Gd675-3c (Aps) Shop Manual

SEBM020908
MACHINE MODEL
GD555-3C GD655-3C GD675-3C
00 00
SERIAL NUMBER
50001 and up 50001 and up 50001 and up
00 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)
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CONTENTS
No. of page 01 10 20 30 90 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . 10-1 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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00-2
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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 New page to be added Page to be replaced
Action Required Add Replace Discard
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Page to be deleted
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES

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GD555, 655, 675-3C
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GD555, 655, 675-3C
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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
Safety notice
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.
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.
00-4
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
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.
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.
Symbols So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Symbol k Item Safety Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
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. 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 Added pages 20-203 12-203-1 12-203-2 12-204
Caution
Weight
3 2 5 6
Tightening torque
Coat
Oil, water
Drain
00-6
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
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.
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.
100%
88%
79%
71%
41%
SAD00479
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 mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
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.
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

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.
Type 1
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
Foreword
Type 2 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. 1)
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.
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.
Disassembly
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
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 LT-1A Part No. 790-129-9030 Qty 150 g Container Tube Main applications, features
LT-1B
790-129-9050
LT-2
09940-00030 790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120 790-129-9140
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
Aron-alpha 201 Loctite 648-50 LG-1 LG-5
790-129-9130
79A-129-9110 790-129-9010 790-129-9080
LG-6 Gasket sealant LG-7 Three bond 1211 Three bond 1207B
790-129-9020
790-129-9070
790-129-9090 419-15-18131
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
00-10
Foreword
Coating materials
Category
Komatsu code LM-G
Part No. 09940-00051 09940-00040 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 SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
Qty 60 g 200 g
Container Can Tube
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
Molybdenum disulphide lubricant
LM-P
G2-LI
Various
Various Used for normal temperature, light load bearing at places in contact with water or steam. Used for heavy load portion
G2-CA 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 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
Various
Various
Grease
400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can 400 g 16 kg
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. 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) Used as primer for glass side (Using limit: 4 months) 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)
400 g 16 kg
Bellows type Can Glass container Glass container Glass container Can Glass container Ecocart (Special container) Polyethylene container Polyethylene container Polyethylene container Polyethylene container Cartridge
20 ml 417-926-3910 20 ml 22M-54-27230 20 ml
Primer
22M-54-27240
150 ml
22M-54-27250 22M-54-27210
20 ml 320 ml
Adhesive
417-926-3910
320 ml
20Y-54-39850 417-926-3920 20Y-54-55130 22M-54-27220
310 ml 320 ml 333 ml 333 ml
Caulking material
Adhesive for cab glass
00-11
Foreword
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 mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 14.7 27 34 59 74 98 123 153 190 235 285 320 400 455 565 610 765 785 980 1150 1440 1520 1910 1960 2450 2450 3040 2890 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2 kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2 kgm 1.2 1.5 2.8 3.5 6 7.5 10 12.5 15.5 19.5 23.5 29.5 33 41 46.5 58 62.5 78 80 100 118 147 155 195 200 250 250 310 295 370
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 mm 14 18 22 24 30 33 36 42
Width across flats mm 19 24 27 32 36 41 46 55 Nm 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
Tightening torque kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5
00-12
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 mm 10 12 16 Width across flats mm 14 17 22 Nm 59 74 98 123 235 285 Tightening torque kgm 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 mm 14 20 24 33 42 Width across flats mm 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 mm 08 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 36 Tightening torque (Nm {kgm}) Range 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} Target 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 mm 6 8 10 12 Nm 10 2 24 4 43 6 77 12 Tightening torque kgm 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 mm 6 8 10 12 14 Nm 82 10 2 12 2 24 4 36 5 Tightening torque kgm 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 inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 Nm 31 82 12 2 15 2 24 4 36 5 60 9 Tightening torque kgm 0.31 0.10 0.81 0.20 1.22 0.20 1.53 0.20 2.45 0.41 3.67 0.51 6.12 0.92
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.
Nominal size of hose Tightening torque (Nm {kgm}) Width across flats Range 34 54 {3.5 5.5} 34 63 {3.5 6.5} 54 93 {5.5 9.5} 59 98 {6.0 10.0} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type
02
19 22 24 27 32 36 41 46 55
Thread size Nominal thread size Root diameter Threads per inch, (mm) (mm) (Reference) Thread series 9 18UN 14.3 16 14 18 22 24 30 33 36 42 11 16UN 16 13 16UN 16 1 14UNS 3 1 12UN 16 17.5 20.6 25.4 30.2
03 04 05 06 (10) (12) (14)
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 0.85 2 5 15 40 60 100 Copper wire Number of strands 11 26 65 84 85 127 217 Dia. of Cross section strands (mm2) (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) 2.4 3.1 4.6 7.0 11.4 13.6 17.6 Current rating (A) 12 20 37 59 135 178 230 Applicable circuit Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
Classification by color and code

Priority Circuits Classification Code 1 Primary Color Code 2 Color Code 3 Color Code 4 Auxiliary Color Code 5 Color Code 6 Color Red & Blue White WR White & Red WB White & Black WL White & Blue WG White & Green Black Black BW White & Black BY Black & Yellow BR Black & Red Red RW Red & White RB Red & Black RY Red & Yellow RG Red & Green RL Yellow YR Rellow & Red YB Yellow & Black YG Yellow & Green YL Yellow & Blue YW Yellow & White Green GW Green & White GR Green & Red GY Green & Yellow GB Green & Black GL Green & Blue Blue LW Blue & White LR Blue & Yellow LY Blue & Yellow LB Blue & Black Charging W Ground B Starting B Lighting R Instrument Y Signal G Other L
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.
Millimeters to inches 0 0 10 20 30 40 (A) 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5
(B) 1 mm = 0.03937 in 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858 9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
00-16
Foreword
Conversion table
Millimeters to Inches 1 mm = 0.03937 in 0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858 9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
Kilogram to Pound 1 kg = 2.2046 lb 0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64 7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85 8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05 9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26
00-17
Foreword
Conversion table
Liter to U.S. Gallon 0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775 1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040 2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096 6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361 7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625
1l = 0.2642 U.S. Gal 8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889 9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal 0 0 10 20 30 40 50 60 70 80 90 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.969 9.899 12.098 14.298 16.498 18.697 20.897 6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117 7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337 8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557 9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777
00-18
Foreword
Conversion table
kgm to ft. lb 1 kgm = 7.233 ft. lb 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7 7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9 8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1 9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4
00-19
Foreword
Conversion table
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499 7 99.6 241.8 384.0 526.3 668.5 810.7 953.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513 8 113.8 256.0 398.3 540.5 682.7 825.0 967.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527 9 128.0 270.2 412.5 554.7 696.9 839.2 981.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 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. 1C = 33.8F C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 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 36 37 38 39 40 41 42 43 44 45 F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 0 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
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)
Item A B C Overall length Overall height (with full height cab) Overall height (with low height cab) Overall width
GD555-3C
8,350 3,330 3,100 2,525
GD655-3C
8,595 3,350 3,120 2,550
GD675-3C
8,611 3,350 3,120 2,550
01-2
(4)
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
SPECIFICATIONS
GD555-3C
Machine Model Serial Number Machine weight On front axle On rear axle Overall length Overall width Overall height (top of muffler) Dimensions Overall height (with ROPS cab) Wheel base Distance between centers of tandem wheels Tread (Front) Tread (Rear) Ground clearance 1st 2nd 3rd Forward 4th 5th 6th 7th 8th 1st Reverse 2nd 3rd 4th Maximum drawbar pull Gradeability Min. Turning radius Static stability kN {kg} deg. m deg. km/h 4.4 8.9 18.7 36.1 77.7 {7,920} 24 6.8 35 km/h mm kg GD555-3C VHP Engine 50001 51000 13,850 3,950 9,900 8,370 2,525 2,980 3,100 5,850 1,535 2,130 2,130 350 3.3 4.8 6.8 9.8 14.9 21.6 29.6 42.9 4.4 9.0 19.7 39.1 78.7 {8,030} 51001 and up 14,040 4,000 10,040 8,350
Travel speed Performance
VHP engine: Variable horsepower engine.
GD555, 655, 675-3C
01-3
(4)
GENERAL
SPECIFICATIONS
Machine Model Serial Number Engine model 50001 51000 SA6D102E-1
GD555-3C VHP Engine 51001 and up SAA6D102E-2
Type
4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh} 6 - 102 x 120 5.88 {5,880} 104.4 to 119.3/2,000 {140 to 160/2,000} 606.3 to 741.6/1,400 {60.9 to 74.5/1,400} 2,200 800 229.4 to 232.4 {171.1 to 173.3} 24 V, 7.5 kW 24 V, 50 A 12 V, 112 Ah x 2 CF19-4 3-element, single-stage Automatic shifting, wet-type clutch Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds Spiral bevel gear, single-stage reduction Fully floating tandem type Double-row chain drive Reverse Elliott, angle type deg. 16 Fully hydraulic type deg. deg. 49 23 575.4 to 728.6/1,500 {58.7 to 74.3/1,500} 2,200 850 214.3 {159.7} 24 V, 5.5 kW
Cylinder number - bore x stroke Piston displacement Flywheel horsepower Engine Performance Front axle Steering Steering system Maximum torque Max. speed at no load Min. speed at no load Fuel consumption ratio Starting motor Alternator Battery Radiator type Torque converter
Power train
Transmission
Reduction gear Rear axle Tandem Type Max. leaning angle Type Steering angle Articulate angle
01-4
(4)
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
Machine Model Serial Number Tires (front) Steering, operating system Tires (rear) Tires Inflation pressure (front) Inflation pressure (rear) Brakes Main brake Parking brake Type x no. Discharge Set pressure l/min. MPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}
GD555-3C VHP Engine 50001 and up 13.00-24-10PR 13.00-24-10PR 275 {2.75} 275 {2.75} Rear 4-wheel braking, multiple-disc wet type Dry disc type Komatsu LPV90 Variable swash plate type x 1 205 206 {210}
Control valve
Hydraulic pump
Type x no.
4-spool type x 2 (CLSS)
Control method Steering Type Cylinder bore Piston rod outside diameter Piston stroke mm mm mm Blade lift 50 35 330 Blade side shift
Hydraulic type Leaning Double-acting piston type 70 35 160 Blade tilt 90 50 325 Drawbar side shift Ripper Articulating
Hydraulic system
Steering related cylinders
Type Work equipment cylinders Cylinder bore Piston rod outside diameter Piston stroke Type Cylinder bore Piston rod outside diameter Piston stroke mm mm mm mm mm mm
Double-acting piston type 80 50 1,160 80 50 1,250 80 40 300 Scarifier Double-acting piston type 80 50 345 80 45 585 100 50 600
GD555, 655, 675-3C
01-5
(4)
GENERAL
SPECIFICATIONS
Machine Model Serial Number Blade dimension (Length x Height x Thickness) Cutting edge dimension (Length x Width x Thickness Number) Max. lift above ground Max. cutting depth Blade base Blade Blade load Turning angle (with scarifier) Max. side shift distance (left) Max. side shift distance (right) Cutting angle [Standard] [Adjustable] deg. kN {kg} deg. mm 68 {6,939} mm 50001 51000
GD555-3C 51001 and up
3,660 x 660 x 22 1,830 x 153 x 16 2 460 635 2,500 68.5 {6,985} 360 (130) 625 625 37 32 to 81
01-6
(4)
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
GD655-3C
GD655-3C Machine Model Serial Number Machine weight On front axle On rear axle Overall length Overall width Overall height (top of muffler) Dimensions Overall height (with ROPS cab) Wheel base Distance between centers of tandem wheels Tread (Front) Tread (Rear) Ground clearance 1st 2nd 3rd Forward 4th 5th 6th 7th 8th 1st Reverse 2nd 3rd 4th Maximum drawbar pull Gradeability Min. Turning radius Static stability kN {kg} deg. m deg. km/h 4.3 8.8 18.1 35.1 83.0 {8,460} 24 6.9 35 km/h mm kg Standard HP Engine 50001 51000 14,800 4,220 10,580 8,595 2,550 3,000 3,120 6,070 1,535 2,130 2,130 370 3.3 4.7 6.7 9.7 14.6 21.2 29.1 42.1 4.3 8.8 18.1 38.4 84.1 {8,580} VHP Engine 51001 and up 15,000 4,270 10,730
Performance
Travel speed
GD555, 655, 675-3C
01-7
(4)
GENERAL
SPECIFICATIONS
GD655-3C Machine Model Serial Number Engine model Standard HP Engine 50001 51000 S6D114E-1 Standard 4-cycle, water cooled, overhead valve, direct-injection type with turbocharger mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh} 159 {213.2} 24 V, 7.5 kW 24 V, 50 A 12 V, 112 Ah x 2 CF19-4 123/1,900 {165/1,900} 793.4/1,300 {80.9/1,300} SA6D114E-1 VHP VHP Engine 51001 and up SAA6D114E-2
Type Cylinder number - bore x stroke Piston displacement Flywheel horsepower Engine Maximum torque Max. speed at no load Min. speed at no load Fuel consumption ratio Starting motor Alternator Battery Radiator type Torque converter
4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler 6 - 114 x 135 8.27 {8,270} 123.3 to 141.7/1,900 {165 to 190/1,900} 794.3 to 913.0/ 1,300 {81.0 to 93.1/1,300} 2,200 800 218 {162.8} 24 V, 7.5 kW 24 V, 60 A 12 V, 112 Ah x 2 CF19-5 749.7 to 926.2/ 1,400 {76.4 to 94.4/1,400}
Performance
3-element, single-stage Automatic shifting, wet-type clutch Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds Spiral bevel gear, single-stage reduction Fully floating tandem type Double-row chain drive
Power train
Transmission
Reduction gear Rear axle Tandem Front axle Type Max. leaning angle Type Steering angle Articulate angle deg. deg.
Reverse Elliott, angle type 16 Fully hydraulic type 49 23
Steering
01-8
(4)
Steering system
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
Machine Model Serial Number Tires (front) Steering, operating system Tires (rear) Tires Inflation pressure (front) Inflation pressure (rear) Brakes Main brake Parking brake Type x no. Discharge at rated rpm Set pressure l/min. MPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}
GD655-3C Standard HP Engine VHP Engine 50001 and up 14.00-24-10PR 14.00-24-10PR 250 {2.5} 250 {2.5} Rear 4-wheel braking, multiple-disc wet type Dry disc type Komatsu LPV90 Variable swash plate type x 1 194 206 {210}
Control valve
Hydraulic pump
Type x no.
Hydraulic system
GD555, 655, 675-3C
01-9
(4)
GENERAL
SPECIFICATIONS
Machine Model Serial Number Blade dimension (Length x Height x Thickness) Cutting edge dimension (Length x Width x Thickness Number) Max. lift above ground Max. cutting depth Blade base Blade Blade load Turning angle (with scarifier) Max. side shift distance (left) Max. side shift distance (right) Cutting angle [Standard] [Adjustable] deg. kN {kg} deg. mm 72.4 {7,378} mm 50001 51000
GD655-3C 51001 and up
3,660 x 660 x 22 1,829 x 153 x 16 2 480 815 2,600 73.2 {7,469} 360 (130) 625 625 37 32 to 81
01-10
(4)
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
GD675-3C
Machine Model Serial Number Machine weight On front axle On rear axle Overall length Overall width Overall height (top of muffler) Dimensions Overall height (with ROPS cab) Wheel base Distance between centers of tandem wheels Tread (Front) Tread (Rear) Ground clearance 1st 2nd 3rd Forward 4th 5th 6th 7th 8th 1st Reverse 2nd 3rd 4th Maximum drawbar pull Gradeability Min. Turning radius Static stability kN {kg} deg. m deg. 83.0 {8,460} 24 6.9 35 km/h km/h mm kg GD675-3C VHP Engine 50001 51000 15,600 4,450 11,150 8,620 2,550 2,995 3,115 6,070 1,535 2,130 2,130 365 3.3 4.7 6.7 9.7 14.6 21.2 29.1 42.1 4.3 8.8 18.1 35.1 88.8 {9,050} 51001 and up 15,810 4,500 11,310 8,595
Travel speed Performance
GD555, 655, 675-3C
01-11
(4)
GENERAL
SPECIFICATIONS
Machine Model Serial Number Engine model 50001 51000 SA6D114E-1
GD675-3C VHP Engine 51001 and up SAA6D114E-2
Type
4-cycle, water cooled, overhead valve, direct-injection type with turbocharger and aftercooler mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh} 236.5 to 237.6 {176.4 to 177.2} 24V, 7.5 kW 24V, 50A 12V, 112Ah x 2 CF19-4 6 - 114 x 135 8.27 {8,270} 134.2 to 149.2/1,900 {180 to 200/1,900} 856.2 to 974.8/1,300 {86.1 to 98.0/1,300} 2,200 800 218.1 {162.7} 24V, 7.5kW 24V, 60A 12V, 112Ah x 2 CF19-5 785 to 974.6/1,400 {80.0 to 99.4/1,400}
Cylinder number - bore x stroke Piston displacement Flywheel horsepower Engine Performance Maximum torque Max. speed at no load Min. speed at no load Fuel consumption ratio Starting motor Alternator Battery Radiator type Torque converter
3-element, single-stage Automatic shifting, wet-type clutch Multiple shaft Fully automatic electric, automatic shifting type, pump force feed type 8 forward speeds, 4 reverse speeds Spiral bevel gear, single-stage reduction Fully floating tandem type Double-row chain drive Reverse Elliott, angle type 16 Fully hydraulic type deg. deg. 49 23
Power train
Transmission
Reduction gear Rear axle Tandem Front axle Type Max. leaning angle Type Steering angle Articulate angle
Steering
01-12
(4)
Steering system
GD555, 655, 675-3C
GENERAL
SPECIFICATIONS
Machine Model Serial Number Tires (front) Steering, operating system Tires (rear) Tires Inflation pressure (front) Inflation pressure (rear) Brakes Main brake Parking brake Type x no. Discharge at rated rpm Set pressure l/min. MPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2}
GD675-3C VHP Engine 50001 51000 14.00-24-12PR 14.00-24-12PR 275 {2.75} 275 {2.75} Rear 4-wheel braking, multiple-disc wet type Dry disc type Komatsu LPV90 Variable swash plate type x 1 194 206 {210} 51001 and up
Control valve
Hydraulic pump
Type x no.
Hydraulic system
GD555, 655, 675-3C
01-13
(4)
GENERAL
SPECIFICATIONS
Machine Model Serial Number Blade dimension (Length x Height x Thickness) Cutting edge dimension (Length x Width x Thickness Number) Max. lift above ground Max. cutting depth Blade base Blade Blade load Turning angle (with scarifier) Max. side shift distance (left) Max. side shift distance (right) Cutting angle [Standard] [Adjustable] deg. kN {kg} deg. mm 76.3 {7,777} mm 50001 51000
GD675-3C 51001 and up
3,660 x 660 x 25 1,830 x 153 x 16 2 480 615 2,600 77.2 {7,872} 360 (130) 625 625 37 32 to 81
01-14
(4)
GD555, 655, 675-3C
GENERAL
WEIGHT TABLE
WEIGHT TABLE
Serial No. 50001 51000
k Use the weight table when handling individual parts or when transporting the entire machine. Unit: kg
GD555-3C GD655-3C 50001 51000 453 51 755 9 1,012 876 418 26 138 x 2 138 x 4 450 49 160 10 12 x 2 11 25 x 2 49 x 2 48 19 32 22 538 625 252 119 1,613 883 595 200 616 51 755 9 1,012 876 548 26 151 x 2 151 x 4 530 49 160 10 12 x 2 15 25 x 2 49 x 2 48 19 32 24 557 625 272 119 1,814 980 900 200 616 51 755 9 1,012 876 548 26 179 x 2 179 x 4 530 49 160 10 12 x 2 15 25 x 2 49 x 2 48 19 32 24 557 675 272 119 1,814 980 900 200 GD675-3C
Machine model Serial Number Engine assembly (dry) Radiator assembly (dry) Transmission assembly (dry) Transmission pump Final drive assembly Tandem drive (one side) Front axle assembly, except leaning cylinder Parking brake assembly Wheel assembly (front) Wheel assembly (rear) Scarifier assembly Hydraulic pump Fuel tank and hydraulic tank (both dry) Circle rotation motor Steering cylinder assembly Leaning cylinder assembly Articulating cylinder assembly Blade lift cylinder assembly Blade side-shift cylinder assembly Blade power tilt cylinder assembly Drawbar side-shift cylinder assembly Scarifier cylinder assembly Drawbar assembly Blade assembly Circle gear Circle rotation gear assembly Front frame assembly Rear frame assembly Ripper Operator's compartment assembly and controls
GD555, 655, 675-3C
01-15
(4)
GENERAL
WEIGHT TABLE
Serial No. 51001 and up

Machine model Serial Number Engine assembly (dry) Radiator assembly (dry) Transmission assembly (dry) Transmission pump Final drive assembly Tandem drive (one side) Front axle assembly, except leaning cylinder Parking brake assembly Wheel assembly (front) Wheel assembly (rear) Scarifier assembly Hydraulic pump Fuel tank and hydraulic tank (both dry) Circle rotation motor Steering cylinder assembly Leaning cylinder assembly Articulating cylinder assembly Blade lift cylinder assembly Blade side-shift cylinder assembly Blade power tilt cylinder assembly Drawbar side-shift cylinder assembly Scarifier cylinder assembly Drawbar assembly Blade assembly Circle gear Circle rotation gear assembly Front frame assembly Rear frame assembly Ripper Operator's compartment assembly and controls 550 115 755 9 1,012 876 418 26 138 x 2 138 x 4 450 49 160 10 12 x 2 11 25 x 2 49 x 2 48 19 32 22 538 625 252 119 1,613 883 595 200 GD555-3C GD655-3C 51001 and up 750 115 755 9 1,012 876 548 26 151 x 2 151 x 4 530 49 160 10 12 x 2 15 25 x 2 49 x 2 48 19 32 24 557 625 272 119 1,814 980 900 200 750 115 755 9
Unit: kg
GD675-3C
1,012 876 548 26 179 x 2 179 x 4 530 49 160 10 12 x 2 15 25 x 2 49 x 2 48 19 32 24 557 675 272 119 1,814 980 900 200
01-16
(4)
GD555, 655, 675-3C
GENERAL
FUEL, COOLANT, AND LUBRICANT SELECTION

According to temperature
Ambient temperature Reservoir Fluid
-22 -30 -4 -20 14 -10 32 0 50 10 68 20 86 30 104 40 122F 50C
Capacity (l) Specified Refill
SAE30 CD SAE10W CD SAE10W-30 CD Engine oil pan SAE15W-40 CD Engine oil SAE5W-40 CD SAE0W-30 CD Transmission case Final drive case Tandem drive case (each) Circle reverse gear Shear-pin type Slip-clutch type Gear oil SAE75 SAE10W CD Hydraulic system Engine oil SAE5W-30 CD ASTM D975 No. 2 Fuel tank Diesel fuel 340 85 45 SAE10W CD SAE90 SAE80 4 7 4 7 SAE10W CD SAE30 CD 60 18 80 45 16 75 GD555-3C 16 GD655-3C GD675-3C 24 GD555-3C 14 GD655-3C GD675-3C 19
Cooling system
Coolant
Add antifreeze ASTM D975 No. 1
44
44
GD555, 655, 675-3C
01-17
(4)
GENERAL
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 0.5 to 1.0% Above 1.0% Change interval of oil in engine oil pan 1/2 of regular interval 1/4 of regular interval
When starting the engine in atmospheric temperature of lower than 0C, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up 10C 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 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
GD555, 655, 675-3C
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.
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
10-2
(4)
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
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.
10-4
(4)
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.
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
GD555, 655, 675-3C
10-5
(4)
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)

