Issuu

KEBM665002

MOTOR GRADER

GD535 -5 Hydraulic drive fan specification SERIAL NUMBERS

B10001 and up

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This is the sample of the manual Click on the download link for complete manual

Download Link

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00 Index and foreword

GD535-5

00-1

Table of contents

00 Index and foreword

00 Index and foreword Table of contents ......................................................................................................................................... 00-2 Acronyms .................................................................................................................................................. 00-12 Foreword and general information ............................................................................................................ 00-17 Safety notice .......................................................................................................................................... 00-17 How to read the shop manual ................................................................................................................ 00-22 Explanation of terms for maintenance standard .................................................................................... 00-24 Handling of electric equipment and hydraulic components.................................................................... 00-26 Handling of connectors newly used for engines .................................................................................... 00-35 How to read electric wire code............................................................................................................... 00-38 Precautions when carrying out work ...................................................................................................... 00-41 Method of disassembling and connecting push-pull type coupler.......................................................... 00-44 Standard tightening torque table ............................................................................................................ 00-47 Conversion table .................................................................................................................................... 00-51 01 Specification Acronyms .................................................................................................................................................... 01-3 Specifications .............................................................................................................................................. 01-8 Specification drawing ............................................................................................................................... 01-8 Specifications ......................................................................................................................................... 01-10 Weight table ........................................................................................................................................... 01-16 Table of fuel, coolant, and lubricants...................................................................................................... 01-17 10 Structure and function Acronyms .................................................................................................................................................... 10-4 Engine and cooling system ......................................................................................................................... 10-9 Cooling system ........................................................................................................................................ 10-9 Cooling fan motor................................................................................................................................... 10-11 Power train system ................................................................................................................................... 10-19 Power train system drawing ................................................................................................................... 10-19 Power train piping drawing..................................................................................................................... 10-20 Transmission control .............................................................................................................................. 10-21 Torque converter .................................................................................................................................... 10-22 Transmission.......................................................................................................................................... 10-25 Transmission control valve..................................................................................................................... 10-44 ECMV..................................................................................................................................................... 10-46 Main relief valve and torque converter relief valve................................................................................. 10-53 Front axle ............................................................................................................................................... 10-55 Rear axle................................................................................................................................................ 10-58 Differential (Non-differential specification) ............................................................................................. 10-59 Differential (Differential lock specification) ............................................................................................. 10-61 Differential lock solenoid valve............................................................................................................... 10-64 Final drive .............................................................................................................................................. 10-65 Tandem drive ......................................................................................................................................... 10-67 Steering system ........................................................................................................................................ 10-69 Steering piping drawing.......................................................................................................................... 10-69 Priority valve .......................................................................................................................................... 10-70 Steering valve ........................................................................................................................................ 10-75 Brake system ............................................................................................................................................ 10-82 Hydraulic piping drawing of brake system ............................................................................................. 10-82 Brake valve ............................................................................................................................................ 10-83 Brake circuit accumulator....................................................................................................................... 10-88 Brake circuit accumulator charge valve ................................................................................................. 10-89 Wheel brake ........................................................................................................................................... 10-95 Parking brake solenoid valve and lifter lock pin solenoid valve ............................................................. 10-96 Parking brake......................................................................................................................................... 10-97

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Table of contents

Undercarriage and frame .......................................................................................................................... 10-98 Frame..................................................................................................................................................... 10-98 Tire......................................................................................................................................................... 10-99 Hydraulic system..................................................................................................................................... 10-100 Hydraulic system.................................................................................................................................. 10-100 Hydraulic piping drawing of work equipment ....................................................................................... 10-102 Work equipment control ....................................................................................................................... 10-104 Hydraulic tank ...................................................................................................................................... 10-105 Work equipment pump and steering pump .......................................................................................... 10-106 Power train pump................................................................................................................................. 10-107 Power train pump and differential lock pump....................................................................................... 10-108 Brake and cooling fan pump ................................................................................................................ 10-109 Control valve .........................................................................................................................................10-110 Functions and valve operations ............................................................................................................10-112 Hydraulic cylinder..................................................................................................................................10-113 Swivel joint ............................................................................................................................................10-114 Pilot check valve ...................................................................................................................................10-115 Work equipment system ......................................................................................................................... 10-124 Circle and drawbar............................................................................................................................... 10-124 Blade.................................................................................................................................................... 10-126 Lifter ..................................................................................................................................................... 10-128 Circle rotation motor............................................................................................................................. 10-130 Circle rotation gear............................................................................................................................... 10-132 Ripper .................................................................................................................................................. 10-134 Cab and its attachments ......................................................................................................................... 10-135 ROPS cab ............................................................................................................................................ 10-135 Electrical system ..................................................................................................................................... 10-136 Layout drawing of electrical system ..................................................................................................... 10-136 System operating lamp system............................................................................................................ 10-138 Battery disconnect switch .................................................................................................................... 10-139 Machine monitor .................................................................................................................................. 10-140 Automatic gear shift control system ..................................................................................................... 10-151 Transmission controller........................................................................................................................ 10-156 Engine controller .................................................................................................................................. 10-159 KOMTRAX system............................................................................................................................... 10-162 KOMTRAX terminal ............................................................................................................................. 10-163 Rearview monitor system..................................................................................................................... 10-165 Rearview monitor ................................................................................................................................. 10-166 Rearview camera ................................................................................................................................. 10-167 Engine starting circuit........................................................................................................................... 10-168 Engine stop circuit................................................................................................................................ 10-170 Preheating circuit ................................................................................................................................. 10-171 Sensors................................................................................................................................................ 10-172 Engine power mode selector circuit ..................................................................................................... 10-181 Cooling fan control system................................................................................................................... 10-182 20 Standard value table Acronyms .................................................................................................................................................... 20-3 Standard value table ................................................................................................................................... 20-8 Standard value table for engine ............................................................................................................... 20-8 Standard value table for machine .......................................................................................................... 20-10 30 Testing and adjusting Acronyms .................................................................................................................................................... 30-4 Tools for testing, adjusting, and troubleshooting......................................................................................... 30-9 Tools for testing, adjusting, and troubleshooting...................................................................................... 30-9 Engine and cooling system ....................................................................................................................... 30-16 Testing engine speed ............................................................................................................................. 30-16 Testing boost pressure........................................................................................................................... 30-18

