 V

a The above table shows the specified potentiometer voltage. The controller interprets the voltage as the throttle angle. When adjusting the potentiometer, leave a margin of error for the judgment field. At low idle, adjust the potentiometer so that voltage is from 1.3 to 1.6 V.


GD555, 655, 675-3C

20-399 (4)

TROUBLESHOOTING

T-18

T-18 Failure code [C4] Short circuit with power source or open inching potentiometer circuit

20-400 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-18

Table 1 T3A

T8

Voltage 0.5 to 4.75V


Between (B) and (C)

0.5 to 1.6 V (inching pedal not depressed) 2.1 V when inching pedal not depressed to 4.75 V when inching pedal fully depressed


Between (A) and (C)

4.75 to 5.25 V

a The above table shows the specified potentiometer voltage. The controller interprets the voltage as the throttle angle. When adjusting the potentiometer, leave a margin of error for the judgment field. At low idle, adjust the potentiometer so that voltage is from 1.3 to 1.6 V.


GD555, 655, 675-3C

20-401 (4)

TROUBLESHOOTING

T-19

T-19 Failure code [C5] Short circuit with the power source or open circuit in the transmission oil temperature sensor circuit


20-402 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-20

T-20 Failure code [C6] Short circuit with the power source or open circuit in the torque converter outlet oil temperature sensor circuit


GD555, 655, 675-3C

20-403 (4)

TROUBLESHOOTING

T-21

T-21 Failure code [C7] Short circuit with the power source or open circuit in the hydraulic oil temperature circuit


20-404 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-22

T-22 Failure code [C8] Open circuit in the transmission input shaft speed sensor circuit


GD555, 655, 675-3C

20-405 (4)

TROUBLESHOOTING

T-23

T-23 Failure code [C9] Open circuit in the transmission output shaft speed sensor circuit


20-406 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-24

T-24 Failure code [d1] Short circuit with power source or open circuit in the differential oil temperature warning lamp circuit


GD555, 655, 675-3C

20-407 (4)

TROUBLESHOOTING

T-25

T-25 Failure code [d2] Short circuit to the power source or open circuit in the transmission oil temperature warning lamp circuit


20-408 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-26

T-26 Failure code [d4] Short circuit to the power source or open circuit in the buzzer alarm system

Note 1: k Always apply the parking brake.


GD555, 655, 675-3C

20-409 (4)

TROUBLESHOOTING

T-27

T-27 Failure code [d5] Short circuit with the power source or open circuit in the transmission control warning lamp system


20-410 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-28

T-28 Failure code [d6] Short circuit with power source or open circuit in the differential control relay system


GD555, 655, 675-3C

20-411 (4)

TROUBLESHOOTING

T-29

T-29 Failure code [d7] Short circuit to the power source or open circuit in the VHP relay circuit


20-412 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-30

T-30 Failure code [E1] Short circuit with the power source or open circuit in the F (for-ward), R (reverse) system

GD555, 655, 675-3C

20-413 (4)

TROUBLESHOOTING

T-31

T-31 Failure code [E2] Short circuit with the power source or open circuit in the neutral signal circuit

T-30, T-31 Related electrical circuit diagram

20-414 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-32

T-32 Failure code [E3] Short circuit with the power source or open circuit in the parking signal circuit

GD555, 655, 675-3C

20-415 (4)

TROUBLESHOOTING

T-32


20-416 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-33, T-34

T-33 Failure code [E4] Short circuit with the power source or open circuit in the logic A signal circuit

T-34 Failure code [E5] Short circuit with the power source or open circuit in the logic B signal circuit

GD555, 655, 675-3C

20-417 (4)

TROUBLESHOOTING

T-35

T-35 Failure code [E6] Short circuit with the power source or open circuit in the logic C signal circuit

T-33, T-34, T-35 Related electrical circuit diagram

20-418 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-36, T-37

T-36 Failure code [E7] Short circuit with the power source or open circuit in the logic D signal system

T-37 Failure code [E8] Short circuit with the power source or open circuit in the logic E signal system

GD555, 655, 675-3C

20-419 (4)

TROUBLESHOOTING

T-37

T-36, T-37 Related electrical circuit diagram

20-420 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-38, T-39

T-38 Failure code [F1] Short circuit with ground in the FL clutch pressure switch signal circuit

T-39 Failure code [F2] Short circuit with ground in the FH clutch pressure switch signal circuit

GD555, 655, 675-3C

20-421 (4)

TROUBLESHOOTING

T-40

T-40 Failure code [F3] Short circuit with ground in the R clutch pressure switch signal circuit


20-422 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-41, T-42

T-41 Failure code [F4] Short circuit to ground in the 1st clutch pressure switch circuit

T-42 Failure code [F5] Short circuit to ground in the 2nd clutch pressure switch circuit

GD555, 655, 675-3C

20-423 (4)

TROUBLESHOOTING

T-43, T-44

T-43 Failure code [F6] Short circuit to ground in the 3rd clutch pressure switch circuit

T-44 Failure code [F7] Short circuit with ground in 4th clutch pressure switch system

T-41, T-42, T-43, T-44 Related electrical circuit diagram

20-424 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-45

T-45 Failure code [F8] Short circuit to ground in the lock-up clutch pressure switch circuit


GD555, 655, 675-3C

20-425 (4)

TROUBLESHOOTING

T-46, T-47

T-46 Failure code [91] Open circuit in the FL clutch pressure switch circuit

T-47 Failure code [92] Open circuit in the FH clutch pressure switch circuit

20-426 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-48

T-48 Failure code [93] Open circuit in the R clutch pressure switch circuit


GD555, 655, 675-3C

20-427 (4)

TROUBLESHOOTING

T-49, T-50

T-49 Failure code [94] Open circuit in the 1st clutch pressure switch circuit

T-50 Failure code [95] Open circuit in the 2nd clutch pressure switch circuit

20-428 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-51, T-52

T-51 Failure code [96] Open circuit in the 3rd clutch pressure switch circuit

T-52 Failure code [97] Open circuit in the 4th clutch pressure switch circuit

GD555, 655, 675-3C

20-429 (4)

TROUBLESHOOTING

T-52

T-49, T-50, T-51, T-52 Related electrical circuit diagram

20-430 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

T-53

T-53 Failure code [98] Open circuit in the lock-up clutch pressure switch circuit


GD555, 655, 675-3C

20-431 (4)

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) FAILURE TABLE: MODES AND CAUSES ................................................................................................. 20-452 H-1 All work equipment is slow or lacks power .................................................................................... 20-454 H-2 No work equipment moves ............................................................................................................ 20-455 H-3 Excessive drop in engine speed, or engine stalls.......................................................................... 20-455 H-4 Abnormal noise generated around the pump ................................................................................ 20-456 H-5 Excessive blade drift...................................................................................................................... 20-456 H-6 Impossible to raise front of machine using the blade .................................................................... 20-457 H-7 Lack of actuating power in the articulating, drawbar shift, scarifier, leaning, and blade shift cylinders (left, right) ............................................................................................... 20-457 H-8 Excessive leaning cylinder drift (tires lean) ................................................................................... 20-458 H-9 Impossible to rotate the circle........................................................................................................ 20-458 H-10 Excessive scarifier drift................................................................................................................ 20-459 H-11 Machine does not move in either forward or reverse................................................................... 20-459 H-12 Transmission does not shift-up or shift-down .............................................................................. 20-460 H-13 Machine is slow or lacks power when traveling........................................................................... 20-460 H-14 Torque converter lock-up malfunction, cannot be actuated or canceled ..................................... 20-461 H-15 Excessive time lag when starting or shifting gear........................................................................ 20-461 H-16 Torque converter oil temperature is high ..................................................................................... 20-462 H-17 Braking force is insufficient.......................................................................................................... 20-463

GD555, 655, 675-3C

20-451 (4)

TROUBLESHOOTING

FAILURE TABLE: MODES AND CAUSES

FAILURE TABLE: MODES AND CAUSES Left control valve

Q

Excessive drop in engine speed, or engine stalls

Q

Abnormal noise is generated

Q

Q

Q

Slow return valve

Q

Circle motor

Q

LS relief valve

Q

Spool

Q

Spool

Q

Pilot check valve

No work equipment moves

Unload valve

Q

Strainer

All work equipment is slow or lacks power

Hydraulic cylinder

Work equipment

Failure mode

PC valve

Pump proper

Cause of failure

Right control valve

Main relief valve

Pump

Q

Q Q

Excessive blade drift Impossible to raise the machine using the blade

Q

Q

Q

Q

Q

Q

Q

Lack of actuating power in articulating, drawbar shift, scarifier, leaning, blade shift cylinders (Left, right)

Q

Q

Q

Q

Q

Q

Q

Excessive leaning cylinder drift (Tires lean)

Q

Impossible to rotate the circle

Q

Q Q

Q

Q

Q

Q

Q

Excessive scarifier drift Machine does not move in either FORWARD or REVERSE

Travel

Transmission does not upshift or downshift Machine is slow or lacks power when traveling

In all speed ranges In certain speed ranges

Torque converter lock-up cannot be actuated or cancelled Excessive time lag when starting or shifting gear Torque converter oil temperature is high Braking force is insufficient

20-452 (4)

GD555, 655, 675-3C

Q Work equipment

Q

Q

Q

GD555, 655, 675-3C Q

Q

Q Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q

Q Q

Q

Q

Q Q

Q

Q

Q

Q

Q

Q

Q Q

Q

Q Q

Q

Q

Q


Drop in engine performance

Slack adjuster

Accumulator

Accumulator charge circuit

Piston/disc/plate

Brake valve

Defective differential or final drive

Defective ECMV valve

Clogged strainer

Air sucked into transmission pump suction circuit

Defective transmission pump

Defective torque converter lock-up clutch

Defective torque converter relief valve

Torque converter proper

Defective transmission clutch

Defective transmission main relief valve

Transmission proper

Loose piping connection or clamp, cracked hose

Shear pin

Circle rotator

TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES

Braking device

H-1

H-2

H-3

H-4

H-5

H-6

H-7

H-8

H-9

H-10

H-11

H-12

H-13a

H-13b

Q

H-14

Q

H-15

H-16

H-17

20-453

(4)

TROUBLESHOOTING

H-1

All work equipment is slow or lacks power

20-454 (4)

H-1

GD555, 655, 675-3C

TROUBLESHOOTING

H-2

No work equipment moves

H-3

Excessive drop in engine speed, or engine stalls

GD555, 655, 675-3C

H-2, H-3

20-455 (4)

TROUBLESHOOTING

H-4

Abnormal noise generated around the pump

H-5

Excessive blade drift

H-4, H-5

Standard drift: Fewer than 10 mm after 10 minutes

20-456 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

H-6, H-7

H-6

Impossible to raise front of machine using the blade

H-7

Lack of actuating power in the articulating, drawbar shift, scarifier, leaning, and blade shift cylinders (left, right)

GD555, 655, 675-3C

20-457 (4)

TROUBLESHOOTING

H-8

H-8, H-9

Excessive leaning cylinder drift (tires lean)

Standard drift: Fewer than 10 mm after 10 minutes

H-9

Impossible to rotate the circle

a Check that dirt or an object doesn’t exist between the pinion and circle. a Check that the specified circle guide clearance exists.

20-458 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

H-10, H-11

H-10 Excessive scarifier drift

H-11 Machine does not move in either forward or reverse

GD555, 655, 675-3C

20-459 (4)

TROUBLESHOOTING

H-12, H-13

H-12 Transmission does not shift-up or shift-down Before troubleshooting, operate the gearshift lever to each speed range to determine the speed ranges where the transmission does not shift-up or shift-down.

H-13 Machine is slow or lacks power when traveling Before troubleshooting, operate the gearshift lever to each speed range to check if the travel is slow or lacks power in all speed ranges, or if it is only in certain speed ranges. a) Travel is slow or lacks power in all speed ranges • Check that the brake is not dragging before troubleshooting.The machine should move after the gearshift lever is at F4 and the engine is at low idle.

b) Travel is slow or lacks power in certain speed ranges: Refer to troubleshooting H-11.

20-460 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

H-14, H-15

H-14 Torque converter lock-up malfunction, cannot be actuated or canceled •

If the torque converter lock-up does not work, the maximum speed is reduced; if it cannot be canceled, the engine stalls when starting or stopping the machine.

H-15 Excessive time lag when starting or shifting gear • •

Before troubleshooting, operate the gearshift lever to each speed range to determine the speed ranges where excessive time lag exists. Check that the travel speed is normal before troubleshooting.

GD555, 655, 675-3C

20-461 (4)

TROUBLESHOOTING

H-16

H-16 Torque converter oil temperature is high • •

Verify that the torque converter oil temperature is high before troubleshooting. Check that the brake is not dragging before troubleshooting. The machine should move when the gear-shift lever is at F4 and the engine is at low idle.

20-462 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

H-17

H-17 Braking force is insufficient a Carry out the following troubleshooting when the steering system and work equipment operate normally.

GD555, 655, 675-3C

20-463 (4)

TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) FAILURE TABLE: MODES AND CAUSES ................................................................................................. 20-502 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM ........................................................ 20-504 M-1 Engine oil pressure caution lamp lights up.................................................................................... 20-508 M-2 Transmission controller caution lamp lights up ............................................................................. 20-509 M-3 Transmission oil temperature caution lamp lights up .................................................................... 20-509 M-4 Differential oil temperature caution lamp lights up (opt) ................................................................ 20-510 M-5 Bank pin caution lamp lights up .................................................................................................... 20- 511 M-6 Brake oil pressure caution lamp lights up ..................................................................................... 20-512 M-7 Battery charge caution lamp lights up ........................................................................................... 20-513 M-8 Preheating display does not light up ............................................................................................. 20-514 M-9 High beam display does not light up ............................................................................................. 20-515 M-10 Working lamp display does not light up (opt) .............................................................................. 20-516 M-11 Differential lock actuation display does not light up (opt) ............................................................ 20-517 M-12 Accumulator actuation display does not light up ......................................................................... 20-518 M-13 Float actuation display does not light up ..................................................................................... 20-518 M-14 Parking brake display does not light up ...................................................................................... 20-520 M-15 Turn signal lamp display does not flash ...................................................................................... 20-521 M-16 Articulation gauge does not work ................................................................................................ 20-522 M-17 Fuel gauge does not work........................................................................................................... 20-524 M-18 Engine water temperature gauge does not work ........................................................................ 20-526 M-19 Torque converter temperature gauge does not work (Opt) ......................................................... 20-527 M-20 Message center does not work ................................................................................................... 20-528 M-21 Service meter does not work....................................................................................................... 20-529

GD555, 655, 675-3C

20-501 (4)

TROUBLESHOOTING


Caution

Transmission controller abnormality caution lamp lights up

Q

Q

Transmission oil temperature caution lamp lights up

Q

Q

Differential oil temperature caution lamp lights up (opt)

Q

Q

Bank pin caution lamp lights up

Q

Brake oil pressure caution lamp lights up

Q

Battery charge caution lamp lights up when the engine is started

Q

Q

Preheating display does not light up when preheating is operated

Q

Q

Actuation display

High beam display does not light up Working lamp display does not light up (opt)

Q

Differential lock actuation display does not light up (opt)

Q

Q

Q

Q

Q

Q

Q

Q

Float actuation display does not light up

Q

Q

Parking brake display does not light up

Q

Q

Q

Turn signal lamp display does not flash

Q

Q

Q

Fuel gauge does not work Engine water temperature gauge does not work Torque converter temperature gauge does not work (opt) Message center does not work (opt) Service meter does not work

20-502

Message center

Q

Accumulator actuation display does not light up

Q

Articulation gauge does not work Gauges

Fuse

Q

Engine oil pressure caution lamp lights up when the engine is started

(4)

Wiring harness

Transmission controller

Relay, flasher, timer

ArticulatIion gauge

Water temperature gauge

Nature of the failure

Fuel gauge

Cause of the failure

Torque converter oil temperature gauge


Q

Q

Q Q

Q Q

Q Q

Q

Q

Q

GD555, 655, 675-3C

Q

Q

GD555, 655, 675-3C Q Q

Q Q

Q Q

Q

Q

Q Q

Q

Q

Q

Q

Q Q Q

Q

Q

Q


Differential lock switch

Lifter lock switch

Float / accumulator switch

Turn switch, hazard switch

Differential oil temperature sensor

Articulation sensor

Torque converter oil temperature sensor

Fuel level sensor (fuel sensor)

Service meter

Bulb

Head lamp switch

Buzzer

Accumulator oil pressure switch

Alternator

Coolant temperature sensor

Transmission oil temperature sensor

Engine oil pressure sensor (switch)

Starting switch

Shifter

Leakage of oil from engine oil pressure piping

TROUBLESHOOTING FAILURE TABLE: MODES AND CAUSES

M-1

M-2

M-3

M-4

M-5

M-6

M-7

Q M-8

Q M-9

Q M-10

M-11

Q Q M-12

Q Q M-13

M-14

M-15

M-16

M-17

M-18

M-19

M-20

M-21

20-503

(4)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM Serial No. 50001 – 51000

20-504 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-505 (4)

TROUBLESHOOTING



20-506 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

GD555, 655, 675-3C


20-507 (4)

TROUBLESHOOTING

M-1

M-1

Engine oil pressure caution lamp lights up

When the engine is started

M-1 Related electrical circuit diagram

20-508 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-2

M-2, M-3

Transmission controller caution lamp lights up


M-3

Transmission oil temperature caution lamp lights up


GD555, 655, 675-3C

20-509 (4)

TROUBLESHOOTING

M-4

M-4

Differential oil temperature caution lamp lights up (opt)


20-510 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-5

M-5

Bank pin caution lamp lights up


GD555, 655, 675-3C

20-511 (4)

TROUBLESHOOTING

M-6

M-6

Brake oil pressure caution lamp lights up


20-512 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-7

M-7

Battery charge caution lamp lights up

After starting the engine


GD555, 655, 675-3C

20-513 (4)

TROUBLESHOOTING

M-8

M-8

Preheating display does not light up

When operating the preheating


20-514 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-9

M-9

High beam display does not light up


GD555, 655, 675-3C

20-515 (4)

TROUBLESHOOTING

M-10

M-10 Working lamp display does not light up (opt)


20-516 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-11

M-11 Differential lock actuation display does not light up (opt)


GD555, 655, 675-3C

20-517 (4)

TROUBLESHOOTING

M-12, M-13

M-12 Accumulator actuation display does not light up

M-13 Float actuation display does not light up

20-518 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-12, M-13

M-12, M-13 Related electrical circuit diagram

GD555, 655, 675-3C

20-519 (4)

TROUBLESHOOTING

M-14

M-14 Parking brake display does not light up Brake released when light is on


20-520 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-15

M-15 Turn signal lamp display does not flash

GD555, 655, 675-3C

20-521 (4)

TROUBLESHOOTING

M-16


M-16 Articulation gauge does not work

20-522 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-16

M-16 Related electrical circuit diagram Serial No. 50001 – 51000


GD555, 655, 675-3C

20-523 (4)

TROUBLESHOOTING

M-17

M-17 Fuel gauge does not work Serial No. 50001 – 51000


20-524 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-17



GD555, 655, 675-3C

20-525 (4)

TROUBLESHOOTING

M-18

M-18 Engine water temperature gauge does not work


20-526 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-19

M-19 Torque converter temperature gauge does not work (Opt)


GD555, 655, 675-3C

20-527 (4)

TROUBLESHOOTING

M-20

M-20 Message center does not work


20-528 (4)

GD555, 655, 675-3C

TROUBLESHOOTING

M-21

M-21 Service meter does not work


GD555, 655, 675-3C

20-529 (4)