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 GD555, 655, 675-3C
10-7-1
(6)
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
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)
10-8
(4)
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
Specifications: Name: TCA38-10A Type: 3 element, 1 stage, 2 phase Stall torque ratio: 2.17
GD555, 655, 675-3C
10-9
(4)
TORQUE CONVERTER
10-10
(4)
GD555, 655, 675-3C
TORQUE CONVERTER
Unit: mm
No. Check item Std. size 1 Pilot O.D. 71.954 35 340 260 125 5 6 3.95 4.8 88.882 72.217 72.32 5 5 55 Criteria Tolerance 0.010 0.040 +0.025 0 +0.089 0 +0.081 0 +0.040 0 0.01 0.04 0.15 0 0.1 0.1 +0.005 0.008 +0.008 0.005 +0.015 0 0 0.1 0.1 +0.030 0 0.160 to 0.407 Repair limit 71.7 35.5 340.1 Replace 260.1 125.5 4.5 5.85 3.56 4.32 88.912 72.187 72.4 4.9 4.7 55.5 Rebuild or replace Rebuild or replace Remedy
2 3 4 5
Pilot seal ring I.D. Clutch housing seal ring I.D. Clutch piston seal ring I.D. PTO drive gear seal ring O.D. Clutch housing seal ring wear Width Thickness Width Thickness
Stator shaft seal ring wear
8 9 10 11 12 13 14
One-way clutch outer race O.D. Stator shaft one-way clutch O.D. Bushing I.D. Bushing thickness Clutch disc thickness Stator shaft seal ring I.D. Backlash between PTO drive gear and idler gear
Replace
GD555, 655, 675-3C
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
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
10-14
(4)
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. 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.
GD555, 655, 675-3C
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. 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.
10-16
(4)
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)
TRANSMISSION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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. Check item Std. size 50 5 6 Clearance between idler gear bearing and case Clearance between pump drive shaft and bearing (F) Clearance between pump drive shaft bearing and case (F) Clearance between pump drive shaft and bearing (R) Clearance between pump drive shaft bearing and case (R) Clearance between idler shaft and bearing Clearance between idler gear and bearing 90 50 Criteria Tolerance Shaft +0.018 +0.002 0 0.015 +0.020 +0.009 0 0.015 +0.030 +0.011 0 0.015 +0.032 +0.002 0 0.018 Hole 0 0.012 +0.016 0.006 0 0.012 +0.030 0 0 0.015 +0.030 0 0 0.015 0.025 0.050 Standard clearance 0.030 to 0.002 0.006 to 0.031 0.032 to 0.009 0 to 0.045 0.045 to 0.011 0 to 0.045 0.047 to 0.002 0.050 to 0.007 Replace Clearance limit Remedy
Clearance between idler gear and bearing
90
70
100
10 11
70 125
GD555, 655, 675-3C
10-19
(4)
TRANSMISSION
10-20
(4)
GD555, 655, 675-3C
TRANSMISSION
Unit: mm
No. Check item Std. size 150 2 3 4 5 6 7 8 9 10 11 12 13 Clearance between FL, R clutch bearing and case (R) Clearance between FH, 1st clutch bearing and case (F) Clearance between FH, 1st clutch bearing and case (R) Clearance between 2nd, 3rd clutch bearing and case (F) Clearance between 2nd, 3rd clutch bearing and case (R) Clearance between 4th clutch bearing and case (F) Clearance between 4th clutch bearing and case (R) Clearance between idler gear and bearing Clearance between idler gear bearing and case Clearance between fan drive shaft and bearing Clearance between fan drive shaft bearing and case Clearance between pump drive shaft and bearing (F) Clearance between pump drive shaft bearing and case (F) Clearance between pump drive shaft and bearing (R) Clearance between pump drive shaft bearing and case (R) Width of input shaft seal ring groove 17 Wear of input shaft seal ring Width Thickness 100 100 110 140 130 140 160 50 90 35 80 50 Criteria Tolerance Shaft 0 0.018 0 0.015 0 0.015 0 0.015 0 0.018 0 0.018 0 0.018 0 0.025 +0.018 +0.002 0 0.015 +0.025 +0.009 0 0.013 +0.020 +0.009 0 0.015 +0.030 +0.011 0 0.015 Hole +0.030 0 +0.022 0.013 +0.030 0 +0.022 0.013 +0.026 0.014 +0.026 0.014 +0.026 0.014 +0.040 0 0 0.012 +0.016 0.006 0 0.012 +0.030 0 0 0.012 +0.030 0 0 0.015 +0.030 0 Tolerance +0.018 +0.010 0.05 0 0.010 Standard clearance 0 to 0.048 0.013 to 0.037 0 to 0.045 0.013 to 0.037 0.014 to 0.044 0.014 to 0.044 0.014 to 0.044 0 to 0.065 0.030 to 0.002 0.006 to 0.031 0.037 to 0.009 0 to 0.043 0.032 to 0.009 0 to 0.045 0.045 to 0.011 0 to 0.045 Repair limit 2.7 2.2 1.5 Replace Clearance limit Remedy
Clearance between FL, R clutch bearing and case (F)
14
90
15
70
16
110
Standard size 2.5 2.4 1.7
GD555, 655, 675-3C
10-21
(4)
TRANSMISSION
No.
Check item Width of input shaft seal ring groove 3.2 3.1 2.29 50 3.2 3.1 2.29
Criteria +0.076 0 0.05 0 0.010 +0.05 0 +0.076 0 0.05 0 0.010 0 0.074 0 0.074 3.5 2.8 2.1 50.1 3.5
Remedy
18
Wear of input shaft seal ring
Width Thickness
Inside diameter of case seal ring sliding portion 19 Width of input shaft seal ring groove Wear of input shaft seal ring Width Thickness
Replace 2.8 2.1
20
Outside diameter of output coupling oil seal sliding portion Outside diameter of fan pulley coupling oil seal sliding portion
80
79.8
21
65
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
4. Dipstick tube mounting port 5. Torque converter lock-up valve 6. Main relief, torque converter relief valve
GD555, 655, 675-3C
10-23
(4)
TRANSMISSION
1. 2. 3. 4. 5. 6. 7. 8.
Torque converter Input shaft FL clutch Upper shaft FH clutch Lower shaft 3rd clutch Coupling
9. 10. 11. 12. 13. 14. 15.
4th clutch Output shaft 2nd clutch 1st clutch R clutch Mounting coupling for fan pulley Shaft for hydraulic pump drive
10-24
(4)
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. Check Item Std. Size 50 5 6 Clearance between idler gear bearing and case Clearance between pump drive shaft and bearing (F) Clearance between pump drive shaft bearing and case (F) Clearance between pump drive shaft and bearing (R) Clearance between pump drive shaft bearing and case (R) Clearance between idler shaft and bearing Clearance between idler gear and bearing 90 50 Criteria Tolerance Shaft +0.018 +0.002 0 0.015 +0.020 +0.009 0 0.015 +0.030 +0.011 0 0.015 +0.032 +0.002 0 0.015 Hole 0 0.012 +0.016 0.006 0 0.012 +0.030 0 0 0.015 +0.030 0 0 0.015 0.038 0.073 Standard Clearance 0.030 to 0.002 0.006 to 0.031 0.032 to 0.009 0 to 0.045 0.045 to 0.011 0 to 0.045 0.047 to 0.002 0.073 to 0.023 Clearance Limit Remedy
Clearance between idler gear and bearing
90
Replace
70
100
10 11
70 100
GD555, 655, 675-3C
10-25
(4)
TRANSMISSION
10-26
(4)
GD555, 655, 675-3C
TRANSMISSION
Unit: mm
No. Check Item Std. Size 150 2 3 4 5 6 7 8 9 10 11 12 13 Clearance between FL, R clutch bearing and case (R) Clearance between FH, 1st clutch bearing and case (F) Clearance between FH, 1st clutch bearing and case (R) Clearance between 2nd, 3rd clutch bearing and case (F) Clearance between 2nd, 3rd clutch bearing and case (R) Clearance between 4th clutch bearing and case (F) Clearance between 4th clutch bearing and case (R) Clearance between idler gear and bearing Clearance between idler gear bearing and case Clearance between fan drive shaft and bearing Clearance between fan drive shaft bearing and case Clearance between pump drive shaft and bearing (F) Clearance between pump drive shaft bearing and case (F) Clearance between pump drive shaft and bearing (R) Clearance between pump drive shaft bearing and case (R) Width of input shaft seal ring groove 17 Wear of input shaft seal ring Width Thickness 100 100 110 140 130 140 160 50 90 35 80 50 Criteria Tolerance Shaft 0 0.018 0 0.015 0 0.015 0 0.015 0 0.018 0 0.018 0 0.018 0 0.025 +0.018 +0.002 0 0.015 +0.025 +0.009 0 0.013 +0.020 +0.009 0 0.015 +0.030 +0.011 0 0.015 Hole +0.030 0 +0.022 0.013 +0.030 0 +0.022 0.013 +0.026 0.014 +0.026 0.014 +0.026 0.014 +0.040 0 0 0.012 +0.016 0.006 0 0.012 +0.030 0 0 0.012 +0.030 0 0 0.015 +0.030 0 Tolerance +0.018 +0.010 0.05 0 0.010 Standard Clearance 0 to 0.048 0.013 to 0.037 0 to 0.045 0.013 to 0.037 0.014 to 0.044 0.014 to 0.044 0.014 to 0.044 0 to 0.065 0.030 to 0.002 0.006 to 0.031 0.037 to 0.009 0 to 0.043 0.032 to 0.009 0 to 0.045 0.045 to 0.011 0 to 0.045 Clearance Limit Replace Remedy
Clearance between FL, R clutch bearing and case (F)
14
90
15
70
16
110
Repair Limit 2.7 2.2 1.5
Standard Size 2.5 2.4 1.7
GD555, 655, 675-3C
10-27
(4)
TRANSMISSION
No.
Check Item Width of input shaft seal ring groove 3.2 3.1 2.29 50 3.2 3.1 2.29
Criteria +0.076 0 0.05 0 0.010 +0.05 0 +0.076 0 0.05 0 0.010 0 0.074 0 0.074 3.5 2.8 2.1 50.1 3.5
Remedy
18
Wear of input shaft seal ring
Width Thickness
Inside diameter of case seal ring sliding portion 19 Width of input shaft seal ring groove Wear of input shaft seal ring Width Thickness
Replace 2.8 2.1
20
Outside diameter of output coupling oil seal sliding portion Outside diameter of fan pulley coupling oil seal sliding portion
80
79.8
21
65
64.8
10-28
(4)
GD555, 655, 675-3C
TRANSMISSION
OUTLINE
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.
Combination of clutches and reduction ratio

Speed range F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 Clutch used FL x 1st FH x 1st FL x 2nd FH x 2nd FL x 3rd FH x 3rd FL x 4th FH x 4th R x 1st R x 2nd R x 3rd R x 4th Reduction ratio 9.950 6.865 4.879 3.367 2.222 1.533 1.118 0.772 7.549 3.702 1.686 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
A. B. C. D.
R clutch oil port FL clutch oil port Lubrication oil port Lock-up clutch oil port
GD555, 655, 675-3C
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
A. 2nd clutch oil port B. 3rd clutch oil port C. Lubrication oil port
10-30
(4)
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
A. 4th clutch oil port B. Lubrication oil port C. Lubrication oil port
GD555, 655, 675-3C
10-31
(4)
TRANSMISSION
FL - R clutches
Unit: mm
No. Check item Std. size 1 Clearance between the piston and shaft (FL) Inside Outside Clearance between the piston and shaft (R) Inside Outside 96.73 140 96.73 140 60 55 Criteria Tolerance Shaft 0 0.050 0.300 0.350 0 0.050 0.300 0.350 +0.030 +0.011 +0.034 +0.021 Hole +0.180 +0.050 +0.130 0 +0.180 +0.050 +0.130 0 0 0.015 0 0.015 Tolerance 0. 05 0.1 0.08 0.1 101 N {10.3 kg} 0.1 0.1 0.30 to 0.76 0.29 to 0.69 Standard clearance 0.050 to 0.230 0.300 to 0.480 0.050 to 0.230 0.300 to 0.480 0.045 to 0.011 0.049 to 0.021 Clearance limit 0.25 0.53 0.25 0.53 Replace Remedy
2 3 4 5 6
Clearance between the FL, R shaft and bearing (F) Clearance between the FL, R shaft and bearing (R) Separator plate
Standard size 7 Thickness Distortion 8 9 10 11 12 13 Friction plate Thickness Distortion 1.7 2.2 1,010 N {103 kg} 3 3
Repair limit 1.6 0.15 1.9 0.25 859 N {87.6 kg} 2.7 2.7
Load of wave spring (height: 2.2 mm) FL clutch thrust washer thickness R clutch thrust washer thickness FL gear end play R gear end play
10-32
(4)
GD555, 655, 675-3C
TRANSMISSION
FH and 1st clutches
Unit: mm
No. Check item Std. size 1 Clearance between piston and shaft (FH) Inside Outside Clearance between piston and shaft (1st) Inside Outside 96.73 145 96.73 164.93 55 60 Criteria Tolerance Shaft 0 0.050 0.300 0.350 0 0.050 0.200 0.250 +0.034 +0.021 +0.034 +0.021 Hole +0.180 +0.050 +0.130 0 +0.180 +0.050 +0.130 0 0 0.015 0 0.015 Tolerance 0. 05 0.1 0.08 0.1 101 N {10.3 kg} 0.1 0.1 0.39 to 0.79 0.26 to 0.74 Standard clearance 0.050 to 0.230 0.300 to 0.480 0.050 to 0.230 0.200 to 0.380 0.049 to 0.021 0.049 to 0.021 Clearance limit 0.25 0.53 0.25 0.42 Replace Remedy
2 3 4 5 6
Clearance between the FH, 1st shaft and bearing (F) Clearance between the FH, 1st shaft and bearing (R) Separator plate
Repair limit 1.6 0.15 1.9 0.25 859 N {87.6 kg} 2.7 2.7
Load of wave spring (height: 2.2 mm) FH clutch thrust washer thickness 1st clutch thrust washer thickness FH gear end play 1st gear end play
GD555, 655, 675-3C
10-33
(4)
TRANSMISSION
2nd and 3rd clutches
Unit: mm
No. Check item Std. size 1 Clearance between piston and shaft (3rd) Inside Outside Clearance between piston and shaft (2nd) Inside Outside 96.73 164.93 96.73 164.93 65 60 Criteria Tolerance Shaft 0 0.050 0.200 0.250 0 0.050 0.200 0.250 +0.030 +0.011 +0.054 +0.044 Hole +0.180 +0.050 +0.130 0 +0.180 +0.050 +0.130 0 0 0.015 0 0.015 Tolerance 0. 05 0.1 0.08 0.1 101 N {10.3 kg} 0.1 0.1 0.38 to 0.82 0.35 to 0.85 Standard clearance 0.050 to 0.230 0.200 to 0.380 0.050 to 0.230 0.200 to 0.380 0.045 to 0.011 0.069 to 0.044 Clearance limit 0.25 0.42 0.25 0.42 Replace Remedy
2 3 4 5 6
Clearance between 2nd, 3rd shaft and bearing (F) Clearance between 2nd, 3rd shaft and bearing (R) Separator plate
Repair limit 1.6 0.15 1.9 0.25 859 N {87.6 kg} 2.7 2.7
Load of wave spring (height: 2.2 mm) 3rd clutch thrust washer thickness 2nd clutch thrust washer thickness 3rd gear end play 2nd gear end play
10-34
(4)
GD555, 655, 675-3C
TRANSMISSION
4th clutches
Unit: mm
No. Check item Std. size 1 Clearance between piston and cylinder (4th) Inside Outside Clearance between 4th shaft and bearing (F) Clearance between 4th shaft and bearing (R) Separator plate 96.73 164.93 65 75 Criteria Tolerance Shaft 0 0.050 0.200 0.250 +0.030 +0.011 +0.030 +0.011 Hole +0.180 +0.050 +0.130 0 0 0.015 0 0.015 Tolerance 0.05 0.01 0.08 0.1 101 N {10.3 kg} 0.1 +0.030 0 +0.076 0 0.05 0 0.10 0.30 to 0.70 mm Standard clearance 0.050 to 0.230 0.200 to 0.380 0.045 to 0.011 0.045 to 0.011 Clearance limit 0.25 0.42 Remedy
2 3 4
Standard size 5 Thickness Distortion 6 7 8 Friction plate Thickness Distortion 1.7 2.2 1010 N {103 kg} 3 70 3.2 3.1 2.29
Repair limit 1.6 0.15 1.9 0.25 859 N {87.6 kg} 2.7 70.1 3.5 2.8 2.1 Replace
Load of wave spring (height: 2.2 mm) Thickness of 4th clutch thrust washer Inside diameter of cylinder seal ring sliding portion
4th shaft seal ring groove width 4th shaft seal ring wear Width Thickness
10
4th cylinder idler gear end play
GD555, 655, 675-3C
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).
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).
GD555, 655, 675-3C
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).
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).
10-38
(4)
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).
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).
GD555, 655, 675-3C
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).
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).
10-40
(4)
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).
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).
GD555, 655, 675-3C
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).
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).
GD555, 655, 675-3C
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 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 F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 N Q Q Q Q Q Q Q Q Q Q Q Q Q Q FL Q Q FH R 1 Q Q Q Q Q Q Q Q 2 3 4
1. 2. 3. 4. 5. 6. 7. 8. 9.
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
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
GD555, 655, 675-3C
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. Main relief pressure Torque converter inlet port pressure 50001 51000 2.37 MPa {24.2 kg/cm2} 0.91 MPa {9.31 kg/cm2} 51001 and up 2.47 MPa {25.2 kg/cm2} 0.91 MPa {9.31 kg/cm2}
10-52
(4)
GD555, 655, 675-3C
MAIN RELIEF VALVE
Unit: mm
No. Check item Std. size 28 Clearance between torque converter relief valve and valve body Criteria Tolerance Shaft 0.035 0.045 0.035 0.045 Standard size 9 Main relief valve spring (Outer) Free length 108 10 11 Main relief valve spring (Inner) Torque converter relief valve spring 108 50 Installed length 82.5 82.5 42 Installed load 226 N {23.1 kg} 290 N {29.6 kg} 153.0 N {15.6 kg} Hole +0.013 0 +0.013 0 Standard clearance 0.035 to 0.058 0.035 to 0.058 Clearance limit 0.08 Remedy
Clearance between main relief valve and valve body
22
0.08
Repair limit Free length 104.8 104.8 48.5 Permissible load 224.6 N {22.9 kg} 287.3 N {29.3 kg} 145.1 N {14.8 kg}
Replace
GD555, 655, 675-3C
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. 1 Check item Side clearance Clearance between inside diameter of plain bearing and outside of diameter of gear shaft Depth for knocking in pin Rotating torque of spline shaft Discharge amount Oil: EO10-CD Oil temperature: 45 55C Rotating speed 2300 rpm Standard clearance 0.13 to 0.18 Criteria Clearance limit 0.22 Remedy
0.067 to 0.125
0.20 Replace
Standard size 3 12
Tolerance 0 0.5
2.9 to 6.9 Nm {0.3 to 0.7 kgm} Delivery pressure 15.2 MPa {155 kg/cm2} Standard delivery amount 137 l/min Standard amount limit 124 l/min
GD555, 655, 675-3C
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. Check item Model 1 Side clearance SAR(2)63 SBR(1)10 Clearance between inside diameter of plain bearing and outside of diameter of gear shaft SAR(2)63 SBR(1)10 Model 3 Depth for knocking in pin SAR(2)63 SBR(1)10 4 Rotating torque of spline shaft Criteria Standard clearance 0.13 to 0.18 0.10 to 0.15 0.067 to 0.125 0.064 to 0.119 Standard size 12 10 Tolerance 0 0.5 Clearance limit 0.22 0.19 0.20 0.20 Repair limit Replace Remedy
4.9 to 11.8 Nm {0.5 to 1.2 kgm} Rotating speed (rpm) 2300 Delivery pressure [MPa {kg/cm2}] 15.2 {155} 20.6 {210} Standard delivery amount (l/min) 137 20 Delivery amount limit (l/min) 124 19
Discharge amount Oil: EO10-CD Oil temperature: 45 55C
Model
SAR(2)63 SBR(1)10
10-56
(4)
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)
6. 7. 8. 9. 10.
Shaft Sprocket (12 teeth) Breather Drain plug Oil filler tube
10-58
(4)
GD555, 655, 675-3C
FINAL DRIVE
Unit: mm
No. 11 Check item Preload of bevel pinion bearing Preload of bevel gear bearing Backlash between bevel pinion and bevel gear Criteria 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) Standard size 0.25 to 0.33 Remedy
12
Adjust
13
GD555, 655, 675-3C
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. 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)
10-60
(4)
GD555, 655, 675-3C
FINAL DRIVE
Unit: mm
No. 19 20 21
Check item
Preload of bevel pinion bearing Preload of bevel gear bearing Backlash between bevel pinion and bevel gear
Criteria 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} Standard size 0.25 to 0.33
Remedy
Adjust
GD555, 655, 675-3C
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 operators 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. 8 9
Check Item Hub bearing preload Extension of chain (10 links)
Criteria Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Size 317.5 Repair limit 322.26
Remedy Adjust Replace
10-64
(4)
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. 8 9
Check Item Hub bearing preload Extension of chain (10 links)
Criteria Turning torque: 11 to 16 Nm {1.15 to 1.65 kgm} Size 508.0 Repair limit 515.62
Remedy Adjust Replace
GD555, 655, 675-3C
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
5. Hydraulic tank 6. Hydraulic pump 7. Steering cylinder
GD555, 655, 675-3C
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
8. 9. 10. 11. 12.
Drive shaft Sleeve Spool Center pin Center spring
GD555, 655, 675-3C
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.
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.
10-72
(4)
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

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
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
10-78
(4)
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
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
: 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)
GD555, 655, 675-3C
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