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Table of contents

00 Index and foreword

Testing exhaust gas temperature ........................................................................................................... 30-20 Testing exhaust gas color ...................................................................................................................... 30-22 Adjusting valve clearance ...................................................................................................................... 30-24 Testing compression pressure ............................................................................................................... 30-26 Testing blowby pressure ........................................................................................................................ 30-29 Testing engine oil pressure .................................................................................................................... 30-30 Handling fuel system devices ................................................................................................................ 30-31 Releasing remaining pressure from fuel system.................................................................................... 30-32 Testing fuel pressure .............................................................................................................................. 30-33 Bleeding air from fuel circuit................................................................................................................... 30-34 Testing fuel circuit for leakage................................................................................................................ 30-35 Handling cylinder cutout mode operation............................................................................................... 30-36 Handling no-injection cranking operation............................................................................................... 30-37 Handling voltage circuit of engine controller .......................................................................................... 30-38 Testing muffler (main body) and stacked muffler for looseness and damage ........................................ 30-39 Testing muffler function .......................................................................................................................... 30-40 Testing installed condition of cylinder heads and manifolds .................................................................. 30-41 Testing of engine piping for damage and looseness.............................................................................. 30-42 Testing fuel discharge, return rate, and leakage .................................................................................... 30-43 Testing and adjusting air conditioner compressor belt tension .............................................................. 30-47 Checking and replacing alternator belt .................................................................................................. 30-49 Checking and replacing auto-tensioner ................................................................................................. 30-51 Power train ................................................................................................................................................ 30-54 Testing power train oil pressure ............................................................................................................. 30-54 Adjusting transmission speed sensor .................................................................................................... 30-68 Retrieval of disabled machine due to transmission valve failure ........................................................... 30-71 Flushing procedure for torque converter and transmission circuits........................................................ 30-74 Testing and adjusting toe-in ................................................................................................................... 30-76 Testing and adjusting differential lock oil pressure (differential lock specification)................................. 30-78 Steering system ........................................................................................................................................ 30-80 Testing and adjusting steering oil pressure ............................................................................................ 30-80 Testing oil leakage of steering cylinder .................................................................................................. 30-81 Bleeding air from steering circuit............................................................................................................ 30-82 Brake system ............................................................................................................................................ 30-83 Releasing remaining pressure from brake circuit................................................................................... 30-83 Testing and adjusting brake oil pressure................................................................................................ 30-84 Bleeding air from brake circuit ............................................................................................................... 30-87 Testing wear of wheel brake disc ........................................................................................................... 30-88 Testing and adjusting parking brake pad................................................................................................ 30-89 Releasing parking brake manually ......................................................................................................... 30-92 Charging brake accumulator with gas.................................................................................................... 30-93 Hydraulic system....................................................................................................................................... 30-95 Testing work equipment oil pressure...................................................................................................... 30-95 Testing lifter lock pin circuit pressure ..................................................................................................... 30-97 Testing cooling fan speed ...................................................................................................................... 30-99 Testing cooling fan circuit oil pressure ................................................................................................. 30-100 Testing oil leakage of work equipment cylinder.................................................................................... 30-102 Bleeding air from work equipment circuit ............................................................................................. 30-105 Work equipment ...................................................................................................................................... 30-106 Adjusting drawbar ball joint clearance ................................................................................................. 30-106 Testing and adjusting circle guide clearance ....................................................................................... 30-107 Testing and adjusting slip clutch type circle drive ................................................................................ 30-109 Electrical system ......................................................................................................................................30-111 Procedure for testing diodes .................................................................................................................30-111 Special functions of machine monitor .................................................................................................. 30-113 Handling high-voltage circuit of engine controller ................................................................................ 30-162 KOMTRAX terminal start-up procedure ............................................................................................... 30-163 Adjusting rearview camera angle ......................................................................................................... 30-167 Handle battery disconnect switch ........................................................................................................ 30-169