30 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL...................... 30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ............................................. 30- 5 SPECIAL TOOL LIST ..................................... 30- 8 SKETCHES OF SPECIAL TOOLS ................. 30- 11 REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 16 INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 17 REMOVAL OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 17 INSTALLATION OF ENGINE HOOD ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 18 REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 19 INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 20 REMOVAL OF RADIATOR ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 21 INSTALLATION OF RADIATOR ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 23 REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 24 INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 50001 – 51000).................. 30- 26 REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 28 INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY (SERIAL NO.: 51001 AND UP) ................. 30- 30 REMOVAL OF ENGINE ASSEMBLY ............. 30- 31 INSTALLATION OF ENGINE ASSEMBLY...... 30- 32 REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT ........................................... 30- 34 INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT ........................................... 30- 35

GD555, 655, 675-3C

REMOVAL OF TRANSMISSION ASSEMBLY...............................................30- 36 INSTALLATION OF TRANSMISSION ASSEMBLY...............................................30- 38 DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...............................................30- 41 ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...............................................30- 43 DISASSEMBLY OF TRANSMISSION ASSEMBLY...............................................30- 47 ASSEMBLY OF TRANSMISSION ASSEMBLY...............................................30- 63 REMOVAL OF FINAL DRIVE ASSEMBLY.....30- 84 INSTALLATION OF FINAL DRIVE ASSEMBLY...............................................30- 87 DISASSEMBLY OF FINAL DRIVE ASSEMBLY...............................................30- 89 ASSEMBLY OF FINAL DRIVE ASSEMBLY...30- 90 DISASSEMBLY OF FINAL BRAKE CASE .....30- 93 ASSEMBLY OF FINAL BRAKE CASE ...........30- 94 DISASSEMBLY OF SIDE CASE ....................30- 96 ASSEMBLY OF SIDE CASE ..........................30- 97 DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...............................................30- 99 ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY...............................................30-100 DISASSEMBLY OF BEVEL GEAR ................30-103 ASSEMBLY OF BEVEL GEAR ......................30-104 DISASSEMBLY OF BEVEL PINION ASSEMBLY...............................................30-105 ASSEMBLY OF BEVEL PINION ASSEMBLY...............................................30-106 REMOVAL OF OPERATOR'S CAB ASSEMBLY...............................................30-107 INSTALLATION OF OPERATOR'S CAB ASSEMBLY...............................................30-109 REMOVAL OF OPERATOR'S CAB FLOOR ..30- 111 INSTALLATION OF OPERATOR'S CAB FLOOR .............................................30- 113 REMOVAL OF STEERING VALVE (ORBIT-ROLL) ..........................................30- 115 INSTALLATION OF STEERING VALVE (ORBIT-ROLL) ..........................................30- 115

30-1 (5)

DISASSEMBLY AND ASSEMBLY

STANDARD INTEGRAL ORBIT-ROLL ..........30- 116 DISASSEMBLY OF STEERING VALVE.........30- 118 ASSEMBLY OF STEERING VALVE...............30-121 REMOVAL OF BLADE ASSEMBLY ...............30-126 INSTALLATION OF BLADE ASSEMBLY .......30-126 REMOVAL OF CIRCLE DRAWBAR ASSEMBLY...............................................30-127 INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY...............................................30-128 REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY ..............................................30-129 INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY ..............................................30-130 REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)..............30-131 INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) ..30-132 DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) ..30-133 ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) .............30-135 DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)..........30-137 ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)..........30-139

30-2 (5)

GD555, 655, 675-3C


METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies 1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. 2) Any special techniques applying only to the installation procedure are marked , and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF QQQQ ASSEMBLY .............................Title of operation

k ................................................................................Precautions related to safety when carrying out the operation 1. XXXX (1) .................................................................Step in operation a.............................................................................Technique or important point to remember when removing XXXX (1). 2. EEEE (2): ............................................................ , Indicates that a technique is listed for use during installation 3. TTTT assembly (3) 6.......................................................................Quantity of oil or water drained

INSTALLATION OF QQQQ ASSEMBLY .....................Title of operation • Carry out installation in the reverse order to removal. .........................................................................Technique used during installation + .............................................................................Technique or important point to remember when installing EEEE (2) • Adding water, oil ...............................................Step in operation +.......................................................................Point to remember when adding water or oil 5...................................................................Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools 1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

GD555, 655, 675-3C

30-3 (5)


METHOD OF USING MANUAL

4. General tightening torque table (when using torque wrench) a For metric nuts and bolts without specified torque, tighten to the torque given in the table below.

Thread Diameter

Width Across Flats

mm

mm

Nm

kgm

6

10

13.2 ± 1.4

1.35 ± 0.15

8

13

31.4 ± 2.9

3.2 ± 0.3

10

17

65.7 ± 6.8

6.7 ± 0.7

12

19

112 ± 9.8

11.5 ± 1.0

14

22

177 ± 19

18.0 ± 2.0

16

24

279 ± 29

28.5 ± 3

18

27

383 ± 39

39 ± 4

20

30

549 ± 58

56 ± 6

22

32

745 ± 78

76 ± 8

24

36

927 ± 98

94.5 ± 10

27

41

1320 ± 140

135 ± 15

30

46

1720 ± 190

175 ± 20

33

50

2210 ± 240

225 ± 25

36

55

2750 ± 290

280 ± 30

39

60

3280 ± 340

335 ± 35

5. Table of tightening torques for flared nuts a For flared nuts without specified torque, tighten to the torque given in the table below. Thread Diameter

Width Across Flats

mm

mm

Nm

Tightening Torque kgm

14

19

24.5 ± 4.9

2.5 ± 0.5

18

24

49 ± 9.8

5±1

22

27

78.5 ± 9.8

8±1

24

32

137.3 ± 29.4

14 ± 3

30

36

176.5 ± 29.4

18 ± 3

33

41

196.1 ± 49

20 ± 5

36

46

245.2 ± 49

25 ± 5

42

55

294.2 ± 49

30 ± 5

6. Table of tightening torques for split flanged bolts a For split flange bolts without specified torque, tighten to the torque given in the table below. Thread Diameter

Width Across Flats

mm

mm

Nm

kgm

10

14

65.7 ± 6.8

6.7 ± 0.7

12

17

112 ± 98

11.5 ± 1

16

22

279 ± 29

28.5 ± 3

30-4 (5)

Tightening Torque

GD555, 655, 675-3C


PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number

Plug (nut end)

Sleeve nut (elbow end) Use the two items below as a set

02

07376-50210

07221-20210 (Nut), 07222-00210 (Plug)

03

07376-50315

07221-20315 (Nut), 07222-00312 (Plug)

04

07376-50422

07221-20422 (Nut), 07222-00414 (Plug)

05

07376-50522

07221-20522 (Nut), 07222-00515 (Plug)

06

07376-50628

07221-20628 (Nut), 07222-00616 (Plug)

10

07376-51034

07221-21034 (Nut), 07222-01018 (Plug)

12

07376-51234

07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

04

07379-00400

07378-10400

07371-30400

05

07379-00500

07378-10500

07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used Dimensions

Nominal number

Part Number

D

d

L

06

07049-00608

6

5

8

08

07049-00811

8

6.5

11

10

07049-01012

10

8.5

12

12

07049-01215

12

10

15

14

07049-01418

14

11.5

18

16

07049-01620

16

13.5

20

18

07049-01822

18

15

22

20

07049-02025

20

17

25

22

07049-02228

22

18.5

28

24

07049-02430

24

20

30

27

07049-02734

27

22.5

34

GD555, 655, 675-3C

30-5 (5)


2. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idling. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-6 (5)

GD555, 655, 675-3C


SPECIAL TOOL LIST

SPECIAL TOOL LIST

Qty.

Wrench

t

1

Removal, installation of cylinder head

A

2 795-799-2250

Installer

t

1

Press fitting of front oil seal

Remover

t

1

Removal, installation of injection pump

Part No.

3

795-799-1390 795-799-1131

Gear

t

1

790-501-5000

Repair stand

q

1

790-501-5200

Repair stand

q

1

Bracket

q

1

1 790-901-2110

Disassembly, assembly of torque converter

C

793-310-2131

Plate

q

1

793-310-2141

Plate

q

1

2 792-390-1210

Wrench

t

1

790-201-2740

Spacer

t

1

790-201-2750

Spacer

t

1

4 790-102-1871

Wrench

t

1

790-201-2740

Spacer

t

1

790-201-2750

Spacer

t

1

Push tool kit

t

1

3 797T-423-1320 Push tool

t

1

794T-423-1130 Push tool

t

1

Grip

t

1

Bolt

t

1

794T-423-1130 Push tool

t

1

794T-423-1140 Spacer

t

1

790-101-5221

Grip

t

1

01010-51225

Bolt

t

1

3

1

2 790-101-5201

4 790-101-5221 01010-51225 Disassembly, assembly of transmission

Part Name

D 5

Disassembly, assembly of toruqe converter

Removal, installation of starting motor shaft round nut Press fitting of bearing Removal, installation of PTO bearing locknut Press fitting of clutch bearing Press fitting of clutch bearing Q

Press fitting of clutch F2 & R bearing

N

Q

N

Q Press fitting of case dust seal at pulley end

N

Q

Press fitting of case oil seal at pulley end

t

1

t

1

Bolt

t

1

7 794T-423-1120 Spacer

t

1

N

Q

8 794T-423-1180 Push tool

t

1

N

Q Press fitting of coupling cover

01010-51225

(5)

Nature of work, remarks

Grip

794T-423-1110 Push tool 6 790-101-5221

30-8

Sketch

Necessity

Disassembly, assembly of engine

1 709-331-1110

Symbol

Component

New/remodel

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity: t: Cannot be substituted, should always be installed (used). q: Very convenient if available, can be substituted with commercially available part. a New/remodel: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).

Press fitting of coupling cage oil seal Press fitting of coupling cage dust seal

GD555, 655, 675-3C

SPECIAL TOOL LIST

Qty. 1

Lifting of clutch assembly

D 10 792-271-2000

Centering tool

t

1

Centering transmission and final drive

11 799-301-1600

Oil leak tester

t

1

Checking actuation of piston

Spacer

t

1

Plate

t

1

790-201-2740

Spacer

t

1

790-101-5401

Push tool kit

t

1

790-101-5441

Plate

1

790-101-5421

Grip

1

01010-51240

Bolt

1

Part No.

9 793-310-2100

790-201-2850 1 790-201-2230

Disassembly, assembly of final drive

Disassembly, assembly of tandem drive

J

2

3 794T-422-1110 Push tool

t

1

1 792-571-1600

Chain puller

t

1

790-101-5401

Push tool kit

t

1

790-101-5551

Plate

1

790-101-5421

Grip

1

01010-51240

Bolt

1

2 K 3

794T-425-1110 Push tool

t

1

794T-659-1110 Push tool

t

1

Oil leak tester

t

1

796-765-1110

Push tool (GD555)

t

1

790-201-2220

Plate

t

1

t

1

4 799-301-1600

1

Disassembly, assembly of axle

H 2

793T-659-1110 Push tool (GD655) 790-201-2240

Plate

t

1

790-101-5401

Push tool kit

t

1

790-101-5491

Plate (GD555)

1

790-101-5421

Grip

1

01010-51240

Bolt

790-101-5401

Push tool kit

790-101-5531

Plate (GD655)

1

790-101-5421

Grip

1

01010-51240

Expander

t

1

Ring

t

1

Clamp

t

1

Push tool

t

1

794T-470-1110 Push tool

t

1

Grip

t

1

Bolt

t

1

07281-00809

Disassembly, assembly of circle rotation

3 796-460-1110

4 790-101-5221 01010-51225

GD555, 655, 675-3C

N

Q

Press fitting of drive shaft collar, bearing Removal, installation of chain

Press fitting of oil seal to cage

N

Q Press fitting of drive shaft bearing inner race Checking actuation of piston Press fitting of shaft bearing Q inner race

Press fitting of housing oil seal

1 1

2 796-720-1740

Press fitting of flange oil seal

1

t

790-720-1000

V

Bolt


Press fitting of bevel pinion bearing inner race

1 t

Wrench

1 791-342-1310 Disassembly, assembly of bank pin

Part Name

Sketch

Necessity t

Symbol

Lifting tool

Component

Disassembly, assembly of transmission

New/remodel


Removal, installation of cover Removal, installation of piston ring Press fitting of worm bearing inner race N

Q Press fitting of houising oil seal

30-9 (5)

1

Cylinder repair stand

t

1

790-101-1102

Hydraulic pump

t

1

Wrench assembly

t

1

790-201-1702

Push tool kit

t

790-201-1731

Push tool

1

790-201-1741

Push tool

1

790-201-1751

Push tool

1

790-201-1761

Push tool

1

790-201-1771

Push tool

1

790-201-5021

Grip

1

01010-50816

Bolt

1

790-201-1500

Push tool kit

790-201-1540

Plate

1

790-201-1550

Plate

1

790-201-1560

Plate

1

790-201-1570

Plate

1

790-201-1580

Plate

1

790-101-5021

Grip

1

01010-50816

Bolt

1

790-720-1000

Expander

t

1

796-720-1620

Ring

t

1

07281-00609

Clamp

t

1

796-720-1740

Ring

t

1

2 790-102-2303

3

4 Disassembly, assembly of hydraulic system

U

30-10 (5)

X

Disassembly, assembly of hydraulic cylinder Removal, installation of cylinder round head

Press fitting of cylinder head coil bushing

1

07281-00809

Clamp

t

1

Ring

t

1

Clamp

t

1

Ring

t

1

796-720-1650

Air conditioner assembly

t


1

796-720-1640 5 07281-00909

6

Part Name

Sketch

790-502-1003

Part No.

New/remodel

Qty.

SPECIAL TOOL LIST

Necessity

Component

Symbol


07281-01029

Clamp

t

1

796-720-1660

Ring

t

1

07281-01159

Clamp

t

1

796-720-1670

Ring

t

1

07281-01279

Clamp

t

1

796-460-1210

Stopper

t

1

23B-60-32121

Rodd

t

1

799-703-1200

Service tool kit

t

1

799-703-1100

Vacuum pump (100 V) t

1

799-703-1110


1

799-703-1120


1

799-703-1400

Gas leak tester

t

1

Installation of cylinder head dust seal

Installation of cylinder piston ring

Removal, installation of hydraulic pump

Discharging and charging air conditioner refrigerant gas

GD555, 655, 675-3C


SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS Note:

Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

D-6

D-4

GD555, 655, 675-3C

30-11 (5)



H-1

J-3

30-12 (5)

GD555, 655, 675-3C



D-8

D-3

GD555, 655, 675-3C

30-13 (5)



K-3

V-4

30-14 (5)

GD555, 655, 675-3C



D-7

D-5

GD555, 655, 675-3C

30-15 (5)


REMOVAL OF ENGINE HOOD ASSEMBLY

REMOVAL OF ENGINE HOOD ASSEMBLY Serial No.: 50001 – 51000 1. Remove battery ground wire (1) from terminal.

2. Remove connectors of left and right working lamp and license lamp (2) on inside. Loosen mounting bolts of radiator guard (3) and remove guard.

4. Loosen clamp (9) of hose (8) connecting air cleaner (6) and precleaner (7), then remove hose (8) from air cleaner (6).

5. Loosen mounting bolts of clamp (11) of air conditioner hose (10) and remove clamp (11). Loosen mounting bolts of guard (12) and remove guard (12). a The clearance between the hood and operator's cab is small, and it is difficult to remove the hood, so remove the guard at this point.

3. Remove left and right mounting bolts (5) (front: 4, center: 4, rear: 6) of hood assembly (4). 6. Install 4 eyebolts to hood assembly (4), then lift off hood assembly (4). 4

30-16 (5)

Hood assembly: 340 kg

GD555, 655, 675-3C


INSTALLATION OF ENGINE HOOD ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY

INSTALLATION OF ENGINE HOOD ASSEMBLY

REMOVAL OF ENGINE HOOD ASSEMBLY

Serial No.: 50001 – 51000


a Carry out installation in the reverse order of removal.

k Disconnect the cable from the negative (–) terminal of the battery. 1. Disconnect the wiring connectors of backup buzzer (1), right and left working lamps (2), and license lamp (3) from inside. 2. Remove radiator guard (4).

3. Disconnect air duct (5).

4. Disconnect clamp (7) of air conditioner hose (6). 5. Remove guard (8). a Since the space between the hood and operator's cab is narrow for work, remove the guard.

GD555, 655, 675-3C

30-17 (5)


INSTALLATION OF ENGINE HOOD ASSEMBLY

INSTALLATION OF ENGINE HOOD ASSEMBLY Serial No.: 51001 and up •

Carry out installation in the reverse order to removal.

6. Remove mounting bolts (10) of hood assembly (9). a Front: 4 bolts, center: 4 bolts, rear: 6 bolts

7. Using eyebolts [1], lift off hood assembly (11). 4

30-18 (5)

Hood assembly: 340 kg

GD555, 655, 675-3C


REMOVAL OF RADIATOR ASSEMBLY

REMOVAL OF RADIATOR ASSEMBLY Serial No.: 50001 – 51000 a Remove the engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.)

3. Remove hoses (8) and (9) of hydraulic oil cooler. a Fit male and female plugs into the hoses and nipples after removing them.

1. Loosen radiator drain plug (1) and drain coolant into container. a If the coolant contains anti-freeze, handle it as a harmful substance. Do not dispose of it illegally. 6 Coolant: 42 l Loosen hydraulic tank drain plug (2) and drain the hydraulic oil into a container.

a The hydraulic cooler forms one unit at the bottom surface of the radiator, so drain the hydraulic oil. 6

Hydraulic oil: 45 l

4. Remove mounting bolts of fan guard (10), then remove fan guard (10). Install lifting tool to radiator lifting hook, sling radiator, then remove bolts of mounts (13) at bottom of radiator, and lift off radiator assembly (14). a Release the gas before removing the air conditioner condenser hose. a Fit male and female plugs into the hoses after removing them.` 4

Radiator assembly: Approx. 80 kg

2. Loosen clamp (4) of radiator upper hose (3) at radiator end, then remove hose (3). Loosen clamp (6) of lower hose (5), then remove lower hose (5). Remove hose (7) from sub tank at radiator cap end.

GD555, 655, 675-3C

30-19 (5)


INSTALLATION OF RADIATOR ASSEMBLY

INSTALLATION OF RADIATOR ASSEMBLY Serial No.: 50001 – 51000 1. Install lifting tool to radiator assembly (14), raise radiator assembly (14), then set at fixed position on top of main frame. 4

3. Install hydraulic oil cooler hoses (8) and (9). Tighten hydraulic tank drain plug (2). Add hydraulic oil to the specified level.

Radiator assembly: Approx. 80 kg

4. Tighten radiator drain plug (1). Insert lower hose (5) to tube at engine end and radiator end, then tighten clamp (6).

2. Sling radiator assembly (14), install cushion to left and right mounts (13) of radiator, then tighten with bolts. Install 2 air conditioner condenser hoses (11). Install mounting bolts of fan guard (10) to each place, and install fan guard (10).