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 : From priority valve : From priority valve : From priority valve : From priority valve : From priority valve GD555, 655, 675-3C
10-92
(8)
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
Specifications: Toe-in: 5 mm Camber: 0
10-94
(4)
GD555, 655, 675-3C
FRONT AXLE
Unit: mm
No. Check item Standard size 7 Clearance between center pin and bushing 55 Criteria Tolerance Shaft 0.030 0.076 0.025 0.064 0.025 0.064 0.025 0.064 0.025 0.064 0.060 0.090 Hole +0.197 +0.137 +0.142 +0.080 +0.142 +0.080 +0.161 +0.118 +0.142 +0.080 +0.020 +0.020 Standard clearance 0.167 to 0.273 0.105 to 0.206 0.105 to 0.206 0.143 to 0.225 0.105 to 0.206 0.060 to 0.110 Clearance limit 3.0 2.0 2.0 0.6 2.0 1.0 Replace bushing Remedy
Clearance between king pin and bushing Clearance between axle end pin and bushing
GD555 GD655 GD675 GD555 GD655 GD675
40 45 40 45 55
10
Clearance between ball joint and bushing Preload of hub bearing GD555 GD655 GD675 GD555 GD655 GD675
Start to rotate: 147 to 196 Nm {15 to 20 kgm} Start to rotate: 78.5 to 117.7 Nm {8 to 12 kgm} 314 to 608 Nm {32 to 62 kgm} 490 to 608 Nm {50 to 62 kgm} Adjust
11
12
Hub nut tightening torque
GD555, 655, 675-3C
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. 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.
10-96
(4)
GD555, 655, 675-3C
FRONT AXLE
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
10-97
(4)
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)
5. 6. 7. 8.
Stop lamp switch Brake valve Accumulator pressure governor valve Priority valve
10-100
(8)
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. Check item Standard size 5 Clearance between roller and pin Outside diameter of roller Size 6 30 Criteria Tolerance Shaft 0.025 0.075 0.025 0.075 Hole +0.013 +0.013 +0.013 +0.013 Standard clearance 0.175 to 0.025 0.175 to 0.025 Clearance limit 0.25 0.25 Remedy
Clearance between pedal mounting hole and bracket
Tolerance 0 0.5 Standard size
Repair limit 29.2 Repair limit
Control spring
Free length 54.5
Installed height 49.7 58 16.5 19.5
Installed load 80 N {8.1 kg} 60.8 N {6.2 kg} 17.7 N {1.8 kg} 16.7 N {1.7 kg}
Free length 33.4 28.7 78 16.2 28
Permissible load
Replace
8 9 10 11
Control spring Return spring Spring Return spring
29.1 86.2 17 31.5
GD555, 655, 675-3C
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. 3 4 5 Check item Disc thickness Plate thickness Total thickness of disc and plate Size 3.8 0.1 2.3 0.08 26.7 0.8 Standard size 6 Return spring Free length 76.5 Installed height 60.5 Installed load 75.0 Criteria Repair limit 3.3 0.1 24.7 0.8 Replace Repair limit Installed load 654 N {66.7 kg} Remedy
10-106
(4)
GD555, 655, 675-3C
SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder 2. Check valve 3. Piston A: Inlet port B: Outlet port
Specifications: Piston actuation pressure: 0.01 0.01 MPa {0.1 0.1 kg/cm2} Check valve cracking pressure: 0.93 0.05 MPa {9.5 0.5 kg/cm2} Check valve closing pressure: 0.6 0.05 MPa {6.0 0.5 kg/cm2}
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.
Check item Standard size
Criteria Tolerance Shaft 0.030 0.076 Standard size Hole +0.074 +0.074 Standard clearance 0.030 to 0.150 Clearance limit 0.25
Remedy
Clearance between body and piston
Repair limit Installed load 43.2 N {4.4 kg} 66.7 N {6.8 kg} Free length Permissible load Replace
Slack adjuster spring
Free length 198
Installed height 38 33
Spring
38.8
GD555, 655, 675-3C
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 5C): 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
Check item Disc thinkness Standard size 10.4 12.5
Criteria Repair limit 9.4 9.5 (Remaining thickness when pad groove has disappeared)
Remedy
Replace
Pad thickness
GD555, 655, 675-3C
10-111
(7)
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
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.
10-112
(8)
GD555, 655, 675-3C
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)
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
10-113
(8)
WORK EQUIPMENT HYDRAULIC PIPING DRAWING

MAIN PIPING (1/2)
Serial No.: 50001 51000
1. Priority ACC governer valve
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GD555, 655, 675-3C
MAIN PIPING (2/2)
1. Shut-off valve 2. Hydraulic tank 3. Hydraulic pump
GD555, 655, 675-3C
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MAIN PIPING (1/2)

1. 2. 3. 4.
Main control valve (left) Main control valve (right) Hydraulic tank Hydraulic pump
5. LS pressure reducing valve 6. Priority valve 7. Accumulator pressure governor valve
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MAIN PIPING (2/2)
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HIGH PRESSURE PIPING (1/3)

Left side
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Right side 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Pilot check valve drawbar shift Pilot check valve leaning Pilot check valve articulate Pilot check valve right blade lift Main control valve right Articulate cylinder Main control valve Pilot check valve left blade lift Pilot check valve blade tip Blade lift cylinder
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1. Swivel joint 2. Drawbar side-shift cylinder 3. Blade tilt cylinder
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LIFTER LOCK PIPING

Serial No.: 50001 51000
1. Parking and bank control valve
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1. Parking and bank control valve 2. Bank pin 3. Lifter bracket
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.
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BANK PIN
1. Pin 2. Piston 3. Cover
4. Shaft 5. Case 6. Bushing
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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
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.
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HYDRAULIC PUMP
1. 2. 3. 4. 5.
Shaft Cradle Case Rocker cam Shoe
6. 7. 8. 9. 10.
Piston Cylinder block Valve plate Spring Servo piston
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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.
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).
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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.
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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).
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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 PC valve 4. Piston 5. Spring 6. 7. 8. 9. 10. 11. Seat Spring Piston Sleeve Piston Plug LS valve 12. Plug 13. Sleeve 14. Spring 15. Piston
Servo piston 1. Servo piston 2. Lever 3. Spring
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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.
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HYDRAULIC PUMP
Operation 1. When control valve is at HOLD position
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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 ( ).
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HYDRAULIC PUMP
2. When opening area of control valve is maximum (lever operated fully)
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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.
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HYDRAULIC PUMP
3. When opening area of control valve is small (small movement of lever)
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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.
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4. When pump flow is amount demanded by control valve
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HYDRAULIC PUMP
PC VALVE
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 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. 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.
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HYDRAULIC PUMP
Operation 1. When actuator load is large (pump discharge pressure PP is high)
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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.
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HYDRAULIC PUMP
2. When actuator load becomes smaller (pump discharge pressure PP drops)
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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.
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3. Action of spring
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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.
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HYDRAULIC PUMP
HYDRAULIC PUMP
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
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.
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HYDRAULIC PUMP
1. 2. 3. 4. 5.
Shaft Cradle Case Rocker cam Shoe
6. 7. 8. 9. 10.
Piston Cylinder block Valve plate Spring Servo piston
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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.
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).
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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.
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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.
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HYDRAULIC PUMP
PC VALVE, LS VALVE, SERVO PISTON
PA PA2 PA3 PLS
: Pump discharge pressure : LS pump pressure inlet : Drain : LS pressure inlet 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
Servo piston 1. Servo piston 2. Lever 3. Spring
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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 E PLS and pump discharge amount Q changes as shown in the figure on the right.
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Operation 1. When control valve is at HOLD position
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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).
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HYDRAULIC PUMP
2. When opening area of control valve is maximum (lever operated fully)
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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 E PLS 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.
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3. When opening area of control valve is small (small movement of lever)
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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.
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4. When pump flow is amount demanded by control valve
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HYDRAULIC PUMP
PC VALVE
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. 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.
GD555, 655, 675-3C
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
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
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
GD555, 655, 675-3C
10-169
(4)
MAIN CONTROL VALVE
10-170
(4)
GD555, 655, 675-3C
MAIN CONTROL VALVE
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 Standard size 16 Spool return spring Free length x OD 56.27 x 20.1 17 18 19 20 Spool return spring (circle) Pressure compensation valve spring (R) Pressure compensation valve spring (F) Unload valve spring 87.7 x 19.7 23 x 8.4 15.4 x 6 35.25 x 19 Installed length 25.4 25.4 15 8 20.5 Installed load 34.8 N {3.55 kg} 34.8 N {3.55 kg} 6.9 N {0.7 kg} 7.45 N {0.76 kg} 137 N {14 kg} Criteria Repair limit Free length Installed load 27.9 N {2.84 kg} 27.9 N {2.84 kg} 5.52 N {0.56 kg} 5.98 N {0.61 kg} 110 N {11.2 kg} Replace spring if damaged or deformed Remedy
GD555, 655, 675-3C
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
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
GD555, 655, 675-3C
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 Standard size 15 Spool return spring Free length x OD 56.27 x 20.1 16 17 Pressure compensation valve spring (R) Pressure compensation valve spring (F) 23 x 8.4 15.4 x 6 Installed length 25.4 15 8 Installed load 34.8 N {3.55 kg} 6.9 N {0.7 kg} 7.45 N {0.76 kg} Criteria Repair limit Free length Installed load 27.8 N {2.84 kg} 5.52 N {0.56 kg} 5.98 N {0.61 kg} Replace spring if damaged or deformed Remedy
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
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
GD555, 655, 675-3C
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.
Criteria Repair limit Installed load 34.8 N {3.55 kg} 34.8 N {3.55 kg} 6.9 N {0.7 kg} 7.45 N {0.76 kg} 137 N {14 kg} Free length Installed load 27.9 N {2.84 kg} 27.9 N {2.84 kg} 5.52 N {0.56 kg} 5.98 N {0.61 kg} 110 N {11.2 kg}
Remedy
19
Spool return spring
Free length x OD 56.27 x 20.1
Installed length 25.4 25.4 15 8 20.5
20 21 22 23
Spool return spring (circle) Pressure compensation valve spring (R) Pressure compensation valve spring (F) Unload valve spring
87.7 x 19.7 23 x 8.4 15.4 x 6 35.25 x 19
Replace spring if damaged or deformed
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
A2 B2 A3 B3 A4 B4 A5 B5
GD555, 655, 675-3C
10-181
(4)
MAIN CONTROL VALVE

GD555-3C
10-182
(4)
GD555, 655, 675-3C
MAIN CONTROL VALVE

GD555-3C
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.
Remedy
19
Spool return spring
20 21 22 23
Spool return spring (circle) Pressure compensation valve spring (R) Pressure compensation valve spring (F) Unload valve spring
87.7 x 19.7 23 x 8.4 15.4 x 6 35.25 x 19
GD555, 655, 675-3C
10-183
(4)
MAIN CONTROL VALVE

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
A2 B2 A3 B3 A4 B4 A5 B5
GD555, 655, 675-3C
10-185
(4)
MAIN CONTROL VALVE

GD655, GD675-3C
10-186
(4)
GD555, 655, 675-3C
MAIN CONTROL VALVE

GD655, GD675-3C
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.
Remedy
20
Spool return spring
21 22 23 24
Spool return spring Pressure compensation valve spring (R) Pressure compensation valve spring (F) Unload valve spring
87.7 x 19.7 23 x 8.4 15.4 x 6 35.25 x 19
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. 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.
10-188
(8)
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 ( E PLS) = 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
5. Safety-suction valve 6. LS pressure reducing valve
GD555, 655, 675-3C
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}.
PP PLS T A B
: Pump circuit : LS circuit : Tank circuit : To valves : To pump LS valve
10-192
(8)
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 E PLS becomes 2.9 MPa {30 kg/cm2}.
PP PLS T A B
GD555, 655, 675-3C
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.
PP PLS T A B
10-194
(8)
GD555, 655, 675-3C
CLSS
INTRODUCTION OF LS PRESSURE
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 to the same pressure as actuation circuit pressure A, and sends it to the LS circuit PLS.
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).
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.
GD555, 655, 675-3C
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.
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.
10-196
(8)
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.
PP PLS T A B
GD555, 655, 675-3C
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. 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.
10-198
(8)
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 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.
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
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}. 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
10-202
(4)
HYDRAULIC SYSTEM
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.
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.
GD555, 655, 675-3C
10-203
(4)
HYDRAULIC SYSTEM
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.
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.
10-204
(4)
GD555, 655, 675-3C
HYDRAULIC SYSTEM

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}.
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.
GD555, 655, 675-3C
10-205
(8)
HYDRAULIC SYSTEM
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.
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.
10-206
(8)
GD555, 655, 675-3C
HYDRAULIC SYSTEM
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.
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.
GD555, 655, 675-3C
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
a. b. c. d.
Blade tilt cylinder head Blade tilt cylinder bottom Blade shift cylinder head Blade shift cylinder bottom
GD555, 655, 675-3C
10-209
(4)
SWIVEL JOINT
1. 2. 3. 4. 5.
Plug Plate Cover Shaft Rotor
a. b. c. d.
Blade tilt cylinder head Blade tilt cylinder bottom Blade shift cylinder head Blade shift cylinder bottom
10-210
(4)
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

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
A B C D
: From main control valve : From main control valve : To cylinder head : To cylinder bottom
GD555, 655, 675-3C
10-217
(4)
FOR BLADE LIFT (RIGHT)
1. 2. 3. 4. 5.
Body Check valve Piston Piston Check valve
A B C D
: From main control valve : From main control valve : To cylinder head : To cylinder bottom
10-218
(4)
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 5C)
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
BLADE FLOAT DEVICE
1. 2. 3. 4. 5. 6.
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 Standard size Steering Blade lift Blade side shift Clearance between piston rod and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper 35 50 50 45 35 50 40 50 50 Criteria Tolerance Shaft 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 Hole +0.132 +0.006 +0.164 +0.007 +0.164 +0.007 +0.152 +0.007 +0.132 +0.006 +0.164 +0.007 +0.132 +0.006 +0.164 +0.007 +0.164 +0.007 Standard clearance 0.031 to 0.219 0.032 to 0.251 0.032 to 0.251 0.032 to 0.239 0.031 to 0.219 0.032 to 0.251 0.031 to 0.219 0.032 to 0.251 0.032 to 0.251 Clearance limit 0.519 0.551 0.551 0.539 0.519 0.551 0.519 0.551 0.551 Remedy
Replace bushing
10-226
(4)
GD555, 655, 675-3C
HYDRAULIC CYLINDER
Unit: mm
No. Check item Standard size Steering Blade lift Blade side shift Clearance between piston rod support and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Steering Blade lift Blade side shift Clearance between cylinder bottom (yoke, support ball joint, support) and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper 55 80 40 80 45 50 40 50 55 35 45 40 80 40 50 40 50 60 Criteria Tolerance Shaft 0.06 0.09 0.05 0.15 0.025 0.064 0.05 0.15 0.025 0.064 0.025 0.064 0.025 0.064 0.025 0.064 0.030 0.076 0.025 0.064 0.080 0.142 0.025 0.064 0.05 0.15 0.025 0.064 0.025 0.064 0.025 0.064 0.025 0.064 0.100 0.174 Hole +0.02 +0.02 +0.1 +0.1 +0.142 +0.080 +0.1 +0.1 +0.142 +0.080 +0.142 +0.080 0.012 0.012 +0.142 +0.080 +0.174 +0.100 0.012 0.012 +0.062 +0.062 +0.142 +0.080 +0.10 +0.10 +0.142 +0.080 +0.142 +0.080 0.012 0.012 +0.142 +0.080 +0.174 +0.100 Standard clearance 0.06 to 0.11 0.05 to 0.25 0.105 to 0.206 0.05 to 0.25 0.104 to 0.206 0.104 to 0.206 0.013 to 0.064 0.105 to 0.206 0.13 to 0.25 0.013 to 0.064 0.080 to 0.204 0.105 to 0.206 0.05 to 0.25 0.105 to 0.206 0.105 to 0.206 0.013 to 0.064 0.105 to 0.206 0.200 to 0.348 Clearance limit 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Replace bushing Remedy
GD555, 655, 675-3C
10-227
(4)
HYDRAULIC CYLINDER
Unit: mm
No. Check item Steering Blade lift Blade side shift Piston nut tightening torque Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Steering Blade lift Blade side shift Cylinder head tightening torque Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Criteria 245 24.5 Nm {25 2.5 kgm} (width across flats: 30) 647 64.7 Nm {66 6.6 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 412 41.2 Nm {42 4.2 kgm} (width across flats: 36) 1420 142 Nm {145 14.5 kgm} (width across flats: 55) 647 64.7 Nm {66 6.6 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 1080 108 Nm {110 11 kgm} (width across flats: 50) 392 39.2 Nm {40 4 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 539 53.9 Nm {55 5.5 kgm} 677 67.7 Nm {69 6.9 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 785 78.5 Nm {80 8 kgm} Retighten Remedy
10-228
(4)
GD555, 655, 675-3C
HYDRAULIC CYLINDER
GD655, 675-3C
Unit: mm
No. Check item Standard size Steering Blade lift Blade side shift Clearance between piston rod and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper 35 50 50 45 40 50 40 50 55 Criteria Tolerance Shaft 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.025 0.087 0.030 0.104 Hole +0.132 +0.006 +0.164 +0.007 +0.164 +0.007 +0.152 +0.007 +0.132 +0.006 +0.164 +0.007 +0.132 +0.006 +0.164 +0.007 +0.163 +0.006 Standard clearance 0.031 to 0.219 0.032 to 0.251 0.032 to 0.251 0.032 to 0.239 0.031 to 0.219 0.032 to 0.251 0.031 to 0.219 0.032 to 0.251 0.036 to 0.267 Clearance limit 0.519 0.551 0.551 0.539 0.519 0.551 0.519 0.551 0.567 Remedy
Replace bushing
GD555, 655, 675-3C
10-229
(4)
HYDRAULIC CYLINDER
Unit: mm
No. Check item Standard size Steering Blade lift Blade side shift Clearance between piston rod support and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Steering Blade lift Blade side shift Clearance between cylinder bottom (yoke, support ball joint, support) and bushing Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper 55 80 40 80 50 50 40 50 60 35 45 40 80 45 50 40 50 60 Criteria Tolerance Shaft 0.06 0.09 0.05 0.15 0.025 0.064 0.05 0.15 0.025 0.064 0.025 0.064 0.025 0.064 0.025 0.064 0.030 0.076 0.025 0.064 0.080 0.142 0.025 0.064 0.05 0.15 0.025 0.064 0.025 0.064 0.025 0.064 0.025 0.064 0.100 0.174 Hole +0.02 +0.02 +0.1 +0.1 +0.142 +0.080 +0.1 +0.1 +0.142 +0.080 +0.142 +0.080 0.012 0.012 +0.142 +0.080 +0.174 +0.100 0.012 0.012 +0.062 +0.062 +0.142 +0.080 +0.10 +0.10 +0.142 +0.080 +0.142 +0.080 0.012 0.012 +0.142 +0.080 +0.174 +0.100 Standard clearance 0.06 to 0.11 0.05 to 0.25 0.105 to 0.206 0.05 to 0.25 0.104 to 0.206 0.104 to 0.206 0.013 to 0.064 0.105 to 0.206 0.13 to 0.25 0.013 to 0.064 0.080 to 0.204 0.105 to 0.206 0.05 to 0.25 0.105 to 0.206 0.105 to 0.206 0.013 to 0.064 0.105 to 0.206 0.200 to 0.348 Clearance limit 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Replace bushing Remedy
10-230
(4)
GD555, 655, 675-3C
HYDRAULIC CYLINDER
Unit: mm
No. Check item Steering Blade lift Blade side shift Piston nut tightening torque Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Steering Blade lift Blade side shift Cylinder head tightening torque Drawbar shift Leaning Articulate Blade tilt Scarifier Ripper Criteria 245 24.5 Nm {25 2.5 kgm} (width across flats: 30) 647 64.7 Nm {66 6.6 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 618 61.8 Nm {63 6.3 kgm} (width across flats: 41) 1420 142 Nm {145 14.5 kgm} (width across flats: 55) 647 64.7 Nm {66 6.6 kgm} (width across flats: 41) 785 78.5 Nm {80 8 kgm} (width across flats: 46) 1770 77 Nm {180 18 kgm} (width across flats: 60) 392 39.2 Nm {40 4 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 588 58.8 Nm {60 6 kgm} 677 67.7 Nm {69 6.9 kgm} 588 58.8 Nm {60 6 kgm} 677 67.7 Nm {69 6.9 kgm} 981 98.1 Nm {100 10 kgm} Retighten Remedy
GD555, 655, 675-3C
10-231
(4)
CIRCLE, DRAWBAR
CIRCLE, DRAWBAR
10-232
(4)
GD555, 655, 675-3C
CIRCLE, DRAWBAR
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
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.
Check item Standard size 150 Clearance between yoke and bushing GD555 GD655 GD675 75 75
Criteria Tolerance Shaft 0.050 0.100 0.030 0.076 0.030 0.076 Hole +0.100 +0.100 +0.174 +0.100 +0.220 +0.160 Standard clearance 0.050 to 0.200 0.130 to 0.250 0.190 to 0.296 Clearance limit 2.0 1.0 to 2.0 Clearance limit 0.6 0.6
Remedy
21
Wear of drawbar ball joint end
Adjust or replace
22
Replace bushing Replace yoke or bushing Adjust or replace
23
Axial clearance of yoke Clearance between circle and drawbar
Standard clearance 0.8 to 1.3 0 to 3.0
24
GD555, 655, 675-3C
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.
1. 2. 3. 4. 5. 6.
Parking, bank control valve Lifter Bank pin Piston Bushing Case
10-234
(4)
GD555, 655, 675-3C
BLADE
BLADE
1. Adjuster 2. Blade tilt cylinder
3. Drawbar side-shift cylinder 4. Blade side-shift cylinder GD555, 655, 675-3C
10-236
(4)
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. 5 6 7a 7b 8a 8b Check item Wear of cutting edge Wear of side edge Wear of blade rail Wear of blade rail guide Height Thickness Height Width of groove Standard size From blade holder: 32 From blade holder: 48 368 25 8 25 Criteria Repair limit From blade holder: 10 From blade holder: 25 364 21 5 33 Replace Remedy
GD555, 655, 675-3C
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. Check item Std. Size 75 8 9 10 11 12 Clearance between worm wheel shaft and bushing Backlash between worm and worm wheel Cleaarance between pinion gear and wear plate Pinion gear wear Wormshaft bearing preload 75 Criteria Tolerance Shaft +0.291 +0.077 +0.035 +0.005 Hole +0.057 +0.010 +0.057 +0.010 Standard clearance 0.281 to 0.02 0.052 to 0.025 Clearance limit 2.0 0.6 Repair limit 20 Clearance limit 0.4 0.4 Replace Adjust Replace Adjust Replace bushing Remedy
Clearance between worm wheel shaft and bushing
Standard clearance 0.3 to 0.4 0.1 to 0.5 Standard size 25
Starting torque: 2.9 to 7.8 Nm (0.3 to 0.8 kgm) when worm wheel is not meshed
GD555, 655, 675-3C
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
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).
10-240
(4)
GD555, 655, 675-3C
SCARIFIER
SCARIFIER
10-242
(4)
GD555, 655, 675-3C
SCARIFIER
1. 2. 3. 4.
Lift arm Scarifier cylinder Scarifier body Wedge Unit: mm
No. 5 6
Check item Tooth wear Point tooth wear Standard size 450 450
Criteria Repair limit 330 407
Remedy Replace tooth Replace point
GD555, 655, 675-3C
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 rippers heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier. Unit: mm
No.
Check item Std. size 50
Criteria Tolerance Shaft 0.025 0.050 0.025 0.055 0.100 0.174 Standard size 198 Hole +0.142 +0.080 +0.046 +0.046 +0.174 +0.100 Standard clearance 0.105 to 0.192 0.025 to 0.101 0.200 to 0.348 Repair limit 123 Clearance limit 0.5 0.5 0.5
Remedy
Clearance between pin and bushing
5 6 7
Clearance between pin and bushing Clearance between trunnion and bushing Point wear
60 60
Replace
10-244
(4)
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 rippers heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier. Unit: mm
No.
Check item Std. size 50
Criteria Tolerance Shaft 0.025 0.050 0.030 0.076 0.100 0.174 Standard size 290 Hole +0.142 +0.080 +0.054 +0.054 +0.174 +0.100 Standard clearance 0.105 to 0.292 0.03 to 0.13 0.200 to 0.348 Repair limit 150 Clearance limit 0.5 0.5 0.5
Remedy
Clearance between pin and bushing Clearance between pin and bushing Clearance between trunnion and bushing Point wear
5 6 7
60 60
Replace
GD555, 655, 675-3C
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 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