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GD535-5 (01)

00 Index and foreword

Table of contents

Preparatory work for troubleshooting of electrical system failure ........................................................ 30-170 Pm Clinic................................................................................................................................................. 30-172 Pm Clinic.............................................................................................................................................. 30-172 40 Troubleshooting Acronyms .................................................................................................................................................... 40-8 Information related to troubleshooting ...................................................................................................... 40-13 Points to remember when troubleshooting ............................................................................................ 40-13 How to proceed in troubleshooting ........................................................................................................ 40-14 Checks before troubleshooting .............................................................................................................. 40-15 Inspection procedure before troubleshooting......................................................................................... 40-17 Troubleshooting procedure .................................................................................................................... 40-32 Failure code list...................................................................................................................................... 40-34 Symptoms and troubleshooting numbers .............................................................................................. 40-42 Information described in troubleshooting table ...................................................................................... 40-45 Diagnosis of open harness in pressure sensor system ......................................................................... 40-47 Connector list and layout ....................................................................................................................... 40-49 Connector pin layout .............................................................................................................................. 40-63 T-box and T-adapter list ......................................................................................................................... 40-99 Locations of fuses ................................................................................................................................ 40-104 Troubleshooting by failure code (display of code)................................................................................... 40-107 Failure code [1500L0] Double Engagement of T/M Clutches .............................................................. 40-107 Failure code [15G0MW] Failure of R-Clutch System ........................................................................... 40-108 Failure code [15H0MW] Failure of Clutch System (FH)....................................................................... 40-109 Failure code [15J0MW] Failure of Clutch System (FL) .........................................................................40-110 Failure code [15K0MW] Failure of Clutch System (1st) ........................................................................40-111 Failure code [15L0MW] Failure of Clutch System (2nd) .......................................................................40-112 Failure code [15M0MW] Failure of Clutch System (3rd) .......................................................................40-113 Failure code [15N0MW] Failure of Clutch System (4th)........................................................................40-114 Failure code [15SBL1] Release Trouble of ECMV (R)..........................................................................40-115 Failure code [15SBMA] Malfunction of ECMV (R) ................................................................................40-117 Failure code [15SCL1] Release Trouble of ECMV (FH) .......................................................................40-119 Failure code [15SCMA] Malfunction of ECMV (FH)............................................................................. 40-121 Failure code [15SDL1] Release Trouble of ECMV (FL) ....................................................................... 40-123 Failure code [15SDMA] Malfunction of ECMV (FL) ............................................................................. 40-125 Failure code [15SEL1] Release Trouble of ECMV (1st) ...................................................................... 40-127 Failure code [15SEMA] Malfunction of ECMV (1st) ............................................................................. 40-129 Failure code [15SFL1] Release Trouble of ECMV (2nd) ..................................................................... 40-131 Failure code [15SFMA] Malfunction of ECMV (2nd) ............................................................................ 40-133 Failure code [15SGL1] Release Trouble of ECMV (3rd)...................................................................... 40-135 Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................................ 40-137 Failure code [15SHL1] Release Trouble of ECMV (4th) ...................................................................... 40-139 Failure code [15SHMA] Malfunction of ECMV (4th)............................................................................. 40-141 Failure code [15SJMA] Malfunction of ECMV (L/U)............................................................................. 40-143 Failure code [15U0NT] Overload of Inching Clutch ............................................................................. 40-144 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ........................................................... 40-145 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)............................................................ 40-147 Failure code [989L00] Engine Controller Lock Caution 1 .................................................................... 40-149 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................... 40-150 Failure code [989N00] Engine Controller Lock Caution 3.................................................................... 40-151 Failure code [AB00KE] Charge Voltage Low ....................................................................................... 40-152 Failure code [AB00KY] Hot Short of Alternator R Terminal.................................................................. 40-153 Failure code [B@BAZG] Derating in speed due to engine oil pressure drop....................................... 40-154 Failure code [B@BCNS] Engine Overheat .......................................................................................... 40-155 Failure code [B@CENS] T/C Oil Temp. Overheat ............................................................................... 40-156 Failure code [B@CKNS] DIFF Oil Temp. Overheat ............................................................................. 40-157 Failure code [B@HANS] HYD Oil Temp. Overheat.............................................................................. 40-159 Failure code [CA111] Engine NE, controller internal error ................................................................... 40-161 Failure code [CA115] Engine NE, Bkup speed sensor error................................................................ 40-162

GD535-5 (01)

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