5. Install upper tank hose (3), then tighten clamp (4). Install sub tank hose (7) to radiator cap end.

30-20 (5)

GD555, 655, 675-3C



REMOVAL OF RADIATOR ASSEMBLY 6. Fill radiator (14) with water through sub tank cap (15) to FULL level. a Start the engine, raise the temperature until the thermostat opens, then circulate the coolant and check the level again. 5

Coolant: 42 l

Serial No.: 51001 and up a The method of removing the radiator, aftercooler, and air conditioner condenser assembly together is described below. 1. Drain the coolant. 6

Coolant: 44 l

2. Drain the transmission oil. 6

Transmission case: 45 l

3. Using tool X, collect air conditioner gas (R134a). 4. Disconnect inlet air hose (1) and outlet air hose (2) from the aftercooler. 5. Disconnect hose (3) between the radiator and sub tank.

6. Disconnect radiator inlet hose (4) from the radiator side.

GD555, 655, 675-3C

30-21 (5)



7. Disconnect radiator outlet hose (5) from the radiator side.

8. Disconnect torque converter oil cooler hoses (6) and (7). 9. Disconnect 2 air conditioner tubes (8).

14. Remove fan shroud (13), and then remove air conditioner condenser (14) and aftercooler (15) from radiator (16). 4

4

Radiator: 120 kg Aftercooler: 25 kg

10. Remove fan guard (9). 11. Sling radiator assembly (10) temporarily and remove 2 radiator stays (11), 1 on each side. 12. Remove 2 radiator mounting bolts (12), 1 on each side. 13. Remove radiator assembly (10). a Take care not to damage the radiator core. 4

30-22 (5)

Radiator assembly (Radiator, aftercooler, and air conditioner condenser): 150 kg

GD555, 655, 675-3C


INSTALLATION OF RADIATOR ASSEMBLY

INSTALLATION OF RADIATOR ASSEMBLY Serial No.: 51001 and up •


3 Aftercooler hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgcm} 3 Radiator hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm} •

Refilling with oil (Transmission) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

•

Refilling with water Close the radiator cap, and add water through the water filler of the sub tank to the full level at the center of the cooling water gauge. Run the engine and warm up the water. Then, check the water level again.

•

Charging air conditioner with refrigerant gas Using tool X, charge the air conditioner circuit with refrigerant (R134a).

GD555, 655, 675-3C

30-23 (5)


REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY

REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY Serial No.: 50001 – 51000 a Remove the engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.)

3. Loosen clamp (8) of coolant circulation hose (7) so that tube inside tank can come out. Loosen clamp (10) of hose (9) between engine and sub tank, then remove hose (9). Loosen 2 mounting bolts of tube (11) and remove tube.

1. Loosen fuel tank drain cock (1) and drain fuel into container. Loosen coolant drain plug (2) and drain coolant into container. a If the coolant contains anti-freeze, handle it as a harmful substance. Do not dispose of it illegally. 6

Coolant: 42 l

4. Loosen clamp of radiator upper hose (12) and remove hose. Pull out (remove) tube (13). Remove clamp of hose (14), then remove hose. Disconnect connector (15) of fuel sensor, and remove clamps (16) of wiring harness. Remove hose (18) of reserve tank (17).

2. Loosen hydraulic tank drain plug (3) and drain hydraulic oil into container. Loosen clamp (5) of hose (4) from bottom of coolant sub tank, then remove hose (4) from main circulation circuit tube (6). 6

30-24 (5)

Hydraulic tank: 45 l

GD555, 655, 675-3C



5. Remove hoses (19), (20), and (21) installed to hydraulic tank. Loosen clamp (23) of pump suction hose (22), then remove hose. Loosen clamp (24) and pull out hose (25). Remove tank drain hose (26). Disconnect connector of sensor (27). a Fit male and female plugs into the hoses and nipples after removing them. Cover any hoses that cannot be fitted with plugs.

8. Do not remove mounting bolts (40) at left side (39) of tank mount. Remove bolts (41) at tank mounting portion at the top of tank mount. (When tank is raised, mount contacts hydraulic pump and tank cannot be removed.)

6. Remove hoses (28) and (29), then remove 2 mounting bolts of tube (30). Loosen mounting nut (32) of tube (31), then remove elbow. Loosen mounting bolts of clamp (34) of breather (33), then remove clamp. a Fit male and female plugs into the hoses after removing them.

9. After raising and moving tank assembly (42), remove tank mount from main frame, and install to bottom surface of tank (43), then place on stable horizontal surface. 4

Tank assembly: 200 kg

7. Install eyebolts to tank, sling tank, then remove 2 front and rear mounting bolts (36) at right side of tank mount (35). Remove clamps (38) of wiring harness (37) at bottom of tank.

GD555, 655, 675-3C

30-25 (5)


INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY

INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY Serial No.: 50001 – 51000 a When assembling, be extremely careful not to cause failures due to dirt, rust, or scratches. a At places where there is double clamping of the hoses, assemble so that the screws are at 180° to each other. a Install the hoses carefully so that there is no twisting. a Coat the blind plugs with LT-2A.

3. Tighten mounting bolts of tank (42) and tank mount (39). Install drain hose (26) and tube (31). Pass hose (25) through clamp (24) and tighten bolt. Install hoses (21), (20), and (19). Install pump suction hose (22), and tighten clamp (23).

1. Install eyebolts to tank (42), raise to a suitable height, remove left side of tank mount (39), then tighten temporarily to mounting position on main frame. Raise tank (42) and set to mounting position on main frame, insert bolts in right side of tank mount, then temporarily tighten left side mount to tank. 4

Tank assembly: 200 kg

4. Install hoses (28) and (29). Install tube (30) and tighten clamp (34) of breather (33) with bolt.

2. Tighten mounting bolts of tank mount (35) fully. Secure wiring harness (37) with clamps (38). Install hose (18) to reserve tank (17).

30-26 (5)

GD555, 655, 675-3C


5. Install hose (14) and secure with clamp. Install connector of fuel sensor (15), and secure wiring harness (44) with clamps (16). Insert tube (13) in tank and install to tank with mounting bolts. Insert hose (12) in radiator (42) and tighten with clamp (45).


7. Tighten drain plug (3) of hydraulic tank. Tighten coolant drain plug (2). a Fill with hydraulic oil through the oil filler. 5

Hydraulic tank: 45 l (Total oil volume: 85 l) a Fill with coolant. Fill the radiator with water from the sub tank cap to the FULL level. 5

6. Insert hose (7) in tube inside tank, then tighten clamp (8). Insert hose (9) in tube and tighten clamp (10). Insert hose (4) in joint portion of circulation tube (6), and tighten clamp (5). a Some intermediate clamps of the hoses and wiring harnesses are at places where it is difficult to install, so be sure to install them all properly.

Total water volume: 42 l

8. Tighten drain valve (1) of fuel tank and fill with fuel through fuel filler. 5

Fuel tank: 352 l

9. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)

GD555, 655, 675-3C

30-27 (5)



REMOVAL OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY Serial No.: 51001 and up

k Disconnect the cable from the negative (–) terminal of the battery.

6. Disconnect water hoses (4) and (6).

1. Drain the coolant. 6

Coolant: 44 l

2. Drain the fuel. 6

Fuel tank: 340 l (When full)

3. Drain the hydraulic oil. 6

Hydraulic tank: 45 l

4. Remove the engine hood assembly. For details, see REMOVAL, INSTALLATION OF ENGINE HOOD ASSEMBLY.

7. Disconnect water hoses (7) and (9). 8. Disconnect tube (11) from the fuel tank.

5. Remove aftercooler inlet hose and tube (1) and outlet hose and tube (2).

9. Disconnect radiator upper hose (12) from the fuel tank side. 10. Remove water tube (13). 11. Disconnect water hose (14) from the sub tank. 12. Disconnect fuel level sensor wiring connector (15) and wire clamp (16). 13. Disconnect water hose (18) from reservoir tank (17).

30-28 (5)

GD555, 655, 675-3C



17. Using eyebolts, sling the tank assembly temporarily and remove 2 mounting bolts (36) from tank assembly right bracket (35). 18. Remove the wire clamp from the tank bottom and disconnect wiring harness (37).

14. Disconnect hoses (19), (20), (21), (22), (25), and (26) from the hydraulic tank. a Plug the disconnected hoses and nipples. 15. Disconnect wiring connector (27). 19. Remove tank assembly mounting bolts (41) from tank assembly left bracket (39). a If the tank assembly is disconnected from mounting bolts (40), it will interfere with the work equipment pump when it is lifted up. Accordingly, do not disconnect the tank assembly from mounting bolts (40).

16. Disconnect hoses (28) and (29), tubes (30) and (31), and breather (33) from the hydraulic tank.

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INSTALLATION OF FUEL TANK, HYDRAULIC TANK, AND COOLING WATER SUB TANK ASSEMBLY 20. Lift off fuel tank, hydraulic tank, and cooling water sub tank assembly together with the right bracket. a Check that all the wires and pipes are disconnected. 4

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Serial No.: 51001 and up •


•

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

•

Refilling with fuel (Fuel tank) Add fuel through the fuel filler.

•

Refilling with water Close the radiator cap, and add water through the water filler of the sub tank to the full level at the center of the cooling water gage. Run the engine and warm up the water. Then, check the water level again.

Fuel tank, hydraulic tank, and cooling water sub tank assembly: 200 kg

GD555, 655, 675-3C


REMOVAL OF ENGINE ASSEMBLY

REMOVAL OF ENGINE ASSEMBLY

1. Remove engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.)

5. Remove 2 mounting bolts of mounting bracket (12) of remote hose (11) for engine oil drain, then remove hose clamp (13), and remove hose.

2. Remove fuel tank and hydraulic tank. (For details, see REMOVAL OF FUEL TANK, HYDRAULIC TANK.) 3. Remove fuel hose (1), accelerator wire (2), electric wiring harnesses (3), air conditioner hose (4), and battery ground from engine block. a Release the air conditioner gas before removing air conditioner hose (4).

6. Use stable stand under rear of transmission to prevent transmission from tilting when separating from engine.

4. Remove wiring harness (6) of starting motor (5). Remove wiring harness (8) of alternator (7). Loosen clamps of coolant system hoses (9) and (10), and remove hoses.

7. Sling engine assembly, and loosen left mounting bolts (14) and right mounting bolts (15), then remove.

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INSTALLATION OF ENGINE ASSEMBLY

INSTALLATION OF ENGINE ASSEMBLY 8. Remove all 12 mounting bolts (18) from mating surface of transmission assembly (17) and engine assembly (16).

1. Raise engine assembly (16), align with mounting face of transmission, then fit spline portion. a When installing, be careful not to damage the O-ring. 4

Engine assembly: 850 kg

9. Using forcing tap bolt (2-10x1.5), disconnect engine assembly (16) from transmission assembly, then raise and set on stable stand. 4

Engine assembly: 850 kg

2. Keep engine assembly (16) raised and tighten bolts to specified torque at mounting surface with transmission (17).

3. Keep engine assembly raised, align positions of holes for frame on left side (14) and right side (15) of engine mount, install mounting bolts, then tighten to specified torque.

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4. Install mounting bracket (12) of remote hose (11) for engine oil drain. Install hose clamp (13).

INSTALLATION OF ENGINE ASSEMBLY

7. Install fuel tank and hydraulic tank. (For details, see INSTALLATION OF FUEL TANK, HYDRAULIC TANK, COOLANT SUB TANK.) 8. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)

5. Install wiring harness (6) of starting motor (5). Install wiring harness (8) of alternator (7). Install coolant hose (10) and tighten clamp. Insert tube (19) in hose (9), and tighten clamp to specified torque.

6. Install fuel hose (1), accelerator wire (2), electric wiring harnesses (3), and air conditioner hose (4), then install battery ground to engine block. a After assembling the air conditioner hose, use the compressor to charge with gas to the specified pressure. After charging, check that there is no leakage of gas.

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REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT

REMOVAL OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT 1. Remove engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.) 2. Remove fuel tank and hydraulic tank. (For details, see REMOVAL OF FUEL TANK, HYDRAULIC TANK, COOLANT SUB TANK.)

6. After lifting engine and transmission assembly, put a stable stand under engine mount portion (3). (A stand of height approx. 630 mm is needed.) a Use a strong and stable stand.

3. Remove transmission related accessories. (For details, see REMOVAL OF TRANSMISSION ASSEMBLY.) 4. Remove engine related accessories. ( For detai ls, see RE MOVAL O F ENGINE ASSEMBLY.) a Do not loosen the mounting bolts at the mating surface of the engine assembly and transmission assembly. Sling the engine and transmission assembly, then loosen and remove the mounting bolts at the mating surface of the engine and transmission. 5. Loosen and remove 2 mounting bolts of engine mount (1) and 4 mounting bolts of transmission mount (2), then lift off engine and transmission assembly. 4

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7. Set stable stand under bottom of torque converter case of transmission, sling engine assembly (4), then remove all 12 bolts of mount portion of engine and transmission. Using forcing tap bolts (2–10x1.5), disconnect engine assembly and put it on stable stand.

Engine, transmission assembly: Approx. 1850 kg

GD555, 655, 675-3C


INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT

INSTALLATION OF ENGINE ASSEMBLY, TRANSMISSION ASSEMBLY AS ONE UNIT 1. Set transmission assembly (5) on stable stand with torque converter case at bottom, and secure in position. Raise engine assembly (4) and mate transmission assembly (5). a When mating, be careful not to damage the O-ring or let it fall out.

3. Raise engine and transmission assembly, and align with specified position on main frame. Align bolt holes of engine mount (1) and transmission mount (2) with holes in frame, then install mounting bolts and tighten to specified torque.

2. Install bolts to mating portion of transmission assembly (5) and engine assembly (4), and tighten to specified torque.

4. Install engine related accessories. (For details, see INSTALLATION OF ENGINE ASSEMBLY.) 5. Install transmission related accessories. (For details, see INSTALLATION OF TRANSMISSION ASSEMBLY. 6. Install fuel tank and hydraulic tank. (For details, see INSTALLATION OF FUEL TANK, HYDRAULIC TANK, COOLANT SUB TANK.) 7. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)

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REMOVAL OF TRANSMISSION ASSEMBLY

REMOVAL OF TRANSMISSION ASSEMBLY 1. Remove engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.) 2. Remove fuel tank, hydraulic tank, and coolant sub tank assembly. (For details, see REMOVAL OF FUEL TANK, HYDRAULIC TANK, COOLANT SUB TANK). 3. Remove drain plug (1) of transmission oil tank, and drain into container. 5

Transmission oil: Approx. 45 l 6. Remove hoses (11), (12), (13), and (14) installed to hydraulic pump (10) at pump end. a Fit male and female plugs in the hoses and nipples after removing them.

4. Loosen mounting bolts of universal joint (2) and remove joint from flange. Loosen mounting nut (4) of speedometer cable (3), then remove cable. 7. Remove hydraulic hose (15) under radiator. Remove filter (16), then remove 2 filter hoses (17). (Because right side mounting bolts cannot be removed)

5. Remove hoses (6), (7), and (8) of pump (5) at pump end. Remove connectors of speed sensor system wiring harness (9). a Fit male and female plugs into the hoses and nipples after removing them. a Cover the removed connectors with a nylon bag to prevent the entry of dust or water.

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8. Remove 4 mounting bolts (18) (2 each on left and right).

REMOVAL OF TRANSMISSION ASSEMBLY

10. Using forcing tap bolts (2–10x1.5), disconnect transmission assembly (21) from engine assembly (20), and put on stable stand. a Place a stable stand under the bottom surface of the transmission and the bottom surface of the torque converter case. Remove hydraulic oil suction hose (22) and oil supply tube (23). 11. Remove transmission accessories. Remove hoses 2 (24) and (25) of pump (10), remove mounting bolts of pump, then lift off pump (10). Remove suction tube (26) of pump (5). Remove 2 hoses (27), then lift off pump (5). 4

9. Place stable stand under engine flywheel so that there is no clearance. Install eyebolts and sling transmission. Remove all 12 bolts (19) at mating surface of engine assembly and transmission assembly. a When installing the eyebolts, install 2 at the fan end and 2 at the torque converter end, and lift at 4 points. 4

4

Hydraulic pump: Approx. 60 kg Transmission pump: Approx. 20 kg

Transmission assembly: Approx. 1,000 kg

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INSTALLATION OF TRANSMISSION ASSEMBLY

INSTALLATION OF TRANSMISSION ASSEMBLY 12. Remove fan pulley assembly (28), belt (29) and hose (30), then remove electric control system cover (31). Remove pulley (32). 4

Fan pulley assembly: Approx. 40 kg

13. Remove mounting bracket (33). Make transmission into individual part (34) to make it possible to carry out overhaul.

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1. Install mounting bracket (33), then install pulley (32).

2. Install electric control system cover (31), then install hose (30). Raise fan pulley assembly (28) and install, then install fan belt (29). a For details of adjusting the fan belt, see TESTING AND ADJUSTING. 4

Fan pulley assembly: Approx. 40 kg

GD555, 655, 675-3C


3. Raise pump (5) and install, then install suction tube (26) and 2 hoses (27). a When installing the hoses, tighten temporarily, then adjust the angle and position and tighten fully so that there is no twisting of the hoses. 4

Transmission pump: Approx. 20 kg

4. Raise hydraulic pump (10) and install, then install hoses (24) and (25). Install hydraulic oil suction hose (22), then install oil supply tube (23). 4


5. Raise transmission assembly (21) and install to engine assembly (20). a Be careful not to damage the O-ring at the mating face of the transmission and engine when installing. 4

Transmission assembly: Approx. 1000 kg

6. Keep engine raised and install mounting bolts to engine (20). Install 2 bolts (18) each of transmission bracket on left and right (total: 4).

Hydraulic pump: Approx. 60 kg

7. Install hydraulic oil hose (15) under radiator. Install filter (16), then install 2 filter hoses (17).

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8. Install hoses (11), (12), (13), and (14) to hydraulic pump (10).


11. Tighten drain plug (1) to specified torque. Fill with oil through oil filler (35). a Oil used: EO 10-CD 5

Specified oil level: 45 l

9. Install hoses (6), (7), and (8) to pump (5). Install connectors of speed sensor system wiring harness (9). 12. Install fuel tank and hydraulic tank. (For details, see INSTALLATION OF FUEL TANK, HYDRAULIC TANK, COOLANT SUB TANK.) a Transmission oil level check Fill with oil to the correct level (as specified above). a After installation and proper fill of the fuel, hydraulic, and coolant tanks, start the engine and bleed the air from the pump piping, then run the engine at low idling and check the transmission oil level. If the oil is not up to the specified level, add oil.

10. Install universal joint (2) to flange with bolts. Install cable (3) of speedometer with nut (4).

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13. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)

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DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY

DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1. Pilot 1) Set torque converter assembly (1) on work stand with pilot side at the top. 2) Remove mounting bolts (2), and using forcing screws, remove pilot (3).

3) Using puller , remove torque converter lock-up housing (7).

4) Remove bearing (8) from housing (7). 5) Remove piston (9) from housing (7). 2. Torque converter lock-up housing 1) Remove snap ring (4), then remove spacer (5).

6) Remove seal ring (10) from piston (9). 7) Remove seal ring (11) from housing (7). 2) Remove housing mounting bolts (6).

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3. Drive case 1) Remove disc (12). 2) Remove mounting bolts (22), then using eyebolts , remove drive case (23).

4. Turbine assembly Remove turbine assembly (24).

5. Stator assembly 1) Remove stator assembly (13). a Rotate to the right as seen from the top and pull up. 2) Disassembly of stator assembly i) Remove snap ring (14), then remove race and flywheel assembly (15) from stator (16).

DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY

ii) Remove snap ring (17) from stator (16). iii) Remove bushings (18) and (19), then remove flywheel (20) from race (21).