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.
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.
10-252
(4)
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.
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
10-254
(4)
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.
Clutches used Low Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q High R 1st Q Q Q Q Q Q Q Q 2nd 3rd 4th
ECMV Speed range F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
GD555, 655, 675-3C
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
LEVER POSITION N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 Speed Range N A B B B B B B B B B B A A F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
MODE 2
LEVER POSITION N F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 Speed Range N A A A A A A A A A C C C C C C C C C C A A A A F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4
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 machines 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 F3 F4 F5 F6 F7 F8 High output Standard output ON
Standard output
High output
10-264
(4)
GD555, 655, 675-3C
MONITOR
MONITOR
MONITOR PANEL
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
1. 2. 3. 4. 5. 6. 7. 8. 9.
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
GD555, 655, 675-3C
10-265
(4)
MONITOR
MONITOR ITEMS DISPLAY

Category Symbol Item indicated Indicated range Description
Differential oil temperature
More than 120 C
Torque converter oil temperature
More than 110 C
Brake oil pressure Caution Monitor transmission electrical circuit
Max. 4.17 MPa {42.5 kg/cm2} Off when normal, lights up when problem detected 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
Lights up when operated
Pilot
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
10-266
(4)
GD555, 655, 675-3C
MONITOR
Category
Symbol
Item indicated
Indicated range
Description Lights up when blade accumulator/float switch is at ACCUMULATOR
Blade accumulator
When operated
Working lamp
When operated
Pilot
AWD
When operated
Lights up when operated
Differential control
When operated
Lift arm lock
When cancelled
Lights up when not locked
Engine water temperature
Displays while starting switch is ON Indicator shows engine water temperature Displays while starting switch is ON Indicator shows angle
Gauges
Articulate
Fuel
Displays while starting switch is ON
Torque converter oil temperature
Displays while starting switch is ON Indicator shows torque converter oil temperature Displays while starting switch is ON Indicator shows vehicle speed Digital display: displays speed range, error code, travel speed
Speedometer
Speedometer
Message center
Message center
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) Resistance (z) 50 0.2 80 10 60 0.2 56.3 5 80 0.2 29.5 2.5 100 0.3 16.5 0.9 106 0.3 14.3 0.5 120 0.3 10 0.3
Function The engine water temperature sensor is installed to the engine cylinder block. As the engine temperature changes, so does the sensors 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) Resistance (z) 50 0.2 80 10 60 0.2 56.3 5 80 0.2 29.5 2.5 100 0.3 16.5 0.9 106 0.3 14.3 0.5 120 0.3 10 0.3
Function The engine water temperature sensor is installed to the engine cylinder block. As the engine temperature changes, so does the sensors 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
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 120C, the switch turns ON. This signal is sent to the transmission controller and is also used to control the transmission.
10-270
(4)
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
Function The articulation sensor is installed to the center of the frame. This sensor uses a variable resistor. The resistors resistance varies according to lever movement. The amount of resistance determines the angle displayed on the gauge, which is located on the monitor panel.
GD555, 655, 675-3C
10-271
(4)
SENSORS
Fuel level gauge sensor
Serial No.: 50001 51000
1. 2. 3. 4.
Connector Variable resistor Gear Float
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 resistors 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.
10-272
(4)
GD555, 655, 675-3C
SENSORS
1. 2. 3. 4.
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
(4)
SENSORS
ACCELERATOR PEDAL POTENTIOMETER
1. 2. 3. 4. 5. 6. 7.
Connector Case Shaft Element Bearing Contact Mold
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.
10-274
(4)
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 FOR ENGINE
Machine model Serial No. Engine Item Measurement condition Unit GD555-3C 50001 51000 Standard machine SA6D102E-1 Standard value Engine speed High idle Low idle Rated speed All speed (intake air temp. 20 C) At rated output Sudden acceleration High idle Intake valve Exhaust valve 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 Fuel injection timing Whole speed range (inside oil pan) Before T.D.C. degrees MPa {kg/cm2} 0.4 {4.1} 0.19 {1.9} Max. 127 12 to 13 mm 14 to 16 Max. 0.27 {2.8} Max. 0.07 {0.7} Max. 127 Max. 11 or Min. 14 Max. 13 or Min. 17 0.4 {4.1} 0.19 {1.9} Max. 127 12.5 to 14.5 12 to 13 14 to 16 Max. 0.27 {2.8} Max. 0.07 {0.7} Max. 127 Max. 11 or Min.14 Max. 13 or Min. 17 kPa {mmH2O} 0.65 {66} 3.3 {337} 0.65 {66} 3.3 {337} rpm 2,200 50 800 50 2,000 0.25 0.51 Permissible value 2,200 50 800 50 2,000 VHP specification machine SA6D102E-1 Standard value 2,200 50 800 50 2,000 385 to 485 130 to 150 {975 to 1,125} Max. 5.5 Max. 1.0 0.25 0.51 Permissible value 2,200 50 800 50 2,000 Max. 6.5 Max. 2.0
Exhaust temperature (turbine inlet temp.) Intake resistance Exhaust gas color Valve clearance (cold) Blowby pressure (SAE 15W-40 oil)
C kPa {mm Hg} Bosch index mm
New belt Deflection when pressed Fan belt with finger force of tension When adjusting approx. 59 N {6 kg}. belt tension
20-2
(4)
GD555, 655, 675-3C
GD555-3C 51001 and up VHP specification machine SAA6D102E-2 Standard value 2,200 50 850 50 2,000 550 to 650 Max. 3.7 {380} Max. 4.5 Max. 1.0 0.25 0.51 Permissible value 2,200 50 850 50 2,000 Max. 6.2 {635} Max. 5.5 Max. 2.0 50001 51000 Standard machine S6D114E-1 Standard value 2,200 50 850 50 1,900 0.3 0.61 Permissible value 2,200 50 850 50 1,900
GD655-3C 51001 and up VHP specification machine SAA6D114E-2 Standard value 2,200 50 800 100 1,900 450 to 550 Max. 3.7 {380} Max. 6.5 Max. 1.0 0.30 0.56 Permissible value 2,200 50 800 100 1,900 Max. 6.2 {635} Max. 8.5 Max. 2.0
VHP specification machine SA6D114E-1 Standard value 2,200 50 850 50 1,900 375 to 475 140 to 160 {1,050 to 1,200} Max. 4.5 Max. 1.0 0.3 0.61 Permissible value 2,200 50 850 50 1,900 Max. 5.5 Max. 2.0
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. 0.15 {1.5} 80 to 110 9.5 to 10.5 12 to 13 14 to 16
Min. 0.25 {2.6} Min. 0.09 {0.9} Max. 120 Max. 11 or Min. 14 Max. 13 or Min. 17
0.4 {4.1} 0.19 {1.97} Max. 127 12 to 13 14 to 16
Max. 0.27 {2.8} Max. 0.07 {0.7} Max. 127 Max. 11 or Min. 14 Max. 13 or Min. 17
0.4 {4.1} 0.16 {1.6} Max. 127 13 to 15 12 to 13 14 to 16
GD555, 655, 675-3C
20-3
(4)
Machine model Serial No. Engine Item Measurement condition Unit
GD675-3C 50001 51000 Standard machine S6D114E-1 Standard value Permissible value 2,200 50 800 50 1,900 VHP specification machine SA6D114E-1 Standard value 2,200 50 800 50 1,900 365 to 465 160 to 180 {1,200 to 1,350} Max. 4.5 Max. 1.0 0.3 0.61 Permissible value 2,200 50 800 50 1,900 Max. 5.5 Max. 2.0
Engine speed
High idle Low idle Rated speed All speed (intake air temp. 20 C) At rated output Sudden acceleration High idle Intake valve Exhaust valve At rated output Coolant temperature: Operating range Coolant temperature: Operating range
rpm
2,200 50 800 50 1,900 0.3 0.61
Exhaust temperature (turbine inlet temp.) Intake resistance Exhaust gas color Valve clearance (cold) Blowby pressure (SAE 15W-40 oil)
C kPa {mm Hg} Bosch index mm
kPa {mmH2O}
2.0 {204}
4.5 {460}
2.0 {204}
4.5 {460}
Oil pressure (SAE 15W-40 oil)
At rated output At low idle
MPa {kg/cm2}
0.4 {4.1} 0.16 {1.6} Max. 127
0.4 {4.1} 0.16 {1.6} Max. 127 13 to 15 12 to 13 14 to 16
Oil temperature Fuel injection timing
Whole speed range (inside oil pan) Before T.D.C. degrees
12 to 13
New belt Deflection when pressed Fan belt with finger force of tension When adjusting approx. 59 N {6 kg}. belt tension
mm 14 to 16
20-4
(4)
GD555, 655, 675-3C
GD675-3C 51001 and up VHP specification machine SAA6D114E-2 Standard value 2,200 50 800 100 1,900 490 to 550 Max. 3.7 {380} Max. 6.5 Max. 1.0 0.30 0.56 Permissible value 2,200 50 800 100 1,900 Max. 6.2 {635} Max. 8.5 Max. 2.0
1.0 {100}
2.0 {200}
GD555, 655, 675-3C
20-5
(4)
STANDARD VALUE TABLE FOR CHASSIS

Category Item Fuel control lever Accelerator pedal Inching pedal NoP N o F1 1o2 2o3 Travel 3o4 4o5 Gearshift lever 5o6 6o7 7o8 N o R1 1o2 2o3 3o4 Fuel control lever Operating effort Accelerator pedal Inching pedal Brake pedal Gearshift lever (including parking brake lever) Inching pedal height (when not operated) Inching pedal height (when operated) Others Inching pedal play 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 rpm Height from floor surface to tip of pedal. mm Measurement conditions Amount of movement at center of lever knob when moved from LOW Amount of up-down movement at tip of pedal Amount of up-down movement at tip of pedal Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Engine speed stopped, travel at tip of lever Max. value at tip of lever to just before end of travel Operating effort at a position 150 mm from center of pedal rotation. Max. value just before end of travel. Operating effort at a position 150 mm from center of pedal rotation. Max. value just before end of travel. Operating effort at a position 150 mm from center of pedal rotation. Measure with wheels fully locked. Measure at center of lever grip. Max. value just before end of travel. N {kg} mm Unit Standard value 216 10 60 10 44 10 35 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 Max. 30 {Max. 3} Max. 90 {Max. 9} 60 to 90 {6 to 9} 275 28 {28.1 2.8} Max. 45 {Max. 4.5} 188 5 104 5 0 1,505 100 1,580 100 1,615 100 1,700 100 1,660 100 1,730 100
Transmission slippage
20-6
(4)
GD555, 655, 675-3C
Category
Standard value Item 1st 2nd 3rd Forward 4th 5th 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 2nd Reverse 3rd 4th Engine stopped: Leaning Measure at the tip of the lever. control lever Measure travel from neutral to end of travel. Engine stopped: Leaning Measure at center of lever control lever grip. Max. value to end of travel Engine stopped: Pedal movement in direction of operation Engine stopped: Measure at the tip of the pedal Hydraulic oil temperature: 45 to 50C When braking from a speed of 32 km/h (20 mph) Travel
Permissible value
Measurement conditions
Unit
GD555-3C 3.3 0.2 4.8 0.3 6.8 0.4 9.8 0.5 14.9 0.8 21.6 1.1
GD655-3C GD675-3C 3.3 0.2 4.7 0.3 6.7 0.4 9.7 0.5 14.6 0.7 21.2 1.1 29.1 1.5 42.1 2.1 4.3 0.2 8.8 0.5
Travel speed
km/h
29.6 1.5 42.9 2.1 4.4 0.2 ( 1) 8.9 0.5 ( 2) 9.0 0.5
( 1) 18.7 1.0 ( 1) 18.1 1.0 ( 2) 19.7 1.0 ( 2) 19.1 1.0 ( 1) 36.1 2.0 ( 1) 35.1 2.0 ( 2) 39.1 2.0 ( 2) 38.4 2.0
mm
22 5
Controls
Operating effort
N {kg}
Max. 24.5 {2.5}
Brake pedal performance
Play
mm
Max. 5
Max. 5
Brake
Travel Brake oil pressure Stopping distance
mm MPa {kg/cm2} m
66 4
+1 3.9 +0.1 0.31 {40 3 }
66 10
+1 3.9 +0.1 0.31 {40 3 }
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)
Category
Standard value Item
Permissible value
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. 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 Engine at low idle when travelling in F1.
Unit
GD555-3C
GD655-3C GD675-3C
Steering wheel play
mm
0 to 10
Steering
Lock-to-lock
5 to 9.5
Steering wheel operating effort
N {kg}
Max. 49 {5}
20-8
(4)
GD555, 655, 675-3C
Category
Item Tire runout
Measurement conditions Put dial gauge in contact with sidewall of both front and rear GD555-3C: 13.00-24-10 PR GD655-3C: 14.00-24-10 PR GD675-3C: 14.00-24-12 PR Flat, paved road surface Angle of knuckle bracket
Unit mm kPa {kg/cm2} degree mm degree
Standard value Max. 7 275 {2.75} 250 {2.50} 275 {2.75} 0 -5 1 21.7 22 5 22 5
Permissible value
Steering
Wheel
Tire inflation pressure Camber Toe-in Leaning angle Blade lift lever (right, left) Blade side shift lever Drawbar shift lever
9.4 1 {93.6 10} 13.4 1 {136.5 10}
Travel
Circle rotation lever Power tilt lever Articulation lever Scarifier lever Ripper lever Blade lift lever (left, right)
Engine stopped: Measure at tip of lever Measure travel from Neutral to end of travel
22 5 mm 22 5 22 5 22 5 22 5 22 5 Max. 24.5 {2.5} Max. 24.5 {2.5} Max. 24.5 {2.5}
Controls
Blade side shift lever Drawbar shift lever Operating effort Circle rotation lever Power tilt lever Articulation lever Scarifier lever Ripper lever Engine stopped: Measure at center of lever grip Max. value to end of travel
N {kg}
Max. 24.5 {2.5} Max. 24.5 {2.5} Max. 24.5 {2.5} Max. 24.5 {2.5} Max. 24.5 {2.5}
Accumulator
Charge cut-in pressure Charge cut-out pressure
Engine at low idle: Hydraulic oil temperature: 40 to 55C
MPa {kg/cm2}
9.4 + 1.0 {93.6 + 10} 13.4 + 0.5 {136.5 + 5}
GD555, 655, 675-3C
20-9
(4)
Category
GD555-3C Item Measurement conditions Unit Std. value 2.7 0.4 Permis. value 4
GD655-3C GD675-3C Std. value 2.7 0.4 Permis. value 4
Blade lifting speed
Engine full throttle: Raise Oil temp. 40 5C Independent op. Make a mark on the cylinLower der rod and operate it 350 mm. Left Right Left Right
Left Right Left Right
2.7 0.4
2.7 0.4
Work equipment speed
Blade sideshift speed with circle movement (drawbar) Blade sideshift speed compared to circle (blade shift)
Engine full throttle: Oil temp. 40 5C. Set height of bottom edge of blade to 100 mm with blade at center as standard condition Engine full throttle: Oil temp. 40 5C Set height of bottom edge of blade to 100 mm with blade at center as standard condition Engine full throttle: Oil temp. 40 5C Time taken to turn 90 Engine full throttle: Raise Oil temp. 40 5C Make a mark on the cylinder rod and operate it the distance shown below: GD555: 200 mm GD655: 180 mm Lower GD675: 180 mm Engine stopped: Oil temp. 40 5C Downward movement of cylinder when blade is suspended at right angle Engine stopped: Oil temp. 40 5C Downward movement of cylinder when scarifier is suspended Engine stopped: Oil temp. 40 5C Downward movement of cylinder after blade is lowered to ground and used to raise front wheels from ground Engine stopped: Oil temp. 40 5C Downward movement of cylinder after scarifier is lowered to ground and used to raise front wheels from ground mm/ 10 min.
6.9 0.8 7.5 0.8 9.1 1.0 Seconds 9.1 1.0
9 10 11 11
6.9 0.8 7.5 0.8 9.1 1.0 9.1 1.0
9 10 11 11
Blade rotation speed
8.8 1.3
12
8.8 1.3 ( 1) 1.8 0.3 ( 2) 1.1 0.2 ( 1) 1.8 0.3 ( 2) 1.5 0.3
12
3 2 3 3
1.6 0.3
Work equipment
Scarifier lifting speed
1.6 0.3
Blade drift
10
20
10
20
Scarifier drift Hydraulic drift
10
20
10
20
Chassis drift when pushed up with blade
20
35
20
35
Chassis drift when pushed up with scarifier
20
35
20
35
20-10
(4)
GD555, 655, 675-3C
Category
GD555-3C Item Measurement conditions Unit Std. value 20.6 1 {210 10} Permis. value
GD655-3C GD675-3C Std. value 20.6 1 {210 10} 15.1 0.4 {154 4} 76 Permis. value
Hydraulic pressure
Work equipment hydraulic pressure
Work Engine full throttle: equip. Oil temperature: 45 to 50C Steer- Operate blade lift cylinder to raise ing Engine at low idle (800 rpm) Work Oil temperature: 45 to 50C equip. Rotate circle Engine full throttle Trans. Oil temperature: 45 to 50C
MPa {kg/cm2} 15.1 0.4 {154 4} 76 l/min. 130 mm Circle: 5 Others: 6
Work equipment
Hydraulic pump discharge amount Spool travel (one side)
130 Circle: 5 Others: 6 Circle: max. 109.8 {11.2} Others: Max. 73.5 {7.5}
Main control valve
Spool operating effort
Engine stopped
N {kg}
Circle: max. 109.8 {11.2} Others: Max. 73.5 {7.5}
GD555, 655, 675-3C
20-11
(4)
Category Main control valve
Item
Spool travel (one side) Spool operating effort
Unit mm
GD555-3C Circle: 5 Others: 6 Circle: Max. 109.8 {11.2} Others: Max. 73.5 {7.5} 2.8 +0.98 {29 + 10} 0.74 0.15 {7.5 1.5}
GD655-3C, GD675-3C Circle: 5 Others: 6 Circle: Max. 109.8 {11.2} Others: Max. 73.5 {7.5} 2.8 + 0.98 {29 + 10} 0.74 0.15 {7.5 1.5} 0.59 0.1 {6 1.0} 2.01 0.15 {20.5 1.5} 2.24 0.1 {22.9 1.0} 2.37 0.1 {24.2 1.0} 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} 2.25 0.2 {23 2.0} 2.25 0.2 {23 2.0} ( 1) GD655-3C STD: 1,615 100 VHP: Base power 1,610 100 High power 1,700 100
Engine stopped
N {kg}
Unload pressure Inlet oil pressure Torque converter Hydraulic pressure Outlet oil pressure Lock-up pressure Main relief pressure Low idle High idle FL R FH 1st 2nd 3rd 4th
Hydraulic oil temperature: 45 to 50C
Oil temperature: 60 to 80C
0.59 0.1 {6 1.0} 2.01 0.15 {20.5 1.5} 2.24 0.1 {22.9 1.0} MPa {kg/cm2} 2.37 0.1 {24.2 1.0} 2.25 0.2 {23 2.0} 2.25 0.2 {23 2.0} 2.25 0.2 {23 2.0}
Oil temperature: 60 to 80C Engine full throttle
Control valve set pressure
Transmission
Oil temperature: 60 to 80C Engine at full throttle
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}
( 1) STD: 1,505 100 Oil temperature: 60 to 80C Engine speed 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
Engine speed at torque converter stall
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) Between T1 (7), (12) - (11), (21) If the condition is as shown in the table below, the condition is normal. Between (4), (12) - chassis 4 to 8V 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 to 30V Measurement condition
1. Turn starting switch OFF 2. Insert the T-adapter. 3. Turn starting switch ON
S-NET
Measure voltage
Transmission control related
VHP select switch
T3B
Measure voltage
If the condition is as shown in the table below, the condition is normal. VHP spec. Without VHP spec. Between (2) and chassis Max. 1V 20 to 30V
Controller
AWD select switch
Measure voltage
If the condition is as shown in the table below, the condition is normal. AWD spec. Without AWD spec. Between (3) and chassis Max. 1V 20 to 30V
Inching select switch T3A Differential lock select switch
If the condition is as shown in the table below, the condition is normal. Measure voltage Inching pedal spec. Without inching pedal spec. Between (20) and chassis 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
Type select switch (spare)
If the condition is as shown in the table below, the condition is normal. T5 Measure voltage Standard spec. Without standard spec. Between (5) and chassis Max. 1V 20 to 30V
GD555, 655, 675-3C
20-13
(4)
System
Component
Connec- Inspection tor No. method
Judgement table If the condition is as shown in the table below, the condition is normal.
Measurement condition
Forward switch
Measure voltage
Gearshift lever at (F1) thru (F8) Gearshift lever at any position except above.
Between (10) and chassis
20 to 30V
Max. 1V
1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
T5
If the condition is as shown in the table below, the condition is normal. Measure voltage Gearshift lever at (R1) thru (R4) Gearshift lever at any position except above. Between (14) and chassis 20 to 30V
Reverse switch
Max. 1V
If the condition is as shown in the table below, the condition is normal. Neutral signal Measure voltage Gearshift lever at Neutral or Park Gearshift lever at any position except above. 20 to 30V Between (8) and chassis
Max. 1V
Controller
T3A
If the condition is as shown in the table below, the condition is normal. Measure voltage Gearshift lever at any position except Neutral or Park Gearshift lever at Neutral or Park Between (18) and chassis 20 to 30V
Drive lever (A)
Max. 1V
If the condition is as shown in the table below, the condition is normal. Drive lever (B) Measure voltage Gearshift lever at (F1), (F5) thru (F7) and (R1) thru (R3) Gearshift lever at any position except above. 20 to 30V Between (7) and chassis Max. 1V 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
T5
If the condition is as shown in the table below, the condition is normal. Measure voltage Gearshift lever at (F1) thru (F5) and (R1) Gearshift lever at any position except above. 20 to 30V 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
Drive lever (C)
Max. 1V
20-14
(4)
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 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
Max. 1V 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
Reset switch Transmission control related
Measure resistance Reset switch ON
If the condition is as shown in the table below, the condition is normal. Between (9) and chassis Max. 1 z Min. 1 z
Reset switch OFF
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 Max. 1 z Between (11) and chassis Min. 1 z
If the condition is as shown in the table below, the condition is normal. Initialize switch Measure (Initialize learning resistance function) Initialize switch (memory reset or OFF) Max. 1 z 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
Initialize switch
Min. 1 z
If the condition is as shown in the table below, the condition is normal. Lockup switch Measure voltage T/C lock-up switch ON T/C lock-up switch OFF Between (17) and chassis 20 to 30V Max. 1V
T5
If the condition is as shown in the table below, the condition is normal. Measure voltage Differential switch ON Differential switch OFF Between (9) and chassis 20 to 30V Max. 1V
Differential switch
GD555, 655, 675-3C
20-15
(4)
System
Component
Measurement condition 1. Turn starting switch OFF 2. Insert the T-adapter 3. Turn starting switch ON
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 Between (12) and chassis Max. 1 z Min. 1 z
If the condition is as shown in the table below, the condition is normal. Transmission control related Between (7) and (16) Between (3) and (16) Controller Accelerator potentiometer signal Between (3) and (16) at low idle Measure voltage 4.75 to 5.25V 0.5 to 4.75V 1.0 to 2.0V
T3A
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. Between (3) and (16) at high idle 2.4 to 4.3V If the condition is as shown in the table below, the condition is normal. Between (7) and (16) Between (13) and (16) 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
Inching potentiometer signal
Measure voltage
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
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
Measurement condition 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
T5
Measure voltage
T4 T5
Measure voltage
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 At any position except above Max. 1 z Between (1) and chassis Min. 1 z
If the condition is as shown in the table below, the condition is normal. FH clutch fill switch Controller T37 At (F2), (F4), (F6), Measure and (F8) resistance At any position except above Max. 1 z Between (1) and chassis Min. 1 z
If the condition is as shown in the table below, the condition is normal. R clutch fill switch T38 Measure resistance At (R1) thru (R4) At any position except above Between (1) and chassis Max. 1 z 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 Max. 1 z Between (1) and chassis 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 Max. 1 z Between (1) and chassis Min. 1 z
GD555, 655, 675-3C
20-17
(4)
SysComponent tem
Measurement condition 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
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 Between (1) and chassis 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 At F1 to F4, (R1) to Measure (R2) resistance T/C lock-up switch ON T/C lock-up switch OFF
T43
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 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. R solenoid T26 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. 1st solenoid T27 Measure Between (1) and (2) resistance Between (1) and chassis 5 to15 z Min. 1 z
20-18
(4)
GD555, 655, 675-3C
SysComponent tem
Measurement condition 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
2nd solenoid
T28
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. 3rd solenoid T29 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. 4th solenoid Transmission control related T30 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. Lock-up solenoid T31 Measure Between (1) and (2) resistance Between (1) and chassis 5 to15 z Min. 1 z
T/C output hydraulic temp. sensor
If the condition is as shown in the table below, the condition is normal. T34 Measure 25C normal temp. resistance 100C 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 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 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 Measure 25C normal temp. resistance 100C Between (1) and (2)
If the condition is as shown in the table below, the condition is normal. Hydraulic temp. sensor E5 Measure 25C normal temp. resistance 100C Between (1) and (2)
GD555, 655, 675-3C
20-19
(4)
SysComponent tem
Judgement table If the condition is as shown in the table below, the condition is normal. Measure with AC range.
Measurement condition 1. Turn starting switch OFF 2. Disconnect the con500 to 1,000 nector z 3. Connect the T-adapter Min. 1 z
Transmission input shaft speed sensor
T32
Measure resistance Between (1) and (2) Between (1), (2), and chassis
Transmission input shaft 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. Measure with AC range.
Transmission output shaft speed sensor
T33
1. Turn starting switch OFF 2. Disconnect the con500 to 1,000 nector z 3. Connect the T-adapter Min. 1 z
Transmission output shaft 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 speed sensor
T46
1. Turn starting switch OFF 2. Disconnect the con500 to 1,000 nector z 3. Connect the T-adapter Min. 1 z
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
0.5 to 1.0 z Min. 1 z
1. Turn starting switch OFF 2. Disconnect the connector 3. Connect the T-adapter
20-20
(4)
GD555, 655, 675-3C
SysComponent tem
Judgement table If the condition is as shown in the table below, the condition is normal. 40 to 60 z Min. 1 z
Lifter lock solenoid
FL7
Measure resistance Between (1) and (2)
If the condition is as shown in the table below, the condition is normal. Parking brake solenoid FL8 Measure Between (1) and (2) resistance Between (1) and chassis 40 to 60 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. Accumulator solenoid (left) FL9 Measure Between (1) and (2) resistance Between (1) and chassis Transmission control related 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 Measure Between (1) and (2) resistance Between (1) and chassis 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 Measure Between (1) and (2) resistance Between (1) and chassis 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 Measure Between (1) and (2) resistance Between (1) and chassis 20 to 30 z Min. 1 z
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 Articulate angle: 0 Between (1) and (2)
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
GD555, 655, 675-3C
20-21
(4)

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 Coolant and oil temperature Symbol 1 A B 2 Part No. 799-203-8001 795-790-2500 799-101-1502 799-101-5002 799-261-1203 2 3 Oil pressure C 4 5 799-401-2320 799-101-5160 799-101-5220 799-401-2701 790-261-1231 790-261-1311 6 790-261-1321 790-261-1331 1 Exhaust color D 2 1 Blowby pressure E 2 795-790-1950 Operating effort Stroke Troubleshooting of wiring harnesses and sensors Measuring voltage and resistance values Charging accumulator Procedure for moving machine when transmission valve fails F G H I J K 79A-264-0021 79A-261-0091 Commercially available 799-601-2500 799-601-9200 Commercially available 792-610-1700 794-423-1190 Push-pull scale Scale T-adapter assembly Tester Charging tool Plug Commercially available 799-201-1504 799-201-1511 Nozzle Smoke meter Blowby checker 799-201-9000 Handy smoke checker Adapter Part Name Multi-tachometer Adapter Digital temperature gauge Hydraulic tester Digital hydraulic tester Hydraulic gauge Nipple Differential pressure gauge Elbow Remarks Digital display L: 60 to 2,000 rpm H: 60 to 19,999 rpm 99.9 to 1,299C Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} 58.8 MPa {600 kg/cm2} 1.0 MPa {10 kg/cm2} RC 1/8 M10 x 1.25 DC 12 V M10 x 1.25 (RC 1/8) Both male and female 14 x 1.5 (R.C. 1/8) Both male and female 14 x 1.5 (R.C. 1/8) Both male and female 14 x 1.5 (R.C. 1/8) Discoloration 0 to 70 percent (with standard color) Discoloration % x 1/10 = Bosch index 0 to 4,900 Pa {0 to 500 mm H2O} Orifice diameter: 7.67 mm (114 engine) Orifice diameter: 5.613 mm (102 engine) 0 to 294 N {0 to 30 kg} 0 to 490 N {0 to 50 kg} For DT series
20-102
(4)
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. 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.
Measuring with D1
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.
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.
GD555, 655, 675-3C
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 MEASURING ENGINE SPEED
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}). GD555-3C
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 80C. c. Hydraulic temperature: 45 to 55C 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 Belt New belt After adjusting tension GD555 Deflection A 12.2 to 13.3 14.7 to 16.0 GD655, 675 Deflection A 11.8 to 12.8 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 80C Hydraulic oil temperature: 45 to 55C 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 New belt After adjusting
DEFLECTION a (mm) 15 to 16 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 80C 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. 1 2 3 4 Oil pressure circuit FL clutch FH clutch 1st clutch 2nd clutch Plug No. 5 6 7 Oil pressure circuit R clutch 3rd clutch 4th clutch Speed Range F1 F2 F3 F4 F5 F6 F7 F8 R1 R2 R3 R4 N
ECMV clutch actuation table

ECMV FL FH R 1st 2nd 3rd 4th
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.
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. 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 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. k Stop the engine before removing or installing the plug or pressure gauge. a Oil temperature: 60 to 80C 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

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
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
Serial No. GD555-3C 50001 51000 51001 and up 290 280 GD655, 675-3C 50001 51000 289 331.5 51001 and up 290 332
Dimension C Dimension D
289 322.5
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. 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.
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).
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.
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TESTING ACCUMULATOR CHARGE PRESSURE TESTING AND ADJUSTING WORK EQUIPMENT OIL
TESTING ACCUMULATOR CHARGE PRESSURE

a Hydraulic oil temperature: 45 to 55C 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 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 55C 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.
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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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4) Set to the conditions in Table 1, and measure the LS differential pressure. Table 1
Accelerator Operation Differential pressure MPa {kg/cm2} 2.84 to 3.9 {29 to 40} 2.35 0.1 {24 1}
Full Full
Levers at neutral Blade lever (operate fully to raise)
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. 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.
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}.
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ADJUSTING PC VALVE BLEEDING AIR FROM HYDRAULIC CIRCUIT
ADJUSTING PC VALVE
a If the load becomes high and the engine speed drops, or the engine speed remains normal and the work equipment becomes slower, but the pump discharge pressure and the LS differential pressure are normal, adjust the PC valves as follows. 1. Loosen the locknut (1) and turn the sleeve (2) to adjust as follows. 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
BLEEDING AIR FROM HYDRAULIC CIRCUIT

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.
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).
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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 55C. 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.
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BLADE SHIFT CYLINDER
LEANING CYLINDER
POWER TILT CYLINDER
ARTICULATION CYLINDER R.H. L.H.
DRAWBAR SHIFT CYLINDER RIPPER CYLINDER
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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).
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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. 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. 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).
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.
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.
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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. 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 5C: 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 5C: 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. 7. Turn the handle (1) slowly clockwise to push the piston of the gas valve (1). 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.
4. Remove the cap from the gas valve (1), then assemble the charging assembly to the gas valve (2).
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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)
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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} 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.
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.
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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.
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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. Installation of cover 1) Install cover (2) and tighten bolts (1).
3 Bolt (1): 65.7 6.8 Nm {6.7 0.7 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.
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.
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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. Measuring voltage
Pedal Accelerator Inching Connector T9 C to B T8 C to B Potentiometer voltage 1 to 2 0.8 to 1.6
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 Accelerator Inching Connector T9 C to B T8 C to B Potentiometer voltage 2.42 to 4.3 3.2 to 4.0
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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. 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.
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 60C. 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.
3) The learning of the correction for individual differences in the valves will start and [FWL1] - [REV3] will be displayed on message center (3).
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Item 1st time for FL 2nd time for FL 3rd time for FL
Display FWL1
Item 1st time for FH 2nd time for FH 3rd time for FH
Display FWH1
Item 1st time for R 2nd time for R 3rd time for R
Display REV1
FWL2
FWH2
REV2
FWL3
FWH3
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.
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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 diodes 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.
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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. 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 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.
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)
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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.
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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) 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.
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.
GD555, 655, 675-3C
20-135
(4)
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. 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.
20-202
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
TROUBLESHOOTING SEQUENCE
TROUBLESHOOTING SEQUENCE
GD555, 655, 675-3C
20-203
(4)
TROUBLESHOOTING
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 3) 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

Item 1. 2. 3. Lubricating oil, coolant 4. 5. 6. 7. 8. 9. Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check the transmission oil level strainer Check the final drive oil level Check the tandem drive oil level Check the circle reverse gear oil level Check the engine oil level (Oil pan oil level), oil type Judgement Value 20 30 V After running for several minutes: 27.5 29.5 V Action Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add oil Add oil Add oil Add coolant Clean or replace Replace Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
10. Check the coolant level 11. Check the dust indicator for clogging 12. Check the hydraulic filter Electrical equipment 1. 2. 3. 1. 2. 3. 1. 2. Electrics, electrical equipment 3. 4. 5. 6. 7. 8. Check for looseness, corrosion of battery terminal, wiring Check for looseness, corrosion of alternator terminal, wiring Check for looseness, corrosion of starting motor terminal, wiring Check for abnormal noise, smell Check for oil leakage Carry out air bleeding Check battery voltage (Engine stopped) Check battery electrolyte level Check for discolored, burnt, exposed wiring Check for missing wiring clamps, hanging wire Check for water leaking on wiring (Pay particular attention to water leaking on connectors or terminals) Check for blown, corroded fuses Check alternator voltage (Engine running at 1/2 throttle or above) Sound of actuation of battery relay (When starting switch is turned ON, OFF)
Hydraulic, mechanical equipment
Replace
20-212
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS

Serial No. 50001 51000
Connector No. Connector No. Address Type SWP SWP SWP DT2 (G) DT2 (Gr) DT2 (Br) DT2 (B) DT2 (G) L DT2 (Br) DT2 (B) DT2 (Gr) DT2 (G) L L DT2 DT2 KES KES KES DT2 DT2 DT2 DT2 DT1 L DT2 (B) DT2 (B) DT2 DT2 DT2 Relay Relay Relay Relay Relay Relay Relay Relay Mounting location 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 Type Relay Relay Relay Relay Relay KES KES KES DT2 M DT2 DT2 DT2 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) DT2 DT1 KES KES KES Mounting location Neutral relay Front work lamp relay Rear work lamp relay 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 Switch panel lamp Cigar lighter Cigar lighter Accumulator float switch Accumulator float switch Accumulator float switch Intermediate connector Intermediate connector Intermediate connector (Wiper) Heater (If equipped) Radio (If equipped) Speaker (R.H.) Speaker (L.H.) Rear wiper switch Address 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 O-5 P-5 N-4 D-7 P-5 P-5 P-5 P-5 P-5 M-3 N-3 N-3 P-5 Q-5 Q-5 G-4 H-4 H-4 H-4 U-8 V-8 X-7 X-4 No. of pins No. of pins 5 6 5 5 5 4 6 4 2 2 2 2 2 8 8 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 6 3 9 2 2 6
AC1 AC3 AC4 AC5 AC6 AC8 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 BR1 BR2 BR3 BR4 BR5 BR6 BR7 BR8 BR9 BR10 BR11
12 14 16 16 20 7 12 12 12 8 8 2 8 12 8 8 2 2 2 2 2 2 2 3 3 2 2 4 1 8 12 2 2 2 5 5 5 5 5 5 5 5
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 H-9 B-8 K-6 L-6 L-6 M-5 M-5 N-4 Q-1 Q-1 R-3 R-2 R-2 R-2 R-3 P-5
BR12 BR13 BR14 BR15 BR16 BR18 BR19 BR20 BR21 BR22 BR23 BR24 BR25 BR26 BR27 BR28 BT30 BT31 BT32 BT33 BT34 BT35 BT36 BT37 BT38 BT41 BT42 BT43 BT44 BT45 BT46 C1 C2 C3 C4 C5 C6 C7 C8
GD555, 655, 675-3C
20-213
(4)
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type KES KES M M M M KES KES KES KES Relay M Relay KES M M M M M M M KES M M M M
Mounting location 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) Beacon 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)
Type
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 Fuel 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 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
C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 CT35
6 2 2 2 2 2 4 4 4 4 5 2 5 3 2 2 2 2 3 3 2 2 2 2 3 3 1 1 2 2 2 2 2 2 2 2
X-3 T-7 X-4 X-5 U-2 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 S-5 X-3 H-9 H-9 I-9 J-8 J-7 J-7 J-4 I-3
E8 E9 E10 E11 E12 E13 E14 E15 E16 E17 E18 E95 ET39 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
DT2 (PKD) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 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
2 3 3 2 3 3 3 6 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 1 1 1 1 1 1 1 1 1 1 1
J-6 J-7 J-7 J-7 J-6 H-4 H-4 J-5 I-4 H-4 I-4 J-8 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
1-pin connector CT41 TERMINAL E1 DT2 E2 E2 E3 E4 E5 E6 E7 X X DT2 X DT2 DT2 DT2
20-214
(4)
GD555, 655, 675-3C
Address
No. of pins
No. of pins
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type 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) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 M M M M M M
Mounting location Starter relay Starter motor (C) Battery relay (+) Battery relay () Gnd Starter relay Starter relay Grid heater relay Grid heater relay Aircon compressor 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) Diode (solenoid) Diode (solenoid) 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)
Type
Mounting location 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 Horn (L.H.) Horn (R.H.) Floor (Floor) Gnd (front frame) Gnd (front frame) Gnd (rear frame) Articulate sensor () Articulate sensor (G) Speed meter (If equipped) T/C HYD temp. gauge
ET73 ET74 ET75 ET76 ET77 ET80 ET81 ET82 ET83 ET88 ET89 ET90 ET91 ET92 ET93 ET94 FB18 FL1 FL2 FL3 FL4 FL5 FL6 FL7 FL8 FL9 FL10 FL11 FL12 FL13 FL14 FL15 FL16 FL17 FL18 FL19 FL20 FL21 FL22 FL23 FL24 FL25 FL26 FL27
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 8 12 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 3 3 2 2 2 2
J-4 H-9 J-4 K-4 I-5 K-2 J-4 I-4 J-2 J-7 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 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 FL29 FP1 FP2 FP3 FP6 FP7 FP8 FP9 FP10 FP11 FP12 FP13 FP14 FP15 FP16 FP17 FP18 FT6 FT7 FT10 FT11 FT12 FT13 FT16 FT17 FT18 FT19 FT20 FT21 FT22 FT23 FT24 FT25
M M DT2 (Gr) DT2 (B) DT2 (Br) DT2 (B) DT2 (Gr) DT2 (Br) KES DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 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
2 2 12 12 12 12 8 12 1 4 3 3 2 2 2 6 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
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 F-4 E-5 E-5 F-4 D-7 J-5 D-9
Water temperature gauge D-9 Fuel gauge Articulate gauge 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 D-9 D-9 D-9 D-9 D-9
FT26 TERMINAL FT27 TERMINAL FT28 TERMINAL
GD555, 655, 675-3C
20-215
(4)
Address
No. of pins
No. of pins
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector 1-pin connector M M M DT2 (Br) M M M M
Mounting location Fuel gauge (B) Fuel gauge (T) Fuel gauge (E) Articulate gauge (E) Articulate gauge (B) Articulate gauge (T) Articulate gauge Horn switch 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
Type DT2 (B) DT2 DT2 (Gr) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL
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)
FT29 FT30 FT31 FT32 FT33 FT34 FT35 FT37 H1 OP1 OP2 RL1 RL2 RL3 RL4 RL5
1 1 1 1 1 1 1 1 2 1 1 8 6 6 2 2 1 1 1 1 1 13 21 20 16 12 17 4 6 3 3 12 8 6 24 2 2 12 8 6 12
D-9 D-9 D-9 D-9 D-9 D-9 D-9 F-9 F-9 F-9 F-9 J-8 I-9 J-8 I-9
T20 T21 T22 T23 T24 T25 T26 T27 T28 T29 T30 T31 T32 T33 T34 T35
12 6 12 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 6 2 6 6 6 6 1 1 1 1 1 1 1 1 1
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
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
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 T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19 DT2 DT2 DT2 DT2 DT2 (G) DT2 (Gr) DT2 DRC DT2 DT2 DT2 (Br) DT2 (B) DT2 DT2 (Gr)
T36 T37 T38 T39 T40 T41 T42 T43 T44 T46 T47 T48 T49 T50 TT1 TT2 TT3 TT4 TT5 TT6 TT7 TT8 TT9
20-216
(4)
GD555, 655, 675-3C
Address
No. of pins
No. of pins
TROUBLESHOOTING

Connector No. Connector No. Address Type SWP SWP SWP DT2 (G) DT2 (Gr) DT2 (Br) DT2 (B) DT2 (G) L DT2 (Br) DT2 (B) DT2 (Gr) DT2 (G) L L DT2 KES KES KES DT2 DT2 DT2 DT2 DT1 L DT2 (B) DT2 (B) DT2 DT2 DT2 DT2 DT2 Relay Relay Relay Relay Relay Relay Mounting location 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 Type Relay Relay Relay Relay Relay Relay Relay KES KES KES DT2 M DT2 DT2 Mounting location Brake pump relay Parking brake relay Neutral relay Front work lamp relay Rear work lamp relay 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 Switch panel lamp Cigar lighter Cigar lighter 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) Address 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 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 P-5 O-5 O-5 G-4 G-4 H-4 H-4 U-8 V-8 X-7 X-4 X-3 No. of pins No. of pins 5 5 6 6 5 5 5 4 6 4 2 2 2 2 2 8 8 3 1 1 1 1 1 1 1 1 1 1 1 1 8 8 6 3 9 2 2 6 6
AC1 AC3 AC4 AC5 AC6 AC8 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 BR1 BR2 BR3 BR4 BR5 BR6 BR7 BR8 BR9
12 14 16 16 20 7 12 12 12 8 8 2 8 12 8 8 2 2 2 2 2 2 3 3 2 2 4 1 8 12 2 2 2 2 2 5 5 5 5 5 5
G-9 X-3 W-2 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 R-2
BR10 BR11 BR12 BR13 BR14 BR15 BR16 BR18 BR19 BR20 BR21 BR22 BR23 BR24 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 C4 C5 C6 C7 C8 C9 DT2 DT1 KES KES KES KES
GD555, 655, 675-3C
20-217
(4)
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type
Mounting location 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) Beacon (If equipped) GND Alternator Thermostat sensor (GD555) Thermostat sensor (GD655, 675) Intermediate connector
Type
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
C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 CT35
KES M M M M KES KES KES KES Relay M Relay KES M M M M M M M KES M M M M
2 2 2 2 2 4 4 4 4 5 2 5 3 2 2 2 2 3 3 2 2 2 2 3 3 1 1 2 2 2 2
T-7 X-4 X-5 U-2 X-6 S-4
E4 E5 E6 E6 E7 E8 E9
X DT2 DT2 DT2 DT2 DT2 DT DT2 DT2 (PKD) DT2 DT2 DT2 DT2 DT2 DT2 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
2 2 2 2 2 2 3 3 2 3 3 3 6 4 2 2 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
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
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 S-5 X-3 H-9 I-9 H-9 J-8
E10 E11 E12 E13 E14 E15 E16 E17 E18 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
1-pin connector CT41 TERMINAL E1 DT2 E2 E2 E3 X X DT2
20-218
(4)
GD555, 655, 675-3C
Address
No. of pins
No. of pins
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL
Mounting location 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)
Type DT2 M M M M M M DT2 (Gr) DT2 (B) DT2 (Br) DT2 (B) DT2 (Gr) DT2 (Br) KES DT2 DT2 DT2 DT2 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
Mounting location 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 Horn (L.H.) Horn (R.H.) 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
ET64 ET65 ET66 ET67 ET68 ET70 ET71
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 8 12 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
L-3 M-8 M-8 M-8 I-2 J-5 I-5 K-2 J-4 H-9 J-4 K-4 I-5 J-4 I-4 J-2 J-7 J-6 J-6 J-5 I-4 J-7 J-7 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
FL21 FL22 FL23 FL26 FL27 FL28 FL29 FP1 FP2 FP3 FP6 FP7 FP8 FP9 FP10 FP11 FP12 FP13 FP19 FT6 FT7 FT10 FT11 FT12 FT13 FT16 FT17 FT18 FT19 FT20 FT21
4 3 3 2 2 2 2 12 12 12 12 8 12 2 4 3 3 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
C-6 A-5 A-2 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 F-4 E-5 E-5 F-4 D-7 J-5 D-9
ET72 TERMINAL ET73 TERMINAL ET74 ET75 ET76 ET77 TERMINAL TERMINAL TERMINAL TERMINAL
ET81 TERMINAL ET82 ET83 ET88 ET89 ET92 ET93 ET94 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL
ET97 TERMINAL ET98 TERMINAL ET99 TERMINAL FL1 FL2 FL3 FL4 FL5 FL6 FL7 FL8 FL9 FL10 FL11 FL12 FL13 FL14 FL15 FL16 FL17 FL18 FL19 FL20 M M DT2(B) DT2(B) DT2(Br) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2
Water temperature gauge D-9 Fuel gauge 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 D-9
FT23 TERMINAL FT24 TERMINAL FT25 TERMINAL FT26 TERMINAL FT27 TERMINAL
GD555, 655, 675-3C
20-219
(4)
Address
No. of pins
No. of pins
TROUBLESHOOTING
Connector No.
Connector No.
Address
Type
Mounting location Water temperature gauge (E) Fuel gauge (B) Fuel gauge (T) Fuel gauge (E) Articulate gauge (E) Articulate gauge (B) Articulate gauge (T) Horn switch 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
Type DT2(B) DT2 DT2(Gr) DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL
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)
FT28 TERMINAL FT29 FT30 FT31 FT32 FT33 FT34 FT37 H1 OP1 OP2 RL1 RL2 RL3 RL4 RL5 RL6 RL7 RT1 TERMINAL TERMINAL TERMINAL TERMINAL 1-pin connector 1-pin connector 1-pin connector M M M DT2 (Br) M M M M M X M
1 1 1 1 1 1 1 1 1 1 1 8 6 6 2 2 2 2 2 1 1 13 21 20 16 12 17 4 6 3 3 12 8 6 24 2 2 12 8 6 12
D-9 D-9 D-9 D-9 D-9 D-9 D-9 E-9 F-9 F-9 F-9 J-8 I-9 J-8 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 T32 T33 T34 T35 T36 T37 T38 T39 T40 T41 T42 T43 T44 T46 T47 T48 T49 T50 TT1 TT2 TT3 TT4 TT5 TT6 TT7 TT8 TT9
12 6 12 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 6 2 6 6 6 6 1 1 1 1 1 1 1 1 1
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
RT2 TERMINAL RT3 TERMINAL T1 MIC T2 MIC T3A 040 T3B 040 T4 040 T5 MIC T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19 DT2 DT2 DT2 DT2 DT2 (G) DT2 (Gr) DT2 DRC DT2 DT2 DT2 (Br) DT2 (B) DT2 DT2 (Gr)
20-220
(4)
GD555, 655, 675-3C
Address
No. of pins
No. of pins
TROUBLESHOOTING
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