6. Stator shaft 1) Using tool C2, remove nut (25).

2) Remove spacer (29). 3) Turn over pump and stator shaft assembly (26), support gear (27) with block , then remove stator shaft (28) with push tool .

4) Remove seal ring (30) from stator shaft (28).

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ASSEMBLY OF TORQUE CONVERTER ASSEMBLY

ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 7. Disassembly of pump assemble 1) Remove mounting bolts (31), then push bearing (32) from opposite side, and remove together with gear (27) from pump assembly (35).

a Wash all the parts clean and check that there is no dirt or damage before assembling. a Check that the snap ring is securely fitted in the groove. 1. Pump assembly 1) Install collar (34) to gear (27). a Align the bolt holes. 2) Install bearing (32) to collar (34).

2) Remove bearing (32) from gear (27). 3) Using forcing screws , remove collar (34) from gear (27). 3) Set gear (27) and bearing (32) to pump (35), and tighten mounting bolts (31). 3 Mounting bolt: 66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}

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2. Stator shaft 1) Install seal ring (30) to stator shaft (28). 2 Outside circumference of seal ring: Grease (G2-LI)

2) Set stator shaft (28) on work stand, and install to pump assembly (35). a Press fit the inner race end of the bearing. 3) Install spacer (29).

4) Using tool C2, tighten nut (25). 2 Nut: Thread tightener (LT-2) 3 Nut: 161.8 ± 14.7 N·m {16.5 ± 1.5 kgm}

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3. Stator assembly 1) Assembly of stator assembly i) Assemble flywheel (20) to race (21), then expand fit bushings (18) and (19). a Coat the sliding surface of the bushing and flywheel with engine oil. a Be careful not to damage the plug of the flywheel.

ii)

Install snap ring (17) to stator (16).

iii) Fit race and flywheel assembly (15) to stator (16), then install snap ring (14).

GD555, 655, 675-3C


2) Rotate stator assembly (13) to right (clockwise) to install. a Check the direction of rotation of the stator from the turbine end (input end). • Clockwise: Free • Counterclockwise: Locked a If the direction of rotation of the stator is not as given above, reverse the race and freewheel assembly, reassemble the stator assembly, then check the direction of rotation again.

4. Turbine assembly Install turbine assembly (24).


5. Drive case 1) Using eyebolt , install drive case (23). 2) Tighten mounting bolts (22). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 53.9 ± 4.9 N·m {5.5 ± 0.5 kgm} 3) Install disc (12).

6. Torque converter lock-up housing 1) Install seal ring (11) to housing (7) and install seal ring (10) to piston (9). 2 Outside circumference of seal ring: Grease (G2-LI)

2) Install piston (9) to housing (7). 3) Using eyebolts , install housing (7). 4) Temporarily assemble several mounting bolts(6).

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30-45 (5)


5) Install bearing (8) with push tool . a Press fit the outer race and inner race at the same time.


7. Pilot Install pilot (3), then tighten mounting bolts (2). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}

6) Fit spacer (5) and install snap ring (4). a Check that the snap ring is securely fitted in the groove.

7) Tighten mounting bolts (6). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 66.15 ± 7.35 N·m {6.75 ± 0.75 kgm}

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DISASSEMBLY OF TRANSMISSION ASSEMBLY

k Set blocks securely to transmission assembly (1), then sling the assembly to prevent it from falling over.

1. Fan assembly 1) Turn fan belt adjustment screw (2) and loosen fan belt tension, then remove fan belt (3).


2. Piston pump assembly Sling pump assembly (5), then remove mounting bolts and lift off.

3. Gear pump assembly 1) Remove suction tube (6). 2) Sling gear pump assembly (7), remove mounting bolts, then remove.

4. Oil lubrication hoses, tube 1) Remove hoses (8) and (9). 2) Remove tube (10). 2) Sling fan bracket, remove mounting bolts, then remove fan assembly (4).

5. Transmission mount (right) Remove transmission mount (right) (11). 6. Speed sensor (for detection of transmission output shaft speed) Remove speed sensor (12).

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7. Fan pulley Remove fan pulley (13).


13. Lubrication tube, block assembly Remove lubrication tube and block assembly (28).

8. Transmission mount (left) Remove transmission mount (left) (14). 9. Return hose, valve cover 1) Remove hose (15). 2) Remove valve cover (16).

14. Worm gear assembly (for speedometer) Remove worm gear assembly (30).

10. Oil lubrication tubes, wiring harness 1) Remove tubes (17), (18), (19), (20), (21), (22), and (27), then remove block (23). 2) Remove wiring harness (24). 11. Oil temperature sensor (for transmission oil) Remove oil temperature sensor (25). 12. Strainer Remove strainer (26). 15. Coupling, retainer 1) Remove coupling (31). 2) Remove mounting bolts, then using forcing screws, remove retainer (32).

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3) Remove dust seal (33) and oil seal (29) from retainer (32).

16. Torque converter relief valve assembly 1) Remove 4 mounting bolts, then remove torque converter relief valve assembly (34).

17. Torque converter lock-up valve assembly, oil pressure tube 1) Remove oil pressure tube (36). 2) Remove mounting bolts at valve seat end, then remove valve assembly (37) together with seat (38).

GD555, 655, 675-3C


3) Remove valve assembly (37) from valve seat (38).

18. Oil lubrication tubes Remove tubes (39) and (40).

19. Cover, breather 1) Remove cover (41). 2) Remove breather (42). 20. Speed sensor (for detection of engine speed) Remove speed sensor (43).

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21. Oil block (torque converter oil outlet) Remove oil block (44).


3) Remove mounting bolts of valve seat, then using eyebolts , remove valve assembly (50).

22. Speed sensor (for detection of transmission input shaft speed) Remove speed sensor (45).

4) Remove ECMV (51) from valve seat. 23. Transmission control valve assembly 1) Face transmission assembly (46) to side so that valve assembly is at the top, then set on block .

24. Transmission cover assembly 1) Remove mounting bolts of cover assembly (52), then using forcing screws , disconnect from transmission case. 2) Remove filter (47) and case (48). a Use forcing screws when removing case (48).

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2) Using eyebolts , remove cover assembly (52). a Using lever block, adjust so that clearance from transmission case is uniform.

3) Remove outer races (53) and (54) and bearing (55) from cover (52).

25. Fan drive shaft 1) Remove bolt (56), then remove plate (49). 2) Remove flange (57). 3) Knock out shaft (58) and remove.

GD555, 655, 675-3C


4) Remove dust seal (59) and oil seal (35). 5) Remove snap ring (60), then remove bearing (61) from cover.

26. Idler gear (for REVERSE) Serial No.: 50001 – 51000 1) Remove bolt (62), then remove plate (63). 2) Using gear puller , remove bearing (64) together with gear (65).

3) Remove bearing (64) and snap ring (66) from gear (65). 4) Using gear puller , remove bearing (64) from shaft. a There is a collar under the bearing.

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26. Idler gear (for REVERSE) Serial No.: 51001 and up 1) Remove bolt (62), then remove plate (63). 2) Using gear puller , remove bearing (64) together with gear (65).

3) Remove bearing (64) from gear (65). 4) Remove spacer (66), bearing (64), and spacer (97) from shaft. a There is a collar under the bearing.


2) Using 2 wire ropes, remove 4th speed clutch assembly (69).

3) Disassembly of 4th speed clutch assembly i) Remove seal ring (70). ii) Using press, remove bearing (71) and gear (72). a Hold the gear and push shaft (73). a The clutch assembly will fall, so use cushioning material to catch it.

iii) Remove snap ring (74) from shaft (73). 27. 4th speed clutch assembly 1) Remove oil guides (67) and (68).

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iv) Using press, remove bearing (75) at clutch end, spacer (76), thrust washer (77), and clutch assembly (78) from shaft (73).

vii) Push in end plate (81) with bar handle , and remove snap ring (82). viii) Remove bar handle, then remove end plate (81).

a Hold the drum end of clutch assembly (78) and push shaft (73). a The shaft will fall, so use cushioning material to catch it.

ix) Remove 7 plates (83), 6 springs (84), and 6 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

v) Remove thrust washer (77) and seal ring (79) from shaft (73). vi) Remove needle bearing (80) from 4th speed clutch gear (137).

x) Remove piston assembly (86). a The piston cannot be removed if it is at an angle, so set it horizontal to remove it. a Be careful not to use force when removing. This will scratch the inside surface of the cylinder. xi) Remove seal rings (87) and (88) from piston assembly (86).

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30-53 (5)


28. 2nd, 3rd speed clutch assembly 1) Using gear puller , remove bearing (90) and gear (91) of 1st speed shaft. a Remove this because the 2nd speed clutch gear is in contact with gear (91) and cannot be removed. 2) Using 2 wire ropes, remove 2nd and 3rd speed clutch assemblies (92).


v) Remove 3rd speed clutch gear (96). vi) Remove needle bearing (80) from 3rd speed clutch gear (96).

vii) Push in end plate (81) with push tool and remove snap ring (82). viii) Remove end plate (81).

,

3) Disassembly of 2nd, 3rd speed clutch assembly i) Remove seal ring (70). ii) Remove bolt (93), then remove worm gear (94) for speedometer.

ix) Remove 8 plates (83), 7 springs (84), and 7 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

iii) Using bearing race puller , remove bearing (95) at 3rd speed end. iv) Remove spacer (76) and thrust washer (77).

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x) Remove thrust washer (77). xi) Remove piston assembly (86). a The piston cannot be removed if it is at an angle, so set it horizontal to remove it. a Be careful not to use force when removing. This will scratch the inside surface of the cylinder. xii) Remove seal rings (87) and (88) from piston assembly (86).


xvi) Push in end plate (81) with bearing race puller and forcing screws , then remove snap ring (82) and end plate (81).

xvii)Remove 15 plates (83), 14 springs (84), and 14 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping. xiii) Using gear puller , remove 2nd speed inner race (98) and intermediate gear (99), then remove snap ring (89) from gear (99).

xiv) Remove thrust washer (77) and 2nd speed clutch gear (100). xv) Remove needle bearing (80) from 2nd speed clutch gear (100).

GD555, 655, 675-3C

xviii)Remove thrust washer (77) and piston assembly (101). a If the piston is at an angle, it will not come out, so set it horizontally and remove it. a Do not use force to remove it. The inside surface of the cylinder will be damaged. xix) Remove seal rings (87) and (88) from piston assembly (101).

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29. 1st, FH clutch assembly, REVERSE, FL clutch assembly 1) Using eyebolt , remove 1st, FH clutch assembly (102) and REVERSE, FL clutch assembly (103) at the same time. a The gears of the two sets of clutch assemblies cross, so both sets must be raised at the same time in order to remove them. a Raise both types of clutch assemblies perpendicularly.


iv) Push in end plate (81) with push tool , and remove snap ring (82). v) Remove end plate (81). vi) Remove 6 plates (83), 5 springs (84), and 5 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

2) Disassembly of 1st, FH clutch assembly a The intermediate gear and bearing at the tip of the 1st gear shaft were removed in Step 29. i) Remove seal ring (70). ii) Remove snap ring (104) and thrust washer (77). iii) Remove 1st speed clutch gear (105), then remove needle bearing (80). vii) Remove thrust washer (77). viii) Remove piston assembly (86). a The piston cannot be removed if it is at an angle, so set it horizontal to remove it. a Be careful not to use force when removing. This will scratch the inside surface of the cylinder. ix) Remove seal rings (87) and (88) from piston assembly (86).

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x) Pull out FH gear (106) with forcing screws , then remove together with bearing (107), spacer (108), and thrust washer (77).

xiii) Remove 13 plates (83), 12 springs (84), and 12 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

xi) Remove thrust bearing (109) and needle bearing (80) from FH clutch gear (106).

xiv) Remove piston assembly (110). a There is a sleeve on the inside, so it can be removed smoothly.

xii) Push in end plate (81) with bar handle , and remove snap ring (82). Remove bar handle, then remove end plate (81).

xv) Remove seal rings (112) and (88) from piston assembly (110). xvi) Remove snap ring (111), then remove sleeve (137) from piston assembly.

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3) Disassembly of R, FL clutch assembly i) Remove seal rings (70) and (113).

ii)

Remove bearing (114) and gear (115) at FL clutch end with bearing race puller . iii) Remove snap ring (116), then remove thrust washer (77).

iv) Remove FL clutch gear (117). v) Remove needle bearing (80) from gear (117).

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vi) Remove thrust bearing (109).

vii) Push in end plate (81) with bar handle , and remove snap ring (82). Remove handle, then remove end plate (81).

viii) Remove 9 plates (83), 8 springs (84), and 8 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

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ix) Remove piston assembly (118). a There is a sleeve on the inside, so it can be removed smoothly.

x) Remove seal rings (120) and (88) from piston assembly. xi) Remove snap ring (111), then remove sleeve (119).

xii) Using bearing race puller , remove R clutch gear (121), bearing (122), spacer (108), and thrust washer (123). xiii) Remove needle bearing (124) from R clutch gear (121).

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xiv) Remove thrust bearing (109). xv) Push in end plate (81) with bar handle , and remove snap ring (82). Remove handle, then remove end plate (81).

xvi) Remove 9 plates (83), 8 springs (84), and 8 discs (85) in turn. a Store the discs and plates in a flat place to prevent them from warping.

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xvii)Remove piston assembly (118). a There is a sleeve on the inside, so it can be removed smoothly.

xviii)Remove seal rings (120) and (88) from piston assembly. xix) Remove snap ring (111), then remove sleeve (119).


2) Remove 8 torque converter assembly mounting bolts (123) from under case. 3) Using eyebolts , remove torque converter assembly (127) from transmission case.

31. Idler gear (procedure is same for both sets, procedure given below is for fan drive shaft end) 1) Turn over transmission case and set securely on block. 2) Use wrench with claw to remove nut (128). a Hold it at the gear end to prevent it from rotating.

30. Torque converter assembly 1) Set transmission case (126) securely on block (height: min. 400 mm).

3) To remove, knock out gear (129) from end where nut is fitted.

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4) Remove snap ring (125), then remove spacer (146), bearing (131), and outer race (132).


3) Remove gear (135) and spacer (142).

4) Remove bearing (137) from shaft (140). 5) Remove bearing (136) and spacer (139) from gear (129).

5) Remove bearing (143), then remove outer race (144). 32. Hydraulic pump drive gear (procedure is same for both sets, procedure given below is for piston pump end) 1) Remove snap ring (138). 2) Using puller , pull out shaft (140). a Support the shaft to prevent the spacer and gear from falling when the shaft comes out.

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33. Outer race (for FH clutch shaft) Remove outer race (145) from transmission case.

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ASSEMBLY OF TRANSMISSION ASSEMBLY

ASSEMBLY OF TRANSMISSION ASSEMBLY a Wash all the parts clean and check that there is no dirt or damage before assembling.

3) Install snap ring (138). a Check that the snap ring is fitted securely in the groove.

1. Outer race Install outer race (145) to transmission case.

4) Install bearing (143) and outer race (144) in order. 2. Hydraulic pump drive gear (procedure is same for both sets, procedure given below is for piston pump end) 1) Install bearing (137) to shaft (140).

2) Assemble gear (135) and spacer (142) in case, then install shaft (140). a Tap the tip of the shaft.

GD555, 655, 675-3C

3. Idler gear (procedure is same for both sets, procedure given below is for fan drive shaft end) a Match the production No. of the inner and outer races and the spacer, and assemble the bearing as a set. 1) Using push tool, press fit bearing (136) to gear (129), then install spacer (139).

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2) Install outer race (132) to case.


4. Torque converter assembly 1) Set transmission case (126) on block with torque converter side at the top. a The mounting bolts for the torque converter assembly are tightened temporarily from below, so use a block at least 400 mm in height.

3) Assemble gear (124) to outer race of case. 4) Install bearing (126) to gear (124). a Hold at the gear end. 5) Fit spacer (146) and install snap ring (125). a Check that the snap ring is fitted securely in the groove. 2) Check position of oil hole and fit guide bolt to stator shaft. a Make a mark by the hole where the guide bolt is inserted. 3) Using eyebolts , install torque converter assembly (127). a Mesh the torque converter PTO gear and idler gear. 4) Install 2 – 3 mounting bolts temporarily from below.

6) Use wrench with claw to tighten nut (128). 2 Nut: Thread tightener (LT-2) 3 Nut: 353 ± 39 N·m {36 ± 4 kgm} a After tightening the nut, drop 6 cc of engine oil (EO-30) on the nut, rotate about 10 times, then check the tightening torque again.

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5) Turn over transmission case (121) and set to block .

6) Tighten mounting bolts (123). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 110.5 ± 12.5 N·m {11.25 ± 1.25 kgm}

5. R.FL clutch assembly, 1st. FH clutch assembly 1) Assembly of R.FL clutch assembly i) Set sleeve (119) to piston, then install snap ring (111). a Check that the snap ring is fitted securely in the groove.

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ii)

Assemble seal rings (120) and (88) to piston. a Be careful to assemble the seal ring with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

iii) Install piston assembly (118) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil.

iv) Assemble 9 plates (83), 9 springs (84), and 8 discs (85) in turn. a Soak the discs for at least 2 minutes in clean transmission oil before assembling. a Be careful not to let the springs and discs overlap.

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v) Assemble end plate (81), then push in with bar handle and install snap ring (82). a Check that the snap ring is fitted securely in the groove.


x) Using push tool , press fit bearing (122) to shaft. a After press fitting the bearing, check that there is no clearance between the end face of the bearing and the spacer. a After press fitting the bearing, check clearance "e" between the thrust washer and the spacer. a Clearance: 0.29 – 0.69 mm

vi) Install thrust bearing (109). a Insert the thick race to the clutch end. vii) Assemble needle bearing (124) to R clutch gear (121). xi) Set sleeve (119) to piston, then install snap ring (111). a Check that the snap ring is fitted securely in the groove.

viii) Align inner teeth of discs and install R clutch gear (121). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing. ix) Install thrust washer (123) and spacer (108).

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xii) Assemble seal rings (120) and (88) to piston. a Be careful to assemble the seal ring with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

xiii) Install piston assembly (118) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil.

xiv) Assemble 9 plates (83), 9 springs (84), and 8 discs (85) in turn. a Soak the discs for at least 2 minutes in clean transmission oil before assembling. a Be careful not to let the springs and discs overlap.

GD555, 655, 675-3C


xv) Assemble end plate (81), then push in with bar handle and install snap ring (82). a Check that the snap ring is fitted securely into the groove.

xvi) Install thrust bearing (109). a Insert the thick race to the clutch end. xvii)Assemble needle bearing (80) to FL clutch gear (117).

xviii)Align inner teeth of disc and install FL clutch gear (117). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing.

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xix) Install thrust washer (77) and snap ring (116). xx) Install gear (115), and using push tool, press fit bearing (114) to shaft. a After press fitting the bearing, check that there is no clearance between the end face of the gear and the bearing. a After press fitting the bearing, check clearance ""e"" between the thrust washer and the gear. a Clearance: 0.30 – 0.76 mm

2) Assembly of 1st. FH clutch assembly i) Set sleeve (137) to piston, then install snap ring (111). a Check that the snap ring is fitted securely in the groove.

xxi) Install seal rings (70) and (113) to shaft. a Coat the outer circumference of the seal ring with grease (G2-LI), and be careful to install it uniformly.

ii)

Install seal rings (112) and (88) to piston assembly (110). a Be careful to assemble the seal ring with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

xxii)Using tool D11, pump in air through oil hole in shaft and check operation of clutch. a If the gear at the end where the air is pumped in is held in position, the clutch is working normally. a Air pressure: 0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

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iii) Install piston assembly (110) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil.



vi) Install thrust bearing (109). a Insert the thick race to the clutch end. vii) Assemble needle bearing (80) to FH clutch gear (106).

viii) Align inner teeth of disc and install FH clutch gear (106). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing.

v) Assemble end plate (81), then push in with bar handle and install snap ring (82). a Check that the snap ring is fitted securely in the groove.