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 Male (Female Housing) Part Number: 08055-00181 Female (Male Housing) Part Number: 08055-00191 T-adapter Part Number 799-601-7010
Number of Pins 1
BWP04702
799-601-7020
Part Number: 08055-00282
799-601-7030
BWP04705
799-601-7040
Part Number: 08055-00481 Terminal part number: 79A-222-3370 Wire size: 0.85 Grommet: black Quantity: 20 pieces Terminal part number: 79A-222-3380 Wire size: 2.0 Grommet: red Quantity: 20 pieces
Part Number: 08055-00491 Terminal part number: 79A-222-3390 Wire size: 0.85 Grommet: black 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) Female (Male Housing) T-adapter Part Number
BWP04707
BWP04708
799-601-7050
BWP04709
BWP04710
799-601-7060
12
BWP04711
BWP04712
799-601-7310
14
BWP04713
BWP04714
799-601-7070
GD555, 655, 675-3C
20-231
(4)
TROUBLESHOOTING
Number of Pins
SWP-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
16
BWP04715
BWP04716
799-601-7320
Part Number: 08055-11681 Terminal part number: Wire size: 0.85 Grommet: black Quantity: 20 pieces Terminal part number: Wire size: 1.25 Grommet: red Quantity: 20 pieces
Part Number: 08055-11691 Terminal part number: Wire size: 0.85 Grommet: black Quantity: 20 pieces Terminal part number: Wire size: 1.25 Grommet: red Quantity: 20 pieces
20-232
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Number of Pins 1
M-Type Connector Male (Female Housing) Part Number: 08056-00171 Female (Male Housing) Part Number: 08056-00181 T-adapter Part Number 799-601-7080
BWP04717
BWP04718
799-601-7090
BWP04719
BWP04720
799-601-7110
BWP04721
BWP04722
799-601-7120
BWP04723
BWP04724
799-601-7130
799-601-7340
BWP04725 BWP04726
GD555, 655, 675-3C
20-233
(4)
TROUBLESHOOTING
Number of Pins
S-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
BWP04727
BWP04728
799-601-7140
10 (White)
BWP04729
BWP04730
799-601-7150
12 (White)
BWP04731
BWP04732
799-601-7350
16 (White)
BWP04733
BWP04734
799-601-7330
20-234
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Number of Pins
S-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
10 (Blue)
BWP04735
BWP04736
12 (Blue)
BWP04737
BWP04738
799-601-7160
16 (Blue)
BWP04739
BWP04740
799-601-7170
GD555, 655, 675-3C
20-235
(4)
TROUBLESHOOTING
Number of Pins 7 11
MIC-Type Connector Male (Female Housing) Body Part Number: 79A-222-2640 (Quantity: 5 pieces) Body Part Number: 79A-222-2680 (Quantity: 5 pieces) Female (Male Housing) Body Part Number: 79A-222-2630 (Quantity: 5 pieces) Body Part Number: 79A-222-2670 (Quantity: 5 pieces) T-adapter Part Number
BWP04741
BWP04742
799-601-2710
Body Part Number: 79A-222-2620 (Quantity: 5 pieces)
BWP04743
BWP04744
799-601-2950
13
BWP04745
BWP04746
799-601-2720
20-236
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Number of Pins
MIC-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
17
BWP04747
BWP04748
799-601-2730
21
BWP04749
BWP04750
799-601-2740
Body Part Number: 79A-222-2750 (Quantity: 2 pieces) Body Part Number: 79A-222-2770 (Quantity: 50 pieces)
Body Part Number: 79A-222-2740 (Quantity: 2 pieces) Body Part Number: 79A-222-2760 (Quantity: 50 pieces)
GD555, 655, 675-3C
20-237
(4)
TROUBLESHOOTING
Number of Pins
AMP040-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
BWP04751
BWP04752
799-601-7180
Housing Part Number: 79A-222-3430
12
BWP04753
BWP047544
799-601-7190
16
BWP04755
BWP04756
799-601-7210
20
BWP04757
BWP04758
799-601-7220
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) Female (Male Housing) T-adapter Part Number
10
BWP04759
BWP04760
799-601-7510
12
BWP04761
BWP04762
799-601-7520
14
BWP04763
BWP04764
799-601-7530
18
BWP04765
BWP04766
799-601-7540
20
BWP04767
BWP04768
799-601-7550
GD555, 655, 675-3C
20-239
(4)
TROUBLESHOOTING
Number of Pins
L-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
Number of Pins
PA-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
Number of Pins
BENDIX MS-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
10
799-601-3460
20-240
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Number of Pins
KES1 Automobile-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
Part Number: 08027-10210 (Natural color) 08027-10220 (Black)
GD555, 655, 675-3C
20-241
(4)
TROUBLESHOOTING
Number of Pins
KES1 Automobile-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
Number of Pins
Socket-Type Connector for Relay Male (Female Housing) Female (Male Housing) T-adapter Part Number
799-601-7360
799-601-7370
Number of Pins
F-Type Connector Male (Female Housing) Female (Male Housing) T-adapter Part Number
20-242
(4)
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) Pin (male terminal) Body (receptacle) Pin (female termial) T-adapter Part No.
799-601-9210
18-8 (1)
Part No.:08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.:08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)
799-601-9210
Part No.:08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)
Part No.:08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)
799-601-9220
18-14 (2)
799-601-9220
Part No.:08191-22201, 08191-22202, 08191-22205, 08191-22206
Part No.:08191-23101, 08191-23102, 08191-23105, 08191-23106
GD555, 655, 675-3C
20-243
(4)
TROUBLESHOOTING
799-601-9230
18-20 (3)
Part No.:08191-31201, 08191-31202 Pin (female terminal)
Part No.:08191-34101, 08191-34102 Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202 Pin (male terminal)
Part No.:08191-33101, 08191-33102 Pin (female termial)
799-601-9240
18-21 (4)
799-601-9240
Part No.:08191-42201, 08191-42202
Part No.:08191-43101, 08191-43102
20-244
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
799-601-9250
24-9 (5)
799-601-9250
Part No.:08191-52201, 08191-52202 Pin (male terminal)
Part No.:08191-53101, 08191-53102 Pin (female termial)
799-601-9260
24-16 (6)
799-601-9260
Part No.:08191-62201, 08191-62202, 08191-62205, 08191-62206
Part No.:08191-63101, 08191-63102, 08191-63105, 08191-63106
GD555, 655, 675-3C
20-245
(4)
TROUBLESHOOTING
799-601-9270
24-21 (7)
799-601-9270
Part No.:08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)
Part No.:08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)
799-601-9280
24-22 (8)
Part No.:08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 Pin (female terminal)
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
Part No.:08191-83101, 08191-83102 08191-83103, 08191-83104 08191-83105, 08191-83106
20-246
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Type (shell size code) HD30 Series connector Body (plug) Pin (male termial) Body (receptacle) Pin (female terminal) T-adapter Part No.
799-601-9290
24-31 (9)
799-601-9290
Part No.:08191-92203, 08191-92204, 08191-92205, 08191-92206
Part No.:08191-93103, 08191-93104, 08191-93105, 08191-93106
GD555, 655, 675-3C
20-247
(4)
TROUBLESHOOTING
No.of pins DT Series connector Body (plug) Body (receptacle) T-adapter Part No.
799-601-9020
Part No.:08192-12200 (normal type) 08192-22200 (fine wire type)
799-601-9030
799-601-9040
799-601-9050
20-248
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
No.of pins DT Series connector Body (plug) Body (receptacle) T-adapter Part No.
8GR:799-601-9060 8B:799-601-9070 8G:799-601-9080 8BR:799-601-9090
12
12GR:799-601-9110 12B:799-601-9120 12G:799-601-9130 12BR:799-601-9140
GD555, 655, 675-3C
20-249
(4)
TROUBLESHOOTING
No.of pins DTM Series connector Body (plug) Body (receptacle) T-adapter Part No.
799-601-9010
Part No.: 08192-02200
Part No.: 08192-02100
No.of pins DTHD Series connector Body (plug) Body (receptacle) T-adapter Part No.
Part No.:08192-31200 (Contact size#12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)
Part No.:08192-31100 (Contact size#12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)
20-250
(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 [2] Rpm (engine speed) [3] Gear (speed range) [4] Err (error code) [5] Lum. (monitor illumination brightness) [6] Ver.T (version of software) [7] M7TT (display in miles) [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 P N F1 F2 F3 Display [T - P - 1] [T - N -] [TTF1] [TTF2] [TTF3] Speed range F4 F5 F6 F7 F8 Display [TTF4] [TTF5] [TTF6] [TTF7] [TTF8] Speed range R1 R2 R3 R4 Display [TTR1] [TTR2] [TTR3] [TTR4]
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 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 C4 C5 C6 C7 C8 C9 d1 Short circuit with power source, or accelerator potentiometer system disconnected Short circuit with power source, or inching potentiometer system disconnected. Short circuit with power source, or transmission oil temperature sensor system disconnected Short circuit with power source, or torque converter outlet oil temperature sensor system disconnected Short or open circuit of power source in the hydraulic oil temperature sensor system Transmission input speed sensor system disconnected Transmission output speed sensor system disconnected Short circuit with power source, or differential oil temperature warning lamp system disconnected F1 F2 F3 F4 F5 F6 F7 F8 91 92 93 94 95 96 97 98 E6 E7 E8 E3 E4 E5 E2 Short circuit with power source, or the neutral signal system disconnected Short circuit with power source, or the parking signal system disconnected Short circuit with power source, or the logic A signal system disconnected Short circuit with power source, or the logic B signal system disconnected Short circuit with power source, or the logic C signal system disconnected Short circuit with power source, or the logic D signal system disconnected Short circuit with power source, or the logic E signal system disconnected Short circuit with ground in the FL clutch pressure switch signal system Short circuit with ground in the FH clutch pressure switch signal system Short circuit with ground in the R clutch pressure switch signal system Short circuit with ground in the 1st clutch pressure switch signal system Short circuit with ground in the 2nd clutch pressure switch signal system Short circuit with ground in the 3rd clutch pressure switch signal system Short circuit with ground in the 4th clutch pressure switch signal system Short circuit with ground in the lock-up clutch pressure switch signal system FL clutch pressure switch signal system disconnected FH clutch pressure switch signal system disconnected R clutch pressure switch signal system disconnected 1st clutch pressure switch signal system disconnected 2nd clutch pressure switch signal system disconnected 3rd clutch pressure switch signal system disconnected 4th clutch pressure switch signal system disconnected Lock-up clutch pressure switch signal system disconnected
Short circuit with power source, or transmission d2 (torque converter outlet) oil temperature warning lamp system disconnected d4 d5 d6 d7 E1 Short circuit with power source, or alarm buzzer system disconnected Short circuit with power source, or warning lamp system disconnected Short circuit with power source, or differential control relay system disconnected Short circuit with power source, or VHP relay system disconnected 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. E-QQ T-QQ H-QQ M-QQ Component Troubleshooting of electrical system Troubleshooting of transmission controller system Troubleshooting of hydraulic, mechanical system 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

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

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

Self-diagnostic display (problem displayed)
Short circuit to the power source in the lock-up solenoid circuit
Failure location Short circuit to the power source in the FH solenoid circuit Short circuit to the power source in the FL solenoid circuit
Short circuit to the power source in the 2nd, 4th solenoid circuit
Short circuit to the power source in the 1st, 3rd solenoid circuit
Short circuit to power source in the R solenoid circuit
Open circuit in the 2nd solenoid circuit
Open circuit in the 3rd solenoid circuit b6 Q Q Q T12
Failure code
Failure mode
Transmission controller error A1 A2 A3 A4 A5 A8 1. Travel is impossible 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 9. Modulation clutch control does not function Troubleshooting code when an error code is displayed Q Q T1 Q Q T2 Q Q T3 Q T4 Q T5 Q T6 Q T7 Q T8 Q T9 Q T10 Q T11 Q T13 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q b1 b2 b3 b4 b5 b7
20-354
(4)
GD555, 655, 675-3C
Open circuit in the 4th solenoid circuit
Open circuit in the 1st solenoid circuit
Open circuit in the FH solenoid circuit
Open circuit in the FL solenoid circuit
Open circuit in the R solenoid circuit
Open circuit in the lock-up solenoid circuit Power supply voltage reduced Engine speed sensor system Accelerator potentiometer system Inching potentiometer system Transmission oil temperature sensor system Torque converter outlet oil temperature system Hydraulic oil temperature sensor system (opt) Transmission input speed sensor system Transmission output speed sensor system Differential oil temperature lamp system (opt) Torque converter outlet oil temperature lamp system (opt) Alarm buzzer A system Warning lamp system Differential control relay system VHP solenoid relay system (opt) F (forward), R (reverse) signal system Neutral signal system Parking signal system Logic A signal system Logic B signal system Logic C signal system
T14 Q
T15
T16
T17
GD555, 655, 675-3C

Q Q Q Q Q b8 C0 C1 C3 C4 C5 C6 C7 C8 C9 d1 d2 d4 d5 Self-diagnostic display (problem displayed) Transmission controller error d6 d7 Q Q Q Q Q Q Q Logic D signal system Q Logic E signal system Stop lamp signal system E1 E2 E3 E4 E5 E6 E7 E8
TROUBLESHOOTING
T18
T19
T20
T21
T22
T23
T24
T25
T26
T27
T28
T29
T30
T31
T32
T33
T34
T35
T36
T37
20-355
(4)
TROUBLESHOOTING
Self-diagnostic display (problem displayed)
Failure location
Differential selector switch system
Failure code
Failure mode
Transmission controller error 1. Travel is impossible 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 9. Modulation clutch control does not function Troubleshooting code when an error code is displayed T38 Q F1 Q
20-356
(4)
GD555, 655, 675-3C
Short circuit to ground in the FL clutch pressure switch signal system
Learning function initialize switch system
Differential selection switch system
Inching selection switch system
Model selection switch system
AWD selection switch system
VHP selection switch system
Memory reset switch system
High set switch system
Lock-up switch system
Low set switch system
Reset switch system
91
Q Q Short circuit to ground in the FH clutch pressure switch signal system Open circuit in the FH clutch pressure switch signal system Short circuit to ground in the R clutch pressure switch signal system Open circuit in the R clutch pressure switch signal system Short circuit to ground in the 1st clutch pressure switch signal system Open circuit in the 1st clutch pressure-switch signal system Short circuit to ground in the 2nd clutch pressure switch signal system Open circuit in the 2nd clutch pressure switch signal system Short circuit to ground in the 3rd clutch pressure switch signal system Open circuit in the 3rd clutch pressure switch signal system Short circuit to ground in the 4th clutch pressure switch signal system Open circuit in the 4th clutch pressure switch signal system Short circuit to ground in the lock-up clutch pressure switch signal system Open circuit in the lock-up clutch pressure switch signal system F2 Q 92 Q F3 Q
Open circuit in the FL clutch pressure switch signal system
T46
T39
T47
T40
GD555, 655, 675-3C

93 Q F4 Q 94 Q F5 Q 95 Q Transmission controller error Self-diagnostic display (problem displayed) F6 96 Q Q F7 97 Q F8 98 H-11 Troubleshooting code when no error code is displayed
TROUBLESHOOTING
T48
T41
T49
T42
T50
T43
T51
T44
T52
T45
T53
20-357
(4)
TROUBLESHOOTING
CONTROLLER ACTION WHEN PROBLEMS OCCUR WITH THE MACHINE

No. Failure code System problem Nature of the problem Normal condition (volts, amps and ohms)
A1
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
Resistance between T2 (female) (7) and (17): 5 to 15 z Voltage between T2 (17) and chassis at neutral: Less than 0.1 V
A2
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
A3
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 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
A4
Short circuit to power source in 1st, 3rd solenoid system
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 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
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
20-358
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Controller action after detecting the problem 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 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 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
Problem with the machine
Code displayed
Warning lamp
Alarm buzzer
Warning chime
Memory
Troubleshooting code
Big transmission shock, but possible to travel in F1, F3, F5, F7
T-1
Big transmission shock, but possible to travel in F2, F4, F6, F8
T-2
Big transmission shock, but possible to travel in R1, R2, R3, R4
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
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
T-5
GD555, 655, 675-3C
20-359
(4)
TROUBLESHOOTING
No.
Failure code
System problem
Nature of the problem 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 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 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 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 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 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 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 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
Normal condition (volts, amps and ohms)
A8
Short circuit to the power source in the lock-up solenoid system
Resistance between T2 (female) (7) and (17): 5 to 15 z Voltage between T2 (17) and chassis at neutral: Less than 0.1 V Resistance between T2 (female) (8) and (18): 5 to 15 z Voltage between T2 (18) and chassis at neutral: Less than 0.1 V Resistance between T2 (female) (9) and (19): 5 to 15 z Voltage between T2 (19) and chassis at neutral: Less than 0.1 V 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) (4) and (15): 5 to 15 z Voltage between T2 (15) 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 Resistance between T2 (female) (5) and (16): 5 to 15 z Voltage between T2 (16) and chassis at neutral: Less than 0.1 V Resistance between T2 (female) (10) and (20): 5 to 15 z Voltage between T2 (20) and chassis at neutral: Less than 0.1 V Voltage between T1 (7), (13) chassis: 19 to 30V Voltage between T2 (1), (12) chassis: 19 to 30 V
b1
Open circuit in the FL solenoid circuit
b2
Open circuit in the FH solenoid circuit
b3
Open circuit in the R solenoid system
10
b4
Open circuit in the 1st solenoid system
11
b5
Open circuit in the 2nd solenoid system
12
b6
Open circuit in the 3rd solenoid system
13
b7
Open circuit in the 4th solenoid system
1. Defective lock-up solenoid

14 b8 Open circuit in the lock-up solenoid system 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)
1. Defective contact or open circuit in wiring harness between T1 (female) (7), (13), T2 (1), (12) - T11 (male) (1)
15 C0 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
20-360
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Controller action after detecting the problem
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
T-6
No action
Does not travel in F1, F3, F5, F7 (coasts)
T-7
No action
Cannot travel in F2, F4, F6, F8 (coasts)
T-8
No action
Does not travel in reverse (coasts)
T-9
No action
Cannot travel in F1, F2, R1
T-10
No action
T-11
No action
Does not travel in F5, F6, R3
T-12
No action
T-13
No action
Always torque converter drive (lock-up is not applied)
T-14
All solenoid outputs OFF (sets to Neutral)
Stays in N
T-15
GD555, 655, 675-3C
20-361
(4)
TROUBLESHOOTING
No.
Failure code
System problem
Nature of the problem 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
16
C1
Open circuit in the engine speed sensor system
Voltage between T3A (13) and (16): 0.5 to 4.75 V
17
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 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 Voltage between T3A (female) (11), T34 (female) (1) and chassis: Max. 4.75 V Resistance between T34 (male) (1) and (2): 25C (normal temperature): 3.5 to 4.0 z 100C: 38.5 to 47.0 z Voltage between T3A (female) (11), T34 (female) (1) and chassis: Max. 4.75 Resistance between T34 (male) (1) and (2): 25C (normal temperature): 3.5 to 4.0 z 100C: 38.5 to 47.0 z Voltage between T3A (female) (1), T35 (female) (1) and chassis: Max. 4.75 V Resistance between T35 (male) (1) and (2): 25C (normal temperature): 3.5 to 4.0 z 100C: 38.5 to 47.0 z Voltage between T3A (female) (1), T35 (female) (1) and chassis: Max. 4.75 V Resistance between T35 (male) (1) and (2): 25C (normal temperature): 3.5 to 4.0 z 100C: 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): 25C (normal temperature): 3.5 to 4.0 z 100C: 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): 25C (normal temperature): 3.5 to 4.0 z 100C: 38.5 to 47.0 z
18
C3
Open circuit in the accelerator potentiometer system
19
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 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
20
C4
21
C5
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
22
C5
Open circuit in the transmission oil temperature sensor circuit
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
23
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)
GD555, 655, 675-3C
TROUBLESHOOTING
Code displayed
Warning lamp
Alarm buzzer
Warning chime
Memory
Engine speed not displayed on message center
None in particular
T-16
Calculates for the accelerator at low position
Reduced power
T-17
Calculates for the accelerator at low position
Reduced power
T-17
No inching output
Inching impossible
T-18
No inching output
Inching impossible
T-18
Outputs with oil temperature map for less than 20C
Normal operation
T-19
Outputs with oil temperature map for less than 20C
Normal operation
T-19
No action
Normal operation
T-20
GD555, 655, 675-3C
20-363
(4)
TROUBLESHOOTING
No.
Failure code
System problem
Nature of the problem
Normal condition (volts, amps and ohms) Voltage between T3A (female) (1), T35 (female) (1) and chassis: Max. 4.75 V Resistance between T35 (male) (1) and (2): 25C (normal temperature): 3.5 to 4.0 z 100C: 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): 25C (normal temperature): 3.5 to 4.0 z 100C: 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): 25C (normal temperature): 3.5 to 4.0 z 100C: 38.5 to 47.0 z
24
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
25
C7
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
26
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 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 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 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
27
C8
Open circuit in the transmission input speed sensor system
Resistance between T5 (2) and (1): 500 to 1000 z
28
C9
Open circuit in the transmission output speed sensor system Short circuit to power source in the differential oil temperature warning lamp system (opt) Open circuit in the differential oil temperature warning lamp system (opt)
Resistance between T4 (1) and T5 (1): 500 to 1000 z
29
d1
Voltage between T1 (1) and chassis: When output is OFF: Max. 1 V
30
d1
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
31
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 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
32
d2
20-364
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Code displayed
Warning lamp
Alarm buzzer
Warning chime
Memory
No action
Normal operation
T-20
No action
Normal operation
T-21
No action
Normal operation
T-21
No action
Normal operation
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
T-23
Differential oil temperature warning lamp output OFF
Differential oil temperature warning lamp stays on and does not go out Warning lamp does not light up when the differential oil temperature is abnormal
T-24
Differential oil temperature warning lamp output OFF
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 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)
T-25
T-25
GD555, 655, 675-3C
20-365
(4)
TROUBLESHOOTING
No.
Failure code
System problem Short circuit to power source in alarm buzzer (alarm buzzer A) system Open circuit in the alarm buzzer (alarm buzzer A) system Short circuit to power source in the transmission control warning lamp system Open circuit in the transmission control warning lamp system Short circuit to power source in the differential control relay system Open circuit in the differential control relay system Short circuit to the power source in VHP solenoid relay system (opt) Open circuit in the VHP solenoid relay system (opt)
33
d4
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 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 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 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 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 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 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 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
34
d4
35
d5
36
d5
37
d6
38
d6
39
d7
Voltage between T1 (2) and chassis: When output is OFF (except for VHP specification): Max. 1 V
40
d7
Voltage between T1 (2) and chassis: When output is ON (VHP specification): 17 to 30 V Voltage between T5 (6) and chassis: Except when gearshift lever is at [F1] to [F8]: Max. 1 V Voltage between T5 (6) and chassis: When gearshift lever is at [F1] to [F8]: 20 to 30 V Voltage between T5 (14) and chassis: Except when gearshift lever is in [R1] to [R4]: Max. 1 V Voltage between T5 (14) and chassis: When gearshift lever is at [R1] to [R4]: 20 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 Open circuit in the F (Forward) signal circuit Short circuit to the power source in R (Reverse) signal system Open circuit in the R (Reverse) signal system 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 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 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
42
E1
43
E1
44
E1
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
T-26
Alarm buzzer output OFF
Alarm buzzer does not sound
T-26
Warning lamp output OFF
Warning lamp stays lit and does not go out
T-27
Warning lamp output OFF
Warning lamp does not light up
T-27
Differential control relay output OFF
Normal differential condition
T-28
Differential control relay output OFF
Normal differential lock condition
T-28
VHP solenoid relay output OFF
Normal VHP condition
T-29
VHP solenoid relay output OFF
Does not change to VHP
T-29
F and R signals input at same time o N
achine coasts, and then stops
T-30
No action
Impossible to travel in FORWARD
T-30
F and R signals input at same time o N
Machine coasts, and then stops
T-30
No action
Impossible to travel in REVERSE
T-30
GD555, 655, 675-3C
20-367
(4)
TROUBLESHOOTING
No.
Failure code
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 (8) and chassis: When gearshift lever is in Neutral, Parking: 20 to 30 V
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 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 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
46
E2
47
E3
Short circuit to power source in parking signal system
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 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 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 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 1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T5 (female) (7) and T13 (female) (5) 3. Defective transmission controller 1. Defective gearshift lever 2. Short circuit to power source in wiring harness between T5 (female) (15) and T13 (female) (12) 3. Defective transmission controller 1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T5 (female) (15) and T13 (female) (12) 3. Defective transmission controller 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 1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T5 (female) (8) and T13 (female) (18) 3. Defective transmission controller
Voltage between T3A (9) and chassis: When gearshift lever is in Park: 20 to 30 V
49
E4
Voltage between T3A (18) and chassis: When gearshift lever is in Park, Neutral: Max. 1 V Voltage between T3A (18) and chassis: Except when gearshift lever is in Park, Neutral: 20 to 30 V Voltage between T5 (7) and chassis: Except when gearshift lever is in [F1], [F5] [F7], [R1] - [R3]: Max. 1 V Voltage between T5 (7) and chassis: When gearshift lever is at [F1], [F5] - [F7], [R1] - [R3]: 20 to 30 V Voltage between T5 (15) and chassis: Except when gearshift lever is at [F1] [F5], [R1]: Max. 1 V Voltage between T5 (15) and chassis: When gearshift lever is at [F1] - [F5], [R1]: 20 to 30 V Voltage between T5 (8) and chassis: Except when gearshift lever is at [F1] - [F3]: Max. 1 V Voltage between T5 (8) and chassis: When gearshift lever is at [F1] - [F3]: 20 to 30 V
50
E4
Open circuit in logic A system
51
E5
Short circuit to the power source in logic B system
52
E5
Open circuit in logic B system
53
E6
Short circuit to power source in logic C system Open circuit in the logic C system Short circuit to the power source in logic D system
54
E6
55
E7
56
E7
Open circuit in logic D system
20-368
(4)
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
T-31
No F, R, N signals o N
Cannot travel
T-31
No action
Danger that machine will move when the lever is operated and the parking brake will seize When machine stops, it does not move when operating the lever. Shifts to Neutral during travel when accelerator pedal is being depressed
T-32
No action
T-32
Set to Neutral
Cannot travel
T-33
Set to Neutral
Cannot travel
T-33
Set to Neutral
Cannot travel
T-34
Set to Neutral
Cannot travel
T-34
Set to Neutral
Cannot travel
T-35
Set to Neutral
Cannot travel
T-35
Set to Neutral
Cannot travel
T-36
Set to Neutral
Cannot travel
T-36
GD555, 655, 675-3C
20-369
(4)
TROUBLESHOOTING
No.
Failure code
System problem Short circuit to power source in logic E system
Nature of the problem 1. Defective gearshift lever 2. Short circuit to power source in wiring harness between T5 (female) (16) and T13 (female) (3) 3. Defective transmission controller 1. Defective gearshift lever 2. Defective contact or open circuit in wiring harness between T5 (female) (16) and T13 (female) (3) 3. Defective transmission controller 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
Normal condition (volts, amps and ohms) Voltage between T5 (16) and chassis: Except when gearshift lever is at [F3] [F6], [R1], [R2]: Max. 1 V Voltage between T5 (16) and chassis: When gearshift lever is at [F3] - [F6], [R1], [R2]: 20 to 30 V Voltage between T3A (19) and chassis: When output is OFF (brake pedal not being depressed): Max. 1 V Voltage between T3A (19) and chassis: When output is ON (brake pedal being depressed): 17 to 30 V 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 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 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 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 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 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 Resistance between T5 (5) and chassis: STD specification: Max. 1 z Specification: Min. 1 MC Resistance between T5 (5) and chassis: STD specification: Max. 1 z Specification: Min.1 Mz
57
E8
58
E8
Open circuit in logic E system Short circuit to power source in stop lamp signal system
59
60
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 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
61
62
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
63
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
64
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
65
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
66
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 Short circuit to ground in the model selection switch system Open circuit in the model selection switch system
67
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)
68
1. Defective contact or open circuit in the wiring harness between T5 (female) (5) and T7 (female) (1)
20-370
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Code displayed
Warning lamp
Alarm buzzer
Warning chime
Memory
Sets to neutral
Cannot travel
T-37
Sets to neutral
Cannot travel
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 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
Normal operation
GD555, 655, 675-3C
20-371
(4)
TROUBLESHOOTING
No.
Failure code
System problem
Normal condition (volts, amps and ohms) Resistance between T5 (9) and chassis: When differential selection switch is ON: Max. 1 z When differential selection switch is OFF: Min. 1 Mz Resistance between T5 (9) and chassis: When differential selection switch is ON: Max. 1 z When differential selection switch is OFF: Min. 1 Mz Resistance between T3A (20) and chassis: With inching specification: Max. 1 z Without inching specification: Min. 1 Mz Resistance between T3A (20) and chassis: With inching specification: Max. 1 z Without inching specification: Min. 1 Mz 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 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 Resistance between T3B (9) and chassis: When reset switch is ON: Max. 1 z When reset switch is OFF: Min. 1 Mz Resistance between T3B (9) and chassis: When reset switch is ON: Max. 1 z When reset switch is OFF: Min. 1 Mz Resistance between T3B (2) and chassis: With VHP specification: Max. 1 z Without VHP specification: Min. 1 Mz Resistance between T3B (2) and chassis: With VHP specification: Max. 1 z Without VHP specification: Min. 1 Mz
69
Short circuit to ground in differential selection switch system
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).
70
Open circuit in the differential selection switch system
1. Defective contact or open circuit in the wiring harness between T3A (female) (10) and T7 (female) (2).
71
Short circuit to ground in inching selection switch system
1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3A (female) (20) and T7 (female) (4).
72
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
73
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
74
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).
75
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).
76
Open circuit in the reset switch system
1. Defective contact or open circuit in the wiring harness between T3B (female) (9) and TT (terminal) (8)
77
Short circuit to ground in VHP selection switch system
1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (2) and T7 (female) (3)
78
Open circuit in the VHP selection switch system
1. Defective contact or open circuit in wiring harness between T3B (female) (2) and T7 (female) (3)
20-372
(4)
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.
Failure code
System problem Short circuit to ground in AWD selection switch system Open circuit in the AWD selection switch system
Normal condition (volts, amps and ohms) Resistance between T3B (3) and chassis: AWD specification: Max. 1 z Except AWD specification: Min. 1 Mz Resistance between T3B (3) and chassis: AWD specification: Max. 1 z Except AWD specification: Min. 1 Mz 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 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 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 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 Resistance between T3B (5) and chassis: At F1, F3, F5, F7: Max. 1 z Except F1, F3, F5, F7: Min. 1 Mz Resistance between T3B (5) and chassis: At F1, F3, F5, F7: Max. 1 z Except F1, F3, F5, F7: Min. 1 Mz Resistance between T3B (13) and chassis: At F2, F4, F6, F8: Max. 1 z Except F2, F4, F6, F8: Min. 1 Mz Resistance between T3B (13) and chassis: At F2, F4, F6, F8: Max. 1 z Except F2, F4, F6, F8: Min. 1 Mz Resistance between T3B (6) and chassis: At R1 - R4 : Max. 1 z Except R1 - R4: Min. 1 Mz
79
1. Short circuit to ground, short circuit, or short circuit to power source in wiring harness between T3B (female) (3) and T7 (female) (5)
80
1. Defective contact or open circuit in the wiring harness between T3B (female) (3) and T7 (female) (5)
81
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) (11) and TT (terminal) (6)
82
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
83
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)
84
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)
85
F1
Short circuit to ground in FL clutch pressure switch system Open circuit in the FL clutch pressure switch system Short circuit to ground in the FH clutch pressure switch system Open circuit in the FH clutch pressure switch system Short circuit to ground in the R 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 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 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 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 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
86
91
87
F2
88
92
89
F3
20-374
(4)
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 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
Normal operation
Sets to neutral
Sets to neutral
T-38
Sets to rapid raise mode
Gearshift shock Gearshift timelag
T-46
Sets to neutral
Sets to neutral
T-39
T-47
Sets to neutral
Sets to neutral
T-40
GD555, 655, 675-3C
20-375
(4)
TROUBLESHOOTING
No.
Failure code
System problem
Normal condition (volts, amps and ohms) Resistance between T3B (13) and chassis: At R1 - R4: Max. 1 z Except R1 - R4: Min. 1 Mz Resistance between T3B (14) and chassis: At F1, F2, R1: Max. 1 z Except F1, F2, R1: Min. 1 Mz Resistance between T3B (14) and chassis: At F1, F2, R1: Max. 1 z Except F1, F2, R1: Min. 1 Mz Resistance between T3B (7) and chassis: At F3, F4, R2: Max. 1 z Except F3, F4, R2: Min. 1 Mz Resistance between T3B (7) and chassis: At F3, F4, R2: Max. 1 z Except F3, F4, R2: Min. 1 Mz Resistance between T3B (15) and chassis: At F5, F6, R3: Max. 1 z Except F5, F6, R3: Min. 1 Mz Resistance between T3B (15) and chassis: At F5, F6, R3: Max. 1 z Except F5, F6, R3: Min. 1 Mz Resistance between T3B (8) and chassis: At F7, F8, R4: Max. 1 z Except F7, F8, R4: Min. 1 Mz Resistance between T3B (8) and chassis: At F7, F8, R4: Max. 1 z Except F7, F8, R4: Min. 1 Mz Resistance between T3B (16) and chassis: When lock-up switch is ON: Max. 1 z When lock-up switch is OFF: Min. 1 Mz Resistance between T3B (16) and chassis: When lock-up switch is ON: Max. 1 z When lock-up switch is OFF: Min. 1 Mz
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 Short circuit to ground in 1st clutch pressure switch system Open circuit in the 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 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
91
F4
92
94
93
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 Open circuit in the 2nd clutch pressure switch system Short circuit to ground in 3rd clutch pressure switch system Open circuit in the 3rd clutch pressure switch system Short circuit to ground in the 4th clutch pressure switch system Open circuit in the 4th clutch pressure switch system Short circuit to ground in the lock-up 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 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 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 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 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
94
95
95
F6
96
96
97
F7
98
97
99
F8
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
100
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
20-376
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
Code displayed
Warning lamp
Alarm buzzer
Warning chime
Memory
T-48
Set to neutral
Set to neutral
T-41
T-49
Set to neutral
Set to neutral
T-42
T-50
Set to neutral
Set to neutral
T-43
T-51
Set to neutral
Set to neutral
T-44
T-52
Set to neutral
Set to neutral
T-45
T-53
GD555, 655, 675-3C
20-377
(4)
TROUBLESHOOTING

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

Open 2nd solenoid circuit
20-392
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
T-12

Open 3rd solenoid circuit
GD555, 655, 675-3C
20-393
(4)
TROUBLESHOOTING
T-13

Open 4th solenoid circuit
20-394
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
T-14

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

Open engine-speed sensor circuit
GD555, 655, 675-3C
20-397
(4)
TROUBLESHOOTING
T-17

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 (3) and (16) 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 (7) and (16) 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

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 (13) and (16) 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 (7) and (16) 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

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

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

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

Open circuit in the transmission input shaft speed sensor circuit
GD555, 655, 675-3C
20-405
(4)
TROUBLESHOOTING
T-23

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

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

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

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

Short circuit with power source or open circuit in the differential control relay system
GD555, 655, 675-3C
20-411
(4)
TROUBLESHOOTING
T-29

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

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

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

Short circuit with the power source or open circuit in the logic A signal circuit

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

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

Short circuit with the power source or open circuit in the logic D signal system

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

Short circuit with ground in the FH clutch pressure switch signal circuit
GD555, 655, 675-3C
20-421
(4)
TROUBLESHOOTING
T-40

Short circuit with ground in the R clutch pressure switch signal circuit
20-422
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
T-41, T-42

Short circuit to ground in the 1st clutch pressure switch circuit

Short circuit to ground in the 2nd clutch pressure switch circuit
GD555, 655, 675-3C
20-423
(4)
TROUBLESHOOTING
T-43, T-44

Short circuit to ground in the 3rd clutch pressure switch circuit

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

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

Open circuit in the FH clutch pressure switch circuit
20-426
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
T-48

Open circuit in the R clutch pressure switch circuit
GD555, 655, 675-3C
20-427
(4)
TROUBLESHOOTING
T-49, T-50

Open circuit in the 1st clutch pressure switch circuit

Open circuit in the 2nd clutch pressure switch circuit
20-428
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
T-51, T-52

Open circuit in the 3rd clutch pressure switch circuit

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

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

Pump Cause of failure Left control valve Right control valve
Hydraulic cylinder
PC valve
Strainer
Failure mode
All work equipment is slow or lacks power No work equipment moves Excessive drop in engine speed, or engine stalls Work equipment Abnormal noise is generated Excessive blade drift Impossible to raise the machine using the blade Lack of actuating power in articulating, drawbar shift, scarifier, leaning, blade shift cylinders (Left, right) Excessive leaning cylinder drift (Tires lean) Impossible to rotate the circle Excessive scarifier drift Machine does not move in either FORWARD or REVERSE Transmission does not upshift or downshift Machine is slow or lacks power when traveling In all speed ranges In certain speed ranges
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
Travel
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
Slow return valve
Pilot check valve
Main relief valve
LS relief valve
Unload valve
Pump proper
Circle motor
Spool
Spool
Q Work equipment Q Loose piping connection or clamp, cracked hose Q Q Transmission proper Defective transmission main relief valve Defective transmission clutch Q Torque converter proper Defective torque converter relief valve Defective torque converter lock-up clutch Q Defective transmission pump Air sucked into transmission pump suction circuit Clogged strainer Defective ECMV valve Defective differential or final drive Brake valve Piston/disc/plate Accumulator charge circuit Accumulator Slack adjuster Q Q Drop in engine performance H-8 H-7 H-6 H-5 H-4 H-3 H-2 H-1 Troubleshooting code Shear pin
Circle rotator
GD555, 655, 675-3C

Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Braking device H-9 H-11 H-12 H-10 H-13b H-13a
TROUBLESHOOTING
H-17
H-16
H-15
H-14
20-453
(4)
TROUBLESHOOTING
H-1
H-1
All work equipment is slow or lacks power
20-454
(4)
GD555, 655, 675-3C
TROUBLESHOOTING
H-2, H-3
H-2
No work equipment moves
H-3
Excessive drop in engine speed, or engine stalls
GD555, 655, 675-3C
20-455
(4)
TROUBLESHOOTING
H-4, H-5
H-4
Abnormal noise generated around the pump
H-5
Excessive blade drift
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-9
H-8
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 doesnt 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
Cause of the failure
Torque converter oil temperature gauge
Water temperature gauge
Transmission controller
Relay, flasher, timer
ArticulatIion gauge
Fuel gauge
Nature of the failure
Engine oil pressure caution lamp lights up when the engine is started Transmission controller abnormality caution lamp lights up Caution Transmission oil temperature caution lamp lights up Differential oil temperature caution lamp lights up (opt) Bank pin caution lamp lights up Brake oil pressure caution lamp lights up Battery charge caution lamp lights up when the engine is started Preheating display does not light up when preheating is operated High beam display does not light up Actuation display Working lamp display does not light up (opt) Differential lock actuation display does not light up (opt) Accumulator actuation display does not light up Float actuation display does not light up Parking brake display does not light up Turn signal lamp display does not flash Articulation gauge does not work Fuel gauge does not work Gauges 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 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 Q Q Q Q Q Q Q Q Q
20-502
(4)
GD555, 655, 675-3C
Message center
Wiring harness
Fuse
Leakage of oil from engine oil pressure piping Shifter
Q Q Starting switch Q Engine oil pressure sensor (switch) Transmission oil temperature sensor Coolant temperature sensor Q Alternator Q Accumulator oil pressure switch Buzzer Head lamp switch Q Bulb Service meter Q Fuel level sensor (fuel sensor) Torque converter oil temperature sensor Q Articulation sensor Q Differential oil temperature sensor Turn switch, hazard switch Q Q Float / accumulator switch Q Lifter lock switch Differential lock switch M-9 M-8 M-7 M-6 M-5 M-4 M-3 M-2 M-1 M-10 Troubleshooting code
GD555, 655, 675-3C

Q Q Q Q Q Q Q Q Q Q Q Q M-11 M-17 M-16 M-15 M-14 M-13 M-12
TROUBLESHOOTING
M-21
M-20
M-19
M-18
20-503
(4)
TROUBLESHOOTING
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-3
M-2
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 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
GD555, 655, 675-3C
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
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GD555, 655, 675-3C
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)
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 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Nm 13.2 1.4 31.4 2.9 65.7 6.8 112 9.8 177 19 279 29 383 39 549 58 745 78 927 98 1320 140 1720 190 2210 240 2750 290 3280 340
kgm 1.35 0.15 3.2 0.3 6.7 0.7 11.5 1.0 18.0 2.0 28.5 3 39 4 56 6 76 8 94.5 10 135 15 175 20 225 25 280 30 335 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 mm 14 18 22 24 30 33 36 42 Width Across Flats mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 9.8 78.5 9.8 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49 Tightening Torque kgm 2.5 0.5 51 81 14 3 18 3 20 5 25 5 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 mm 10 12 16 Width Across Flats mm 14 17 22 Nm 65.7 6.8 112 98 279 29 Tightening Torque kgm 6.7 0.7 11.5 1 28.5 3
30-4
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GD555, 655, 675-3C
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 02 03 04 05 06 10 12 Plug (nut end) 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 Sleeve nut (elbow end) Use the two items below as a set 07221-20210 (Nut), 07222-00210 (Plug) 07221-20315 (Nut), 07222-00312 (Plug) 07221-20422 (Nut), 07222-00414 (Plug) 07221-20522 (Nut), 07222-00515 (Plug) 07221-20628 (Nut), 07222-00616 (Plug) 07221-21034 (Nut), 07222-01018 (Plug) 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used
Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D 6 8 10 12 14 16 18 20 22 24 27 d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5 L 8 11 12 15 18 20 22 25 28 30 34
GD555, 655, 675-3C
30-5
(5)
2.
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
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GD555, 655, 675-3C
SPECIAL TOOL LIST
SPECIAL TOOL LIST

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).
New/remodel
Necessity
Symbol
Component
Part No.
Part Name
Sketch Q Q Q Q
Qty.
Nature of work, remarks
1 709-331-1110 Disassembly, assembly of engine A 2 795-799-2250 3 795-799-1390 795-799-1131 790-501-5000 790-501-5200 1 790-901-2110 793-310-2131 Disassembly, assembly of torque converter 793-310-2141 C 2 792-390-1210 3 790-201-2740 790-201-2750
Wrench Installer Remover Gear Repair stand Repair stand Bracket Plate Plate Wrench Spacer Spacer Wrench Spacer Spacer Push tool kit
t t t t q q q q q t t t t t t t t t t t t t t t t t t t t
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 N N N N N
Removal, installation of cylinder head Press fitting of front oil seal Removal, installation of injection pump
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 Press fitting of clutch F2 & R bearing Press fitting of case oil seal at pulley end
4 790-102-1871 1 790-201-2740 790-201-2750
2 790-101-5201
3 797T-423-1320 Push tool 794T-423-1130 Push tool 4 790-101-5221 01010-51225 Disassembly, assembly of transmission D 5 Grip Bolt
794T-423-1130 Push tool 794T-423-1140 Spacer 790-101-5221 01010-51225 6 790-101-5221 01010-51225 Grip Bolt Grip Bolt
Q Press fitting of case dust seal at pulley end
794T-423-1110 Push tool
Press fitting of coupling cage oil seal Press fitting of coupling cage dust seal
7 794T-423-1120 Spacer 8 794T-423-1180 Push tool
Q Press fitting of coupling cover
30-8
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GD555, 655, 675-3C
SPECIAL TOOL LIST
New/remodel
Necessity
Symbol
Component
Part No.
Part Name
Sketch Q Q
Qty.
9 793-310-2100 Disassembly, assembly of transmission D 10 792-271-2000 11 799-301-1600 790-201-2850 1 790-201-2230 790-201-2740 Disassembly, assembly of final drive 790-101-5401 J 2 790-101-5441 790-101-5421 01010-51240
Lifting tool Centering tool Oil leak tester Spacer Plate Spacer Push tool kit Plate Grip Bolt
t t t t t t t
1 1 1 1 1 1 1 1 1 1
Lifting of clutch assembly Centering transmission and final drive Checking actuation of piston Press fitting of bevel pinion bearing inner race
Press fitting of flange oil seal
3 794T-422-1110 Push tool 1 792-571-1600 790-101-5401 Disassembly, assembly of tandem drive 2 K 3 790-101-5551 790-101-5421 01010-51240 Chain puller Push tool kit Plate Grip Bolt
t t t
1 1 1 1 1 1
Press fitting of drive shaft collar, bearing Removal, installation of chain
Press fitting of oil seal to cage
794T-425-1110 Push tool 794T-659-1110 Push tool Oil leak tester Push tool (GD555) Plate Plate Push tool kit Plate (GD555) Grip Bolt Push tool kit Plate (GD655) Grip Bolt Wrench Expander Ring Clamp Push tool 796-765-1110
t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1
Q Press fitting of drive shaft bearing inner race Checking actuation of piston Press fitting of shaft bearing Q inner race
4 799-301-1600 790-201-2220 790-201-2240 790-101-5401 Disassembly, assembly of axle H 2 790-101-5491 790-101-5421 01010-51240 790-101-5401 790-101-5531 790-101-5421 01010-51240 1 791-342-1310 Disassembly, assembly of bank pin V Disassembly, assembly of circle rotation 790-720-1000 2 796-720-1740 07281-00809 3 796-460-1110
793T-659-1110 Push tool (GD655)
1 1 1 1
Press fitting of housing oil seal
t t t t t t t t
1 1 1 1 1 1 1 1 N
Removal, installation of cover Removal, installation of piston ring Press fitting of worm bearing inner race Press fitting of houising oil seal
794T-470-1110 Push tool 4 790-101-5221 01010-51225 Grip Bolt
GD555, 655, 675-3C
30-9
(5)
SPECIAL TOOL LIST
New/remodel
Necessity
Symbol
Component
Part No.
Part Name
Sketch
Qty.
790-502-1003 790-101-1102
Cylinder repair stand Hydraulic pump Wrench assembly Push tool kit Push tool Push tool Push tool Push tool Push tool Grip Bolt Push tool kit Plate Plate Plate Plate Plate Grip Bolt Expander Ring Clamp Ring Clamp Ring Clamp Ring Clamp Ring Clamp Ring Clamp Stopper Rodd Service tool kit
t t t t
1 1 1 1 1 1 1 1 1 1 1
Disassembly, assembly of hydraulic cylinder Removal, installation of cylinder round head
2 790-102-2303 790-201-1702 790-201-1731 790-201-1741 3 790-201-1751 790-201-1761 790-201-1771 790-201-5021 01010-50816 790-201-1500 790-201-1540 790-201-1550 4 Disassembly, assembly of hydraulic system U 790-201-1560 790-201-1570 790-201-1580 790-101-5021 01010-50816 790-720-1000 796-720-1620 07281-00609 796-720-1740 07281-00809 796-720-1640 5 07281-00909 796-720-1650 07281-01029 796-720-1660 07281-01159 796-720-1670 07281-01279 6 796-460-1210 23B-60-32121 799-703-1200 799-703-1100 Air conditioner assembly X 799-703-1110 799-703-1120 799-703-1400
Press fitting of cylinder head coil bushing
1 1 1 1 1 1 1 1 Installation of cylinder head dust seal
t t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Discharging and charging air conditioner refrigerant gas Removal, installation of hydraulic pump Installation of cylinder piston ring
Vacuum pump (100 V) t Vacuum pump (220 V) t Vacuum pump (240 V) t Gas leak tester t
30-10
(5)
GD555, 655, 675-3C
SKETCHES OF SPECIAL TOOLS