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ix) Install thrust washer (77) and spacer (108). x) Using push tool, install bearing (107). a After press fitting the bearing, check that there is no clearance between the end face of the bearing and the spacer. a After press fitting the bearing, check the clearance between the thrust washer and the spacer. a Clearance: 0.39 – 0.79 mm

xiv) Assemble 6 plates (83), 6 springs (84), and 5 discs (85) in turn. a Soak the discs for at least 2 minutes in clean transmission oil before assembling. a Be careful not to let the springs and discs overlap.

xi) Assemble seal rings (88) and (87) to piston assembly (86). a Be careful to assemble the piston with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

xv) Assemble end plate (81). xvi) Push end plate with push tool , then install snap ring (82). a Check that the snap ring is fitted securely in the groove. xvii)Assemble needle bearing (80) to 1st speed clutch gear (105). xii) Install piston assembly (86) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil. xiii) Install thrust washer (77).

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xviii)Align inner teeth of disc and install 1st speed clutch gear (105). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing. xix) Fit thrust washer (77) and install snap ring (104). xx) Install seal ring (70) to shaft. a Coat the outer circumference of the seal ring with grease (G2-LI), and be careful to install it uniformly.

6. 2nd, 3rd speed clutch assembly 1) Assembly of 2nd, 3rd speed clutch assembly i) Assemble seal rings (88) and (87) to piston assembly (101). a Be careful to assemble the piston with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

xxi) Using tool D11, pump in air through oil hole in shaft and check operation of clutch. a If the gear at the end where the air is pumped in is held in position, the clutch is working normally. a Air pressure: 0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

ii)

Install piston assembly (101) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil. iii) Install thrust washer (77).

3) Using eyebolts , install 1st. FH clutch assembly (102) and REVERSE. FL clutch assembly (103) at same time. a Raise both clutch assemblies perpendicularly. a If it is difficult to insert the 1st. FH clutch assembly, remove the outer race from the transmission case end, then assemble to the shaft bearing and install.

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v) Assemble end plate (81). vi) Push in with bearing race puller and forcing screws , and install snap ring (82). a Check that the snap ring is fitted securely in the groove. vii) Install needle bearing (80) to 2nd speed clutch gear (100).

viii) Align inner teeth of disc and install 2nd speed clutch gear (100). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing. ix) Install thrust washer (77).

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x) Fit snap ring (89) to intermediate gear (99), then install to shaft. xi) Using press, install inner race (98). a After press fitting the inner race, check that there is no clearance between the end face of the gear and the inner race. a After press fitting the inner race, check clearance "e" between the gear and the thrust washer. a Clearance: 0.35 – 0.85 mm

xii) Assemble seal rings (88) and (87) to piston assembly (86). a Be careful to assemble the piston with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

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xiii) Install piston assembly (86) to cylinder portion. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil. xiv) Install thrust washer (77).

xv) Assemble 8 plates (83), 8 springs (84), and 7 discs (85) in turn. a Soak the discs for at least 2 minutes in clean transmission oil before assembling. a Be careful not to let the springs and discs overlap.

xvi) Install end plate (81). xvii)Push in end plate with push tool , and install snap ring (82). a Check that the snap ring is fitted securely in the groove. xviii)Assemble needle bearing (80) to 3rd speed clutch gear (96).

GD555, 655, 675-3C

xix) Align inner teeth of disc and install 3rd speed clutch gear (96). a Move the gear carefully a little at a time to the left, right, up, and down to align the teeth of the gear and discs when installing. xx) Install thrust washer (77) and spacer (76).

xxi) Using press, install bearing (95). a After press fitting the bearing, check that there is no clearance between the end face of the spacer and the bearing. a After press fitting the bearing, check the clearance "e" between the thrust washer and the spacer. a Clearance: 0.38 – 0.82 mm

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xxii)Install speedometer worm gear (94), and tighten bolts (93). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 277 ± 32 N·m {28.25 ± 3.25 kgm} xxiii)Install seal ring (70) to shaft.

xxiv)Using tool D11, pump in air through oil hole in shaft and check operation of clutch. a If the gear at the end where the air is pumped in is held in position, the clutch is working normally. a Air pressure: 0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}


3) Install gear (91) to 1st speed clutch shaft. 4) Using push tool , install bearing (90). a After press fitting the bearing, check that there is no clearance between the end face of the bearing and the spacer. a After press fitting the bearing, check clearance "e" between the thrust washer and the spacer. a Clearance: 0.26 – 0.74 mm

7. 4th speed clutch assembly 1) Assembly of 4th speed clutch assembly i) Assemble seal rings (88) and (87) to piston assembly (86). a Be careful to assemble the piston with the side receiving the pressure facing in the correct direction. a Replace the seal ring with a new part.

2) Using 2 wire ropes, install 2nd, 3rd speed clutch assembly (92).

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ii)

Assemble piston assembly (86) to cylinder portion of 4th speed clutch gear. a When installing the piston assembly, coat the contact surface and the inside and outside circumference of the seal ring with transmission oil. iii) Install needle bearing (80) to 4th speed clutch gear (78).

iv) Install thrust washer (77) and seal ring (79) to shaft (73). a Coat the outer circumference of the seal ring with grease (G2-LI), and be careful to install it uniformly. v) Set with spline of shaft (73) at the top and support with block. a It is unstable, so support it by hand. vi) Install 4th speed clutch gear (137) to shaft (73). a The piston assembly will fall out, so be careful. vii) Install thrust washer (77) and spacer (76).

ix) Turn over 4th speed clutch and shaft assembly, and assemble 7 plates (83), 7 springs (84), and 6 discs (85) in turn. a It is unstable, so support by hand. a Soak the discs for at least 2 minutes in clean transmission oil before assembling. a Be careful not to let the springs and discs overlap.

x) Assemble end plate (81), then push in end plate with bar handle and install snap ring (82). a Check that the snap ring is fitted securely in the groove.

viii) Press fit bearing (75) to shaft. a After press fitting the bearing, check that there is no clearance between the end face of the spacer and the bearing. a After press fitting the bearing, check clearance "e" between the spacer and the bearing. a Clearance: 0.3 – 0.7 mm

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xi) Install snap ring (74) to tip of shaft (73) on opposite side from clutch. a Check that the snap ring is fitted securely in the groove. xii) Install gear (72).

xiii) Using press, press fit bearing (71). a After press fitting the bearing, check that there is no clearance between the end face of the bearing and the gear. xiv) Install seal ring (70). a Coat the outer circumference of the seal ring with grease (G2-LI), and be careful to install it uniformly.


xv) Using tool D11, pump in air through oil hole in shaft and check operation of clutch. a If the gear at the end where the air is pumped in is held in position, the clutch is working normally. a Air pressure: 0.5 – 0.6 MPa {5.0 – 6.0 kg/cm2}

2) Using 2 wire ropes, install 4th speed clutch assembly (69).

3) Install oil guides (68) and (67).

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8. Idler gear (for REVERSE) Serial No.: 50001 – 51000 1) Fit snap ring (66) to gear (65) and install bearing (64). a Press fit the outer race of the bearing.


8. Idler gear (for REVERSE) Serial No.: 51001 and up 1) Using the push tool, install outer race (64a) to gear (65). a Check the manufacturer numbers and match symbols of the inner and outer races of the bearing and make "match marks". 2) Install spacer (97) to the shaft. a Install the spacer with the largely cut inside down. 3) Push bearing (64) with spacer (66) and the push tool to install it to the shaft. a Align the match mark on the bearing with that on the outer race installed to the gear.

2) Install collar (97) to shaft. 3) Assemble gear (65) and bearing (64) into one unit, then shrink fit to install. a Shrink-fitting temperature: 100 – 120° a To prevent damage to the rolling surface of the bearing, do not hit the bearing under any circumstances.

4) Align the match marks and install gear (65), then install bearing (64) with the push tool.

4) Fit plate (63) and tighten bolts (62). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 277 ± 32 N·m {28.25 ± 3.25 kgm}

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5) Check that there is clearance a of 0.15 – 0.91 mm between the end face of bearing (64) and that of the shaft. 6) Install plate (63) and tighten bolts (62). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 110.5 ± 12.5 N·m {11.25 ± 1.25 kgm}

9. Fan drive shaft 1) Using push tool shaft (58).

, press fit bearing (61) to

2) Install shaft (58) to cover. 3) Install snap ring (60). a Check that the snap ring is fitted securely in the groove.

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4) Install oil seal (35) and dust seal (59). a Coat the area between the oil seal lip surface and oil seal and dust seal with silicon grease. (Three Bond 1855 or equivalent)

5) Install flange (57). 6) Fit plate (49) and tighten bolts (56). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 110.5 ± 12.5 N·m {11.25 ± 1.25 kgm}

10. Transmission cover assembly 1) Install bearing (55) and outer races (54) and (53) to transmission cover (52) with push tool.

GD555, 655, 675-3C


2) See diagram below and coat transmission case with gasket sealant. 2 Mating face of front cover: Gasket sealant (Three Bond 1207B or equivalent) a Be careful not to let the gasket sealant be squeezed inside the case; be careful not to coat with too much gasket sealant. a Check that there are no scratches or damage to the front cover.


11. Transmission control valve assembly 1) Install ECMV (51) to valve seat.

2) Using eyebolts and guide bolt , set control valve assembly (50) to transmission case, and tighten temporarily with mounting bolts.

3) Using eyebolts and lever block, raise transmission assembly (52) horizontally. 4) Align outer race and bearing of cover with each clutch shaft, align spline of fan drive shaft at same time, then lower cover assembly (52) slowly and install. 5) Tighten mounting bolts of cover assembly (52). 3 Mounting bolt: 110.5 ± 12.5 Nm {11.25 ± 1.25 kgm} 3) Install case (48) and filter (47) for 2nd, 3rd speed clutch, then tighten mounting bolts. a The bolts are of different lengths, so be careful to install at the correct place.

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12. Speed sensor (for detection of transmission input shaft speed) 1) Set transmission assembly (46) securely on block with torque converter side at top.

2) Install speed sensor (45). a Screw it in until it contacts the gear lightly, then turn it back 1/2 – 1 turn and tighten with the locknut. 3 Locknut: 58.8 ± 9.8 N·m {6.0 ± 1.0 kgm}


15. Cover, breather 1) Install breather (42). 2) Install cover (41).

16. Oil lubrication tubes Install tubes (40) and (39). 3 Joint bolt: 11.25 ± 1.45 N·m {1.15 ± 0.15 kgm}

13. Oil block (torque converter oil outlet) Install oil block (44).

17. Torque converter lock-up valve, oil pressure tube 1) Install valve (37) to valve seat (38).

14. Speed sensor (for detection of engine speed) Install speed sensor (43). a Screw it in until it contacts the gear lightly, then turn it back 1/2 – 1 turn and tighten with the locknut. 3 Locknut: 58.8 ± 9.8 N·m {6.0 ± 1.0 kgm}

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2) Install lock-up valve (37) and seat as one unit. 3) Install oil pressure tube (36).

18. Torque converter relief valve 1) Install torque converter relief valve assembly (34), then tighten 4 mounting bolts. 3 Mounting bolt: 49 ± 4.9 N·m {5.0 ± 0.5 kgm}


2) Install retainer (32) to case. 3) Install coupling (31).

20. Worm gear assembly (for speedometer) Install worm gear (30).

21. Oil lubrication tube, block assembly Install oil lubrication tube and block assembly (28). 19. Coupling, retainer 1) Install oil seal (29) and dust seal (33) to retainer (32). a Coat the area between the oil seal lip surface and oil seal and dust seal with silicon grease. (Three Bond 1855 or equivalent)

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22. Strainer Install strainer (26). 23. Oil temperature sensor (for transmission oil) Install oil temperature sensor (25). 24. Oil lubrication tube, wiring harness 1) Install wiring harness (24). 2) Install block (23). 3) Install tubes (22), (21), (20), (19), (18), (17), and (27). 3 Joint bolt: 49 ± 4.9 N·m {5.0 ± 0.5 kgm}

25. Valve cover, return hose 1) Install valve cover (16). 2) Install hose (15).


28. Speed sensor (for detection of transmission output shaft speed) Install speed sensor (12). a Screw it in until it contacts the gear lightly, then turn it back 1/2 – 1 turn and tighten with the locknut. 3 Lock-nut: 58.8 ± 9.8 N·m {6.0 ± 1.0 kgm} 29. Transmission mount (right) Install transmission mount (right) (11).

30. Lubrication tube, lubrication hoses 1) Install hoses (9) and (8). 2) Install tube (10). 3 Joint bolt: 29.4 ± 4.9 N·m {3.0 ± 0.5 kgm}

26. Transmission mount (left) Install transmission mount (left) (14). 27. Fan pulley Install fan pulley (13).

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31. Gear pump assembly 1) Install gear pump assembly (7), then tighten mounting bolts. 2) Install suction tube (6).


2) Install fan belt (3), then turn adjustment screw (2) and adjust fan belt.

32. Piston pump assembly 1) Raise piston pump assembly (5) with wire rope and install, then tighten mounting bolts.

33. Fan assembly 1) Raise bracket portion of fan assembly (4), set to transmission case, then tighten mounting bolts.

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REMOVAL OF FINAL DRIVE ASSEMBLY

REMOVAL OF FINAL DRIVE ASSEMBLY a To prepare for disassembly and assembly of the final drive assembly, jack up the machine and support it with strong, stable stands. a The height of the bottom surface of the main frame must be approx. 1000 mm. 1. Set stand

4. Lower work equipment (1) to ground.

to front of front frame.

5. Set blocks

2. Set stand

under 4 rear wheels.

to center of main frame.

6. Remove engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.)

3. Set stand to rear of frame. a Lower ripper to ground.

30-84 (5)

7. Drain final drive oil. (Non-spin differential type) Loosen drain plug (2) and drain oil into container. Remove breather hose (4), then remove oil filler tube (9). 6

EO 30: 17 l

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7. Drain differential oil. (With differential lock type) Loosen drain plug (2) and drain oil into container. Remove differential lock and 2 temperature connectors (3), then remove 2 hoses and hose (4). 6


9. Loosen mounting bolts of universal joint (6) between transmission and differential, remove universal joint (6), then remove brake hose (7).

EO 30: 17 l

10. Sling final drive assembly, and disconnect brake hoses (8) (front, rear, left, right: 4). a Fit male and female plugs into the hoses. 8. Sling wheel (5), loosen 2 wheel nuts and 8 bolts, then lift off wheel, and place it in a stable posture where there is no danger. (Remove 4 rear wheels.) a When the wheel is removed, the tandem case will tilt, so insert a stand of a height equal to the bottom surface of the case before removing the wheel. a When lifting the wheel, use a sling and fit it to the center of the tire so that the tire does not come out, then lift the wheel.

11. Remove oil filler tube of differential from intermediate thread portion (9). (With differntial lock type)

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30-85 (5)


12. Remove cover (10) of electric relay system box. (Because mounting bolts and nuts of final drive assembly cannot be removed.) Remove left and right batteries (11).


14. After raising final drive assembly (13), use a crane and forklift truck together. Insert forks of lift truck from right side (or left side) of final drive and remove lifting tool from fork. With left side of final drive raised, operate crane slowly and drive lift truck in reverse. When tip of forks is holding tandem case on left side, check that forks can support final drive, then remove lifting tool on left side and use lift truck to remove to outside of machine. Then raise with crane and set on stable stand.

13. Raise final drive assembly, remove bolts (12) mounting assembly to main frame (2 each at left, right, front, rear: total 8), then lower. 4

30-86 (5)

Final drive assembly: 2750 kg

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INSTALLATION OF FINAL DRIVE ASSEMBLY

INSTALLATION OF FINAL DRIVE ASSEMBLY 1. Raise final drive assembly (13), bring as close as possible to frame at side of machine (on either left or right side), then remove lifting tool at frame side. Use lift truck from opposite side of machine to support tandem case on side where lifting tool has been removed, then operate crane and lift truck together to place at specified position. 4

Final drive assembly: 2,750 kg

4. Install oil filler tube of final drive to intermediate thread portion (9), then remove oil filler cap (17) and fill with oil. (Non-spin differential type) 5

EO 30: 17 l

2. Raise final drive assembly (13), and align position of mounting bolt holes. a To ensure safety during the operation, set a stand of a height equal to the bottom surface of the case.

4. Install 2 differential lock solenoid connectors and 2 oil temperature sensor connectors (3). Install other 2 hoses (4). Tighten drain plug (2). (With differential lock type)

3. Keep raised with crane, tighten mounting bolts (12) and nuts (14) (2 each at left, right, front, rear: total 8), and install final drive assembly to main frame. a Insert the bolts from below, install the nuts from above, then tighten the bolts from below. 3 Mounting bolt: 927 – 1133 N·m {94.5 – 115.5 kgm} 2 Mounting bolt: Thread tightener (LT-2)

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5. Install universal joint (6) between differential and transmission. Install parking brake hose (7). a Install the hoses without twisting or interference.

6. Install electric relay system box cover (10) and left and right batteries (11). a After completing the operation, install the battery cables immediately before starting the engine.

INSTALLATION OF FINAL DRIVE ASSEMBLY

8. Install oil filler tube of differential to intermediate thread portion (9), then remove oil filler cap (17) and fill with oil. 5

EO 30: 17 l

9. Raise wheel (5) and install to final case, then tighten 2 nuts and 8 bolts. a When lifting the wheel, use a sling and fit it to the center of the tire so that the tire does not come out, then lift the wheel. 3 Mounting bolt: 392 – 490 N·m {40 – 50 kgm} Target: 441 N·m {45 kgm}

7. Install hoses (8) to front, rear, left, and right of final brake. Install step (15) and cover (16). 10. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)

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DISASSEMBLY OF FINAL DRIVE ASSEMBLY

DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Loosen tandem case oil drain plug (1) and drain oil into container. Remove non-slip pad (2) on step, then remove chain removal covers (3) (2 places at the top) and side covers (4) (inside, outside, front, rear: 4 places). 6

4. Extend cotter pin (8) and pull it out, then remove plate (9) and push master pin (10) to remove.

Tandem case: 80 l

5. Remove chain (11) from sprocket, then pull out and remove.

2. Using hand pump , release parking brake (5), then remove pad and rotate disc (6) to align master chain portion (7) with removal hole.

6. Raise final brake case assembly (12), then remove mounting bolts, and remove case assembly. 4

3. Using tool

Final brake case: 200 kg

, shorten chain.

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30-89 (5)


7. Raise tandem case (13), remove bolts mounting to side case (14), then disconnect from side case and set on stable stand.

ASSEMBLY OF FINAL DRIVE ASSEMBLY

ASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Raise final brake case (12) and install front, rear, left, and right. 3 Mounting bolt: 245 – 309 N·m {26 – 31.5 kgm} Target: 277 N·m {28.2 kgm} 2 Mounting bolt: Coat with LG-1

8. Raise side case assembly (14), remove bolts mounting to differential (15), then disconnect from differential and set on stable stand. 4

Side case: 310 kg 2. Raise right side case (14) and install to tandem case (13). 3 Mounting bolt: 245 – 309 N·m {26 – 31.5 kgm} Target: 277 N·m {28.2 kgm} 2 Mounting bolt: Coat with LG-1

9. Raise differential assembly (15), remove bolts mounting to side case (14), then disconnect from side case and set on stable stand. Raise right side of side case (14), remove bolts mounting to tandem case (13), then disconnect from tandem case and set on stable stand. 4

30-90 (5)

Differential: 320 kg

GD555, 655, 675-3C


3. Install shaft (16) to side case planetary gear (17), raise differential assembly (15), and install to side case. a If the shaft spline does not match, rotate the parking brake disc to align. 3 Mounting bolt: 245 – 309 N·m {26 – 31.5 kgm} Target: 277 N·m {28.2 kgm} 2 Fitting face of side case: Adhesive (LOCTITE 515)


5. Raise tandem case (13) and install to side case (14). 3 Mounting bolt: 245 – 309 N·m {26 – 31.5 kgm} Target: 277 N·m {28.2 kgm} 2 Mounting bolt: Coat with LG-1

6. Insert chain (11) in tandem case (13), and mesh tip portion with sprocket. Rotate disc of center brake, wind chain on, then align with master pin mounting hole (4). 4. Raise left side case (14) and install shaft (16), then install to differential assembly (15). a If the shaft spline does not match, rotate the parking brake disc to align. 3 Mounting bolt: 245 – 309 N·m {26 – 31.5 kgm} Target: 277 N·m {28.2 kgm}

7. Using tool pin (10).

GD555, 655, 675-3C

, shorten chain, then install master

30-91 (5)


8. Install plate (9), then install cotter pin (8) and connect chain. a Assemble the chain so that the front is on the inside of the machine and the rear is on the outside.


11. Tighten drain plug (1) of tandem case, and fill with oil through oil filler (18). a After filling with oil, rotate the final drive input coupling 7 turns, and rotate the disc 1/2 turn to immerse it in oil. 3 Drain plug: 58.8 – 78.4 N·m {6.0 – 8.0 kgm} Target: 68.6 N·m {7.0 kgm} 5

Tandem case EO 30: 80 l

9. Use hand pump to release pad of parking brake (5), then install.

12. After refilling with oil, coat top surface of tandem case (13), front, rear, left, and right chain mounting holes, covers (3) and gasket (19) with gasket sealant. 2 Mounting bolt and gasket: Coat with LG-1

10. Install parking brake. For details of procedure for adjusting, see TESTING AND ADJUSTING.

a For details of procedure for adjusting parking brake mount, see TESTING AND ADJUSTING.

30-92 (5)

GD555, 655, 675-3C


DISASSEMBLY OF FINAL BRAKE CASE

DISASSEMBLY OF FINAL BRAKE CASE 1. Remove and install final brake case assembly. For details, see REMOVAL, INSTALLATION OF FINAL BRAKE ASSEMBLY. a Set on a stable stand with the sprocket side at the top.

5. Remove guide (14), then remove spring (15). Remove piston (16).

2. Remove mounting bolts (1), then remove holder (2), shim (3), sprocket (4), and cage (5) in order.

3. Remove brake plate (6) and disc (7).

4. Remove gear (8), then remove shaft (9) from cage (10). Remove bearing (11), seal (12), and spacer (13) from shaft (9).

GD555, 655, 675-3C

30-93 (5)


ASSEMBLY OF FINAL BRAKE CASE

ASSEMBLY OF FINAL BRAKE CASE 1. Insert O-ring and spacer to shaft (9), press fit oil seal (17), then press fit bearing (11). a Oil seal space: Fill 80% with grease (G2-LI) a Bearing: Coat with EO 30.

2. Put cage (10) on stable stand and install disc wear gauge (18).

3. Assemble O-ring (19) to brake piston (16). 2 Groove portion of piston and O-ring: Coat with G2-LI.

30-94 (5)

4. Coat piston insertion portion inside cage (10) with grease, and assemble piston (16). 2 Cage: Coat with G2-LI.

5. Install brake spring (15) to piston with guide (14). a Installed length: 60.5 mm Installed load: 735 N {75 kg} Free length: 76.5 mm

6. Tighten guide (14) to specified torque, and check torque with torque wrench H. 3 Guide: 49 N·m {5 kgm} a Guide thread portion: Coat with LT-2.

GD555, 655, 675-3C


ASSEMBLY OF FINAL BRAKE CASE

7. Install cage (10) to shaft (9). Install bleeder (20), then install plug (21). 3 Plug: 68.7 ± 9.8 N·m {7 ± 1 kgm} a Before installing bleeder (20), insert mounting bolts (22) connecting to the tandem.

11. Insert collar, and press fit bearing (24). a Coat the bearing with EO 30.

8. Assemble collar first, then install gear (8).

9. Assemble brake plates (6) and discs (7) in turn. a Plates: 5 (outside teeth), discs: 4 (inside teeth)

12. Insert collar and install sprocket (4), then insert shim (3) and install holder (2), then tighten bolt (1). 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} a Using push-pull gauge , measure the starting torque of the shaft. Adjust with shims so that the preload of the left and right bearings is within a range of shaft starting torque +11 – 16 N·m {1.15 – 1.65 kgm}. a Types of shim: 0.1, 0.2, 0.5 mm

10. Install O-rings (23) to inside and outside of cage (5), then install cage (5) to cage (10). a For details of adjusting the disc wear gauge, see TESTING AND ADJUSTING.

GD555, 655, 675-3C

30-95 (5)


DISASSEMBLY OF SIDE CASE

DISASSEMBLY OF SIDE CASE 1. Raise side case (1), set sprocket at bottom, then set on stable stand. Remove center shaft bolt (2), remove plate (3), then remove shim. Lift off planetary gear (4). Pull out 4 roll pins (5), then remove ring gear (6). 4

4

4. Set side case (1) to press stand, and use press to remove shaft together with bearing. Using press in same way, remove bearing from shaft.

Side case assembly: 310 kg Planetary gear: 45 kg

5. Remove dowel pin of cage (14) and flange (13), lift off flange (13), then remove 2 bushings (15).

2. Raise side case (1) and turn over to set sprocket at the top, then set on stable stand. Remove bolt (7), remove plate (8), then remove shim. Remove outside sprocket (9).

6. Remove mounting bolts of side case (1) and cage (14), lift off cage, then remove oil seal (16).

3. Remove collar (10), then remove inside sprocket (11). Using ring pliers , remove snap ring (12).

30-96 (5)

GD555, 655, 675-3C


ASSEMBLY OF SIDE CASE

ASSEMBLY OF SIDE CASE 1. Install oil seal (16) to cage (14), and fill with grease. 2 Oil seal lip: Fill 50% of space with G2-LI

2. Install cage (14) to side case (1), coat split washer with LM-P, assemble, then install plate (17) and tighten with bolts (18). 2 Split washer: LM-P 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm}

4. Knock dowel pins in cage (14) and flange (13) and secure.

5. Coat shaft (20) and bearing (21) with EO-30, press fit to side case, then install snap ring (12) with ring pliers .

6. Turn over side case, install ring gear (6), then secure with 4 dowel pins (22).

3. Install 2 bushings (15) to outside of flange (13), and assemble collar and oil seal to inside. Install O-rings (19) to inside and outside of top of flange (13), and insert in side case (1). 2 Oil seal lip: Fill 80% of space with G2-LI

GD555, 655, 675-3C

30-97 (5)


7. Install collar (23), then install eyebolts to planetary gear (4), raise planetary gear, and install. 4

ASSEMBLY OF SIDE CASE

9. Raise side case (1), turn over, and put on stable stand. Install inside sprocket (11) and insert collar (10).

Planetary gear: 45 kg

8. Insert shim (24) and plate (3), and tighten bolt (2). a Install the same thickness of adjustment shim as was removed. Types of shim: 0.1, 0.2, 0.5 mm 3 Bolt: 490 – 608 N·m {50 – 62 kgm} Target: 549 N·m {56 kgm} Target: 111 N·m {11.3 kgm} 2 Mounting bolt: Thread tightener (LT-2)

10. Install to outside sprocket (9), then install shim (25) and plate (8), and tighten bolt (7). a Install the same thickness of adjustment shim as was removed. Types of shim: 0.1, 0.2, 0.5 mm

11. Tighten bolt (7) to specified torque. 3 Bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm}

30-98 (5)

GD555, 655, 675-3C


DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY

DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY 1. Put differential gear case assembly (1) on stable stand, and remove oil supply tube (2), solenoid valve (3), hose (4), oil temperature sensor (5), and cover (6). Raise differential (1), turn over, and put parking brake disc facing up. 4

4. Sling bevel gear (11), and remove left and right mounting bolts of bearing gauge (12). Install guide bolt to differential, screw in forcing screws (13), then pull out gauge and remove.

Differential gear assembly: 320 kg

5. Lift off bevel gear (11). Remove left and right bearing gauges (12) and shims (14). 2. Remove mounting bolts of parking brake (7), then remove disc. Remove mounting bolts of pinion (8), and lift off pinion. 4

4

Bevel gear: 90 kg

Pinion: 35 kg

3. Raise differential (1), turn over, remove brake tube (9), then remove nipple (10).

GD555, 655, 675-3C

30-99 (5)


ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY

ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY 1. Put differential case (15) on stable stand, raise bevel gear assembly (11), and assemble. Keep bevel gear raised, and use a guide bolt to install shims (14) on right side. a Install the same thickness of adjustment shim as was removed. a Types of shim: 0.05, 0.1, 0.2, 0.5 mm 4

Bevel gear assembly: 90 kg

2. Assemble bearing inside cage (16), then insert in spider case (17) and install to differential case (15). a Coat the bearing roller with EO 30.

30-100 (5)

3. Using guide bolt, install shim (14) on left side. Assemble bearing (18) to cage (12), then install to differential case (15). a Install the same thickness of adjustment shim as was removed. a Types of shim: 0.05, 0.1, 0.2, 0.5 mm (The Part Nos. for the left and right shims are different.)

4. Tighten mounting bolts of right cage (12) to specified torque. 3 Mounting bolt: 98 – 113 N·m {10 – 11.5 kgm} Target: 111 N·m {11.3 kgm} Tighten mounting bolts of left cage (16) to specified torque. 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm} 2 Mounting bolt: Thread tightener (LT-2)

GD555, 655, 675-3C


5. Raise pinion assembly (8) and install to differential case. Install shim (19) to flange portion. (Standard shim thickness: 1.5) a Types of shim: 0.05, 0.1, 0.2, 0.5 mm

6. Tighten mounting bolts of pinion assembly (8) to specified torque. Install coupling (21) to parking brake disc (7), then install to pinion shaft (20). 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm}

GD555, 655, 675-3C


7. Coat coupling mounting bolts (22) with thread tightener, install shim (23) and holder (24), then tighten bolts (22) to specified torque. (Standard shim thickness: 2.0 mm) a Types of shim: 0.1, 0.2, 0.5 mm 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 – 309 N·m {25 – 31.5 kgm} Target: 277 N·m {28.2 kgm}

8. To adjust backlash of bevel gear and pinion gear, set dial gauge in position, then change thickness of shim at pinion gear and differential case mount to adjust. a Select a shim and adjust. a Backlash: 0.25 – 0.33 mm

30-101 (5)


9. To adjust preload and backlash of bevel gear and side bearing, use push-pull gauge , and change thickness of shim at left and right of cage to adjust. a Adjust the preload with the bevel pinion meshed. Select shims to adjust so that the preload is 0.7 – 1.5 N·m {0.07 – 0.15 kgm} added to the starting torque of the bevel pinion, and the backlash is 0.25 – 0.33 mm.

a The tooth contact is as shown in the diagram below. A: 46 – 58% of tooth width; B: 28 – 40% of tooth width

30-102 (5)


10. Install nipple (10) for differential lock, then install tube (9).

11. Coat inside of cover (6) with LG-1, and install gasket, then install cover with bolts. Install magnet assembly, spring, and O-ring to oil supply tube (2), then install solenoid valve (3), oil temperature sensor (5), and hose (4), and tighten drain plug (25) to specified torque. 2 Solenoid valve mounting bolt: Coat with LG-1 2 Hose elbow mounting thread: Coat with LT-2 2 Cover: Coat with LG-1 3 Cover mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm} 3 Oil supply tube mounting bolt: 59 – 74 N·m {6 – 7.5 kgm} Target: 67 N·m {6.8 kgm} 3 Drain plug: 55.8 – 78.4 N·m {6 – 8.0 kgm} Target: 68.6 N·m {7.0 kgm}

GD555, 655, 675-3C


DISASSEMBLY OF BEVEL GEAR

DISASSEMBLY OF BEVEL GEAR 1. Remove mounting bolts of brake cage (1), then remove cage.

2. Remove plate (2), disc (3), gear (4), washer (5), and piston (6).

4. Remove spider gear assembly (10).

5. Remove 12 bolts of bevel gear case (7), then pull out dowel pin (11), and separate bevel gear (12) and case (7).

3. Turn over bevel gear (7), and install spider case (8). Remove bolts, then remove case. Remove washer, then remove gear (9).

GD555, 655, 675-3C

30-103 (5)


ASSEMBLY OF BEVEL GEAR

ASSEMBLY OF BEVEL GEAR 1. Tighten bolts to bevel gear case (7) and bevel gear (12) temporarily, and knock 4 dowel pins (11) and tighten bolts. a After knocking in the dowel pin, caulk at 2 places. 3 Mounting bolt: 157 – 198 N·m {16 – 20 kgm} Target: 117 N·m {18 kgm}

2. Turn over bevel gear case (7) and install spider gear assembly (10). a Coat the inside surface of the bushing of the spider gear with EO 30.

3. Install gear (9) to spider assembly. Install 2 rings (13) to outside of spider gear case (8), then install washer to inside case, and tighten case (8) with bolts. a Coat the outside and side surfaces of the ring with LM-P. 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm}

4. Turn over bevel gear case (7), assemble seal to piston (6), and install. a Be careful to assemble the seal facing in the correct direction.

a Seal direction diagram

30-104 (5)

GD555, 655, 675-3C


DISASSEMBLY OF BEVEL PINION ASSEMBLY

DISASSEMBLY OF BEVEL PINION ASSEMBLY 5. Install gear (4), and install plates (2), then install discs (3). Install plates and discs in turn. a Coat both sides of the plates and discs with EO 30.

6. Install washer (5) to cage (1). Assemble cage (1) to bevel gear case, and knock in 4 dowel pins.

7. Install cage (1) and tighten with bolts to bevel gear case (7) to specified torque. 3 Mounting bolt: 98 – 123 N·m {10 – 12.5 kgm} Target: 111 N·m {11.3 kgm}

GD555, 655, 675-3C

1. Remove mounting bolts of coupling (1). Remove coupling (1), then remove holder, shim, and Oring.

2. Set pinion assembly (2) on press stand, and fit jig to top of shaft (3), then push out shaft (3) with press. a When the pinion shaft is removed, the cage and top bearing will also come off at the same time.

3. Remove bearing (4) of pinion shaft (3).

30-105 (5)


ASSEMBLY OF BEVEL PINION ASSEMBLY

ASSEMBLY OF BEVEL PINION ASSEMBLY 1. Press fit bearing (4) to pinion shaft (3) with press . 2 Bearing: Coat with EO 30

3. Install deflector and coupling (1), assemble Oring, shim, and holder, then tighten bolts (6). 2 Mating surface of coupling and seal: Coat with G2-LI. 2 Coupling mounting bolt: Thread tightener (LT-2) 3 Coupling mounting bolt: 245 – 309 N·m {25 – 31.5 kgm} Target: 227 N·m {28.2 kgm} a Types of shim: 0.1, 0.2, 0.5 mm

2. Press fit cage (5) and bearing to pinion shaft (3), and install seal (6). 2 Bearing: Coat with EO 30 2 Oil seal lip: Fill 80% of space with G2-LI

4. Install torque wrench to coupling mounting bolt, and measure starting torque. a Starting torque: 8.73 – 10.69 N·m {0.89 – 1.19 kgm}

30-106 (5)

GD555, 655, 675-3C


REMOVAL OF OPERATOR'S CAB ASSEMBLY

REMOVAL OF OPERATOR'S CAB ASSEMBLY 1. Remove right side (1) and left side (2) of cover under cab door. a There are 2 washer tanks installed to the rear left cover.

4. Loosen mounting clamp of air conditioner vent hose (10), then remove hose. Disconnect connectors (12) of electrical system wiring harnesses (11). a Cover the removed connectors with a nylon bag to prevent the entry of dust or water.

2. Disconnect connectors of motor wiring harness (5) and hose (4) of washer tank (3). 5. Install 4 eyebolts to top of operator's cab, and sling. Remove left and right mounting bolts of cab mounts (13) and (14). Remove 8 mounting bolts of left and right step portions of floor at same time. 4 Operator's cab: Approx. 700 kg a The 2 mounting bolts at the rear left contact the case under the floor, so when removing or installing the cap without removing them, be careful not to cause damage.

3. Remove operator's seat (6). Remove controller box (7). Loosen mounting clamp of air conditioner vent hoses (8) and (9), then remove hoses.

GD555, 655, 675-3C

30-107 (5)


REMOVAL OF OPERATOR'S CAB ASSEMBLY

6. Remove mounting box (16) of rear air conditioner vent hose (15).

7. Left cover (17) and right cover (18) of work equipment control levers contact when cap is removed, so remove cover mounting bolts and leave covers free.

8. Raise operator's cab assembly (19) and put on stable stand, horizontally. 4

30-108 (5)

Operator's cab assembly: Approx. 700 kg

GD555, 655, 675-3C


INSTALLATION OF OPERATOR'S CAB ASSEMBLY

INSTALLATION OF OPERATOR'S CAB ASSEMBLY 1. Install 4 eyebolts to top of operator's cab, raise cab assembly (19), then set in specified position on cab floor. 4

3. Insert mounting bolts in left cover (17) and right cover (18) of work equipment control lever.

Operator's cab assembly: Approx. 700 kg

4. Install box (16) for mounting air conditioner hose. 2. Keep cab raised, align position of left and right mounting bolt holes of mounts (13) and (14), then install bolts and tighten temporarily. Temporarily tighten mounting bolts of left and right step portions of floor, put cab in contact with floor, tighten mounting bolts fully, then tighten floor bolts fully. a The 2 mounting bolts at the rear left protrude, so be careful not to damage them.

5. Tighten air conditioner hose (10) with mounting clamp. Install connectors (12) to electric wiring harness (11). a After mating the connectors, check that they are securely locked.

GD555, 655, 675-3C

30-109 (5)


6. Install air conditioner hoses (8) and (9) and tighten clamp. Install controller box (7). Install operator's seat (6).

INSTALLATION OF OPERATOR'S CAB ASSEMBLY

9. Carry out shower test to check that no water is entering cab from door seal of cab (19), weather strip, and seals. Check that the wiper works smoothly and stops at the specified position. Check that the head lamps and combination lamp light up. Check that the door opens and closes smoothly without any squeaking or play.

7. Install cover (installed to washer tank (3)) to mounting position, then install hoses (4) of washer tank (3) and connectors (5) of electric wiring harness.

8. Install right (1) and left (2) covers under cab door.

30-110 (5)

GD555, 655, 675-3C


REMOVAL OF OPERATOR'S CAB FLOOR

REMOVAL OF OPERATOR'S CAB FLOOR 1. Remove operator's cab assembly. For details, see REMOVAL OF OPERATOR'S CAB ASSEMBLY. 2. Pull out roll pin of spool (3) portion of right (1) and left (2) control valves, and disconnect rod of work equipment control lever.

5. Remove steering filter (7) together with mounting bracket (8).

3. Disconnect connectors of transmission system wiring harnesses (3) and (4) under right floor. a Cover the connectors with a nylon bag.