Note: D-6 Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
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

Serial No.: 50001 51000
1. Remove battery ground wire (1) from terminal. 4. Loosen clamp (9) of hose (8) connecting air cleaner (6) and precleaner (7), then remove hose (8) from air cleaner (6).
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.
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 Hood assembly: 340 kg
30-16
(5)
GD555, 655, 675-3C
INSTALLATION OF ENGINE HOOD ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY
INSTALLATION 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)

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 Hood assembly: 340 kg
30-18
(5)
GD555, 655, 675-3C
REMOVAL OF RADIATOR ASSEMBLY

Serial No.: 50001 51000
a Remove the engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.) 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. 3. Remove hoses (8) and (9) of hydraulic oil cooler. a Fit male and female plugs into the hoses and nipples after removing them.
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

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 Radiator assembly: Approx. 80 kg 3. Install hydraulic oil cooler hoses (8) and (9). Tighten hydraulic tank drain plug (2). Add hydraulic oil to the specified level.
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

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

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 Radiator assembly (Radiator, aftercooler, and air conditioner condenser): 150 kg
30-22
(5)
GD555, 655, 675-3C

Carry out installation in the reverse order to removal.
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
Serial No.: 50001 51000
a Remove the engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.) 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 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.
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 Hydraulic tank: 45 l
30-24
(5)
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
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. 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. 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).
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. 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 Total water volume: 42 l 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.
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)
k Disconnect the cable from the negative () terminal of the battery. 1. Drain the coolant. 6 Coolant: 44 l 6. Disconnect water hoses (4) and (6).
2. Drain the fuel. 6 Fuel tank: 340 l (When full)
3. Drain the hydraulic oil. 6 Hydraulic tank: 45 l 7. Disconnect water hoses (7) and (9). 8. Disconnect tube (11) from the fuel tank.
4. Remove the engine hood assembly. For details, see REMOVAL, INSTALLATION OF ENGINE HOOD ASSEMBLY. 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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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 Fuel tank, hydraulic tank, and cooling water sub tank assembly: 200 kg

Carry out installation in the reverse order to removal. 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.
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REMOVAL OF ENGINE ASSEMBLY
REMOVAL OF ENGINE ASSEMBLY
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.) 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).
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.
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

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).
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.) 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 Engine, transmission assembly: Approx. 1850 kg 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.
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 (210x1.5), disconnect engine assembly and put it on stable stand.
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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

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).
10. Using forcing tap bolts (210x1.5), 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 4 Hydraulic pump: Approx. 60 kg Transmission pump: Approx. 20 kg
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 Transmission assembly: Approx. 1,000 kg
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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 1. Install mounting bracket (33), then install pulley (32).
13. Remove mounting bracket (33). Make transmission into individual part (34) to make it possible to carry out overhaul.
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
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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
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
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 Hydraulic pump: Approx. 60 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).
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. 13. Install engine hood assembly. (For details, see INSTALLATION OF ENGINE HOOD ASSEMBLY.)
10. Install universal joint (2) to flange with bolts. Install cable (3) of speedometer with nut (4).
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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).
ii) Remove snap ring (17) from stator (16). iii) Remove bushings (18) and (19), then remove flywheel (20) from race (21).
4. Turbine assembly Remove turbine assembly (24).
6. Stator shaft 1) Using tool C2, remove nut (25).
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).
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

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 Nm {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)
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.
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).
ii)
Install snap ring (17) to stator (16).
4) Using tool C2, tighten nut (25). 2 Nut: Thread tightener (LT-2) 3 Nut: 161.8 14.7 Nm {16.5 1.5 kgm}
iii) Fit race and flywheel assembly (15) to stator (16), then install snap ring (14).
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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.
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 Nm {5.5 0.5 kgm} 3) Install disc (12).
4. Turbine assembly Install turbine assembly (24).
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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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 Nm {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 Nm {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.
2. Piston pump assembly Sling pump assembly (5), then remove mounting bolts and lift off.
1. Fan assembly 1) Turn fan belt adjustment screw (2) and loosen fan belt tension, then remove fan belt (3).
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). 8. Transmission mount (left) Remove transmission mount (left) (14). 9. Return hose, valve cover 1) Remove hose (15). 2) Remove valve cover (16).
13. Lubrication tube, block assembly Remove lubrication tube and block assembly (28).
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).
3) Remove valve assembly (37) from valve seat (38).
16. Torque converter relief valve assembly 1) Remove 4 mounting bolts, then remove torque converter relief valve assembly (34).
18. Oil lubrication tubes Remove tubes (39) and (40).
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).
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). 22. Speed sensor (for detection of transmission input shaft speed) Remove speed sensor (45).
3) Remove mounting bolts of valve seat, then using eyebolts , remove valve assembly (50).
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.
4) Remove dust seal (59) and oil seal (35). 5) Remove snap ring (60), then remove bearing (61) from cover.
3) Remove outer races (53) and (54) and bearing (55) from cover (52).
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).
25. Fan drive shaft 1) Remove bolt (56), then remove plate (49). 2) Remove flange (57). 3) Knock out shaft (58) and remove.
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).
2) Using 2 wire ropes, remove 4th speed clutch assembly (69).
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.
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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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).
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).
vi) Remove thrust bearing (109).
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).
vii) Push in end plate (81) with bar handle , and remove snap ring (82). Remove handle, then remove end plate (81).
iv) Remove FL clutch gear (117). v) Remove needle bearing (80) from gear (117).
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).
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).
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).
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.
2) Remove 8 torque converter assembly mounting bolts (123) from under case. 3) Using eyebolts , remove torque converter assembly (127) from transmission case.
xviii)Remove seal rings (120) and (88) from piston assembly. xix) Remove snap ring (111), then remove sleeve (119).
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

a Wash all the parts clean and check that there is no dirt or damage before assembling. 1. Outer race Install outer race (145) to transmission case. 3) Install snap ring (138). a Check that the snap ring is fitted securely in the groove.
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.
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 Nm {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 .
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.
6) Tighten mounting bolts (123). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 110.5 12.5 Nm {11.25 1.25 kgm}
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.
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.
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.
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.
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.
xvi) Install thrust bearing (109). a Insert the thick race to the clutch end. xvii)Assemble needle bearing (80) to FL clutch gear (117).
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.
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).
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
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).
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.
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).
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).
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 Nm {28.25 3.25 kgm} xxiii)Install seal ring (70) to shaft.
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
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}
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).
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}
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.
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 Nm {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 Nm {11.25 1.25 kgm}
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)
9. Fan drive shaft 1) Using push tool shaft (58).
, press fit bearing (61) to
5) Install flange (57). 6) Fit plate (49) and tighten bolts (56). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 110.5 12.5 Nm {11.25 1.25 kgm}
2) Install shaft (58) to cover. 3) Install snap ring (60). a Check that the snap ring is fitted securely in the groove.
10. Transmission cover assembly 1) Install bearing (55) and outer races (54) and (53) to transmission cover (52) with push tool.
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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.
15. Cover, breather 1) Install breather (42). 2) Install cover (41).
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 Nm {6.0 1.0 kgm} 13. Oil block (torque converter oil outlet) Install oil block (44).
16. Oil lubrication tubes Install tubes (40) and (39). 3 Joint bolt: 11.25 1.45 Nm {1.15 0.15 kgm}
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 Nm {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).
2) Install retainer (32) to case. 3) Install coupling (31).
18. Torque converter relief valve 1) Install torque converter relief valve assembly (34), then tighten 4 mounting bolts. 3 Mounting bolt: 49 4.9 Nm {5.0 0.5 kgm}
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 Nm {5.0 0.5 kgm}
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 Nm {6.0 1.0 kgm} 29. Transmission mount (right) Install transmission mount (right) (11).
25. Valve cover, return hose 1) Install valve cover (16). 2) Install hose (15). 26. Transmission mount (left) Install transmission mount (left) (14). 27. Fan pulley Install fan pulley (13).
30. Lubrication tube, lubrication hoses 1) Install hoses (9) and (8). 2) Install tube (10). 3 Joint bolt: 29.4 4.9 Nm {3.0 0.5 kgm}
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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

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 to front of front frame. 4. Lower work equipment (1) to ground.
5. Set blocks
under 4 rear wheels.
2. Set stand
to center of main frame.
6. Remove engine hood assembly. (For details, see REMOVAL OF ENGINE HOOD ASSEMBLY.) 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
3. Set stand to rear of frame. a Lower ripper to ground.
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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 EO 30: 17 l
9. Loosen mounting bolts of universal joint (6) between transmission and differential, remove universal joint (6), then remove brake hose (7).
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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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 Final drive assembly: 2750 kg
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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 Nm {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.
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
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.
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 Nm {40 50 kgm} Target: 441 Nm {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 Tandem case: 80 l 4. Extend cotter pin (8) and pull it out, then remove plate (9) and push master pin (10) to remove.
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 Final brake case: 200 kg
3. Using tool
, shorten chain.
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ASSEMBLY OF FINAL DRIVE ASSEMBLY
7. Raise tandem case (13), remove bolts mounting to side case (14), then disconnect from side case and set on stable stand.

1. Raise final brake case (12) and install front, rear, left, and right. 3 Mounting bolt: 245 309 Nm {26 31.5 kgm} Target: 277 Nm {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 Nm {26 31.5 kgm} Target: 277 Nm {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 Differential: 320 kg
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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 Nm {26 31.5 kgm} Target: 277 Nm {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 Nm {26 31.5 kgm} Target: 277 Nm {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 Nm {26 31.5 kgm} Target: 277 Nm {28.2 kgm}
7. Using tool pin (10).
, shorten chain, then install master
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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 Nm {6.0 8.0 kgm} Target: 68.6 Nm {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.
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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. 2. Remove mounting bolts (1), then remove holder (2), shim (3), sprocket (4), and cage (5) in order. 5. Remove guide (14), then remove spring (15). Remove piston (16).
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).
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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. 4. Coat piston insertion portion inside cage (10) with grease, and assemble piston (16). 2 Cage: Coat with G2-LI.
2. Put cage (10) on stable stand and install disc wear gauge (18).
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
3. Assemble O-ring (19) to brake piston (16). 2 Groove portion of piston and O-ring: Coat with G2-LI.
6. Tighten guide (14) to specified torque, and check torque with torque wrench H. 3 Guide: 49 Nm {5 kgm} a Guide thread portion: Coat with LT-2.
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7. Install cage (10) to shaft (9). Install bleeder (20), then install plug (21). 3 Plug: 68.7 9.8 Nm {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 Nm {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 Nm {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.
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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 Side case assembly: 310 kg Planetary gear: 45 kg 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.
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).
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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 4. Knock dowel pins in cage (14) and flange (13) and secure.
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 Nm {10 12.5 kgm} Target: 111 Nm {11.3 kgm}
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
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7. Install collar (23), then install eyebolts to planetary gear (4), raise planetary gear, and install. 4 Planetary gear: 45 kg
9. Raise side case (1), turn over, and put on stable stand. Install inside sprocket (11) and insert collar (10).
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 Nm {50 62 kgm} Target: 549 Nm {56 kgm} Target: 111 Nm {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 Nm {10 12.5 kgm} Target: 111 Nm {11.3 kgm}
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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 Differential gear assembly: 320 kg 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.
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 Pinion: 35 kg 4 Bevel gear: 90 kg
3. Raise differential (1), turn over, remove brake tube (9), then remove nipple (10).
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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 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.)
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.
4. Tighten mounting bolts of right cage (12) to specified torque. 3 Mounting bolt: 98 113 Nm {10 11.5 kgm} Target: 111 Nm {11.3 kgm} Tighten mounting bolts of left cage (16) to specified torque. 3 Mounting bolt: 98 123 Nm {10 12.5 kgm} Target: 111 Nm {11.3 kgm} 2 Mounting bolt: Thread tightener (LT-2)
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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
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 Nm {25 31.5 kgm} Target: 277 Nm {28.2 kgm}
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 Nm {10 12.5 kgm} Target: 111 Nm {11.3 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
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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 Nm {0.07 0.15 kgm} added to the starting torque of the bevel pinion, and the backlash is 0.25 0.33 mm.
10. Install nipple (10) for differential lock, then install tube (9).
a The tooth contact is as shown in the diagram below. A: 46 58% of tooth width; B: 28 40% of tooth width
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 Nm {10 12.5 kgm} Target: 111 Nm {11.3 kgm} 3 Oil supply tube mounting bolt: 59 74 Nm {6 7.5 kgm} Target: 67 Nm {6.8 kgm} 3 Drain plug: 55.8 78.4 Nm {6 8.0 kgm} Target: 68.6 Nm {7.0 kgm}
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DISASSEMBLY OF BEVEL GEAR
DISASSEMBLY OF BEVEL GEAR

1. Remove mounting bolts of brake cage (1), then remove cage. 4. Remove spider gear assembly (10).
2. Remove plate (2), disc (3), gear (4), washer (5), and piston (6).
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).
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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 Nm {16 20 kgm} Target: 117 Nm {18 kgm} 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 Nm {10 12.5 kgm} Target: 111 Nm {11.3 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.
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
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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. 1. Remove mounting bolts of coupling (1). Remove coupling (1), then remove holder, shim, and Oring.
6. Install washer (5) to cage (1). Assemble cage (1) to bevel gear case, and knock in 4 dowel pins.
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.
7. Install cage (1) and tighten with bolts to bevel gear case (7) to specified torque. 3 Mounting bolt: 98 123 Nm {10 12.5 kgm} Target: 111 Nm {11.3 kgm}
3. Remove bearing (4) of pinion shaft (3).
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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 Nm {25 31.5 kgm} Target: 227 Nm {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 Nm {0.89 1.19 kgm}
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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.
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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 Operator's cab assembly: Approx. 700 kg
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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 Operator's cab assembly: Approx. 700 kg 3. Insert mounting bolts in left cover (17) and right cover (18) of work equipment control lever.
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.
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6. Install air conditioner hoses (8) and (9) and tighten clamp. Install controller box (7). Install operator's seat (6).
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.
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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.
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.
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7. Remove 3 hoses (11) inside orbit motor from under left side of 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.
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..
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 Floor assembly: Approx. 260 kg
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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.
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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.
8. Install connectors of transmission system wiring harnesses (3) and (4). a After mating connectors, check that they are securely locked.
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).
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.
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REMOVAL OF STEERING VALVE (ORBIT-ROLL) INSTALLATION OF STEERING VALVE (ORBIT-ROLL)
REMOVAL 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.
INSTALLATION OF STEERING VALVE (ORBIT-ROLL)

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.
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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 (7) Plastic hammer (8) Small amount of grease (9) Vice (10)Oil-based felt pen (11) Tweezers
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Part No. 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 36 37 38 39 40 41 42 Screw
Part name
Qty 6 1 1 1 1 (1) 1 1 1 1 1 1 6 4 (2) 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 1 1 1 2 Part No.: BA0271A Part No.: BA0273A Part No.: 5776 Part No.: BA0098A X-ring or Teflon seal
Remarks
Retainer screw assembly End cap Gerotor Spacer Spacer Spacer plate Drive Housing Sleeve Spool Pin Centering spring Centering spring Flat spring Race bearing Thrust needle O-ring Oil seal Dust seal Retaining ring Seal gland bushing O-ring O-ring Inlet check valve sub assembly Valve seat Poppet Spring Plug O-ring Retainer plug Spring Ball Valve seat Ball Ball holder Spring Plug O-ring Adapter screw Ball Name plate Rivet Seal kit (X-ring) Seal kit (Teflon seal)
For standard input torque specification For low input torque specification Only for low input torque specification
(Cannot be disassembled) (Cannot be disassembled)
(Cannot be disassembled)
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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. 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. 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.
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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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.
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.
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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.
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 The diagram below is the standard seal specification drawing.
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.
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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GD555, 655, 675-3C
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 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 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.
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.
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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 (22) to Gerotor (4).
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.
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.
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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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.
a After tightening to torque given below, install handle to spool and check that spool rotates. Screw tightening torque
Discharge capacity (cc/rev) 51 230 277 369 737 Tightening torque (Nm {kgm}) 22.6 {2.3} 23.5 {2.4} 28.4 {2.9}
List of capacities and spacers

Discharge Discharge Spacer capacity symbol capacity (cc/rev) thickness (mm) A B C D E G K M P S T 51 69 96 120 159 184 230 277 369 461 553 737 3.6 6.1 12.2 12.2 3.6 22.0 24.4 41.1 53.7 66.4 91.8
Order for tightening end cap mounting screws is as shown in diagram below.
GD555, 655, 675-3C
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REMOVAL OF BLADE ASSEMBLY INSTALLATION OF BLADE ASSEMBLY
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.
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. Sling blade (1), move position of wire to center of blade while pushing blade out, then lift off. 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
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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. 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 4. Disconnect 2 motor hoses (11), 2 side cylinder hoses (9), and 2 swivel hoses (10).
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.
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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 Nm {60 105 kgm} 4 Circle drawbar assembly: Approx. 1,250 kg 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.
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
5. Install blade assembly. (For details, see INSTALLATION OF BLADE ASSEMBLY.)
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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 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 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.
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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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 Circle rotation gear: Approx. 135 kg 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.
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.
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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. 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.
4. Lift off circle gear assembly (3).
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).
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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} 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).
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 3. Make clearance a of the same dimension between plate (11) and pinion gear (9).
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GD555, 655, 675-3C
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 Quantity of oil: Approx. 4 l 5. Worm gear and bearing assembly 1) Remove worm gear and bearing assembly (9).
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).
6. Worm wheel shaft assembly 1) Remove worm wheel shaft assembly (12). a Remove washer (18).
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2) Remove gear (14) from shaft (13). a Remove washer (17).
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GD555, 655, 675-3C
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).
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)
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.
3) Install gear (14) to shaft (13). a Install washer (17).
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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}
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GD555, 655, 675-3C
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. 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
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.
4. Pull out 8 mounting bolts of housing (9), then using 2 forcing screws (10), remove housing.
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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.
8. Separate circle gear (17) and shaft (14). Remove spacer (18) under shaft.
6. Install eyebolts to circle gear shaft (14), and lift off gear assembly. Remove belleville spring (15) and collar (16).
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.
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GD555, 655, 675-3C
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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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 Nm {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)
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
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)
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.
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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 Nm {93 105 kgm} 3 2 bolts at left and right of machine: 490.3 608 Nm {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 Nm {3.3 4.5 kgm} 3 Oil filler plug: 73.5 122.6 Nm {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
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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.
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
GD555, 655, 675-3C
90-3
(4)
TRANSMISSION HYDRAULIC CIRCUIT (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.
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
GD555, 655, 675-3C
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)

GD555, 655, 675-3C
90-9
(8)
HYDRAULIC CIRCUIT DIAGRAM (2/2) (Serial No.: 51001 and up)

1. For GD655, 675-3C: Serial No. 50001 51000 2. For GD655, 675-3C: Serial No. 51001 and up
GD555, 655, 675-3C
90-11
(4)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (Serial No.: 50001 51000)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-13
(4)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-15
(4)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-17
(4)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-19
(4)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-21
(4)

Serial No.: 50001 51000
GD555, 655, 675-3C
90-23
(4)
ELECTRICAL CIRCUIT DIAGRAM (1/6) (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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Gd675-3c (Aps) Shop Manual

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SEBM020908

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

GD555, 655, 675-3C

Indication New page to be added Page to be replaced

Action Required Add Replace Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Mark Number

Revision Mark Number

Revision Mark Number

Revision Mark Number

(8) (4) (8) (8) (8)

GD555, 655, 675-3C

Revision Mark Number

Revision Mark Number

Revision Mark Number

Revision Mark Number

GD555, 655, 675-3C

Revision Mark Number

Revision Mark Number

Revision Mark Number

Revision Mark Number

GD555, 655, 675-3C

How to read the shop manual

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.

Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type coupler

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

Aron-alpha 201 Loctite 648-50 LG-1 LG-5

79A-129-9110 790-129-9010 790-129-9080

Komatsu code LM-G

Container Can Tube

Molybdenum disulphide lubricant

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

20Y-54-39850 417-926-3920 20Y-54-55130 22M-54-27220

310 ml 320 ml 333 ml 333 ml

Adhesive for cab glass

Standard tightening torque

Standard tightening torque

Tightening torque kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5

Standard tightening torque

Standard tightening torque

03 04 05 06 (10) (12) (14)

Electric wire code

Electric wire code

Classification by color and code

GD555, 655, 675-3C

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

GD555, 655, 675-3C

Travel speed Performance

VHP engine: Variable horsepower engine.

GD555, 655, 675-3C

Machine Model Serial Number Engine model 50001 51000 SA6D102E-1

GD555-3C VHP Engine 51001 and up SAA6D102E-2

GD555, 655, 675-3C

4-spool type x 2 (CLSS)

Steering related cylinders

GD555, 655, 675-3C

GD555-3C 51001 and up

GD555, 655, 675-3C

GD555, 655, 675-3C

Reverse Elliott, angle type 16 Fully hydraulic type 49 23