4. Remove left and right floor mounts (5). Remove ground connection (6). At same time, disconnect wiring harness connector CN-B20 (for improvement of engine starting ability) from under rear left floor.

GD555, 655, 675-3C

6. Disconnect hoses (9) from brake line, and at same time, pull out roll pin and disconnect wire of accelerator linkage (10) from linkage of lever. Then, loosen 2 bolts of wire mounting bracket from under floor and remove. a Before removing the hoses, mark each hose and its partner with a number to prevent any mistake when installing. a Fit male and female plugs into the hoses and nipples after removing them.

30-111 (5)


7. Remove 3 hoses (11) inside orbit motor from under left side of floor.

8. Release air conditioner gas, remove cover under operator's seat, then remove hoses (12) and (13). Cover mouthpiece, remove hose clamps under floor, pull down hoses (12) and (13), loosen hose clamps under floor at rear left of heater hose (14), remove 2 intermediate clamps, then remove 2 hoses..

REMOVAL OF OPERATOR'S CAB FLOOR

9. Remove mounting cover (16) of speedometer (15), then loosen mounting nut (18) of cable (17) of speedometer (15) from rear, and pull out cable (17) from bottom side of post stand to bottom surface of floor. a Wind the cable and nut with plastic tape to make it easier to remove.

10. Install eyebolts to floor assembly, then lift off floor assembly (19). a Prepare a stable stand, set the assembly horizontally on the stand, and check that there is no obstruction of the accessories installed under the floor. 4

30-112 (5)

Floor assembly: Approx. 260 kg

GD555, 655, 675-3C


INSTALLATION OF OPERATOR'S CAB FLOOR

INSTALLATION OF OPERATOR'S CAB FLOOR 1. Install eyebolts to floor assembly (19), raise floor assembly, set in position on frame, align holes for mounting bolts of floor assembly, then lower assembly and put in contact with frame. a The 2 mounting bolts at the rear left of the floor protrude, so be careful not to damage them. 4

Floor assembly: Approx. 260 kg

4. Pull up air conditioner hoses (12) and (13) from under floor and install, then install intermediate clamp of hose to bottom surface of floor. Install 2 heater hoses (14), then install 2 hose intermediate clamps to bottom surface of floor. a Install the hoses without twisting or interference. a After completing the assembly at all points, fill the air conditioner with gas. 2. Tighten left and right mounting bolts of floor mount (5) to specified torque. Install chassis ground connection (6), then install wiring harness connector B20 at rear bottom left. (For improving ease of starting engine.)

5. Connect 3 hoses (11) inside orbit motor under floor on left side.

3. Pass cable (17) of speedometer (15) through center of post stand from under floor, pull up to meter, insert in rear of meter, then tighten nut (18). Install mounting cover (16) of meter (15). a It is easier to pass the cable through if the intermediate cover of the post stand is removed.

GD555, 655, 675-3C

30-113 (5)


6. Connect accelerator wire to accelerator linkage (10), and install bracket and wire to bottom surface of floor. Install hoses (9) of brake line system. a Install the hoses without twisting.

a Adjustment procedure for accelerator control 1) Set height of pedal stopper bolt to 75 mm from top surface of floor. 2) Set height of pedal to 193 mm, then adjust length of rod so that engine low idling speed is 850 ± 50 rpm. 3) Adjust length of rod so that engine governor lever reaches end of stroke (engine full throttle 2200 ± 50 rpm) when pedal is depressed until it contacts stopper bolt. 4) Loosen stop bolt 1/2 turn and fix it in position. (Set so that engine governor lever does not contact engine end strongly.) 5) Adjust length of rod so that regulator lever can change speed from low idling (800 ± 50 rpm) to full throttle (2200 ± 50 rpm). 7. Install steering filter (7) and bracket (8).

INSTALLATION OF OPERATOR'S CAB FLOOR

8. Install connectors of transmission system wiring harnesses (3) and (4). a After mating connectors, check that they are securely locked.

9. Connect right control valve (1) and left control valve (2) to rod of work equipment control lever with roll pins, then insert beta pin.

10. Install operator's cab. (For details, see INSTALLATION OF OPERATOR'S CAB.) a For details of bleeding air from brake line, see TESTING AND ADJUSTING.

30-114 (5)

GD555, 655, 675-3C


REMOVAL OF STEERING VALVE (ORBIT-ROLL) INSTALLATION OF STEERING VALVE (ORBIT-ROLL)

REMOVAL OF STEERING VALVE (ORBIT-ROLL)

INSTALLATION OF STEERING VALVE (ORBIT-ROLL)

1. Remove cover (1) of post stand, then remove gauge mounting cover (2), and remove wiring harness and cable of each gauge.

a Carry out installation of the steering valve in the reverse order of removal.

2. Remove 5 hoses (4) installing to Orbit-roll (3).

3. Remove mounting bolts of Orbit-roll (3), then remove Orbit-roll (3) and steering shaft (5), and separate.

GD555, 655, 675-3C

30-115 (5)


STANDARD INTEGRAL ORBIT-ROLL


Tools needed for disassembly and assembly (1) Torque wrench (torque capacity: 49 Nm {5 kgm}) (2) 5/12 in - 12 point socket (3) Flat-headed screwdriver (large) (4) Flat-headed screwdriver (small) (5) Spring insertion tool (P/N: 600057) (6) 3/16 in hexagonal wrench

30-116 (5)

(7) Plastic hammer (8) Small amount of grease (9) Vice (10)Oil-based felt pen (11) Tweezers

GD555, 655, 675-3C


Part No. 1

Part name Screw


Q’ty

Remarks

6

2

Retainer screw assembly

1

3

End cap

1

4

Gerotor

1

5

Spacer

1

6

Spacer

(1)

7

Spacer plate

1

8

Drive

1

9

Housing

1

10

Sleeve

1

11

Spool

1

12

Pin

1

Centering spring

6

For standard input torque specification

Centering spring

4

For low input torque specification

13 14

Flat spring

15

Race bearing

(2) 2

16

Thrust needle

1

17

O-ring

1

18

Oil seal

1

19

Dust seal

1

20

Retaining ring

1

21

Seal gland bushing

1

Only for low input torque specification

X-ring or Teflon seal

22

O-ring

2

Part No.: 5776

23

O-ring

1

Part No.: BA0098A

24

Inlet check valve sub assembly

1

(Cannot be disassembled)

25

Valve seat

1


26

Poppet

1

27

Spring

1

28

Plug

1

29

O-ring

1

30

Retainer plug

2

31

Spring

2

32

Ball

2

33

Valve seat

2

34

Ball

2

35

Ball holder

2

36

Spring

2

37

Plug

2

38

O-ring

2

39

Adapter screw

1

40

Ball

1

41

Name plate

1

42

Rivet

2

—

Seal kit (X-ring)

—

Part No.: BA0271A

—

Seal kit (Teflon seal)

—

Part No.: BA0273A

GD555, 655, 675-3C


30-117 (5)


DISASSEMBLY OF STEERING VALVE

DISASSEMBLY OF STEERING VALVE a When disassembling the valve, cleanliness is extremely important. Carry out the work in a clean place. a Before removing the piping, remove all dirt and dust from around the ports and joints on the outside circumference of the motor. a In the following explanation diagrams, it is not absolutely necessary to hold the unit in a vice, but it is recommended to use a vice as far as possible. k Be extremely careful not to injure yourself on the edges of sleeves, spools, housing, and other machined parts.

3. Remove spacer (5) inside spline on inside of star of Gerotor (4). Remove Gerotor (4). Be careful not to drop star from ring of outer circumference of Gerotor. Remove O-ring (22) from Gerotor.

1. Put end cap (3) at the top, fit side face of housing between copper sheets in vice , and be careful not to tighten vice too strongly.

4. Remove drive (8), then remove spacer plate (7). Remove O-ring (23) from housing.

2. Remove 6 screws (1) and 1 retainer screw (2), then remove end cap (3). Remove O-ring (22) from end cap (3). 5. Using flat-headed screwdriver, remove adapter screw (39). Remove housing from vice, set upside down, then remove ball (40). a Be careful not to drop or lose the ball.

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GD555, 655, 675-3C



6. Set housing upside down, remove 2 springs (31), 2 retainer lugs (30), and 2 balls (32). a Be careful not to drop or lose the parts.

9. Remove 2 race bearings (15) and thrust needle (16). 7. Set on clean cloth with flange surface of housing facing up to prevent damage to finished surface. Use flat-headed screwdriver to raise tip of retaining ring (20), then remove from housing. k The retaining ring may fly out from the housing, so always wear protective glasses.

8. Set housing on clean cloth with axial line of valve horizontal. Turn spool and sleeve assembly to set sleeve pin in horizontal position, then push out spool and sleeve assembly slightly, and remove seal gland bushing (21) from housing. Remove oil seal and dust seal from gland bushing. a When removing the seal, be careful not to damage the seal gland bushing.

GD555, 655, 675-3C

10. Push spline portion inside spool with thumb and remove spool and sleeve assembly from opposite side of housing flange. When doing this, be careful not to let outside diameter of sleeve get caught in inside diameter of housing. a Depending on the assembly of sleeve and spool, it may not work properly if it is assembled 180° from the proper direction, so make marks to show the position of spool and sleeve (43). Remove pin (12). k The retaining ring may fly out from the housing, so always wear protective glasses.

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11. Push out spool inside sleeve slightly, and remove centering spring (13) carefully by hand from spool.


DISASSEMBLY OF OVERLOAD RELIEF VALVE • Using hexagonal wrench (width across flats: 3/16 inch), remove plugs (37) (2 places). Remove Oring (38) from plug. Using tweezers, remove 2 springs (36), 2 ball holders (35), and 2 balls (34). a The valve seat is stuck to the housing and cannot be removed.

12. Rotate spool slowly and pull out spool (11) from sleeve (10). Remove O-ring from housing.

DISASSEMBLY OF STEERING RELIEF VALVE • Using hexagonal wrench (width across flats: 3/16 inch), remove plug (28). Remove O-ring (29) from plug. Using tweezers, remove spring (27) and poppet (26). a The valve seat is stuck to the housing and cannot be removed.

30-120 (5)

GD555, 655, 675-3C


ASSEMBLY OF STEERING VALVE a Check all the joining parts. Parts with gouges or burrs will cause leakage of oil, so replace them with new parts. Wash all metal parts with clean solvent and blow dry with compressed air. If they are wiped with rags or paper, pieces of cloth or paper will stick to the parts or get inside the valves. This will cause the hydraulic system to become dirty, so do not wipe with cloth or paper. Do not polish parts with sandpaper or modify with a file. k Be extremely careful not to injure yourself on the edges of sleeves, spools, housing, and other machined parts. a As a basic rule, assemble new O-rings and seal after disassembling. Coat the O-rings with a small amount of clean grease before assembling. a The O-rings in front of or behind the spacer plate are of very similar sizes, so check the part number before opening the seal kit, and be extremely careful not to mix them. 1. Turn spool (11) and insert slowly into sleeve (10). Grip spline portion of spool and check that spool rotates smoothly inside sleeve. Align mark made when disassembling.

ASSEMBLY OF STEERING VALVE

k The centering spring may fly out from the spool, so always wear protective glasses.

3. Set housing on clean cloth with axial line of valve horizontal. Insert spool and sleeve assembly from opposite end of housing to flange end. In this condition, check that spool and sleeve assembly rotates smoothly inside housing. a When inserting spool and sleeve assembly, be careful not to insert it at an angle and get it caught. Keep the pin at near the horizontal position, and rotate slightly to left and right to insert. a Insert so that the end face of the spool and sleeve assembly is level with the end face of the housing. If it is inserted further, the pin will fall inside the housing, so stop inserting when the end face is level.

2. Align 2 spring grooves at 180° in spool and sleeve, then stand on a horizontal plate. Insert spring insertion tool (Part No.: 60057) in spring groove, then fit centering spring to insertion tool so that notched portions at both ends are at bottom. When doing this, it is easier to insert if spool is lifted up slightly from sleeve. Hold centering spring at opposite end with a finger and compress it to push it into spool sleeve groove. When doing this, slide insertion tool at same speed as pushing in spring. After inserting, align end of spring with outside diameter of sleeve. Insert sleeve pin into hole in sleeve, and align both ends of pin with outside diameter of sleeve. GD555, 655, 675-3C

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4. Place housing on clean flat surface, then assemble O-ring (17). Assemble 2 race bearings (15) and thrust needle (16). Always insert thrust needle between race bearings.

a There are two types of seal: Teflon seal and standard seal. 5. Assemble dust seal (19) to seal gland bushing (21). Assemble dust seal so that flat surface is at seal gland bushing end. Assemble oil seal (18) to seal gland bushing. a Assemble the oil seal carefully so that there is no twisting or deformation. a The diagram below is the Teflon seal specification drawing; (44) is the distinguishing groove.


a The diagram below is the standard seal specification drawing.

6. After assembling seals, rotate seal gland bushing (21) and insert to spool. Tap with plastic hammer to insert to specified position. Assemble retaining ring (20) to housing. a Push open with a flat-headed screwdriver so that the whole circumference of the retaining ring fits securely in the groove in the housing. k The retaining ring may fly out from the housing, so always wear protective glasses.

a Seal assembly drawing Screwdriver , dust seal (19), retaining ring (20), seal gland bushing (21), oil seal (18), O-ring (17)

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ASSEMBLY OF STEERING RELIEF VALVE • Assemble O-ring (29) to plug (28). Using tweezers, assemble spring (27) and poppet (26) to housing. Using hexagonal wrench (width across flats: 3/ 16 inch), assemble plug (28) to housing.

ASSEMBLY OF OVERLOAD RELIEF VALVE • Assemble O-ring (38) to plug (37). Fit grease to ball holder (35) and install ball (34). Using tweezers, assemble ball holder (35) and spring (36) to housing. Using hexagonal wrench (width across flats: 3/16 inch), assemble plug (37) to housing. a The size of the overload valve ball and the anti- cavitation check valve ball is different, so be careful not to mix them.

GD555, 655, 675-3C


ASSEMBLY OF ANTI-CAVITATION CHECK VALVE • Grip the port surface and side surface of the housing lightly in a vice. Fit copper sheets in the vice, and be careful not to tighten the vice too strongly. Of the 7 bolt holes in the end face of the housing, insert 1 each of spring (31), retainer plug (30), and ball (32) in the 2 holes shown in the drawing. a Be careful not to drop or lose the ball. Be careful of the assembly direction of the retainer plug.

ASSEMBLY OF GEROTOR END • Grip the port surface and side surface of the housing lightly in a vice. (45): 25 mm. Fit copper sheets in the vice, and be careful not to tighten the vice too strongly.

30-123 (5)


•

Of the 7 bolt holes in the end face of the housing, insert ball (40) in the holes shown in the drawing. Assemble adapter screw (39) in holes in same drawing.

•

Assemble O-ring (23) to housing. Set spacer plate (7) on top and align position of bolt holes. a The pitch diameter of the bolt holes and oil holes is different.

•

Turn spool and sleeve assembly and set pin (12) and port surface (46) of housing in parallel. Insert drive (8) into portion (47), then mate drive yoke and pin (12). To carry out positioning exactly, use a felt pen to draw line on end face of drive (8) parallel to pin.

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•

Assemble O-ring (22) to Gerotor (4).

•

Set O-ring end at end face of Gerotor (4) at spacer plate (7) side, align concave portions (48) of Gerotor star teeth with pin (12), align with mark drawn on end face of drive (8), and assemble. When doing this, check carefully that lines A, B, C, and D are parallel as shown in diagram below. a Turn Gerotor ring to align bolt holes. Do not remove mating of drive and Gerotor star. a The above procedure is important for aligning the valve timing.

GD555, 655, 675-3C


•

•

Assemble spacer (5) to spline inside Gerotor star. a Do not assemble spacers to 51 cc/rev and 69 cc/rev discharge capacity Orbit-rolls. Assemble 2 spacers to 184 cc/rev discharge capacity Orbit-roll. Assemble O-ring (22) to end cap (3), set on top of Gerotor, then align bolt holes. Coat 6 screws (1) and thread of retainer screw assembly (2) with oil, then assemble to end cap. Install retainer screw assemblies to bolt holes where adapter screws have already been assembled. Tighten 7 screws to torque of approx. 1.5 kgfm, then tighten in order to following torque.

Order for tightening end cap mounting screws is as shown in diagram below.

GD555, 655, 675-3C


a After tightening to torque given below, install handle to spool and check that spool rotates. Screw tightening torque Discharge capacity (cc/rev)

Tightening torque (N·m {kgm})

51 – 230

22.6 {2.3}

277

23.5 {2.4}

369 – 737

28.4 {2.9}

List of capacities and spacers Discharge Discharge Spacer capacity symbol capacity (cc/rev) thickness (mm) A

51

B

69

C

96

D

120

6.1

E

159

12.2

G

184

12.2 3.6

3.6

K

230

22.0

M

277

24.4

P

369

41.1

S

461

53.7

T

553

66.4

U

737

91.8

30-125 (5)


REMOVAL OF BLADE ASSEMBLY

k Start the engine, operate the work equipment control levers, raise blade so that bottom is approx. 100 mm from ground, set stable stand to match height under circle, then lower. 1. Operate blade control lever and shift blade (1) fully to left. Sling blade, remove mounting bolts of blade side shift cylinder rod (2), remove rod head, then operate control lever to retract cylinder rod fully. a After completing operation of the control lever, stop the engine and lock the lever.

2. Sling blade (1), move position of wire to center of blade while pushing blade out, then lift off. 4

30-126 (5)

REMOVAL OF BLADE ASSEMBLY INSTALLATION OF BLADE ASSEMBLY

INSTALLATION OF BLADE ASSEMBLY 1. Raise center of blade (1), and install right tip of blade to adjuster. Extend blade side shift cylinder rod fully, and move position of lifting wire while pushing in blade to point where it is possible to connect cylinder rod. a Do not coat the rail at the rear of the blade with grease. 4

Blade assembly: Approx. 755 kg (differs according to blade)

2. Install cylinder rod (2) to blade (1) and tighten mounting bolts to specified torque. Remove stand from under circle. 2 Cylinder rod pin hole: Coat with G2-LI

Blade assembly: Approx. 755 kg (differs according to blade)

GD555, 655, 675-3C


REMOVAL OF CIRCLE DRAWBAR ASSEMBLY

REMOVAL OF CIRCLE DRAWBAR ASSEMBLY 1. Remove blade assembly. For details, see REMOVAL OF BLADE ASSEMBLY.

4. Disconnect 2 motor hoses (11), 2 side cylinder hoses (9), and 2 swivel hoses (10).

2. Operate drawbar side shift control lever, and set center of drawbar to bottom surface of front frame. Operate blade control lever to set drawbar (1) horizontal, set stand under blade mounti ng b r a c k e t, t h e n l ow e r b l a d e . Re m o v e mounting bolts of cap (3) at bottom of side shift cylinder (2), and disconnect cylinder (2) from drawbar (1). Remove mounting bolts of left and right caps (5), and of blade cylinder rod (4), then disconnect rod (4) from drawbar (1). 5. Sling circle and drawbar, remove mounting nut of mounting holder (13) of stud ball (12) at tip of drawbar, raise circle drawbar assembly, then remove from front frame. 4

Circle drawbar assembly: Approx. 1250 kg

3. Disconnect hoses (6) and (7) of drawbar side shift cylinder, and remove clamp (8). a Fit male and female plugs into the hoses and nipples.

GD555, 655, 675-3C

30-127 (5)


INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY

INSTALLATION OF CIRCLE DRAWBAR ASSEMBLY 1. Raise circle drawbar assembly and set in position. Insert stud ball (12) at tip of drawbar at front frame mount, install holder (13) and shim (14) placed in front of ball, then tighten nut to specified torque. a Types of shim: 0.29 mm x 16 Standard shim thickness: 4 – 4.64 2 When assembling stud ball: Coat with LM-P 2 After assembling stud ball: Fill with G2-LI 3 Mounting nut: 588.4 – 1029.5 N·m {60 – 105 kgm} 4

3. Install 2 side cylinder hoses (9), 2 swivel hoses (10), and 2 motor hoses (11). a Install the clamp at right angles to the hose so that there is no twisting.

Circle drawbar assembly: Approx. 1,250 kg

4. Install side cylinder hoses (6) and (7), then install clamp (8).

2. Install cap (3) of drawbar side shift cylinder (2) to ball joint and tighten bolt to specified torque. Install left and right caps (5) of blade cylinder rod (4) to ball joint of drawbar (1) and tighten bolt to specified torque. 2 Ball joint portion: Coat with LM-P

30-128 (5)

5. Install blade assembly. (For details, see INSTALLATION OF BLADE ASSEMBLY.)

GD555, 655, 675-3C


REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY

REMOVAL OF BLADE CIRCLE GEAR ASSEMBLY 1. Remove blade assembly. ( F o r d e t a i l s , s e e R E M O VA L O F B L A D E ASSEMBLY.) 2. Operate drawbar side shift control lever, and set center of drawbar at bottom surface of front frame. Operate blade control lever to set drawbar (1) horizontal, set stand to match height under blade mounting bracket, then lower. Disconnect 2 hoses (3) of blade side shift cylinder (2). Sling cylinder (2), remove bottom bolt and washer, then lift off cylinder. Loosen left and right mounting nuts of adjuster (4) and remove. Loosen mounting bolts of cover (5) and remove, then remove rod (6). a Fit male and female plugs into the hoses and nipples. 4

4. Raise lock plate of mounting bolt of pinion gear (13) of circle rotating gear, loosen bolt, remove plate (14), shim (15), and joint (19) then remove pinion gear (13). a When the bolt is removed, the pinion gear will fall under its own weight, so support it by hand when removing.

Side shift cylinder assembly: Approx. 50 kg 5. Sling circle rotating gear, loosen mounting bolts and adjustment bolts of circle rotating guide (16), remove 6 guides (16), raise circle gear (17), lower below drawbar (18), and remove. 4

Circle rotating gear: Approx. 135 kg

3. Disconnect hoses (8) and (9) of power tilt cylinder (7). Sling cylinder (7), then remove lock plate and bolt of pins (10) and (11), and lift off cylinder. Remove mounting bolts of cylinder mounting bracket (12), then remove bracket. 4

Power tilt cylinder assembly: Approx. 20 kg

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30-129 (5)


INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY

INSTALLATION OF BLADE CIRCLE GEAR ASSEMBLY 1. Raise circle rotating gear (17) to mounting position at bottom surface of drawbar (18). Align mounting bolt position of circle rotating guide (16), install 6 guides (16), and tighten temporarily. After adjust, tighten fully. a For details of method for adjusting circle, see TESTING AND ADJUSTING. a After adjusting all parts, check that that all nuts and bolts are tightened to the specified tightening torque. 3 Guide mounting bolt: 490 – 608 Nm {50 – 62 kgm} 2 Circle teeth, guide, top surface of circle, surface in contact with guide: Coat with LM-P 4

3. Install power tilt cylinder mounting bracket (12) with mounting bolts. Raise power tilt cylinder (7), install to bracket (12), install pins (10) and (11), fit lock plate, then tighten bolts to tightening torque. Install hoses (8) and (9). 4

Power tilt cylinder assembly: Approx. 20 kg a After installing the bracket, put a stand that matches the height under the bottom surface of the bracket.

Circle rotation gear: Approx. 135 kg

4. Install rod (6) to bracket (12). Install left and right adjusters (4) to support (19) and rod (6) of circle gear (17), then tighten nuts and secure. Install 2 covers (5) to rod (6) and support (19). Raise blade side shift cylinder (2), install bottom end to right adjuster (4), then install 2 hoses (3). 4

Side shift cylinder: Approx. 50 kg

2. Install pinion gear (13), joint (19) of circle rotating gear, install plate (14) and shim (15), then tighten mounting bolts to specified torque, bend lock plate of bolt securely, and lock. a When installing the pinion gear, be careful not to let it fall. a Types of shim: 0.2, 0.5, 1.0 mm (shim thickness: 3 mm)

5. Install blade assembly. (For details, see INSTALLATION OF BLADE ASSEMBLY.) a After completion of the operation, check that each component works properly.

30-130 (5)

GD555, 655, 675-3C


REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

REMOVAL OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

k Stop the engine and operate the circle rotation control lever to release the residual pressure in the piping.

4. Lift off circle gear assembly (3).

1. Disconnect 2 hoses (2) from circle motor (1). a Plug the removed hoses and nipples. 2. Drive out dowel pin (4) from underside and remove the 4 mounting bolts of circle gear assembly (3) from underside.

3. Remove holder (6) and shim (7), and then remove joint (8) and pinion gear (9). a Raise lock plate (5) of the mounting bolts of holder (6) and remove the mounting bolts. a When removing the bolts, hold pinion gear (9) with the hand so that it will not fall. a Check the thickness and quantity of shims (7).

GD555, 655, 675-3C

30-131 (5)


INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

INSTALLATION OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) 3 Mounting bolt: 911 – 1,029 Nm {93 – 105 kgm}

1. Install pinion gear (9) and joint (8) and fix them temporarily. 2. Measure clearance b between the ends of shaft (10) and joint (8), and then select shims 0.1 – 0.5 mm thicker than b. • Standard shim thickness: 3 mm • Kinds of shim thickness: 0.2 mm, 0.5 mm, 1.0 mm

4. Install pinion gear (9), joint (8), and shim (7) in order. 5. Install holder (6) with the mounting bolts and bend lock plate (5) securely. 2 Plate (11), pinion gear, and contact face of shaft: Lubricant containing molybdenum disulfide (LM-P) 2 Filling for part c at top of pinion gear: Grease (G2-LI).

3. Make clearance a of the same dimension between plate (11) and pinion gear (9).

30-132 (5)

GD555, 655, 675-3C


DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) 1. Draining oil Remove the drain plug and drain the oil from the circle rotation gear case. 6

5. Worm gear and bearing assembly 1) Remove worm gear and bearing assembly (9).

Quantity of oil: Approx. 4 l

2. Disconnection of circle rotation gear and motor Remove mounting bolts (2) and disconnect circle rotation gear assembly (3) and motor assembly (4). a Take care not to drop or lose the motor shaft key. 3. Cover Remove cover (5). 2) Remove 2 bearings (11) from shaft (10).

4. Housing Remove housing (7) and shim (8) from case (6). a Check the thickness and quantity of shims (8).

GD555, 655, 675-3C

6. Worm wheel shaft assembly 1) Remove worm wheel shaft assembly (12). a Remove washer (18).

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DISASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

2) Remove gear (14) from shaft (13). a Remove washer (17).

30-134 (5)

GD555, 655, 675-3C


ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN) 1. Worm gear and bearing assembly 1) Press fit 2 bearings (11) to worm gear (10).

2) Install worm gear and bearing assembly (9) to case (6).

2. Housing 1) Set the O-ring to housing (7) and install them to the case, inserting shim (8). a Adjust the shim so that the rotating torque of the worm shaft will be 2.94 – 7.8 Nm {0.3 – 0.8 kgm} to give a preload to the bearing. a When measuring the rotating torque, check that the worm gear is not meshed with the worm wheel gear. • Types of shim: 0.1, 0.2, 1.0 mm 2) Check the quantity of the shims, loosen the bolts on the housing side, and pull the housing out of the case a little. a Remove the worm gear and bearing assembly from the outer race of the bearing.

GD555, 655, 675-3C

3. Worm wheel shaft assembly 1) Using push tool kits (70 mm and 73 mm), press fit bushing (15) to case (6). 2) Using push tool kit (85 mm), press fit oil seal (16). 2 Oil seal lip: Grease (G2-LI)

3) Install gear (14) to shaft (13). a Install washer (17).

30-135 (5)


ASSEMBLY OF BLADE CIRCLE ROTATION GEAR ASSEMBLY (WITH SHEAR PIN)

4) Install worm wheel shaft assembly (12). a Matching the teeth of the worm wheel gear and worm wheel, tighten the nuts on the housing side. a Install washers (17) and (18) to the top and bottom of the worm wheel shaft assembly.

6. Cover Set the O-ring and install cover (5). 2 Bolts at 2 through parts of case tap on worm gear side: Adhesive (LT-2)

4. Connection of circle rotation gear and motor assembly Matching circle rotation gear (3) and motor assembly (4), install mounting bolts (2). a Install the key to the motor assembly shaft.

a Install cover (5) so that oil filler plug (19) will be positioned as shown in the illustration. 3 Oil filler plug: 73.55 – 122.58 Nm {7.5 – 12.5 kgm}

5. Refilling with oil Tighten drain plug (1) and add gear oil to the specified level.

5 Circle rotation gear case: 4 l 3 Drain plug: 32.36 – 44.13 Nm {3.3 – 4.5 kgm}

30-136 (5)

GD555, 655, 675-3C


DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)

DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH) 1. Remove 2 hoses (2) of circle motor (1). Knock out 2 dowel pins (4) of circle rotating gear from bottom. Remove 6 mounting bolts of circle rotating gear from bottom. a Fit male and female plugs into the hoses and nipples.

2. Raise stopper plates for mounting bolts of lock plate (6) and pinion gear, then remove bolts. Remove lock plate (6) and take out pinion gear (5). It will fall out, so remove it quickly. a When raising the lock plate, support the pinion gear by hand to prevent it from falling out when it is removed.

GD555, 655, 675-3C

3. Install eyebolt to circle rotating gear assembly (3), then raise and set on strong, stable stand. Loosen 4 mounting bolts of circle motor (1) and remove motor. Loosen 8 mounting bolts of cover (8) of circle rotating gear assembly (3), then remove cover. 4

Circle rotating gear assembly: Approx. 125 kg

4. Pull out 8 mounting bolts of housing (9), then using 2 forcing screws (10), remove housing.

30-137 (5)


5. Remove 3 bolts of circle gear shaft, then remove plate (11) and collar (12). Remove 4 mounting nuts of worm gear bearing cage (13), then remove cage together with shim.

6. Install eyebolts to circle gear shaft (14), and lift off gear assembly. Remove belleville spring (15) and collar (16).

DISASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)

8. Separate circle gear (17) and shaft (14). Remove spacer (18) under shaft.

9. Remove worm gear (19) from gear case, then remove 2 left and right bearings (20). Turn over gear case, remove oil seal (21), then remove bushing (22).

7. Remove 5 plates (18) and 6 discs (19) from circle gear (17) in order.

30-138 (5)

GD555, 655, 675-3C


ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH)

ASSEMBLY OF CIRCLE ROTATING GEAR ASSEMBLY (WITH SLIP CLUTCH) 1. Press fit bushing (22) to circle gear insertion portion of gear case. Turn over gear case and press fit oil seal (21). a Coat the shaft seal surface of seal (21) with G2-LI and bushing (22) with LM-P.

4. Press fit bearing (20) to worm gear (19).

5. Assemble worm gear (19) to gear case.

2. Assemble circle gear (17), shaft (14), and spacer (18).

6. Install bearing cage (13) to gear case.

3. Assemble plates (18) and discs (19) to circle gear (17) in order. a NOTICE: When assembling, coat the whole surface of the discs (front and rear faces) with GO#90 oil.

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30-139 (5)


7. Install nuts to mounting bolts of bearing cage (13), set to condition where shim (23) adjustment is possible, then adjust shim and tighten nut. a To apply the preload to the bearing, adjust with shims so that the friction torque of the worm shaft is 2.9 – 7.85 N·m {0.3 – 0.8 kgm}. When measuring the rotating torque, the worm and worm wheel must not be meshed (measure before assembling worm and worm wheel). a Types of shim: 0.1, 0.2, 1.0 mm (Shim adjustment: 1.65 mm)

8. Install plate (18) and belleville spring (15) to circle gear (17), then install lifting tool to shaft, raise gear assembly, and assemble to gear case. Using forcing screws, hold housing (9), and install to gear case. a When installing housing (9), set with oval hole (24) in housing facing oil level gauge side of gear case (rear of machine), then install. (Relationship with oil filler plug) 2 Only 2 mounting bolts of cover at case tap hole: Coat with thread tightener (LT-2)


9. Install collar (12), then install bolts to housing (9), and tighten to specified torque. Assemble shim (25). a Types of shim: 0.2, 0.5 mm

10. Install lock plate (11) to gear shaft, and tighten 3 bolts to specified torque. Install gear case cover (8), then install bolt and tighten to specified torque. a When installing cover (8), set position of oil filler plug (26) at oil level gauge side of gear case (rear of machine), then install. Make sure that oval hole in housing (9) is aligned. If it is not aligned, change mounting position of cage (9).

11. Assemble circle motor (1) to worm gear, and tighten 4 mounting bolts to specified torque. a Install the gear case securely to the motor before installing.

30-140 (5)

GD555, 655, 675-3C


12. Raise circle gear assembly and install to drawbar, then install pinion gear (5) from bottom, install shim (27) and lock plate (6) with 2 bolts, install stopper plate (7) to bolt, then tighten to specified torque. a Bend lock plate (7) fully to lock in position, then tighten mounting bolts of rotation assembly to specified tightening torque. a When installing the pinion gear, be careful not to drop it. a Types of shim at pinion gear portion: 0.2, 0.5, 1.0 mm (Standard: 3.0 mm). 3 4 bolts at dowel pin mounts at front and rear of machine: 911.4 – 1029 N·m {93 – 105 kgm} 3 2 bolts at left and right of machine: 490.3 – 608 N·m {50 – 62 kgm}


13. Knock in 2 dowel pins (4), and install 2 hoses (2) to circle motor (1). Tighten drain plug, remove oil filler plug (26), then fill with oil. After filling with oil, tighten fully. a After knocking in the dowel pin, caulk the circumference at 2 places. a When adding oil, set the rotating gear horizontal, and add oil until oil comes out from level plug hole. 3 Drain plug: 32.36 – 44.13 N·m {3.3 – 4.5 kgm} 3 Oil filler plug: 73.5 – 122.6 N·m {7.5 – 12.5 kgm} 5

GO #90: Approx. 7 l

a For details of the procedure for adjusting the slip clutch, see TESTING AND ADJUSTING

GD555, 655, 675-3C

30-141 (5)

90 OTHERS TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 50001 – 51000) ........................................................90- 3 TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 51001 and up) ..........................................................90- 5 HYDRAULIC CIRCUIT DIAGRAM (Serial No.: 50001 – 51000)...................................................................90- 7 HYDRAULIC CIRCUIT DIAGRAM (1/2) (Serial No.: 51001 and up) ............................................................90- 9 HYDRAULIC CIRCUIT DIAGRAM (2/2) (Serial No.: 51001 and up) ...........................................................90- 11 ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 50001 – 51000) .........................................................90- 13 ELECTRICAL CIRCUIT DIAGRAM (2/6) (Serial No.: 50001 – 51000) .........................................................90- 15 ELECTRICAL CIRCUIT DIAGRAM (3/6) (Serial No.: 50001 – 51000) .........................................................90- 17 ELECTRICAL CIRCUIT DIAGRAM (4/6) (Serial No.: 50001 – 51000) .........................................................90- 19 ELECTRICAL CIRCUIT DIAGRAM (5/6) (Serial No.: 50001 – 51000) .........................................................90- 21 ELECTRICAL CIRCUIT DIAGRAM (6/6) (Serial No.: 50001 – 51000) .........................................................90- 23 ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 51001 and up) ...........................................................90- 25 ELECTRICAL CIRCUIT DIAGRAM (2/6) (Serial No.: 51001 and up) ...........................................................90- 27 ELECTRICAL CIRCUIT DIAGRAM (3/6) (Serial No.: 51001 and up) ...........................................................90- 29 ELECTRICAL CIRCUIT DIAGRAM (4/6) (Serial No.: 51001 and up) ...........................................................90- 31 ELECTRICAL CIRCUIT DIAGRAM (5/6) (Serial No.: 51001 and up) ...........................................................90- 33 ELECTRICAL CIRCUIT DIAGRAM (6/6) (Serial No.: 51001 and up) ...........................................................90- 35

GD555, 655, 675-3C

90-1 (4)

TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 50001 – 51000) Serial No.: 50001 – 51000

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

GD555, 655, 675-3C

Transmission case Strainer Transmission pump Oil filter Main relief valve Torque converter relief valve Torque converter Oil cooler Transmission lubrication PTO lubrication Last chance filter Lock-up clutch ECMV FL clutch ECMV R clutch ECMV FH clutch ECMV 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 4th clutch ECMV Fill switch Pressure control valve Lock-up clutch FL clutch R clutch FH clutch 1st clutch 2nd clutch 3rd clutch 4th clutch FL clutch lubrication dividing piston R clutch lubrication dividing piston FH clutch lubrication dividing piston FL clutch lubrication R clutch lubrication FH clutch lubrication

90-3 (4)

TRANSMISSION HYDRAULIC CIRCUIT (Serial No.: 51001 and up) Serial No.: 51001 and up

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

GD555, 655, 675-3C

Transmission case Strainer Transmission pump Oil filter Main relief valve Torque converter relief valve Torque converter Oil cooler Transmission lubrication PTO lubrication Last chance filter Lock-up clutch ECMV FL clutch ECMV R clutch ECMV FH clutch ECMV 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 4th clutch ECMV Fill switch Pressure control valve Lock-up clutch FL clutch R clutch FH clutch 1st clutch 2nd clutch 3rd clutch 4th clutch FL clutch lubrication dividing piston R clutch lubrication dividing piston FH clutch lubrication dividing piston FL clutch lubrication R clutch lubrication FH clutch lubrication

90-5 (4)

HYDRAULIC CIRCUIT DIAGRAM (Serial No.: 50001 – 51000) Serial No.: 50001 – 51000

GD555, 655, 675-3C

90-7 (4)

HYDRAULIC CIRCUIT DIAGRAM (1/2) (Serial No.: 51001 and up) Serial No.: 51001 and up

GD555, 655, 675-3C

90-9 (8)

HYDRAULIC CIRCUIT DIAGRAM (2/2) (Serial No.: 51001 and up) Serial No.: 51001 and up

GD555, 655, 675-3C

1. For GD655, 675-3C: Serial No. 50001 – 51000 2. For GD655, 675-3C: Serial No. 51001 and up

90-11 (4)

ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 50001 – 51000) Serial No.: 50001 – 51000

GD555, 655, 675-3C

90-13 (4)


GD555, 655, 675-3C

90-15 (4)


GD555, 655, 675-3C

90-17 (4)


GD555, 655, 675-3C

90-19 (4)


GD555, 655, 675-3C

90-21 (4)


GD555, 655, 675-3C

90-23 (4)

ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 51001 and up) Serial No.: 51001 and up

GD555, 655, 675-3C

90-25 (4)


GD555, 655, 675-3C

90-27 (4)


GD555, 655, 675-3C

90-29 (4)


GD555, 655, 675-3C

90-31 (4)


GD555, 655, 675-3C

90-33 (4)


GD555, 655, 675-3C

90-35 (4)

Gd675-3c (Aps) Shop Manual

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